FIAT IDEA 2008 1.G LPG Supplement Manual

LPG
FIATIDEA
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FIAT IDEA LPG
This appendix deals with the LPG version
of the Fiat Idea (Petrol-LPG).
For anything not included in this Supple-
ment, please refer to the enclosed Own-
er’s Manual.CONTENTS
KNOWING YOUR CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL SYSTEM 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
AT THE PETROL STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REPLACING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
LUGGAGE COMPARTMENT VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CO
2EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FUEL CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FLUIDS AND LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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FIAT IDEA 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 the phased, sequential multipoint type
with special injectors.LPG Multipoint injection system
This product is produced in strict collab-
oration with prestigious suppliers in the
LPG sector.
The injection system used on the car is an
efficient system in terms of engine per-
formance and is based on the injection of
LPG in a gaseous state.
In this four-injector system, one for each
intake manifold, the fuel is injected directly
into the engine heat transfer ducts there-
by metering the LPG very precisely im-
proving combustion and, at the same time,
excluding any possibility of flame return.
By adapting the electronic control tech-
nology of petrol engines to meet LPG
specifications, important results in terms
of driveability and controlling exhaust
emissions have been obtained.
Engines running on LPG have almost the
same torque/power specifications as when
running on petrol and, as a result, car per-
formance is also comparable. What is LPG?
LPG (the acronym for Liquefied Petrole-
um Gas) is a mixture of gas used as a safe
and economical 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 naturally present
in oil fields and methane-producing de-
posits.
In its natural state this mixture takes the
form of a gas, but as the pressure in-
creases, at room temperature, it can eas-
ily be turned into liquid.
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 IDEA LPG
The system extreme operat-
ing temperatures are between
-20°C and 100°C.
Selecting the type of fuel supply
The car is configured to run independently
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 accel-
eration.
This is the time required to reach opti-
mum conditions (engine coolant temper-
ature, minimum revs level) for the switch
to LPG. As far as what has been said
is concerned, there must always be
some petrol in the tank (at least 1/4
full)in order not to compromise fuel
pump operation.
In addition, from time to time it is advis-
able to use up all the petrol in the tank
(until the reserve warning light comes on),
in order to ensure that the petrol does
not become old and possibly deteriorate. When running on LPG, when
the last red LED gas quantity
indicator (visible on the
switch) comes on, you should
refuel. If the LPG runs out during LPG
operation, the system automatically
switches to running on petrol shown by:
the amber LED coming on constantly
and the green LED flashing, the fuel
level LEDs going out and a buzzer
sounded by the switch.
The petrol/LPG switch A - Fig. 1, locat-
ed on the protective fuse compartment
(on the left of the dashboard) allows the
driver to select petrol or LPG operation
at your own discretion.
fig. 1F0H0774m
Please remember that after
filling the LPG tank, you will
need to switch fuel by press-
ing the button A-fig 1 to run
the engine on LPG.
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 varia-
tion in fuel level has been detected. You
are therefore advised to fill up with fu-
el at the first LPG refuelling to obtain a
more precise indication of the “level".
WARNING
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FIAT IDEA LPG
When oven painting, the LPG
tank should be removed from
the car and later carefully re-
fitted by a Fiat Dealer. Al-
though the LPG system has numerous
safety features, it is advisable to close
the manual tap on the tank whenever
the car is not used for a long period, is
transported on other vehicles or moved
in an emergency as a result of a break-
down or accident.
Active safety
The car has the same active safety speci-
fications as other versions.
The Fiat Idea LPG is equipped
with a gaseous LPG injection
system designed specifically
for the car: it is therefore
strictly prohibited to alter the config-
uration of the system and components.
The use of other components or ma-
terials could cause malfunctioning and
lead to a reduction in safety. Please re-
fer to a registered Fiat dealer for any
assistance necessary. When towing or
raising the car, to prevent damage to
the gas system parts, follow the in-
structions in the Owner’s Handbook in
the ‘Towing the car’ chapter.
It should be pointed out that
in some countries (including
Italy) there are legal restrictions in
force for parking/garaging motor ve-
hicles with gas that has a higher den-
sity than air. LPG comes under this
category.
WARNINGPASSIVE SAFETY -
ACTIVE SAFETY
Passive safety
The car has the same passive safety spec-
ifications as other versions. Specifically,
tank mountings (located in the spare
wheel housing) have been designed to pass
impact tests in accordance with Fiat safe-
ty standards.
When running on LPG, the flow of gas (in
a liquid state) leaving the tank, passes
through the specific pipe to the pressure
regulator, where there is a safety solenoid
valve that stops the flow of LPG when the
key is turned off or when the driver se-
lects a fuel change (decision to run on
petrol).
Together with the regulator solenoid
valve, a second solenoid valve, in the tank,
closes the LPG pipe at the tank outlet.
In the event of impact, the two solenoid
valves are closed, after which the engine
cuts out due to the fuel cut off system.
The LPG tank meets the legal safety stan-
dards of the countries in which the ver-
sion illustrated in this Supplement is mar-
keted.
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FIAT IDEA LPG
FUNCTIONAL SYSTEM DIAGRAM
Description of the functional system diagram Fig. 2
1LPG tank - 2Multivalve assembly and safety devices - 3LPG refuelling filler - 4LPG piping - 5Pressure regulator - 6LPG injec-
tors - 7LPG in gaseous state filter element - 8LPG injection system electronic control unit - 9LPG-petrol switch and LPG gauge
- 10Petrol tank.
F0H0778mfig. 2
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FIAT IDEA LPG
LPG TANK
The vehicle has a (pressurised) tank A -
Fig. 3for LPG in a liquid state that is
toroidal in shape and located in the spare
wheel housing, where it is suitably pro-
tected.
The LPG in the tank Ais always in both liq-
uid and gaseous state, in a physical balanced
condition.
The liquid, which cannot be compressed,
dilates by around 0.25% for each increase
in temperature of one degree. For this
reason a suitable space allowing the in-
crease in volume of the liquid for all fore-
seeable temperature increases is guaran-
teed (e.g. car parked in the sunshine in
summer), without compromising tank in-
tegrity.
There is a safety valve that automatically
limits tank refilling (during refuelling) to a
maximum level of 80% (liquid) of its total
capacity.Periodically (at least once
every six months) it is advis-
able to let the LPG in the tank
run out and, at the first refu-
elling, check that it does not exceed the
maximum capacity of 31 litres (with a
tolerance of 2 litres excess) (see in-
structions in ‘Capacities’ paragraph in
this Supplement). If the value exceeds
31 litres, please go to a Fiat Dealer im-
mediately.
LPG TANK CERTIFICATION
The LPG tank is certified in accor-
dance with current regulations.
In Italy, the tank has a life of 10 years
as from car registration. If the car
has been registered in a different
country from Italy, the life of the
LPG tank and test/inspection proce-
dures may vary depending on the
laws in force in that particular coun-
try. In any case, when the time lim-
it in the individual country has run
out, go to a Fiat Dealer to have the
tank replaced.There is a plate on the tank B - Fig. 3con-
taining the following information:
- homologation country identification and
homologation number;
- type of gas for it has been designed
(LPG);
- name of tank manufacturer;
- tank test pressure (30 bar);
- maximum refilling percentage (80%);
- tank dimensions;
- nominal tank capacity in litres;
- tank manufacture date (month/year);
- tank serial number.
fig. 3F0H0775m
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FIAT IDEA 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 multivalve as-
sembly on the tank.
The main function of these solenoid valves
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;
– optimum engine conditions are satisfied
(engine coolant temperature, minimum
revs level) for running on LPG;– there is enough LPG in the tank for op-
eration;
The multiple valve 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 gives the go ahead 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 work;
– a fuse pad which, in the event of
overheating (temperature above 120°C),
totally eliminates the danger of excess
pressure making the LPG in the tank flow
out as quickly as possible in a controlled
manner;
– an analogue gauge showing the level of
LPG in the tank.
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FIAT IDEA 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 tank solenoid
valve. It closes each flow 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 inertia switch is ac-
tivated.
fig. 4F0H0776m
The pressure regulatorallows the
change of the LPG from a liquid state to
a gaseous state via a dilation chamber and
maintains the pressure required for the
operation of the system at a preset val-
ue.
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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