Fiat Panda 2009 User Manual

FIATPANDA

PANDA CROSS

FIAT PANDA PANDA CROSS

The Fiat Panda Panda Cross Petrol­Methane version is dealt with in this ap­pendix.

For anything not included in this supple­ment, refer to the Fiat Panda Owner Man­ual.

CONTENTS

INTRODUCTION ............................................................................................................ 3

FUNCTIONAL SYSTEM DIAGRAM ............................................................................ 5

CANISTERS ....................................................................................................................... 6

SOLENOID VALVE/SAFETY DEVICES ........................................................................ 7

PIPING ................................................................................................................................. 8

PRESSURE REGULATOR/REDUCTION UNIT ....................................................... 8

METHANE INJECTORS ................................................................................................. 8

METHANE ELECTRONIC CONTROL UNIT ......................................................... 8

PETROL/METHANE SWITCH ...................................................................................... 9

FUEL CUT OFF SWITCH ............................................................................................. 10

STARTING THE ENGINE ............................................................................................. 10

AT THE PETROL STATION ......................................................................................... 11

WHEN NEEDING TO CHANGE AN EXTERNAL BULB ..................................... 12

CANISTER IDENTIFICATION DATA ....................................................................... 15

MAINTENANCE SCHEDULE ...................................................................................... 16

WHEELS ............................................................................................................................. 17

ENGINE ............................................................................................................................... 18

WEIGHTS ........................................................................................................................... 20

LOAD COMPARTMENT VOLUME ............................................................................. 20

TYRES .................................................................................................................................. 21

DIMENSIONS .................................................................................................................... 22

CAPACITIES ....................................................................................................................... 23

2

INTRODUCTION

The Fiat Panda Natural Power version fea­tures two fuel systems, one for petrol and
one for natural gas (methane).

The two systems are independent of one
another and the methane one is the
phased, sequential, multipoint type.

The starting system runs on petrol and is
the only one.

What is natural gas?

Natural gas is a mixture of gas used as a
main source of energy.

Its main component is methane so for this
reason it is usually known as methane in
Italy but it contains small amounts of oth­er hydrocarbons and inert gases.

It is extracted in a gaseous stage and trans­ported to where it is used via gas pipelines;
world reserves are plentiful and evenly dis­tributed. Methane is fuel with a low impact
on the environment because it significantly
reduces the contribution of the exhaust
gases to the greenhouse effect and creat­ing pollution.

The methane multipoint injection
system

This is an original product from Fiat’s re­search in the field of alternative fuels that
comes from close co-operation with im­portant suppliers in the methane sector.

By adapting the sophisticated electronic
control technology of petrol engines to
meet the specifications of methane, it has
been possible to achieve important results
in terms of driveability, exhaust emissions
and consumption.

Using the methane multipoint injection
system the engine offers the same driving
conditions as running on petrol.

It should be borne in mind that, in all dri­ving conditions, methane operation gives
engine power and torque specifications
that are 10% lower than petrol operation.

Petrol operation is therefore rec­ommended if a lot of power is re­quired (e.g. driving uphill with a
laden car, setting off on a steep in­cline).

Selecting the type of fuel supply

The Fiat Panda Panda Cross version is
configured to normally run on methane.

fig. 1

F0G0654m

When the methane is running out and the
pressure in the canister is close to the cor­rect operating limit, the system automat­ically switches to petrol operation.

The engine is always started up using
petrol (to keep this fuel supply system ef­ficient) with an automatic switch to
methane after a few seconds.

For this reason there always needs
to be petrol in the tank.

The petrol/methane switch A - Fig. 1, on
the hatch for the fuse box unit (left dash­board), makes it possible to select petrol
operation. The system does not switch au­tomatically to methane operation if the
petrol runs out.

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3

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Passive safety

The Fiat Panda Panda Cross version has
the same passive safety features as the
other versions.

In particular, the location and mountings
of the canisters have been designed to
pass the impact tests in accordance with
Fiat safety standards. The flow of methane
coming out of the canisters is governed by
a solenoid valve that is only open during
methane operation.

The solenoid valve unit includes protec­tion against excess flows (if the high pres­sure system breaks, the flow of methane
is restricted to values that are not dan­gerous), overheating (fuse pad that allows
the methane to drain off if the tempera­ture exceeds 110 °C) and a pressure cal­ibration device that intervenes if the pres­sure goes above 300 bar ensuring the
methane escapes in a controlled manner
and as quickly as possible.

The solenoid valve is connected to the
Fire Protection System (inertia switch or
fuel cut off switch).

Active safety

The Fiat Panda Panda Cross version has
the same active safety features as the oth­er versions.

WARNING

The Fiat Panda Panda Cross

version is equipped with a
high pressure methane system de­signed to run at 200 bar.
It is dangerous to force the system
with higher pressures. When towing
or lifting the vehicle, the instructions
in this booklet at the end of the chap­ter should be followed in order to pre­vent damage to the methane system
parts: ‘Towing the vehicle’.
If there is a problem with the methane
system, only go to an authorised Fiat
Dealer.
Do not alter the methane system con­figuration or components; they are de­signed exclusively for the Fiat Panda
Panda Cross. The use of other com­ponents or materials may lead to mal­functioning and compromise safety.

WARNING

When oven painting, the

canisters should be removed
from the vehicle and later carefully
refitted by a Fiat Dealer. Although the
methane system has numerous safe­ty features, it is advisable to close the
manual taps for the canisters every
time the car is not in use for a long
period, transported on other vehicles
or moved in an emergency as a result
of a breakdown or accident.

4

FUNCTIONAL SYSTEM DIAGRAM

Description of the functional system diagram Fig. 2
1 Methane canisters - 2 Methane repressurising filler - 3 Methane-Petrol switch - 4 Methane piping - 5 Pressure regulator/reduction

unit - 6 Methane injection system electronic control panel - 7 Methane injector carrier manifold - 8 Petrol tank

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fig. 2

F0G0811m

5

CANISTERS

The car has two canisters (total capacity
about 72 litres) located under the floor of
the car and protected by two special
guards. The canisters Fig. 3 and Fig. 4 are
the tank that contains the methane in the
compressed gaseous state (pressure 200
bar at 15 °C). The methane, stored in the
canisters at high pressure, flows through
a dedicated pipe to reach the pressure
regulator/reduction unit which supplies
the 4 methane injectors at low pressure
(about 9 bar).

fig. 3

F0G0656m

The plates handed over by the Dealership
with the documentation contain the date
for the first inspection of the canisters.

Those responsible for the
methane supply are not autho­rized to refill the canisters when
the inspection date has expired.

IMPORTANT If the vehicle has
been registered in a country oth­er than Italy, the certification da­ta, identification and inspection
procedures for the methane can­isters should conform to the leg­islation in that country. In any
case, it should be remembered
that the life of the canisters is 20
years from the production date
as set out in Regulation (ECE) no.

110.

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6

fig. 4

Canister certification

The methane canisters are certified in ac­cordance with ECE Regulation no. 110

F0G0657m

The canisters should be inspect­ed, in accordance with ECE Reg­ulation Procedure no. 110, every
4 years from the vehicle regis­tration date or in accordance
with specific regulations in indi­vidual countries (see ‘Identifica­tion data’ chapter).

SOLENOID VALVES/

D

1

2

SAFETY DEVICES

The solenoid valves Fig. 5 and Fig. 6 are
bolted directly onto the methane canis­ters with the main function on interrupt­ing the flow of methane to the supply cir­cuit.

The solenoid valves are open when:

❒

the switching button is in the methane
position;

❒ t

he pressure in the canister is sufficient

for operation;

❒

the engine is running;

❒

the inertia switch has not been trig­gered.

The solenoid valve assembly is equipped
with the following safety devices:

1) Fuse pad, in the case of overheating
(temperature above 110 °C), it totally
eliminates the danger of excess pressure
making the methane in the canister flow
out as quickly as possible in a controlled
manner.

2) Mechanical excess pressure device
(Burt Disk), in the case of excess pres-

sure (above 300 bar), it ensures that the
methane escapes as quickly as possible in
a controlled manner.

fig. 5

fig. 6

F0G0658m

F0G0659m

3) Excess flow, it intervenes if the piping
is broken limiting the flow of methane to
values that are not dangerous.

The flow restrictor valve is located to al­low it to operate even if the solenoid valve
casing is broken due to an impact.

4) Manual tap, it is located upstream of
the solenoid valve.

fig. 7

F0G0660m

This separates the canister from the
methane system to allow maintenance op­erations.

The taps are accessible from outside the
car and are located, in the case of the
lengthwise centre canister, at the rear of
the canister and, in the case of the trans­verse rear canister, towards the left wheel
side.

To close the taps D - Fig. 7: turn the
knob in the direction (1) shown by the ar­row (clockwise

OFF)

To open the taps D - Fig. 7: turn the knob
in the direction (2) shown by the arrow
(anti-clockwise

ON)

5) Single-acting valve, positioned on

the piping that comes from the filler, to
prevent the methane from flowing back.

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7

PIPING

METHANE INJECTORS

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The methane piping from the filler to the
pressure regulator/reduction unit is made
from galvanized steel and covered in plas­tic (high pressure) and is located outside
the passenger compartment; the piping
from the pressure regulator/reduction
unit to the methane injectors is in gal­vanised steel (rigid pipe) and stainless steel
(flexible hose).

PRESSURE
REGULATOR/
REDUCTION UNIT

The pressure reduction unit Fig. 8 is in­stalled in the engine compartment.

It has the function of reducing the pres­sure of the methane from the value in the
canister to the supply value for the
methane injectors (about 9 bar) and keep­ing it constant in all operating conditions.

fig. 8

fig. 9

F0G0661m

F0G0662m

There are 4 dedicated injectors for the
methane gas A - Fig. 9, fitted on the in­take manifold near the cylinder head, one
for each intake duct; they are supplied at
a constant pressure (about 9 bar) and op­erated by the specific electronic control
unit.

ELECTRONIC CONTROL
PANEL FOR
METHANE SYSTEM

Specific electronic control panel for
methane supply and advance ignition.

If the methane has run out, the control
unit fig. 10 automatically handles the
switch to running on petrol.

fig. 10

F0G0663m

8

PETROL/METHANE

D

A

C

B

SWITCH

❒

A Methane/Petrol switch.

❒

B Methane quantity indicator; 5 LEDs
of which four green and one amber to
indicate reserve. The amber LED is
turned on when only one green LED
is on; as the green LED turns off, the
amber LED remains on alone, meaning
that you are running on reserve.

❒

C Petrol operating mode indicator: am­ber LED next to switch A. This func­tion is controlled directly by the
Methane control unit.

❒

D Methane operating mode indicator:
green LED next to switch
tion is controlled directly by the
Methane control unit.

WARNING By taking the ignition key to
MAR, all the device LEDs will stay on for
approximately 4 seconds (check function).

WARNING By taking the ignition key to
STOP, the LED for the operating mode
selected will stay on for approximately 2
seconds (LED C or D).

A. This func-

fig. 11

Normal engine function is Methane (ex­cept for start-up which is always petrol):

❒

the switch A pressed on the right side
(identified by the symbol K indicates
petrol functioning with switching on of
the relative amber LED C;

❒

the switch A pressed on the left side
(identified by the symbol G) indicates
methane functioning with switching on
of the relative green LED D.

There are 5 LEDs B (1 amber and 4
green) on the top part of the switch that
display the amount of methane in the can­isters.

When the amount of methane remaining
falls below 1/5 of the capacity of the can­isters, only the amber LED above the
switch (reserve) remains on, signalling the
need to refuel.

F0G0664m

If the methane has run out, switching to
petrol takes place automatically: the am­ber LED C next to the switch turns on and
the green one turns off D relative to
methane operation.

By refuelling with methane, after normal
start-up with petrol, the supply automat­ically returns to methane: the amber LED
C next to the switch turns on and the
green one D relative to methane opera­tion, turns on.

If you specifically wish to run on petrol
(for greater power, not to use methane,
etc.), press the switch A on the right-hand
side.

The amber LED C next to the switch will
turn on to indicate that the switch has tak­en place (the methane power system has
been entirely disabled).

You can only return to running on
methane by acting on the switch once

A, the green LED D next to the

again
switch, will turn on to indicate that the
switch has taken place.

The manual selection of the op­erating mode from petrol to
methane and vice versa is only ac­tivated if the engine speed is be­low 2000 rpm.

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9

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In addition, in the case of starting at out­side temperatures of below around -10°C,
the switching times from Petrol to
Methane increase to allow the pressure
regulator/reduction unit to become warm
enough.

IMPORTANT If the switching takes place
during acceleration or pick-up, there may
be a brief flat spot (fall in power).

WARNING

Do not switch between the
two operating modes whilst

starting the engine

FUEL CUT OFF SWITCH

The safety switch is triggered in the case
of an impact, cutting off the methane sup­ply and causing the engine to cut out.

For further information, see the “Fuel cut
off switch” paragraph in the “Controls”
chapter in the Owner Handbook.

STARTING THE ENGINE

To carry out the starting manoeuvre, see
the warnings and advice in the Owner
Handbook under the chapter “Starting the
engine”.

WARNING

Start-up of the Fiat Panda

Panda Cross engine always
takes place with petrol, even when
the switch is set to ‘methane’. In this
case, the amber LED is on, indicat­ing petrol supply, and will remain
such until the automatic switch to
methane, at which the amber LED
goes off, and the green one comes on.
There must, therefore, always be
some petrol in the tank.

10

AT THE FILLING

B

A

STATION

METHANE GAS FILLER

The methane gas filler is on the right-hand
side of the vehicle.

It is comes complete with a double ‘sin­gle-acting’ valve: one in the filler itself, and
the other near the rear canister under the
floor.

To access the filler, undo the cap B-fig.
13 unscrew the cap A-fig. 12, turning it
anticlockwise.

The profile of the filler
universal type compatible with Italia and
NGV1 standards.

B for refilling is the

fig. 12

The other plates (handed over with the
car documentation) contain the date for
the first inspection of the canisters.

Those responsible for the methane supply
are not authorized to refill the canisters
when the inspection date has expired.

F0G0666m

fig. 13

F0G0665m

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In some European countries adaptors are
considered ILLEGAL (e.g. in Germany).

In the case of service stations with m

3

(dif­ferent pressure) nozzles, to measure the
residual pressure in the canister, the sin­gle-acting valves must be undone supply­ing a small amount of methane.

11

WHEN NEEDING TO
CHANGE AN
EXTERNAL BULB

For the type of bulb and relative power,
please see the paragraph ‘Bulb replace­ment’ at chapter ‘In an emergency’ of the
attached Use and Maintenance manual.

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12

FRONT LIGHT CLUSTER

To change the low beam bulb, proceed
as follows:

❒

remove the cover A-fig. 14;

❒

disconnect the connector C-fig. 15;

❒

release the bulb holder fixing clip A;

❒

remove the bulb B and insert the new
bulb.

fig. 14

fig. 15

F0G0617m

F0G0618m

To change the side light bulb, proceed as
follows:

❒

remove the cover A-fig.: 14;

❒

remove the bulb-holder A-fig.: 16

❒

remove the bulb B;

❒

insert the new bulb.

fig. 16

fig. 17

F0G0619m

F0G0628m

To replace the fog light bulb, proceed as
follows:

❒

remove the cover A-fig. 14;

❒

disconnect the connector D-fig. 17;

❒

turn the bulb holder slightly B and pull
it out;

❒

remove the bulb C and insert the new
bulb.

fig. 18

F0G0620m

fig. 20

F0G0622m

fig. 22

F0G0624m

fig. 19

F0G0621m

To replace the full beam light bulb, pro­ceed as follows:

❒

remove the head light mask by un­screwing the three fixing screws A-fig.
18;

❒

remove the mask, freeing it from the
fixing devices B;

❒

remove the light fig. 19 by unscrew­ing the three fixing screws A;

❒

turn the connector anticlockwise A-fig.
20 and pull it out;

fig. 21

❒

remove the bulb B-fig. 20 and insert

F0G0623m

the new bulb.

To change a direction indicator bulb, pro­ceed as follows:

❒

undo both fastening bolts A-fig 21 and
remove the mask B;

❒

undo the fastening screws A-fig 22 and
remove the lamp B;

❒

remove the boot A-fig. 23 from the lens
B and pull out the bulb-holder C;

fig. 23

❒

remove the bulb D by pushing it

F0G0631m

slightly and turning it in an anticlock­wise direction, now insert the new
bulb.

To replace the direction indicator light
bulbs, the third brake light bulbs and the
number plate bulbs, follow the descrip­tions and explanations given in the para­graph ‘Bulb replacement’ in the chapter ‘In
an emergency’ of the Use and Maintenance
Manual to which this supplement is at­tached.

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13

fig. 24

F0G0627m

fig. 25

F0G0625m

fig. 26

F0G0626m

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14

REAR LIGHT UNIT

The bulbs are arranged inside the rear light
unit as follows fig. 24:

A dual filament bulb 12V-W5W for
brake/side lights.

B 12V-P21W bulb for direction indica­tor lights.

C 12V-P21W bulb for rear fog lights (left
head light) or reverse lights (right head
light).

To change the bulb proceed as follows:

❒

unscrew the three screws A-fig. 25
then pull the complete head light gen­tly outwards, until complete release of
the three fixing clamps;

❒

unscrew the four screws A-fig. 26 and
disconnect the two connectors;

❒

remove the bulb-holder rotating it an­ticlockwise;

❒

remove the desired bulb (A, B or C-

fig. 24), by pushing it slightly and turn-

ing it in an anticlockwise direction
(bayonet fastening), now insert the
new bulb.

IDENTIFICATION DATA

IMPORTANT If the car has been
registered in a country other than
Italy, the certification data, identifi­cation and inspection procedures for
the methane canisters should con­form to the legislation in that coun­try. In any case, it should be re­membered that the life of the can­isters is 20 years from the produc­tion date as set out in ECE Regula­tion no. 110.

Canister marking

Each methane canister is identified in the
factory with a stamp on the nose of the
actual canister.

The stamp includes:

❒

type of gas it is designed for (methane);

❒

twenty-year canister expiry date
(month/year);

❒

name of canister manufacturer;

❒

canister serial number;

❒

nominal canister capacity in litres;

❒

canister weight in kg (specific for each
canister);

❒

operating pressure (200 bar at 15°C);

❒

canister test pressure (300 bar);

❒

identification stamp for homologating
country;

❒

ECE homologation number;

❒

inspection stamp;

❒

ENI stamp;

❒

canister manufacture test date
(month/year).

The other plates (handed over with the
car documentation) contain the date for
the first inspection of the canisters.

SYSTEM INSPECTION

The canisters should be inspected, in ac­cordance with ECE Regulation Procedure
no. 110, every 4 years from the vehicle
registration date or in accordance with
specific regulations in individual countries.

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15

MAINTENANCE SCHEDULE

Additional operations to the Maintenance Schedule in the Owner’s Handbook.

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Thousands of kilometres

Cold cylinder compression check

Visually inspect the condition of: methane pipes and connectors,
fastening of methane tank, renew if necessary (*)

Check pressure regulator and, if necessary, replace
internal filter (*)

Check operation and parameters of fuel supply system
using self-diagnostic socket

Check correct assembly of injectors
(positioning clip holding)

Check mechanical tappet clearance and restore if necessary

Check tightening torque of canister fastening
bands

(*) or every 12 months

20 40 60 80 100 120 140 160 180

●●●●● ●● ●●

●●●●● ●● ●●

●●●●● ●● ●●

●●●●● ●● ●●

●●●●● ●● ●●

●●●●● ●● ●●

●●●●●

16

WHEELS

A

WHEEL REPAIR

The car does not have a spare wheel but
comes with a quick tyre repair kit known
as Fix&Go automatic.

The kit A-fig. 27 is located on the left of
the luggage compartment and is fastened
by Velcro. See the instructions in the
booklet that this supplement comes with.

The tool box Fig. 28 is located under the
driver’s seat and fastened by Velcro.

fig. 27

F0G0668m

fig. 28

F0G0607m

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17

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ENGINE

ENGINE CODE - BODYWORK VERSIONS

Engine code Bodywork version

1.2 188A4000 169 AXB1A 01T

GENERAL FEATURES 1.2

Engine identification code 188A4.000
Bodywork version code 169 AXB1A 01T
Cycle Otto
Number and layout of cylinders 4 in line
Number of valves per cylinder 2
Piston bore and stroke mm 70.8 x 78.86
Total displacement cm
Compression ratio 9,8:1

Max. EEC power HP

corresponding speed rpm

Max. EEC torque kgm

at a speed of rpm

Spark plugs NGK DCPR7E-N-10

Fuel

kW

Nm

3

Methane Petrol

38
52

5000

88

9,0

3000

Methane

1242

44
60

5000

102

10,4

2500

BOSCH YR7DEU

Green petrol unleaded

95 RON

18

FUEL SYSTEM (methane)

Dedicated electronic injection for
methane.

Type: Phased, sequential, multipoint.

Injection pressure; about 9 bar.

Stoichiometric metering of the
air/methane gas mixture.

The methane injection system is con­trolled by a dedicated control unit using
the sensors already on the car, including
the Lambda sensor for controlling the fu­el metering.

IGNITION

Static advance, electronic, integrated with
the injection.

ENGINE COOLING SYSTEM

Engine cooling system with pressure re­duction unit heating circuit subject to
strong cooling during operation.

PERFORMANCE

Top speed in km/h.

Running on petrol: 148

Running on methane: 140

WARNING

Modifications or repairs to

the fuel feed system that are
not carried out properly or do not
take the system’s technical specifica­tions into account can cause mal­functions leading to fire risk.

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19

WEIGHTS

Weights (kg) for versions

Unladen weight (with all fluids, fuel tank
filled to 90% and without optional equipment):

1070

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Payload including the driver (1):

Maximum permitted loads (2)
– front axle:
– rear axle:
– total:

Maximum permitted load on the roof:

(1) In the presence of optional equipment the unladen weight increases and, as a result, the payload decreases in relation to the max­imum permitted loads.

(2) Loads not to be exceeded. The user is responsible for arranging goods in the luggage compartment and/on load carrying plat­form within the maximum permitted loads.

IMPORTANT A trailer cannot be towed so there are no provisions for fitting a tow hook.

380

750
735

1450

50

LOAD COMPARTMENT VOLUME

The volume of the load compartment measured in dm3is as follows:

With rear backrests not folded over:

With rear backrests folded over:

190

840

20

TYRES

COLD TYRE INFLATION PRESSURES

Rim

Tyres

1.2 Petrol/Methane

5.5J X14

175/65 R14

Medium load Full load

Engine front rear front rear

1.2 2,2 2,2 2,4 2,4

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21

DIMENSIONS

Dimensions are expressed in mm and re­fer to the vehicle equipped with its origi­nal tyres.

Height is measured with vehicle unladen.

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22

fig. 29

ABCDEFGH

3581 734 2305 542 1614 / 1576 (*) 1358 1611 1366

(*) Without longitudinal bars

F0G0709m

CAPACITIES

Petrol

Petrol . . . . . . . . . . . . . . . . . litres 30

– including a reserve of . . . litres 5÷7

Methane

- Methane (*) . . . . . . . . kg (approx.) 12

(*) The amount of methane depends on
the outside temperature, the supply pres­sure, the quality of the gas and the type
of refuelling system. The total volume of
the canisters is about 72 litres.

IMPORTANT It should be remembered
that when using a fuel such as methane the
range is very variable because as well as
the driving conditions and car maintenance
it also depends on the temperature of the
gas in the canister.

The methane actually heats up during the
refuelling and cools down whilst driving,
undergoing variations in pressure that re­duce the quantity that can be used.

It should also be pointed out that whilst
the vehicle is being run in (up to around
3000 km) the fuel consumption may be
higher than the figures given.

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23

Fiat Group Automobiles S.p.A. - Customer Services - Technical Services -

Service Engineering - Largo Senatore G. Agnelli, 5 - 10040 Volvera - Torino (Italia)

Print no. 603.97.109 - 04/2009 -1 Edition