te.se.o. newsletter – no. 10/10 -...

Copyright © by Fiat Group Automobiles S. p. A

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Mirafiori, 27/09/2010

Te.Se.O. Newsletter – No. 10/10 What is Te.Se.O.? Te.Se.O. (Technical Service Operation) is the technical body for Customer Services – Technical Services. The function of Te.Se.O. is to provide technical/diagnosis support to both authorised and independent Dealerships when product faults are identified after sale in the cases listed below. Starting from 1st January 2008, the services offered by Te.Se.O. are given free of charge in the following cases: (i) cases regarding FGA cars under contractual or extended warranty (ii) when a subscription to the technical documentation is effective at the time of contacting Te.Se.O. (iii) following a report by a Dealer Expert Technician (DET.), level 1, either certified or being certified by FGA according to the training program of the Training Academy and (iv) limited to European Union Countries. To the benefit of the Authorised and Independent Dealerships, and on a test basis, the free-of-charge support provided by Te.Se.O. is also temporarily extended to all those vehicles under 10 years old whose contractual or extended warranty (see item "i") has expired. What is the newsletter? It is a preliminary technical investigation relating to specific reported faults about the product irrespective of contractual warranty expiry. The structural elements of the Newsletter are: Vehicle data (MVS, engine version, chassis group - if any) Customer's reported fault Result of workshop analysis Operation What is it used for? The Newsletter is used to certify a specific Customer's reported fault and provide standard technical and conduct guidelines to Dealerships and Customers. Homogeneity of the technical problem, based on a clear diagnosis track, reduces repeated service interventions that do not find a permanent solution to the fault.


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How is it used? The document provides a technical "cycle" that gives service recommendations for each reported fault until official service solutions are issued. It therefore provides field operators with standard information and can be used by technical workshop personnel for correct technical management of the serviced chassis. The updating is part of product improvement. If you need to contact Te.Se.O. follow the instructions provided in the section “What is Te.Se.O.?" and check the method of contact (electronic ticket or fax) for the country as well as the type of workshop making the request. NOTE: remember that when making explicit reference to Tutorship, the reports must be sent through the appropriate eSIGI channel, whereas in Countries where they are not present, draft a TK for the Te.Se.O. of your Market, according to the standard procedure.

Sheet Model Subject Release date

Date of last update

Closing date Notes

24 Grande Punto Noisy front suspensions 21/09/07

27e New Panda The car does not start 21/09/07

37 Various models

Injector IMA code writing procedure using Examiner 21/03/08

38e Grande Punto Difficult cold start-up 21/03/08

41 Various models

Handsfree device for mobile phone 09/05/08

47ts Croma Main beam headlights not working 28/05/08 13/11/09 13/11/09 See sheet no. 73

48e New Bravo Error U0422 in inertia switch 27/06/08

49e New Bravo Car keeps braked 27/06/08 05/09/08

51e Sedici Mirror vibrations 27/06/08 05/09/08 Varied rubber shim thickness

52e Various models

Power decrease at constant speed 27/06/08

54e Various models Steering noise 17/07/08

55e Croma Gearshifting lever vibration 17/07/08

56 Various models Seat belt locking 05/09/08

57e Croma Noise from front drive shafts 05/09/08

58ts Various models Blue&Me - Blue&Me nav 24/04/09 18/12/2009 Table modified

59 New 500 Brake noise origin identification procedure 24/04/09

60 New 500 Impossible to perform Proxy 24/04/09

61 New Bravo Clutch pump squeaking 24/04/09

64 G-Punto Missed operation/irregular operation of electrical components 09/12/09


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65 New Bravo CD playing 30/07/09 10/03/10 S.N. release

55.03.10

66 Various models Incorrect fuel level reading 25/09/09

67 Various models Removal of petrol-LPG switch 13/11/09 10/03/10

68 Various models

Failed switching between petrol and LPG and vice versa 13/11/09

69 Various models

Impossible / hard LPG complete refuelling 13/11/09

70 Various models LPG smell in the compartment 13/11/09

71 Various models

Instantaneous leak of a small LPG quantity 13/11/09

72 Various models

Impossible switching from petrol to gas 13/11/09

73 Croma Failed rear window wiper and main beam headlight operation 13/11/09

74 Various models

The engine does not start/works irregularly 13/11/09

75 New 500 c

The heated rear window does not work. The automatic climate control system fan does not perform. The boot lid does not open.

09/12/09

76 New Bravo

Occasional white smoke from the front area 18/12/09

78 Punto EVO

Missed operation of the Blue&Me system. 18/12/09 21/05/10

Operation mode

modification

79 New Bravo

Engine judder, poor performance, power losses. 29/01/10 22/07/10

80 Various models

Models with Start&Stop Error P0555.

29/01/10 10/03/10

81 New 500 During cold starting, the electric driving warning light switches on occasionally.

29/01/10

82 New Panda

During cold starting, the water high temperature warning light switches on occasionally.

29/01/10

83 Fiorino / Qubo Impossible switching to methane. 24/02/10

85 New Panda

The odometer occasionally flashes. 24/02/10

86 Various models

Switching off when idling with LPG supply engaged. 24/02/10 23/04/10

87 Various models

Impossible to install the "Ecodrive" software 10/03/10

88 Various models Radio Nav. system failure 23/04/10 27/09/10

Issued S.N. 55.15.10 for

Croma 55.16.10 for

Bravo


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89 Various models

The engine does not perform/does not start 23/04/10

90 500 ABS/ESP warning light switching on 21/05/10

91 500 Milometer flashing fault 18/06/10

92 Ulysse Campaign 5445 - Information about steering column stalk 18/06/10

93 Punto EVO Excessive oil consumption 03/09/2010

94 Various models Irregular idle / difficult starting 30/09/10

Te.Se.O. Newsletter – No. 10/10


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Sheet 24 – Grande Punto VERSIONS All models CUSTOMER'S REPORTED FAULT Noisy front suspensions RESULT OF WORKSHOP ANALYSIS Check the noise originating from the front lower part of the vehicle then proceed as described below: OPERATION

− Ensure that the noise is not coming from the steering box − Ensure that the noise is not coming from the right-hand engine mounting − Ensure that the noise is not coming from the anti-roll bar and associated linkage − Ensure that the noise is not coming from the front and rear strikers (grease them if

necessary). Note: check that the front suspension fastenings are correctly tightened and restore if necessary. If the customer's reported fault persists, contact Te.Se.O. Do not carry out any replacement.


Date of last update

Closing date Notes

24 Grande Punto

Noisy front suspensions 21/09/07



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Sheet 25 – Grande Punto VERSIONS All models with opt. 320 “leather knob + steering wheel” CUSTOMER'S REPORTED FAULT Leather on the steering wheel/gear shift lever knob is creased/detached RESULT OF WORKSHOP ANALYSIS Check the reported fault (as shown in Figures 1 and 2) and proceed as described below: Fig. 1 Fig. 2

OPERATION

• Check that the problem is not caused by mechanical systems such as the steering lock; • Check that the problem is not caused by alcohol/solvent-based products such as insect

repellent creams/protections.


Date of last update

Closing date Notes

25 Page 1/2

Grande Punto

Leather on the steering wheel/gear shift lever knob is creased/detached 21/09/07 21/03/08



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Note: do not use upholstery cleaners such as dashboard polishing products or similar products. Clean with neutral pH products. After checking that the fault is not attributable to any of the points listed above, replace the component.


Date of last update

Closing date Notes

25 Page 2/2

Grande Punto

Leather on the steering wheel/gear shift lever knob is creased/detached 21/09/07 21/03/08



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Sheet 27e – New Panda VERSIONS All models CUSTOMER'S REPORTED FAULT a) Vehicle fails to drive off and various warning lights come on (code/I.E.) on the instrument panel. b) Engine rotates but does not start. RESULT OF WORKSHOP ANALYSIS

1) Engine fails to start. Power windows, central door locking and fuel level gauge occasionally do not work regardless of whether the engine is cold or hot. 2) When an Examiner diagnosis is run on the control units, the following messages are displayed (even individually):

− NCM: u1600 electronic key signal is not plausible. − Body computer: no error − ABS: c1108 serial line, invalid signal, intermittent.

3) Disconnect and reconnect the battery: the car starts and runs correctly, even for long periods of time. OPERATION

1) check for errors in the control units. 2) check the body computer software. 3) check the battery status. 4) Report the case to Te.Se.O. and attach any tests as instructed above.


Date of last update

Closing date Notes

27e New Panda

The car does not start 21/09/07



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Sheet 37 – Various models VERSIONS All models. with 1.9 - 2.4 Mjt engines and EDC16C39 engine management control unit

Injector IMA code writing procedure using Examiner OPERATION After the injectors and/or engine management control unit replacement, during the IMA code writing phase using Examiner proceed as follows:

• Write the IMA codes directly from the injectors • Place the key on STOP (key-off) position • Wait for the power latch (control unit deactivation delay) end; the operation takes a couple

of minutes on average • Place the key on MAR (key-on) position • Use Examiner to check the correct injector IMA code by reading the injector codes and

visually checking the injectors If this procedure is not followed, the IMA code is recorded in the EEPROM memory of the engine control unit but the self-learning parameters of the injector flow are not adjusted. This can cause irregular engine function (knock, wrong corrections). The INCOMPLETE procedure on Examiner currently operates as follows:

1) write a 9-figure alphanumeric code and press CONTINUE


Date of last update

Closing date Notes

37 Page 1/2

Various models




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2) Writing in progress

If the writing is successful, the Examiner returns to the active diagnosis screen without prompting to place the key on STOP position, to wait for the power latch end and then to place the key on MAR.


Date of last update

Closing date Notes

37 Page 2/2

Various models




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Sheet 38e – Grande Punto VERSIONS 1.3 JTD (all models) CUSTOMER'S REPORTED FAULT Difficult cold starting which takes more than 3 seconds and excessive exhaust smokes RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION

• Check the diesel filter • Check the fuel supply system • Check the battery efficiency • Check the alternator charge • Check the earth resistance between the battery/body/engine • Check starter absorption at start-up using ammeter pliers • Check cylinder compression when cold

If the customer's reported fault persists, contact Te.Se.O. Do not carry out any replacement.


Date of last update

Closing date Notes

38e Grande Punto

Difficult cold start-up 21/03/08



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Sheet 41 – Various models VERSIONS All Versions with the Blue&Me system CUSTOMER'S REPORTED FAULT Handsfree device for mobile: the volume perceived by the listener during the phone call is very low and distorted, especially when the car's speed is greater than 70 km/h RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed by connecting the mobile in the conditions indicated by the customer. OPERATION Check that the inconvenience is not due to the microphone not operating by activating the voice commands; if these are not recognised, replace the microphone. If the customer's reported fault persists, contact Te.Se.O. Do not carry out any further replacement.


Date of last update

Closing date Notes

41 Various models Handsfree device for mobile phone 09/05/08



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Sheet 48e – New Bravo VERSIONS 1.6 MJT CUSTOMER'S REPORTED FAULT Diagnosis of the engine management control unit reveals error U0422 in the inertia switch counter, with error message. This is due to a software incompatibility between the engine management control unit and body computer. OPERATION When the above error is detected, do not carry out any interventions and/or replacement in the vehicle. Contact Te.Se.O. attaching a printout of the error detail.


Date of last update

Closing date Notes

48e New Bravo

Error U0422 in inertia switch 27/06/08



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Sheet 49e – New Bravo VERSIONS All models CUSTOMER'S REPORTED FAULT 1) Prolonged braking 2) Car keeps braked RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION Once the claimed fault is confirmed, proceed as described below:

• For customer's reported fault as per item (1), contact Te.Se.O. without carrying out any intervention and/or replacement.

• For customer's reported fault as per item (2), implement SN 33.04.08; if the customer's reported fault persists, contact Te.Se.O. without carrying out any further intervention and/or replacement.


Date of last update

Closing date Notes

49e New Bravo

Car keeps braked 27/06/08 05/09/08



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Sheet 51e - Fiat Sedici VERSIONS All JTD versions CUSTOMER'S REPORTED FAULT Internal rear view mirror vibrates at 110 km/h RESULT OF WORKSHOP ANALYSIS Vibration related to the internal rear view mirror, caused by vibrations in the engine through engine and windscreen suspensions. OPERATION Once the customer's reported fault has been confirmed, carry out the operations described below: 1) Remove the internal rear view mirror


Date of last update

Closing date Notes

51e Page 1/3 Sedici Mirror vibrations 27/06/08 05/09/08

Varied rubber shim

thickness



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2) Insert a rubber shim of approx. 2 mm in the contour area of the mirror insertion location

3) Insert a rubber shim of approx. 10 mm in the hole at the bottom of the mirror insertion location on the relevant mounting

4) Refit the rear view mirror


Date of last update

Closing date Notes


Varied rubber shim

thickness



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If the customer's reported fault persists, contact Te.Se.O. Do not carry out any interventions and/or replacements. Remember that vibrations perceived in diesel engines can be a standard feature.


Date of last update

Closing date Notes


Varied rubber shim

thickness



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Sheet 52e – Various models (G. Punto - Idea) VERSIONS 1.3 MJT 75 HP - 90 HP CUSTOMER'S REPORTED FAULT Power decrease at constant speed RESULT OF WORKSHOP ANALYSIS Occasional power decrease at constant speed; the engine does not maintain speed during successive acceleration. If the accelerator pedal is completely released after accelerating, the engine reacts correctly. OPERATION Once the customer's reported fault is confirmed, operate as described in the following check list.


Date of last update

Closing date Notes

52e Page 1/3

Various models




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yes

continue as instructed by the diagnosis equipment 1 Diagnose all control units, ensuring

that no errors are detected. Have errors been

detected? no move on to step 2

yes

update the CCM software. Has the fault

been solved?

2

Check that the engine management control unit has been updated with the latest SW version available in the Control unit update section of Examiner

Are updates available?

no

print the engine management control unit diagnosis, including the

control unit hardware and software identification

details, and move on to step 3

yes move on to step 4

3

Connect the diagnosis equipment and select the following parameters:

Engine rpm Accelerator pedal EGR opening Target air flow Measured air flow Target diesel pressure Measured diesel pressure Supercharging pressure

On a stretch of road with little traffic, acquire at least two of the parameters indicated in the following conditions: In third gear and starting from a speed of 1500 rpm, depress the accelerator pedal fully (pedal position 100% on Examiner). Wait until the EGR opening parameter is 3% and the engine speed is between 2500 and 3000 rpm (ideally the target air mass and the target diesel pressure values should be stable at maximum value). Press the record button when all the conditions described are satisfied.

Do the values fall within standard

levels? (Compare with

the target values) no

diagnose the individual components involved in

the adjustment/measurement

of the individual parameter that is found to

be irregular. Follow the procedure given in e-

LEARN.

4 Test the vehicle further, attempting to reproduce the conditions indicated by the customer. Record the parameters again as described previously while the fault occurs.


Date of last update

Closing date Notes

52e Page 2/3

Various models




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When the operations described above are complete, contact Te.Se.O. providing printouts of the parameters acquired, printouts of the engine management control unit with the identification details highlighted and the following table filled in. Do not carry out further operations and/or replacements. Chassis: Mileage: Was the fault reproduced? YES/NO Conditions in which the fault is detected (short description):

Were irregular values detected? YES/NO (if yes, specify which values) Operations already carried out: NOTES:


Date of last update

Closing date Notes

52e Page 3/3

Various models




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Sheet 54e – Various models (Idea – Punto (188)) VERSIONS All models with petrol engine CUSTOMER'S REPORTED FAULT Noisy steering, especially during manoeuvres at low speeds. RESULT OF WORKSHOP ANALYSIS Noise ("clack" or "tock" or crack or bump) coming from the front axle assembly (front-wheel area), during full steering to the right or left at low speeds, in forward and reverse gear (parking manoeuvres, take-off, etc). The noise may be due to insufficient interference between the front wheel hub bearing and the relative suspension pillar. OPERATION In order to avoid the replacement of components not significant to solve the fault, ensure that the noise corresponds to the reported fault (noise coming from the front axle assembly during manoeuvres at low speeds with steered wheels). If the noise corresponds to the fault, check that:

• With the car stationary, no anomalous noise occurs when steering to the right and to the left.

• When full steering to simulate parking manoeuvres, both in forward and reverse gear, the

noise is coming from the front axle assembly and, in particular, from the front wheel hub area.

When the noise is due to insufficient interference between the bearing and the hub (above described inspections) report the case to Te.Se.O. & Product Support without performing any further operations and/or replacements.


Date of last update

Closing date Notes

54 Page 1/1

Various models

Steering noise 17/07/08



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Sheet 55e – Croma VERSIONS All models CUSTOMER'S REPORTED FAULT Vibration/noise from gearshifting lever, in particular in third gear RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION Once the customer's reported fault has been confirmed, perform the below mentioned inspections/controls: Step Control Ok Ko

1 Check the correct routing of Bowden cables inside the central tunnel and the engine compartment

Move on to step 2

Restore the routing of Bowden cables and retest the car to be sure that the fault is no longer present

2 Check the correct fastening of Bowden cables inside the central tunnel and the engine compartment

Move on to step 3

Restore the fastening of Bowden cables and retest the car to be sure that the fault is no longer present

3 Check the correct adjustment of Bowden cables Move on to step 4

Restore the adjustment of Bowden cables and retest the car to be sure that the fault is no longer present

4 Car production date after 10/2007. Move on to step 5

Replace the Bowden cables with those available at Spare Parts and retest the car to make sure that the fault is no longer present

5 If the car production date is after 10/2007. If the fault persists after all the above described actions. Send a report to Te.Se.O.


Date of last update

Closing date Notes

55e Page 1/1 Croma Gearshifting lever vibration

17/07/08



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Sheet 56 – Various models (500 – Croma) VERSIONS All models CUSTOMER'S REPORTED FAULT Seat belt locking RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION • Check the locking of the seat belt by trying to remove the belt • If the belt is locked, proceed as follows:

-Grasp the belt in the area indicated in the picture


Date of last update

Closing date Notes

56 Page 1/3

Various models Seat belt locking 05/09/08



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- Forcefully pull the belt section outside of the finishing (snapback trap and end stirrup on the seat) as shown in the picture

- Release the belt so that it goes back a few millimetres into the rewinder


Date of last update

Closing date Notes

56 Page 2/3




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If the belt is still locked, disassemble the rewinder section, loosen the rewinder fastener and remove the belt. If the customer's reported fault persists even after these operations, contact Te.Se.O. Do not carry out any interventions and/or replacements.


Date of last update

Closing date Notes

56 Page 3/3




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Sheet 57e – Croma VERSIONS 1.9/2.4 JTD CUSTOMER'S REPORTED FAULT Noise from front drive shafts and/or vibration of the rear axle at speeds between 50/70 km/h that can increase when changing direction. RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION If the customer's reported fault persists, proceed as described below:

• Check the tyre wear • Check the tyre pressure • Check the tyre balancing • Check the wheel geometry

Contact Te.Se.O. without performing any further operations and/or replacements, attaching the printout of the tyre geometry values.


Date of last update

Closing date Notes

57e Page 1/1 Croma Noise from front drive shafts 05/09/08



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Sheet 58ts – Various models

VERSIONS All models

CUSTOMER'S REPORTED FAULT Specific fault to Media Player (MP3) – USB – iPod Specific faults to handsfree phone

RESULT OF WORKSHOP ANALYSIS Preliminary control (for all types of faults)

OPERATION Read the following guided diagnosis to solve Blue&Me problems; if the problem persists, proceed with the TUTORSHIP request (in the Markets where it is active) or draft a TK for Te.Se.O. attaching the following checklist


Date of last update

Closing date Notes

58ts Page 1/4

Various models Blue&Me - Blue&Me nav 24/04/09 18/12/2009 Table

modified

Convergence device Part no.: SW version: Device used: (note down the mobile phone and USB device used by the customer) Mobiles used USB devices used

Manufacturer: Files contained (Ex. MP3; WMA)

Mobile model: SW version: Manufacturer:

USB model:

Operator brand: Note: Has the customer activated the services? Yes No Which ones? Blue&Me help desk Ticket No. Customer's reported fault:



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PRELIMINARY CONTROL (for all types of faults)

OK Check the SW

version and move on to step 3 1 Connect the Examiner and try to enter the

diagnosis Diagnosis trial

KO Move on to step 2

OK Continue with the Tutorship request

on ESIGI 2 Check the correct operation of the electrical system (power supply and CAN network)

Check power supply and CAN

network KO Repair the detected failure

YES Implement SN

3 With the Examiner, enter the diagnosis with the Convergence control unit and print the SW version and possible errors found. Check if there are any SN for the read SW version

Availability of SN for SW

update NO Continue with the Tutorship request

on ESIGI

YES Continue with the checklist 4 Check that the LED of the USB key is lit up USB LED

NO Check USB port wiring

SPECIFIC FAULT TO MEDIA PLAYER (MP3) – USB – iPod If the media player does not correctly play the file when the USB key is inserted, perform the following controls:

OK

5

Check that the Convergence control unit is not a C1V1 because this model does not allow for Media Player function (the USB port on the control unit only serves to update the language and the software).

Convergence control unit KO

Move on to step 6

OK Move on to step 7

6 Check that the "AUTOMATIC PLAY" function is active. To know how to activate the different functions, read the Owner Handbook.

"Automatic play" function KO

Activate the “Automatic play"

mode OK Move on to step 8

7 Check the wiring/connectors. Wiring/connectorsKO Restore the

connections OK Move on to step 9

8 Check that the format of the files used is that called for by the Owner Handbook. File format

KO Use only the files

called for

OK 9 Check the Media player operation using a USB

key other than the customer's. USB key KO

Continue with the Tutorship request on

ESIGI


Date of last update

Closing date Notes

58ts Page 2/4


modified



29

iPod


10 Check that the iPod model used is configured to be used as a mass memory device, not all models have this characteristic

iPOP model KO

Read the manufacturer's

manual OK Move on to step 12

11 Check that the i-Pod used is not formatted for Apple Formatting

KO Format it for Windows as

described in the OH

OK Continue with the

Tutorship request on ESIGI 12

Check that the file formats downloaded on the IPOP are those that can be read by the Blue&Me, as indicated in the Owner Handbook

File format

KO Use compatible formats

SPECIFIC FAULTS TO HANDSFREE PHONE


13

Check that the SW model and version of the mobile phone are compatible with the system, as reported on the Brand's commercial site

(www.fiat.com – www.alfa.com – www.lancia.com )

SW model/version of

mobile KO Use a model and/or

compatible SW

OK Move on to step 15 14

HANDSFREE VOLUME LOW INSIDE OF THE PASSENGER COMPARTMENT: check RADIO menu settings (External Audio)

RADIO menu settings KO Adjust the volume

OK Send report to Tutorship 15

THE LISTENER HEARS DISTORTED TELEPHONE CALL VOLUME: check the wiring and connectors to the microphone

Microphone wiring/connectors KO Restore the

wiring/connectors


Date of last update

Closing date Notes

58ts Page 3/4


modified

http://www.fiat.com/

http://www.alfa.com/

http://www.lancia.com/



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GPS – CAR LOCATOR


16

With the car outdoor, enter the diagnosis mode with Blue&Me nav (Convergence) using the Examiner and check that there are no errors concerning:

- GPS ANTENNA - GPS MODULE

Errors detected with Examiner KO

Send report to Tutorship

< 3 Check the

conformity of the cable

17 Check the satellite number received by the systemSatellites

received by the system > 3

Send report to Tutorship

ROUTE CALCULATION (BLUE&ME NAV)

OK Move on to step 19 18 Check the USB key (the Mapsregion directory with

contents having a .psf extension must be present) KO Refer to the OH

< 3 Check the

conformity of the cable 19 Check the satellite number received by the system

> 3 Send report to

Tutorship

If the problem persists, describe the fault: ............................................................................................................................................... ...............................................................................................................................................


Date of last update

Closing date Notes

58ts Page 4/4


modified



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Sheet 59 – New 500 VERSIONS 1.2 Petrol – 1.3 Mjet CUSTOMER'S REPORTED FAULT Whistling / hissing while braking RESULT OF WORKSHOP ANALYSIS NOISE ORIGIN IDENTIFICATION PROCEDURE (front / rear) OPERATION Once the customer's reported fault has been confirmed, proceed as below described: - Check the lining and drum cleaning conditions - Heat the brakes following this procedure:

PROCEDURE TO IDENTIFY THE BRAKE NOISE ORIGIN Carry out three braking cycles from 30 km/h to 0 km/h until stopping the car completely and check for the whistle/hissing of brakes.

1- If the whistling occurs while braking, repeat some braking cycles as above described and pull the handbrake softly (max. 4th-5th notch) and make sure the whistle disappears and changes intensity/tone (frequency of resonance)

A - If it disappears/changes: ITALY report to Tutorship - ABROAD make TK to Te.Se.O (stating in the TK that in the cycle occurred the condition A) B - If it does not disappear or change: send a report to Te.Se.O stating in the TK that in the cycle occurred the condition B

2 – If the whistle cannot be reproduced repeat the cycle twice according to the above methods 3 - If, after having tested the car with 3 cycles there is no whistle give the car back to the customer explaining him that the event could not be reproduced and - if it occurs again - it does not influence the car operation. If the whistling/hissing persists, contact Tutorship / Te.Se.O. without carryout out any further interventions and/or replacement as above stated.


Date of last update

Closing date Notes

59 New 500 Brake noise origin identification procedure 24/04/09



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Sheet 60 – New 500 VERSIONS All models CUSTOMER'S REPORTED FAULT None. The customer comes to the workshop to have his car repaired after an accident. RESULT OF WORKSHOP ANALYSIS Impossibility to make a correct proxy due to:

1. the vehicle was restored as the safety system had been activated. 2. the ECU was replaced with/without a front collision

OPERATION CASE 1: as a result of an accident, the ECU operates front seat belts, formed by two pyrotechnical sections on driver's and passenger's sides (2 + 2). In case of component replacement, check that both front belt sections (passenger's and driver's side) are operated (rewinder and pretensioner of the lumbar section). In this case, they must be replaced.

lumbar section pretensioner rewinder


Date of last update

Closing date Notes

60 Page 1/2 New 500 Impossible to perform Proxy 24/04/09



33

CASE 2: air bag ECU replacement. The currently produced ECU is the following: 51848079 (replacing 51782985). The new ECU can work with or without front collision sensor outfit. The air bag control unit loads the software according to the car outfit; if the car has a standard front collisions sensor, it must be connected during the Proxy alignment stages (to make the control unit work).

• Otherwise, the control unit, while making plausibility controls, REJECTS the Proxy alignment procedure because it detects that the front collision sensor is missing.

If, after these procedures, the Proxy alignment gives no result, contact Te.Se.O. without making further interventions and/or replacements.


Date of last update

Closing date Notes

60 Page 2/2 New 500 Impossible to perform Proxy 24/04/09



34

Sheet 61 – New Bravo VERSIONS All models CUSTOMER'S REPORTED FAULT Clutch pump squeaking during engagement/release of the pedal. RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION If the customer's reported fault persists, proceed as described below:

• Make sure that the noise actually comes from the pump rather than from the pedal or pedal board; to check this, disconnect the pump from the pedal and move it manually, to check that it is squeaking.

• Check that SN 33.01.08 has already been implemented. • Remove the clutch pump and read the printing on the pump casing; if the drawing number

is 55212401 (or lower) for diesel models or 55212403 (or lower) for petrol models, replace the pump with 55221358 for diesel models or 55221357 for petrol models.

• While replacing the pump, make sure that the new one has the printed number 55221358 (or 55221357) and that the manufacturing date is after “206-08”.

If the noisy pump is 55221358 (or 55221357) with manufacturing date after “206-08”, do not carry out any adjustments and/or replacement and report it to Te.Se.O.


Date of last update

Closing date Notes

61 New Bravo Clutch pump squeaking 24/04/09



35

Sheet 64 – Grande Punto VERSIONS All models produced from 2008 not subject to Tutorship CUSTOMER'S REPORTED FAULT Missed operation / irregular operation of the car electrical and electronic components (central locking, power windows, code, lighting, windscreen wiper, etc.) resulting from Body Computer failures. RESULT OF WORKSHOP ANALYSIS Check that the failure is really due to the Body Computer rather than to loose connection or failures of the component claimed as faulty (e.g., if the failure is on power windows, before replacing the Body Computer, make sure that all the system connections are OK and there are no problems on the push-button panel, on the power window motor, on the operating mechanism, etc.). OPERATION If the claimed fault is confirmed, do not replace the Body Computer immediately, rather make the following checks. If the claimed fault is confirmed:

• Connect the Examiner, enter the diagnosis function and save a first diagnosis printout with the error reports;

• If possible, delete the errors found; • Disconnect the battery, connect and reconnect the Body Computer (according to

the procedure on the e-LEARN manual) and reconnect the battery, paying special attention to make tight connections;

• Test the car making sure everything works correctly and save a second diagnosis printout to detect possible errors.

After the intervention, make sure the failure does not occur again. If the failure persists, before replacing the Body Computer contact Te.Se.O. attaching Examiner printouts with the detected errors to the Ticket.


Date of last update

Closing date Notes

64 G-Punto Missed operation/irregular operation of electrical components 09/12/09



36

Sheet 67 – Various models (Grande Punto, Bravo) VERSIONS LPG CUSTOMER'S REPORTED FAULT Removal of petrol-LPG switch RESULT OF WORKSHOP ANALYSIS Switch not connected to the base OPERATION Restore the switch using Loctite

‐ Without disconnecting the wiring of the switch, place 2 drops of Loctite on the switch mounting base (on the double-sided tape adhesive)

‐ Place the switch on the mounting quickly ‐ Hold it pressed for 15 seconds, for an easier adhesion ‐ Place it as shown in figure 1

Figure 1


Date of last update

Closing date Notes

67 Various models Removal of petrol-LPG switch 13/11/09



37

Sheet 68 – Various models (Grande Punto, Bravo, Panda, Punto) VERSIONS LPG CUSTOMER'S REPORTED FAULT Failed switching between petrol and LPG and vice versa RESULT OF WORKSHOP ANALYSIS

1) disconnected gas injector connector 2) damaged gas injector wiring 3) reduction unit solenoid valve and gas high pressure pipes restricted due to metal dust

inside After checking the claimed fault, proceed according to the following check-list OPERATION Once the customer's reported fault is confirmed, carry out following checks/inspections:

1) Reconnect the removed connector and check the gas injection sequence 1-2-3-4 according to figure 2.


Date of last update

Closing date Notes

68 Page 1/3

Various models




38

Figure 2

1) Restore the wiring by reconnecting possible interrupted wires by thermal shrinking tapes

with integrated tin (with possible reference to operation 1057B90). Reciprocally insulate the wires with insulating tape and cover the wiring with corrugated sheath. Fasten the wiring to the clip (2) secured in the rail fastening point on the bracket, according to figure 4.

Figure 3 Figure 4


Date of last update

Closing date Notes

68 Page 2/3

Various models




39

1) If the car does not switch to gas anymore (even though it has not run out of gas), check for the presence of metal dust inside the reduction unit solenoid valve, preventing gas flow. After ensuring safety in the system (with reference to operation 1043A02), disconnect the high pressure copper pipe. If dust is found, disconnect the 6-mm high pressure pipe on the multivalve and blow. Remove the gas solenoid valve on the reduction unit, open it, remove dust and replace the paper filter.

Figure 4 Figure 5


Date of last update

Closing date Notes

68 Page 3/3

Various models




40

Sheet 69 – Various models (Grande Punto, Bravo, Panda) VERSIONS LPG CUSTOMER'S REPORTED FAULT Impossible / hard LPG complete refuelling RESULT OF WORKSHOP ANALYSIS Tank partial filling at first refuelling OPERATION If LPG cannot be refuelled the first time, or in case of partial filling, deplete the residual gas in the tank filled in the production site. To do this, run the car on gas until petrol switching occurs. If the car cannot be run on gas because it shifts to petrol (due to a gas low level), let it run on gas at idling speed until it switches to petrol again.


Date of last update

Closing date Notes

69 Various models

Impossible / hard LPG complete refuelling 13/11/09



41

Sheet 70 – Various models (Grande Punto, Bravo, Panda) VERSIONS LPG CUSTOMER'S REPORTED FAULT LPG smell in the compartment RESULT OF WORKSHOP ANALYSIS The problem can be due to:

1) connector tightening on charge pipe 2) connector tightening on delivery pipe to solenoid valve 3) connector tightening on delivery pipe from multivalve

After checking the claimed fault, proceed according to the following check-list. OPERATION Once the customer's reported fault is confirmed, carry out following checks/inspections:

1) Connector tightening on 8-mm charge pipe (on multivalve and/or charge intake); if the connectors are loose, restore the correct tightening with a torque wrench, to 14 Nm.

Figure 1 Figure 2


Date of last update

Closing date Notes

70 Page 1/3

Various models LPG smell in the compartment 13/11/09



42

2) Connector tightening on 6-mm charge pipe to reduction unit solenoid valve; if the connector

is loose, restore the correct tightening with a torque wrench, to 12 Nm.

Figure 3

3) Connector tightening on 6-mm charge pipe from multivalve; if the connector is loose, restore the correct tightening with a torque wrench, to 11 Nm.


Date of last update

Closing date Notes

70 Page 2/3




43

Figure 4


Date of last update

Closing date Notes

70 Page 3/3




44

Sheet 71 – Various models (Grande Punto, Bravo, Panda) VERSIONS LPG CUSTOMER'S REPORTED FAULT The instantaneous leak of a small quantity of LPG (between the ball valve and the cap) can occur when the charging cap is opened; it can be felt due to a pressure accumulation on the charge cap itself. RESULT OF WORKSHOP ANALYSIS Tank partial filling at first refuelling OPERATION This phenomenon is standard with LPG quantity up to 15 Ncc/h, according to regulation ECE/ONU R 67. For this fault, the complete valve must not be replaced, rather only the cap with a new one (P/N 71754515) including a bleed system according to figure 2.

Figure 2 Figure 3


Date of last update

Closing date Notes

71 Various models

Instantaneous leak of a small LPG quantity 13/11/09



45

Sheet 72 – Various models (Grande Punto, Bravo, Panda) VERSIONS LPG CUSTOMER'S REPORTED FAULT Impossible switching from petrol to gas RESULT OF WORKSHOP ANALYSIS Impossible switching to gas due to loose multivalve coil OPERATION Due to impossibility of gas flow caused by a loose multivalve coil, restore the correct tightening with a torque wrench, to 3 Nm.

Figure 1


Date of last update

Closing date Notes

72 Various models

Impossible switching from petrol to gas 13/11/09



46

Sheet 73 – Croma VERSIONS All models that are not subjected to Tutorship CUSTOMER'S REPORTED FAULT Rear screen wipers not working Main beam headlights not working RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION Once the customer's reported fault has been confirmed, perform the below mentioned inspections/controls to verify the correct functionality of the steering column stalk, as shown in the section Tests 5550A STEERING COLUMN STALK on e-Learn.


Date of last update

Closing date Notes

73 Croma Failed rear window wiper and main beam headlight operation 13/11/09



47

Sheet 74 – Various models (Panda, 500) VERSIONS All models CUSTOMER'S REPORTED FAULT The engine does not start/works irregularly RESULT OF WORKSHOP ANALYSIS Irregular operation of the submerged pump. OPERATION If the fault persists in the car: remove the submerged pump assembly as described in the corresponding procedure (Op. 1040A70) of the Service Manual. If the assembly metal parts are oxidised, do not remove, rather contact Te.Se.O., enclosing the ticket and some pictures of the oxidised areas, whenever feasible.


Date of last update

Closing date Notes

74 Various models

The engine does not start/works irregularly 13/11/09



48

Sheet 75 – New Fiat 500 c VERSIONS ALL CABRIO MODELS CUSTOMER'S REPORTED FAULT The heated rear window does not work. The automatic climate control system fan does not perform. The boot lid does not open. RESULT OF WORKSHOP ANALYSIS The soft top handling system can influence the operation of some car features, so that it can be operated safely. Occasionally some operating modes can be interpreted by the customer as car operating faults. In particular, when the soft top is not fully closed, the system deactivates the heater rear window operation and reduces climate control system performance; what is more, the boot lid can be opened only if the soft top is closed, in spoiler position or in an intermediate position. The soft top control unit can lose the stored position and therefore, though being closed mechanically, the system considers it open and deactivates the heated rear window or reduces the climate control system performance. OPERATION Before carrying out any intervention for the above fault, proceed as follows:

- initialise the soft top correctly using the Examiner (the Body Computer active diagnosis of Fiat 500 c includes the item "Soft Top Control Module Initialisation")


Date of last update

Closing date Notes

75 Page 1/2

New 500 c


09/12/09



49

- read the errors on the Body Computer Node by the Examiner.

After collecting the required information, if the fault persists, contact Te.Se.O. without carrying out further interventions and/or replacements; attach the diagnosis printouts to the TK.


Date of last update

Closing date Notes

75 Page 2/2

New 500 c


09/12/09



50

Sheet 76 – New Bravo VERSIONS 2.0 JTD CUSTOMER'S REPORTED FAULT Occasional white smoke coming from the front side of the engine compartment. RESULT OF WORKSHOP ANALYSIS The white smoke is visible by the customer as well, during the regeneration procedure. Removing the aluminium guard of the turbocharger and disassembling the V-Clamp, the turbocharger-DPF filter matching is not aligned. OPERATION Check the engine oil level: if it is above max. level, drain oil to restore the correct level. Remove the turbocharger guard and release the V-Clamp, start the engine and make a forced regeneration with the Examiner; if exhaust gas comes out, stop the engine and realign the turbocharger and the DPF, then reassemble the V-Clamp. Before reinstalling the aluminium guard, test the car again forcing a new regeneration; if the claimed fault disappears, reinstall the aluminium guard and recheck the oil level. If it is correct, hand over the car to the customer. If the problem persists, contact Te.Se.O. without replacing any component.


Date of last update

Closing date Notes

76 New Bravo

Occasional white smoke from the front area

18/12/09



51

Sheet 78 – Punto EVO VERSIONS All models with OPT. 54K (Punto EVO), unless subject to Tutorship CUSTOMER'S CLAIMED FAULT Missed operation of the Blue&Me system after connecting the USB stick to read multimedia files. RESULT OF WORKSHOP ANALYSIS - Check that the Blue&Me system works correctly when the USB stick is not fitted. - Check if the fault reoccurs after resetting the system (Battery disconnection - reconnection). - Check that the car has the OPT. 54K (TomTom navigation system presetting: mounting on dashboard + application SW) and if the customer has installed the ECODRIVE SW (to be downloaded from www.fiat.com). ACTION On Punto EVO cars with OPT. 54K, produced up to March 2010, chassis numbers from production starting date up to Line 1: 00652798 Line 2: 01642981 The TomTom and Ecodrive application software could be not mutually compatible. In the event of claimed fault confirmation, if the car falls with the chassis batch above, contact Te.Se.O.


Date of last update

Closing date Notes

78 Punto EVO

Missed operation of the Blue&Me system. 18/12/09 21/05/10




52

Sheet 79 – New Bravo VERSIONS 1.6 JTD – 2.0 JTD CUSTOMER'S REPORTED FAULT Engine judder, poor performance, power losses. RESULT OF WORKSHOP ANALYSIS Intake circuit fouled with oil. Filter, flow meter, pressure sensor and throttle body fouled with oil. OPERATION

1 Apply the check list below:

CHECK LIST CAR DATA:

MVS Chassis Number plate Miles Vehicle registration date Number of oil changes performed * Date of last oil change Covered miles since last oil change Usual customer route (urban route, motorways, ...)

Daily mileage covered by the customer

Sheet Model Subject Release date Date of last update

Closing date Notes

79 Page 1/3

New Bravo




53

Particulate filter blockage Miles covered with DPF warning

light on

Average temperature of last regenerations Particulate filter status

Milometer since last regeneration. Average distance since the last

regenerations.

Average duration of last 5 regenerations Odometer since last DPF

replacement (5 - 20 min)

Regen. total number Covered miles with DPF warning light on

Number of regenerations interrupted by key OFF Number of regenerations from the

last oil change.

Check correspondence between injector IMA codes and EXAMINER (give both codes) Examiner IMA Engine IMA 1° 1° 2° 2° 3° 3° 4° 4° Remarks and errors found:

Oil decay indicator (in oil change procedure function)

Odometer since last change Oil (in oil change procedure function)

Interval from next "oil change" (in oil change procedure function)

Odometer last programming

Max. speed time counter Maximum engine speed Number of overrevolutions Programming date

SW number

Odometer at oil change request Number of automatic warning light resets

(in oil change procedure environment)


Closing date Notes

79 Page 2/3

New Bravo




54

CONTROLS TO BE PERFORMED ON THE ENGINE: Check of injector conformity: part number and possible bleeds OK KO Check part number and spark plug

operation OK KO

Check the number of washers in the injector housing and their thickness: (1.5 mm for 1.3 SDE version)

No.

Air flow check between flow meter and engine inlet (Check the sealing of the intake circuit and relevant tightening)

OK KO

Check oil presence in intake circuit / Intercooler OK KO

Engine oil level MIN MED MAX >MAX >MAX

1 Check the control unit upgrade and, if necessary, reprogramme the control unit with the

latest CD-Flash; change oil. 2 Check oil level.

If the fault cannot be solved, open a Ticket to Te.Se.O. attaching the Check List as per item 1. IMPORTANT: before sending the TK to Te.Se.O. DO NOT CLEAN THE INTAKE CIRCUIT.


Closing date Notes

79 Page 3/3

New Bravo




55

Sheet 80 – Various models Start&Stop VERSIONS All models with Start&Stop system . IMPORTANT COMMUNICATION Due a wrong writing, the error diagnosis P0555 on the cars with Start&Stop system does not refer to an error on the brake pedal, rather to an error on the brake servo vacuum sensor. The description will be corrected with the next Examiner release. In case of error P0555

- By Examiner, print the errors in the Body Computer control unit. After collecting the required information, contact Te.Se.O without carrying out further interventions and/or replacements; attach the diagnosis printouts to the TK.


Closing date Notes

80 Various models

Models with Start&Stop Error P0555. 29/01/10



56

Sheet 81 – New 500 VERSIONS All 1200 8v versions CUSTOMER'S REPORTED FAULT During cold starting, the electric driving warning light switches on occasionally. The warning light is on until the next KEY ON. RESULT OF WORKSHOP ANALYSIS During cold starting, the electric driving warning light switches on occasionally, with error U1700 (intermittent). OPERATION Before carrying out any intervention: - Make a battery test with Midtronic instrument and print the result. - Read the errors on the Engine Management Control Unit by the Examiner.

After collecting the required information, contact Te.Se.O without carrying out further interventions and/or replacements; attach the Midtronic diagnosis printouts and the diagnosis printouts to the TK.


Closing date Notes

81 New 500 During cold starting, the electric driving warning light switches on occasionally.

29/01/10



57

Sheet 82 – New Panda

VERSIONS All 1200 8v versions

CUSTOMER'S REPORTED FAULT Switching on of the engine water high temperature warning light during cold starting.

RESULT OF WORKSHOP ANALYSIS During starting, the engine water high temperature warning light switches on occasionally.

ACTION Before carrying out any intervention: - make a battery test with the Midtronic instrument and print the result. - Read the errors on the Engine Management Control Unit by the Examiner.

After collecting the required information, contact Te.Se.O. without carrying out further interventions and/or replacements; attach the Midtronic diagnosis printouts and the diagnosis printouts to the TK.


Date of last update

Closing date Notes

82 New Panda

During cold starting, the water high temperature warning light switches on occasionally.

29/01/10



58

Sheet 83 – Fiorino/Qubo

VERSIONS 1.4 8v Methane

CUSTOMER'S REPORTED FAULT Engine check warning light switching on, impossibility of switching to methane.

RESULT OF WORKSHOP ANALYSIS Error P0087 found (present), with measured pressure on the rail over 12 bar. The pressure on the rail exceeded the threshold of 12 bar (sensor full scale). To avoid injector missed opening, the CCM does not switch the car to methane supply.

ACTION 1- Check if the rail pressure is over 12 bar.

2- Disconnect the system to reduce pressure and make sure the pressure on the rail decreases.

3- Reconnect the system and leave the car at a standstill for a few hours (6 or 7).

4- If, after the stop, pressure in the rail increases and high pressure decreases, replace the methane regulator, as there is a methane leak.

5- If pressure does not increase, check with the multimeter the solenoid valve resistance on the cylinders (about 10 Ω) and on the reducer (about 9 Ω).

6- If the resistance is correct, carry out the active diagnosis on the solenoid valves to see if they are correctly powered.

7- If they are correctly powered, check the pressure sensor: undo it, connect the connection, measure the signal cable and the earth cable with a multimeter, to see if, with key on MAR-ON and connected connections, there are 0.5 V (voltage at atmospheric pressure); reinstall the unit, recharge the circuit, measure the signal again in the same mode and make sure voltage increases proportionally to pressure.

8- If no faults are found after this check, send a ticket to Te.Se.O. for further support.


Date of last update

Closing date Notes

83 Fiorino / Qubo Impossible switching to methane. 24/02/10



59

Sheet 85 – New Panda

VERSIONS All 4x4 models with electrohydraulic joint.

CUSTOMER'S REPORTED FAULT During start-ups, the odometer occasionally flashes.

RESULT OF WORKSHOP ANALYSIS Occasional flashing of the odometer at key-on without any error storage in the control unit.

ACTION - By Examiner, print the errors in the Body Computer control unit. - Make a DEBUG A2 printout.

After collecting the required information, contact Te.Se.O. without carrying out further interventions and/or replacements; attach the diagnosis printouts and the DEBUG A2 printout to the Ticket.


Date of last update

Closing date Notes

85 New Panda The odometer occasionally flashes. 24/02/10



60

Sheet 86 – Various Models

VERSIONS All models, LPG supply. NOTE: remember that when reference is made to Tutorship, the reports must be sent through the appropriate eSIGI channel, whereas in Areas where they are not present, draft a TK for the Te.Se.O. of your Market, according to the standard procedure.

CUSTOMER'S REPORTED FAULT Switching off when idling with LPG supply engaged.

RESULT OF WORKSHOP ANALYSIS When LPG supply is engaged, occasionally the engine switches off without storing any error in the control unit.

ACTION For Grande Punto 1.4 8v LPG: If the claimed fault is confirmed, contact Te.Se.O. without carrying out further interventions and/or replacements; attach the diagnosis printouts to the TK.

For all other models with LPG. If the claimed fault persists, proceed as below indicated:

o Check that the injector sequence is correct o Start the parameter acquisition o Reset the adaptive parameters (including Throttle Body and Toothed wheel).

If the fault still persists. o Check the tappet clearance and restore if it wrong.

If the fault persists, contact Te.Se.O. without carrying out further interventions and/or replacements; attach the diagnosis printouts to the TK.


Date of last update

Closing date Notes

86 page 1/2

Various models




61

1. Start engine parameter acquisition. 2. Reset the self-adaptive parameters (including Throttle Body and Toothed wheel).

If the fault persists, check tappet clearance; if it is wrong, restore the correct tappet clearance.

If, in spite of the above operations, the fault still persists, contact Te.Se.O. without carrying out further interventions and/or replacements; attach the diagnosis printouts to the TK. Te.Se.O. shall supply further information on how to handle the matter.


Date of last update

Closing date Notes

86 page 2/2

Various models




62

Sheet 87 – Various Models (New 500 – Bravo – New Croma)

VERSIONS All models with Blue&Me navigator and Ecodrive

NOTE: remember that when reference is made to Tutorship, the reports must be sent through the appropriate eSIGI channel, whereas in Areas where they are not present, draft a TK for the Te.Se.O. of your Market, according to the standard procedure.

CUSTOMER'S REPORTED FAULT Impossible to install the "Ecodrive" software on the car Blue&Me system.

RESULT OF WORKSHOP ANALYSIS

ACTION Check the following parameters:

• For 500: displaying of error USB 10. • For Bravo and Croma: in case of error USB 10 and if the Build 8132 is installed (check by

Examiner).

If the above information is confirmed, do not carry out any intervention and inform the Customer that the fault is not due to the vehicle, rather he should wait until the Internet site www.fiat.com (recommend to the Customer to use the company site of the country of origin, for example for Italy www.fiat.it to speed up the operation) contains the relevant software; in this case, the Customer can upgrade the software by himself. If the software is not included in the listed ones, continue the standard troubleshooting.


Date of last update

Closing date Notes

87 Various models

Impossible to install the "Ecodrive" software 10/03/10


http://www.fiat.it/



63

Sheet 89 – Various models with DPF

VERSIONS All models New CCM software with addition of Recovery.

CUSTOMER'S CLAIMED FAULT The engine does not perform/does not start.

RESULT OF WORKSHOP ANALYSIS Found errors P0521 P0524 in the CCM

ACTION After reprogramming the CCM with the latest DPF handling SW, two Recovery levels were added, to protect the engine from damage due to the lacked control of the engine warning light by the customer.

These two Recovery situations are handled by the CCM by setting two errors, when the oil degradation exceeds two thresholds:

P0521 for the "lightest" Recovery

P0524 for the "heaviest" Recovery

These errors can be removed only by changing engine oil.

Therefore, if errors P0521 or P0524 occur, engine oil must be changed.

Note: if the CCM is upgraded before the engine oil replacement, if the oil degradation has exceeded the relevant threshold, the relevant error is validated and the engine recovery is set.


Date of last update

Closing date Notes

89 Various models

The engine does not perform/does not start 23/04/10



64

Sheet 90 – 500 ABS/ESP warning light switching on VERSIONS All models NOTE: remember that when reference is made to Tutorship, the reports must be sent through the appropriate eSIGI channel, whereas in Areas where they are not present, draft a TK for the Te.Se.O. of your Market, according to the standard procedure. CUSTOMER'S CLAIMED FAULT ABS and EPS warning lights switching on. RESULT OF WORKSHOP ANALYSIS ABS and ESP warning lights switched on with errors C1002 on ESP control unit and C0051 on the ABS control unit. ACTION By Examiner, print the errors in the brake and electric steering control units attaching them to the Ticket, then contact Te.Se.O.. Do not carry out further interventions and/or replacements.


Date of last update

Closing date Notes

90 500 ABS/ESP warning light switching on 21/05/10



65

Sheet 91 – 500

VERSIONS

All Blue&Me models

FAULT:

Milometer flashing after replacing the Blue&Me control unit, due to missed PROXI alignment.

IMPORTANT INFORMATION:

Starting from March 2010 (chassis: 504557) a new HW has been introduced in production, called Lauberhorn. The Blue&Me Lauberhorn control unit replaced the old control unit, called Convergence.

Some control units were produced and added to the network by Part & Service (part. no. 51873547) which could cause PROXI alignment problems due to a SW bug.

If a similar fault is found after replacing the Blue&Me control unit, proceed as below described:

1. Check the car chassis: • If the car chassis is before no. 504557, replace the control unit ordering the control

unit with Convergence HW (p/n 51857617). • If the car chassis is after no. 504557 replace the control unit ordering p/n 51873547

again. The Spare Parts stocks have been updated with configurable control units. The compliant control units have been marked by a yellow dot.

For possible problems, contact the market Te.Se.O. or the Tuturshop, where available.


Date of last update

Closing date Notes

91 500 Milometer flashing fault 18/06/10



66

Sheet 92 – Ulysse

VERSIONS

All models

IMPORTANT INFORMATION

As a result of the implementation of the campaigns

5445 Fiat

Due to the features of the Body Computer SW added, while reprogramming, a new function has been implemented, increasing the switching time of the steering column stalk switches. Therefore, after reprogramming, to switch the lights off you need to stop for a while in each position, the lights cannot be switched off anymore in a single move. In case of Customer's claimed fault, show the operation of the lights, explaining that this is a feature of a car rather than a fault. Do not perform any replacement, as this would not solve the problem.


Date of last update

Closing date Notes

92 Ulysse Campaign 5445 - Information about steering column stalk 18/06/10



67

Sheet 93 – Punto EVO Oil consumption – 1.4 petrol MultiAir 105 HP engine

VERSIONS

All models with 1.4 petrol MultiAir 105 HP engine (aspirated engine and NOT turbocharged one)

CUSTOMER'S CLAIMED FAULT

• Too high oil consumption (over 120 g/1,000 km), oil level visibly under the minimum mark every 10,000 km

• Irregular operation, with EOBD warning light switching on • Some light blue smokiness at the exhaust during starting


If the customer claims a too high engine oil consumption, or in case of different workshop operations on cars having 1.4 MultiAir 105 HP engine, keep under control the oil level to determine the consumption. Check the residual oil quantity in the sump, the frequency of topping up and the possible memorisation of errors in the CCM.

ACTION

If the analyses show: • reduced oil quantity in the sump (about 1.5 l compared with the min. level of 2.2 l). • CCM errors: P300÷304 (misfiring) and/or P069/P106/P111 (plausibility of sensor for

intake manifold temperature/pressure) • Presence of oil in intake and in the chamber on the head cover, under the PCV

valve. Restore the correct engine oil level, making sure that the max. allowed oil mark is not exceeded, using products complying with the specifications of the Owner Handbook (table below).


Date of last update

Closing date Notes

93 Page 1/2

Punto EVO Excessive oil consumption 03/09/2010



68

FLUIDS AND LUBRICANTS

SPECIFICATIONS AND RECOMMENDED PRODUCTS

Use Fluid and lubricant features for a correct use of the car

Genuine fluids and lubricants

Lubricants for petrol engines

SAE 5W-40 ACEA C3 grade totally synthetic lubricant FIAT Classification 9.55535-S2

SELENIA K P.E. Contractual Technical Reference No. F603.C07

Remind the customer to make a regular check of engine oil level, as described on the Owner Handbook.

Do not modify engine mechanical components nor engine management/control software in any way. For critical situations, contact Te.Se.O. or, where available, the Tutorship.

NOTE: The tampering with the engine and/or the use of lubricants with specifications inferior to ACEA C3 and SAE grade other than 5W-40 could cause damage to the engine not covered by the warranty.


Date of last update

Closing date Notes

93 Page 2/2

Punto EVO Excessive oil consumption 03/09/2010



69

Sheet 94 – Various Models (G. Punto – Punto EVO) ENGINE Irregular idle / difficult starting with possible presence of Examiner errors - P0101; P0105; P0106; P0110 – Network Information

VERSIONS

1.2 8v

CUSTOMER'S CLAIMED FAULT

The Customer complains of one or more of the following problems: – Irregular idle (swinging) – Long starting – Difficult starting. The analysis with Examiner detects the presence of one or more of the following errors: - P0101: intake manifold air leak; - P0105: Pressure sensor; - P0106: Pressure sensor; - P0110: Air temperature sensor.


If case of claimed fault, before any operation, follow and fill in the below Check List (Table 1).

OPERATION

IMPORTANT: the following Check List (Table 1) must be filled in, carefully together with the Car Data Registration Table in order to help the FGA staff to find out what the problem is.


Date of last update

Closing date Notes

94 Page 1/6

Various models Irregular idle / difficult starting 03/09/2010



70

IMPORTANT: Repairs under warranty will only be refund if the Check List and the Car Data

Registration Table are available, correctly filled in and stamped by the workshop and signed by the Dealer Expert Technician. If not, all repairs will be written off.

NOTE Before performing the Check List (table 1) fill in the table with the car identification data.

CUSTOMER CAR ANALYSIS TABLE SEC. 1

GENERAL DATA

Analysis table no.:

Table date:

Car type:

Model/version/series:

Chassis:

Repair date:

Mileage (miles):

Manual gearbox

Automatic transmission

Engine type

Engine Serial no.:

Repairing dealer Code:

Company name:

Address:

Tel./fax/re.:

Claimed Fault Fault detected Chassis history (operations) No. km Date Description


Date of last update

Closing date Notes

94 Page 2/6




71

Table 1 - Check List CHECK LIST OF PRELIMINARY CHECKS FOR POWER UNIT GENERAL CONDITIONS ANALYSIS

Step Check YES (OK)

NO (KO) Notes

1

Check the ECU with the diagnosis equipment: do errors occur at Key-On?

If errors are found, print the EXAMINER screens with error code and operating parameters, then: • In case of error P0101-P0106, go to Step 2 • In case of error P0105-P0110, go to Step 4 • For other error types, proceed as indicated by the

diagnosis equipment

2

Check of OVERREVVING events (ENGINE OVERSPEED): are there values other than zero?

In particular in case of errors P0101, P0106, write the value here below and go to Step 5 • Number of overrevs .............................................. • RPM out of revs.................................................... • Time of overreving event ...................................... If the values are ZERO, go to Step 3

3

At Key-On, check the values of: • water temperature • intake air temperature • intake pressure (MAP) Are the measured values consistent with operating values?

If the values are not consistent, replace the sensor with irregular values

If no faults are found, go to Step 6

4

With engine off, check the connectors (integrity, cleaning, excess oxidation, excess moisture) and the relevant connections, making sure that the safety locks (secondary lock – CPA) have been correctly locked and there is electrical continuity between the sensor connector pin and the ECU connector pin.

If faults are found, restore the correct electrical connections

5

Can the engine be started regularly?

If starting is impossible or difficult (two or more trials are required), perform the standard checks (starting, battery, electrical connections, fuel supply, etc.), including that of Step 14 then: • state the most probable causes for the failed

starting • restore the system and hand the car over


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Step Check YES

(OK)NO

(KO) Notes

6

Start the engine and reach the operating temperature, then set the Examiner on water temperature reading and check: • correct operation of the

fan, with repeated activation cycles when hot

• correct opening of the engine thermostat

Does the fan activation/deactivation occur at the right temperatures?

The fan switches on when the temperature exceeds 95°C (1st speed) and 105°C (2nd speed). It switches off with a hysteresis of 3°C below the engagement threshold (approximate values).

Replace the faulty components and go to Step 7

7

With idle speed and engine at operating temperature, measure the intake pressure with the Examiner: does the value range between 270 and 380 mbar?

Mark the measured value and go to Step 8

Value ....................................................................

8

In particular, in case of error P0101 – P0106, check in the areas upstream and downstream of the throttle body and between intake manifold and cylinder head: are there air leaks?

In case of air leaks, restore the system.

If no leaks are found, go to Step 9

9 Check the vapour/gas recirculation circuit from the engine block: are there leaks?

In case of leaks, restore the system.

If no leaks are found, go to Step 10

10

Remove: • intake air temperature and

pressure sensor • engine block vapour/gas

recirculation circuit pipes Are there solid and/or liquid obstructions or water/oil emulsions?

If no faults are found, go to Step 11.

If obstructions are found, restore the system and note down the result:

• obstructions in the filler from tappet cover and in pipes/connectors

• presence of water-oil emulsion (bleed pipes, intake pressure sensor housing on manifold or too high quantity of intake oil)


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Step Check YES

(OK)NO

(KO) Notes

11

Are there oil leaks in the engine upper part?

Note down the area showing oil leaks:

• pipes in the bleed circuit ................................... • Throttle body sealing ........................................ • tapper cover gasket ......................................... • cylinder head gasket ........................................ If leaks are found, restore the system; otherwise, go to Step 12

12

Are the oil dipstick, with holder and gaskets the right ones for the engine type; are they correctly installed? Is the oil level with hot engine correct?

If faults are found, restore them, otherwise go to Step 13.

Note down the oil level:

• Regular (between max. and min.) ................... • Above max. ...................................................... • Below min. .......................................................

13

Is the coolant fluid level correct?

• Note down the fluid level:

• Regular (between max. and min.) ................... • Above max. ..................................................... • Below min. .......................................................

If it is below min.:

• Restore the standard level after engine cooling • Check if after heating/reaching operating

temperature with fan activation and following engine cooling the fluid goes back to the starting level

• If this is not the case, check: • Cooling circuit sealing, locating leaks/losses • Expansion vase valve cap operation

If it is over max.:

• Check the thermostat opening • Expansion vase cap operation • Temperature detection operation for water

temperature sensor. If no faults are found, go to Step 14


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Step Check YES (OK)

NO (KO) Notes

14 Is there gas flow in the cooling fluid?

15

Are cylinder compression values consistent with the target ones?

The compression values measured in the cylinders should not be excessively different. Note down the measured values both when hot and cold and attach a copy of the MOTOMETER ticket, then go to Step 16.

16

Do the timing angle values correspond to the stated ones?

Intake opening (after TDC) 7° Intake closing (after BDC) 35° Exhaust opening (before BDC) 62° Exhaust closing (before TDC) -9°

Note down the timing angle values:

Intake opening (after TDC) ...................................... Intake closing (after BDC) ....................................... Exhaust opening (before BDC) ............................... Exhaust closing (before TDC) .................................

If faults are found, restore the system.

If no faults are found, go to Step 15.

After collecting the required information, contact Te.Se.O. without carrying out further interventions and/or replacements, attaching the Examiner printouts to the ticket.


Date of last update

Closing date Notes

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