FIAT BRAVO 2009 2.G LPG Supplement Manual

FIATBRAVO
LPG
603_97_467 BRAVO GPL EN 24-11-2009 12:29 Pagina 1

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FIAT BRAVO LPG
This supplement is about the Fiat Bravo
LPG version (Petrol-LPG).
For anything not included in this supple-
ment, refer to the enclosed Owner Hand-
book.CONTENTS
KNOWING YOUR CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SYSTEM FUNCTIONAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LPG TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SOLENOID VALVES AND SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REGULATION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PAPER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LPG INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRONIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LPG/PETROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL CUT-OFF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REFUELLING THE CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REPLACING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SCHEDULED SERVICING PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FUEL CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CO
2EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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FIAT BRAVO LPG
KNOWING YOUR CAR
INTRODUCTION
The LPG version of the car features two
fuel systems, one for petrol and one for
LPG.
Like the petrol system, the LPG system
is timed, sequential multipoint type with
special injectors.LPG MULTIPOINT
INJECTION SYSTEM
This product is produced by working clo-
sely with qualified suppliers in the LPG sec-
tor. The injection system used on the car
is an efficient system in terms of engine
performance and is based on the injection
of LPG in a gaseous state.
In this system with four injectors, one for
each intake manifold, the fuel is injected
directly into the engine heat transfer ducts,
thereby metering the LPG very precisely.
This improves combustion and, at the sa-
me time, excludes any possibility of back-
draught.
By adapting the electronic control tech-
nology of petrol engines to meet the spe-
cifications of LPG, it has been possible to
achieve significant results in terms of dri-
veability and controlling exhaust emissions.
Engines running on LPG have almost the sa-
me torque/power specifications as when
running on petrol and, as a result, the
performance of the car is also comparable.
The system operates at tem-
peratures are between −20 °C
and 100°C.
WHAT IS LPG?
LPG (which stands for “liquefied petro-
leum gas”) is a gas mixture used as an eco-
nomical and safe primary energy source.
Its main components are: propane gas and
butane gas mixed in various proportions.
These gases are a product of petroleum
refinement and are also present naturally
in oil fields and methane-producing depo-
sits.
In its natural state this mixture is in a ga-
seous state but, as the pressure increa-
ses at ambient temperature, it can easily
be turned into a liquid state.
LPG is a fuel with a low environmental im-
pact because it reduces the pollution pro-
duced by vehicle exhaust gases.
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FIAT BRAVO LPG
SELECTING THE TYPE
OF FUEL SUPPLY
The car is configured for running inde-
pendently on either petrol or LPG.
The engine is always started on petrol
with an automatic shift to LPG after about
40 seconds at the first significant accele-
ration.
This is the time required to reach opti-
mum conditions (engine coolant tempe-
rature, minimum revs level) for the swit-
ch to LPG. Therefore, there must
always be some petrol in the tank (at
least 1/4 full)in order not to compro-
mise the operation of the fuel pump. When running on LPG, when
the last red LED on the gas
gauge (visible on the switch)
comes on, refuelling is advisa-
ble. If the LPG runs out when in LPG mo-
de, the system automatically switches to
petrol mode. This is indicated by: the
amber LED staying on and the green
LED flashing, the fuel level LEDs going
out and an audio signal from the switch.
In addition, it is advisable to periodically
use up the petrol in the tank (until the re-
serve warning light comes on) in order to
ensure that the petrol does not become
old and possibly deteriorate.
The petrol/LPG switch fig. 1, located on
the central tunnel (next to the gear lever)
allows the driver to select petrol or LPG
operation as they see fit.
fig. 1F0Q0804m
Remember that, once LPG re-
fuelling is complete, it is ne-
cessary to switch again by
pressing the button fig. 1 to
run the car on gas.
The LPG supply system is
equipped with a “consump-
tion” function linked to the
LED display of LPG level on
the switch; this function activates only
after a consistent variation in fuel level
has been detected. You are therefore
advised to fill up with fuel at the first
LPG refuelling to obtain a more preci-
se indication of the “level”.
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FIAT BRAVO LPG
When painting in an oven, the
LPG tank should be removed
from the car and later care-
fully refitted by a Fiat Dea-
lership. Although the LPG system has
numerous safety features, it is advisa-
ble to close the manual tap on the tank
every time the car is not in use for a
long period, transported on other vehi-
cles or moved in an emergency as a re-
sult of a breakdown or accident.
Active safety
The car has the same active safety speci-
fications as other versions. The LPG tank complies with the national
standards in force in countries where the
version illustrated in this supplement is sold.
The car is equipped with a ga-
seous LPG injection system de-
signed specifically for it: it is
therefore absolutely forbidden
to alter the configuration of the system
or its components. The use of other
components or materials could cause
malfunctions and lead to a reduction
in safety. Therefore, in the case of pro-
blems, go to a Fiat Dealership. To pre-
vent damage to the LPG system parts
when towing or raising the car, follow
the instructions in the “Towing the car”
chapter of the Owner Handbook.
It should be pointed out that
in some countries (including
Italy) there are legal restrictions in
force for parking/garaging motor
vehicles with gas that has a higher
density than air; LPG comes under
this category.
IMPORTANT
PASSIVE SAFETY/ACTIVE
SAFETY
Passive safety
The car has the same passive safety spe-
cifications as other versions. In particu-
lar, the cylinder mountings (located in the
spare wheel housing) have been designed
to exceed the Fiat safety standards for im-
pact tests.
When running on LPG, the flow of gas (in
a liquid state) leaving the cylinder passes
through the dedicated pipe to the pres-
sure regulator where there is a safety so-
lenoid valve that stops the flow of LPG
when the key is removed or when a chan-
ge of fuel is selected by the driver (deci-
sion to run on petrol).
Together with the regulator solenoid val-
ve, a second solenoid valve, in the tank,
closes the LPG pipe at the tank outlet.
The two solenoid valves are closed in the
case of an impact after the engine is swit-
ched off by the fuel cut-off system.
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FIAT BRAVO LPG
SYSTEM FUNCTIONAL DIAGRAM
DESCRIPTION OF THE SYSTEM FUNCTIONAL DIAGRAM fig. 2
1LPG tank – 2Multivalve unit and safety devices – 3LPG refuelling cap – 4LPG piping 5Pressure regulator – 6LPG injectors
– 7Gaseous LPG filter element – 8LPG injection system electronic control unit – 9LPG-petrol switch and LPG gauge – 10Petrol tank.
F0Q0809mfig. 2
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FIAT BRAVO LPG
LPG TANK
The car has a (pressurised) tank A-fig. 3
for collecting LPG in a liquid state. It is
ring-shaped and located in the spare wheel
compartment with suitable protection.
The LPG in the tank Ais always in a liquid
and gaseous state, in physical equilibrium
conditions.
The liquid, which cannot be compressed,
dilates by around 0.25 % for each increa-
se in temperature of one degree. For this
reason there is a suitable space allowing
for the increase in volume of the liquid for
all foreseeable temperature increases (e.g.
car parked in the full sunlight in the sum-
mer) without compromising the integrity
of the tank.
There is a safety valve that automatically
limits the refilling of the tank (during re-
fuelling) to a maximum level of 80 % (li-
quid) of its total capacity.Periodically (at least once
every six months), it is advi-
sable to let the LPG in the
tank run out and, at the next
refuelling, check that it does not ex-
ceed the maximum capacity of 41 li-
tres (with a tolerance of 2 litres excess)
(see instructions in the “Capacities”
paragraph of this supplement). If the
value is above 41 litres (with a toleran-
ce of 2 litres excess), contact a Fiat Dea-
lership immediately.
LPG TANK CERTIFICATION
The LPG tank is certified in accor-
dance with the regulations in force.
In Italy, the tank has a life of 10 years
from the registration date of the car.
If the car has been registered in
a country other than Italy, the dura-
tion and the testing/inspection pro-
cedures of the LPG tank can vary de-
pending on the legal requirements in
that country. In any case, after the ti-
me prescribed by the legal require-
ments in the individual countries, ha-
ve it replaced by a Fiat Dealership.There is a plate on the tank B-fig. 3con-
taining the following information:
– homologation country identification and
homologation number;
– type of gas for which it is designed (LPG);
– name of cylinder manufacturer;
– cylinder test pressure (30 bar);
– maximum refilling percentage (80%);
– tank dimensions;
– nominal tank capacity in litres;
– cylinder manufacture date (month/year);
– cylinder serial number.
fig. 3
A
B
F0Q0801m
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FIAT BRAVO LPG
SOLENOID VALVES
AND SAFETY DEVICES
The system has a solenoid valve located
on the pressure reduction unit and a so-
lenoid valve fitted inside the multiple val-
ve assembly on the tank.
The main function of these solenoid val-
ves is to interrupt/allow the flow of LPG
to the supply circuit.
The solenoid valves are open when:
– a request to run on LPG has been made;
– the optimum engine running conditions
are satisfied (engine coolant temperature,
minimum revs level) for running on LPG;
– there is enough LPG in the tank for
operation.The multivalve assembly fitted on the tank
includes:
– a valve that automatically stops the sup-
ply of LPG when the maximum permitted
filling level is reached (80% of the total
tank capacity);
– a flow limiter which, if a pipe is broken,
prevents the complete and sudden escape
of LPG;
– a one-way valve, located on the gas re-
turn pipe in the tank, which prevents LPG
reflux;
– a safety solenoid valve on the LPG sup-
ply which, either permits or prevents the
escape of gas to the pressure reduction
unit; – a manual tap, upstream of the solenoid
valve, that separates the tank from the
LPG system to allow maintenance opera-
tions;
– a fuse pad which, in the event of
overheating (temperature above 120 °C),
totally eliminates the danger of excess
pressure by making the LPG in the tank
flow out as quickly as possible in a con-
trolled manner;
– an analogue gauge showing the level of
LPG in the tank.
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FIAT BRAVO LPG
REGULATION UNIT
The regulation unit fig. 4includes:
– cut out solenoid valve with gauze filter;
– pressure regulator.
The cut out solenoid valveopens or
closes together with the solenoid valve on
the tank. It closes all flows of LPG when
the engine is not running on gas.
It also acts as a safety device that prevents
the flow of LPG if the fuel cut-off system
intervenes.
fig. 4F0Q0810m
The pressure regulatorallows the
change of the LPG from a liquid state to
a gaseous state through an expansion
chamber and maintains the pressure re-
quired for the operation of the system at
a preset value.
PIPING
The piping for the LPG in a liquid state
(from the filler to the tank and from the
tank to the pressure regulator) is made
from copper and coated in plastic.
The piping for the LPG in a gaseous state
(from the pressure regulator to the LPG
injectors) is made from rubber.
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