engine FIAT PALIO 2003 178 / 1.G India Version Workshop Manual

129
CAR IDENTIFICATION DATA
CHASSIS MARKING fig. 1
This is stamped on the floor pan of
the passenger compartment under the
front right-hand seat.
It can be reached by lifting the bon-
net lid and it includes:
– car model MAG 178000;
– chassis number.
ENGINE MARKING
Fig. 2
- versions 1.2
Fig. 3- versions 1.6
Fig. 4- versions 1.9 D
The marking is stamped on the cylin-
der block and includes the model and
the serial number.
fig. 1
P4E01667
fig. 2
P4E01482
fig. 3
P4E01828
MODEL PLATE fig. 4
This label is secured to the bonnet
and bears the following identification
data:
A - Manufacturer’s name
B - Homologation number
C - Vehicle type code
D - Chassis number
E - Maximum vehicle weight fully
loaded
F- Maximum vehicle weight fully
loaded plus trailer
G - Maximum vehicle weight on
front axle
H - Maximum vehicle weight on rear
axle
I - Engine type
L - Body version code
M- Number for spares
fig. 4
P4E02334
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130
ENGINES CODE -
BODYWORK VERSIONS
fig. 5
P4E01455
BODYWORK
PAINT
IDENTIFICATION
PLATE
fig. 5
This adhesive label is applied to the
inner side of the front right-hand door.
It bears the following data:
A - Paint manufacturer
B - Colour name
C - Fiat colour code
D- Respray and touch up code.
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178C4066 182B6000
Otto Otto
4 in line 4 in line
24
70,80 x 78,86 80,50 x 78,40
1242 1596
9,1:1 9,5 : 1
54 73.5
72 100
6000 5500
102 137
10,4 14
3250 4250
850 ± 50 850 ± 50
7° 0°
41° 34°
43° 24°
5° 0°
0,40 ± 0,05 Tappets
0,45 ± 0,05 hydraulic
131
1.2 1.6 1.9
ENGINE
223A6000
Diesel
4 in line
2
82x90.4
1910
22.5 : 1
46
63
4500
120
12.2
2500
900 ± 100
5°
37°
31°
3°
0.3 ± 0.05
GENERAL
Type code
Cycle
Number and layout of cylinders
Number of valves per cylinder
Diameter x stroke mm
Total capacity cm3
Compression ratio
Maximum power (DIN) kW
PS
at RPM
Maximum torque (DIN) Nm
kgm
at RPM
Idle ratio rpm
TIMING
Intake:
opens BTDC
closes ABDC
Exhaust:
opens BBDC
closes ATDC
Cold-operation tappet clearance:
intake mm
exhaust mm
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132
FUEL SUPPLY/ IGNITION
Integrated multipoint electronic in-
jection and ignition system: only one
electronic control unit controls both
functions. It processes both the time
the injection lasts (for petrol meter-
ing) and the ignition advance angle.
Type: Multipoint.
Air cleaner: dry, with paper filtering
element.
Fuel pump: by immersion, in the tank.
Injection pressure 3 barMixture metered by electronic pro-
cessing of the data picked up by the
engine speed sensor and absolute
pressure sensor in the intake manifold.
Petrol metering system : a “Closed
Loop” (information on the combus-
tion trend transmitted by the sensor
Lambda).
Ignition order: 1-3-4-2.
Spark plugs:
Modifications or repairs
to the fuel feed system
that are not carried out
properly or do not take the sys-
tem’s technical specifications in-
to account can cause malfunc-
tions leading to the risk of fire.
LUBRICATION
Forced-feed with gear pump with
pressure relief valve incorporated.
Oil purification through full-flow car-
tridge filter.
COOLING
Cooling system with radiator, cen-
trifugal pump and expansion tank.
Thermostat on the secondary circuit
for recirculating the water from the
engine to the radiator. “By-pass con-
trolled” thermostat.
Electrical fan for cooling the radiator
with connection/disconnection, con-
trolled by a thermostatic switch lo-
cated on the radiator.
Spark plug (type)
1.2
Champion RC7BMCChampion RC8BYC
1.6NGK BKR5EZ
Champion RC10YCC
Bosch FR8DE
Other equivalent Spark plug for 1.6 engine
is Champion RC10YCC.
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135
STEERING
Energy absorbing steering wheel (air
bag, if provided).
Rake adjustable, jointed energy ab-
sorbing steering column.
Mechanical or hydraulic rack and pin-
ion command with permanent lubri-
cation.
Hydraulic power steering (as pro-
vided).
Permanent lubrication joints.
Minimum turning diameter:
10.2 metres.
Number of steering wheel turns lock
to lock:
3.69 turns for mechanical steering;
2.66 turns for hydraulic steering.
Do not push the power
steering to its limit while
the engine is running for
more than 15 seconds: this will
make a noise and could damage
the system.
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Delivered power
1.20.8 kW
1.61.3 kW
1.9 D1.4 kW
137
ALTERNATOR
Rectifier bridge and built-in elec-
tronic voltage regulator. Battery be-
gins recharging as soon as the engine
starts.
STARTER MOTOR Modifications or repairs
to the electrical system
carried out incorrectly
and without bearing the features
of the system in mind can cause
malfunctions with the risk of fire.
ELECTRIC SYSTEM
Supply voltage: 12 Volt.
BATTERY
With negative earth.
Discharge capacity Discharge current 20 hour fast cold (–18°C)
1.250 Ah 250A
1.650 Ah 250A
1.9 D60 Ah 320A
Max supplied nominalcurrent
1.290A
1.690A
1.9 D90A
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1.2
litres kg
47 –
5.5-7.5 –
5.9 6.1
3.05 2.75
1.8 1.5
0.68 0.54
– 0.075
0.40
0.50
2.3 –
1.6
litre kg
47 –
5.5-7.5 –
6.6 6.8
3.88 3.5
1.8 1.5
0.68 0.54
– 0.075
0.40
0.50
2.3 –
140
Prescribed fuels
Recommended products
Super unleaded petrol 87 R.O.N.
Mixture composed by 70% distilled water
and 30% fluid
PARAFLU11
VS MAX PETROL(*)
ZC 80/S
GI/A
MRM 2
TOP 4
TOP 4
Mixture of distilled water and 10% of fluid DPI
CAPACITIES
(*) Do not top up with oil having specifications different from the oil present in the car.
47 –
5.5-7.5 –
4.8 3.9
43.3
2.0 1.73
0.68 0.54
– 0.075
0.40 –
0.50
2.3 –
1.9
litre kg
Fuel tank:
including a reserve of:
Engine cooling system:
– with manual climate control system
ngine sump:
Engine sump and filter:
Transaxle:
Hydraulic power steering:
CV joint cavities and boots :
Front and rear hydraulic brake circuit:
Hydraulic brake circuit with
ABS antilock device:
Windscreen/rear window washer
fluid reservoir:
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141
FLUIDS AND LUBRICANTS
PRODUCTS WHICH MAY BE USED AND THEIR SPECIFICATIONS
Specifications of fluids and lubricants to use
for best car operation
SAE 15W40 grade mineral multigrade oils that exceed the API
SG and CCMC G4 specifications
SAE 15W40 multi grade synthetic based oil exceeding
API CD CC MCPDZ
SAE 80W EP oil exceeding API GL4 and
MIL-L-2105 specifications
“ATF DEXRON II D LEV” oil
Molybdenum disulphide, lithium-soap based grease.
water resistant N.L.G.I. consistency = 2 Transmission lubri-
cants and greases
Recommended lu-
bricants and fluids
VS MAX
PETROL
VS MAX
DIESEL
ZC 80/S
GI/A
MRM 2
CV jointsUse temperatures
from –15°C to 40°C
7,500 kms or 6 months
whichever is earlier
from previous change
Use temperatures
from –15°C to 40°C
7,500 kms or 6 months
whichever is earlier
from previous change
Manual transmissions
and differentials
Hydraulic power steer-
ing
Applications Use
Lubricants for
petrol engines
Lubricants for
Diesel engines
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145
Dipped beam headlights
- control ..................................... 13-41
- bulb replacement ................. 88
Doors.............................................. 17-48
Electric system ........................... 137
Electric window winder ............ 15-49
Electronic central units ............. 120
Engine compartment .................. 16-54
Engine compartment
(washing) ................................... 127
Engine cooling fluid
thermometer ........................... 34
Engine cooling fluid level ............ 113
Engine oil consumption ............. 112
Engine oil level ............................. 112
Engine oil
- consumption .......................... 112
- checking the level ................. 112
Engine
- power supply/ignition ........... 132
- engine type code .................. 130
- characteristic data ................ 131
- engine compartment
washing ................................... 127
- lubrication ............................... 132- marking .................................... 129
- cooling ...................................... 132
Filling ............................................ 140
First-aid kit ................................... 103
Flashing ........................................... 13-42
Front foglights ............................... 56
Front foglights
- switch on/off button ............ 15-44
- bulb replacement ................. 90
Fuel filler cap ................................ 18-63
Fuel flap opening lever............... 18-63
Fuel flap
- opening lever ......................... 18-63
Fuel level indicator ..................... 33
Fuel lock switch .......................... 44
Fuel
- level indicator ........................ 33
- fuel lock switch ...................... 44
- fuel flap opening level ........... 18-63
Fuses................................................ 93
- replacement ............................ 93
Gearbox
- gearbox use ........................... 68
- transmission ........................... 133Getting to know the car ........... 20
Glove compartment .................... 45
Handbrake ............................... 67-134
Hazard lights ................................. 13-43
Head rest ....................................... 11-23
Headlight trim .............................. 56
Headlights (upward slant
compensation) ......................... 56
Heated rear window .................. 15-44
Heating ........................................... 39
Identification data ..................... 129
If an accident occurs ................... 102
Ignition device .............................. 21
In an emergency .......................... 80
Instrument panel ......................... 10
Interior lights ............................... 92
Interior equipment ..................... 45
Keys ............................................. 11-21
Kilometer counter ....................... 33
Level control ............................. 111
Lubricants(specifications) .......... 141
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147
Spark plugs ................................... 121
Speedometer................................. 33
Starter (specifications) ............... 137
Starting the engine ...................... 65
- Jump starting ......................... 81
- bump starting ........................ 66-82
- ignition switch ....................... 21
- turning off the engine .......... 66
- starting procedure ................ 65
- engine warm up (just
started) ................................... 66
Steering column lock .................. 11-22
Steering column stalks ............... 13-41
Steering........................................... 135
Storing the car ............................. 78
Sun visors ...................................... 47
Suspensions .................................. 134
Symbols .......................................... 4
Technical specifications ........... 128
Third brake light ......................... 91Towing the car ........................... 101
Transmission ................................. 133
Transporting children in
safety .......................................... 29
Tubing ............................................ 123
Tyre pressure ......................... 121-143
Tyres
- specifications........................... 136
- Correct reading .................... 136
- maintenance .......................... 121
- inflation pressure ............ 121-143
- changing the wheel................ 82
Useful accessories ................... 79
Ventilation.................................. 40
Warning lights
- injection system failure ....... 35
- air bag failure ......................... 36- engaged handbrake .............. 35
- direction indicators ............. 36
- low brake-clutch fluid level 35
- low engine oil pressure........ 35
- low battery recharge ......... 35
- main beam headlights .......... 36
- Exterior lights ......................... 36
- unserviceable ABS ................. 36
Weights .......................................... 138
Wheel rims.................................... 136
- correct reading of the rim .. 136
Wheels
- wheel geometry ..................... 136
- specifications........................... 136
- maintenance .......................... 121
- replacement ........................... 82
Windows
- electric window winder .... 15-49
- manual window winder ...... 16-50
- cleaning operation ................. 126
Windscreen washer
- control .................................... 13-42
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