Fiat Doblo 2010-2021
Fiat Doblo 2010-2021
Fiat Doblo 2010-2021
ATTENTION
the images of the doblo present in the
manual are purely coincidental,
the topics covered in this manual
concern only and exclusively
the 263 model in production from 2010 onwards.
Machine Translated by Google
FIAT DOBLÒ
generality
IDENTIFICATION LIFT
IDENTIFICATION TABLE To lift the car with an arm lift or a workshop lift, arrange the
ends of the arms or the lift only
Trading name Fiat Doblo in the areas indicated in the figure.
MANUFACTURER'S PLATE
The manufacturer's identification plate is applied to the front cross member
of the engine compartment.
Manufacturer's plate
Use:
The car must only be lifted laterally. After lifting the
support the vehicle with safety stands. It absolutely is
It is forbidden to lift the car by placing the workshop lift in
correspondence with the swinging arms and the front suspension strap or in
correspondence of the rear suspension bridge.
TOWING
The tow ring supplied with the car is located in the container
tool storage, present in the trunk.
C
Vehicle type identification code
AND
Maximum authorized weight of the vehicle when fully loaded
F
Maximum authorized weight of the vehicle when fully loaded plus the trailer
I
Engine type
2
Machine Translated by Google
FIAT DOBLÒ
generality
MAINTENANCE FREQUENCY
Check the condition and wear of the front disc brake pads and operate the pad wear indicator x x x x x
Visually check conditions and integrity: exterior bodywork, underbody protection, rigid and flexible sections of the pipes
x x x x x
(exhaust - fuel supply - brakes), rubber elements (boots - sleeves - bushings etc.)
Check the cleanliness of the bonnet and boot locks, cleanliness and lubrication of the levers x x x x x
Check and, if necessary, restore fluid levels (engine cooling, hydraulic brakes/clutch, windshield washer, battery, etc.) x x x x x
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
1. engine > technical data
1. engine
technical data
GENERALITY
4-cylinder in-line engine, 4 valves per cylinder, supercharged with Multijet direct injection. Transversal position with cast iron block and head
light alloy.
Engine view
HEAD GROUP
TEST
The cylinder head is monolithic in aluminum and silicon alloy. Measure Value
Two overhead camshafts, in ductile iron, housed in an overhead
camshaft; the control is by belt and gears. The four valves per cylinder,Engine cylinder head lower surface flatness (mm) < 0,1
parallel and vertical, are positioned in the relevant valve guides e
controlled by rocker arms actuated by the eccentrics of the camshafts Engine
e cylinder head nominal height (mm) 107 ± 0,05
kept in contact with the valves via hydraulic tappets.
4
Machine Translated by Google
FIAT DOBLÒ
1. engine > technical data
CYLINDER HEAD GASKET Operated by a double overhead camshaft and roller balancer counteracted by a
Based on the average values of maximum piston protrusion, they are available hydraulic tappet.
three different types of gasket identifiable according to the number of notches
present. The gasket between the cylinder head and the crankcase is metallic and non-metallicMeasure Value
head tightening is foreseen for the entire life of the engine.
Valve stem diameter - Intake (mm) 4.982 ÷ 5.000
VALVE SEATS
Locations reported in the header.
protrusion
Valve seat band angle in contact with valves - exhaust 45° 0’ +/- 1°
-0.020 ÷ +0.100
Cylinder head gasket thickness with protrusion
Valve seat external diameter - intake (mm) 29.600 ÷ 29.611
maximum pistons (mm) thickness (no hole)
0.82 +/- 0.05 External diameter of valve seats - exhaust (mm) 26.100 ÷ 26.111
protrusion
+0.101 ÷ +0.200
Cylinder head gasket thickness with protrusion VALVE GUIDES
maximum pistons (mm) thickness (one hole) Bring back, mount with the press in the head.
0.92 +/- 0.05
Measure Value
protrusion
+0.201 ÷ +0.295 Valve guide external diameter (mm) 10.010 ÷ 10.030
Cylinder head gasket thickness with protrusion
maximum pistons (mm) thickness (two holes)
Valve guide internal diameter (mm) 5.015 ÷ 5.033
1.02 +/- 0.05
Valve guide external diameter increase (mm) 0.05 / 0.10 / 0.25
VALVES BALANCERS
Sixteen valves, four valves per cylinder, in line and different between intake and Roller rocker arms, driven by double overhead camshafts, open the
exhaust. valves opposed by hydraulic tappets.
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
1. engine > technical data
< 0.005
BASEMENT Barrel taper (mm)
The base is made of ductile cast iron. The cylinders are machined directly into the 0.1
Internal barrel diameter increase (mm)
base and are selected in three size classes plus an increase. The
crankshaft rotates on five main bearings.
Special ducts, created in the walls of the base, allow
the passage of the coolant and lubricating oil. POWERTRAIN SUPPORTS
The powertrain mounts serve the connecting function
Size 1.6 16V Multijet Value structural between powerplant and body.
Internal diameter of cylinder liners - Class A (mm) 79.500 ÷ 79.510 They are sized to support the weight of the engine and support the
Cylinder liners internal diameter - Class B (mm) 79.510 ÷ 79.520 loads deriving from the torque transmitted by the engine.
Cylinder liners internal diameter - Class C (mm) 79.520 ÷ 79.530 Each support is provided with a rubber-metal plug with the task of
dampening the vibrations generated by the engine, greatly reducing
Value part of the vibrations transmitted to the body.
Size 2.0 16V Multijet
This is a barycentric type support, composed of two dowels plus a
Cylinder liners internal diameter - Class A (mm) 83.000 ÷ 83.010
reaction tie rod, aligned on an axis passing through the center of gravity
Cylinder liners internal diameter - Class B (mm) 83.010 ÷ 83.020 of the engine in order to obtain reaction forces with the arm
Cylinder liners internal diameter - Class C (mm) 83.020 ÷ 83.030 none
Main journal diameter - Class A (mm) 52.994 ÷ 53.000 1.6 JTD 16v Increase in main bearing half-bearings - 0.508 1.6 JTD 16v
Class C (black) (mm)
Main journal diameter - class B (mm) 52.988 ÷ 52.994 1.6 JTD 16v
Main journal diameter - Class C (mm) 52.982 ÷ 52.988 1.6 JTD 16v
Measure Value Validity
Main bearing clearance -
Measure Value Validity 0.011 ÷ 0.071 1.6 JTD 16v
crankshaft journals (mm)
Main journal diameter - Class A (mm) 59.994 ÷ 60.000 2.0 JTD 16v
Main journal diameter - class B (mm) 59.988 ÷ 59.994 2.0 JTD 16v
Measure Value Validity
Main journal diameter - Class C (mm) 59.982 ÷ 59.988 2.0 JTD 16v
Thickness of connecting rod half bearings -
1.536 1.6 JTD 16v
Class A (red) (mm)
Measure Value Validity Thickness of connecting rod half bearings -
1.539 1.6 JTD 16v
56.705 ÷ 56.718 1.6 JTD 16v Class B (blue) (mm)
Main journal seat diameter (mm)
Thickness of connecting rod half bearings -
1.542 1.6 JTD 16v
Class C (yellow) (mm)
Measure Value Validity
Increase in main bearing half-bearings - 0.127 1.6 JTD 16v
Main journal seat diameter (mm) 63.705 ÷ 63.718 2.0 JTD 16v Class A (brown) (mm)
Increase in main bearing half-bearings - 0.254 1.6 JTD 16v
Measure Value Validity Class B (green) (mm)
Increase in main bearing half-bearings - 0.508 1.6 JTD 16v
Connecting rod pin diameter - Class A (mm) 48.238 ÷ 48.244 1.6 JTD 16v
Class C (black) (mm)
Connecting rod pin diameter - Class B (mm) 48.232 ÷ 48.238 1.6 JTD 16v
Connecting rod pin diameter - Class C (mm) 48.226 ÷ 48.232 1.6 JTD 16v
Measure Value Validity
Connecting rod pin diameter - Class A (mm) 50.799 ÷ 50.805 2.0 JTD 16v Main bearing half thickness - 1.835 ÷ 1.839 2.0 JTD 16v
Class B (Blue) (mm)
Connecting rod pin diameter - Class B (mm) 50.793 ÷ 50.799 2.0 JTD 16v
Main bearing half thickness - 1.838 ÷ 1.842 2.0 JTD 16v
Connecting rod pin diameter - Class C (mm) 50.787 ÷ 50.793 2.0 JTD 16v
Class C (Yellow) (mm)
6
Machine Translated by Google
FIAT DOBLÒ
1. engine > technical data
Increase in main bearing half-bearings - Class A Internal diameter of connecting rod small end bushings (mm) 30.006 ÷ 30.014 2.0 JTD 16v
0.127 2.0 JTD 16v
(marrone) (mm) Connecting rod head internal diameter (mm) 53.897 ÷ 53.909 2.0 JTD 16v
Increase in main bearing half-bearings - Class B Allowable weight difference between connecting rods
0.127 2.0 JTD 16v +/- 2.5
(verde) (mm) complete (g)
Increase in main bearing half-bearings (mm) 0.254 2.0 JTD 16v Allowable weight difference between connecting rods
+/- 2.5
complete (g)
Measure Value Validity
BANDS
Main bearing clearance - shaft main journals
0.031 ÷ 0.051 2.0 JTD 16v
engine (mm) The pistons have three piston rings. Assembly staggering (I, II,
III) at 120° with the “TOP” reference facing upwards.
Measure Value Validity
Measure Value Validity
Connecting rod half bearing thickness - Class A (red)
1.528 ÷ 1.532 2.0 JTD 16v
Thickness of 1st cylinder compression seal ring
(mm) 1.970 ÷ 2.005 1.6 JTD 16v
(mm)
Connecting rod half bearing thickness - Class B (blue)
1.532 ÷ 1.536 2.0 JTD 16v Thickness of 2nd cylinder compression seal ring
(mm) 1.970 ÷ 2.005 1.6 JTD 16v
(mm)
Connecting rod half bearing thickness - Class C (yellow) 1.535 ÷ 1.539 2.0 JTD 16v Thickness of 3rd cylinder compression seal ring
1.970 ÷ 1.990 1.6 JTD 16v
(mm)
(mm)
Piston external diameter - Class B (mm) 79.450 ÷ 79.460 1.6 JTD 16v
Measure Value Validity
Piston external diameter - Class C (mm) 79.460 ÷ 79.470 1.6 JTD 16v
1.6 JTD 16v
1.6 JTD 16v 1st cylinder compression sealing ring opening
Piston external diameter increase (mm) 0.1 0.20 ÷ 0.35
(mm) 2.0 JTD 16v
Piston external diameter - Class B (mm) 82.940 ÷ 82.950 2.0 JTD 16v
Measure Value Validity
Piston external diameter - Class C (mm) 82.950 ÷ 82.960 2.0 JTD 16v
Sealing ring seat on piston - 1st groove (mm) 2.120 ÷ 2.140 1.6 JTD 16v
Piston external diameter increase (mm) 0.1 2.0 JTD 16v
Sealing ring seat on piston - 2nd groove (mm) 1.800 ÷ 1.820 1.6 JTD 16v
Measure Value Validity Sealing ring seat on piston - 3rd groove (mm) 2.020 ÷ 2.040 1.6 JTD 16v
Sealing ring seat on piston - 2nd groove (mm) 1.550 ÷ 1.570 2.0 JTD 16v
Pins Sealing ring seat on piston - 3rd groove (mm) 2.020 ÷ 2.040 2.0 JTD 16v
The floating type pins are retained by two elastic rings
expansion which are located in the special cavities obtained on the hubs of the
Measure Value Validity
pistons.
Axial play 1st compression seal ring
Measure Value Validity 0.115 ÷ 0.170 1.6 JTD 16v
cylinders (mm)
Pin seat diameter (mm) 25.991 ÷ 25.996 1.6 JTD 16v
Axial play 2nd compression seal ring
25.982 ÷ 25.988 0.050 ÷ 0.090 1.6 JTD 16v
Pin external diameter (mm) 1.6 JTD 16v
cylinders (mm)
7
Machine Translated by Google
FIAT DOBLÒ
1. engine > technical data
1.6 JTD 16v The clutch clutch, positioned between the double flywheel and the gearbox,
Engine piston oil scraper ring axial clearance
0.030 ÷ 0.070 is made up of a rigid disk (without springs) which, having a reduced inertia, improves
(mm) 2.0 JTD 16v
ra the maneuverability of the gearbox.
The exhaust camshaft is driven directly by the belt 1.6 JTD 16v
Quarter shaft support diameter
toothed and transmits the motion to the intake distribution shaft, 43.046 ÷ 43.071
distribution (mm) 2.0 JTD 16v
via a pair of spur-toothed gears.
The exhaust distribution shaft also controls the depressor which Fifth shaft support diameter
1.6 JTD 16v
30.045 ÷ 30.070
is keyed on the gear side. The camshafts are made of cast iron, with distribution (mm) 2.0 JTD 16v
induction hardening on the cams.
8
Machine Translated by Google
FIAT DOBLÒ
1. engine > technical data
0,98 INJECTORS
Exhaust valve opening pressure (bar)
The electro-injectors are mounted on the cylinder head and controlled by
the injection control unit.
ELECTRIC FANS
The two-speed electric cooling fans allow you to PRESSURE REGULATOR
increase the heat dissipation capacity of the radiator and/or It is mounted on the pressure pump and controlled by the injection
condenser of the air conditioning system. It is controlled directly by thecontrol unit, it regulates the fuel supply pressure to the electro-
injection control unit. injectors.
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
1. engine > technical data
RAIL
The fuel distribution manifold (rail) has the purpose of dampening the resistant to high operating pressures, it has the shape of a very
pressure oscillations due to the three pumping strokes that occur at each lapelongated cylinder, in which a cylindrical cavity has been created, with a diameter o
pump and the injector openings. The rail, built in steel to resist for the entire length of the rail; the volume of the cavity is approximately 33 cm3.
AIR SUPPLY intake manifold a butterfly which has the task of closing the passage of
air to the cylinders.
Air supply circuit consisting of a paper filter placed in its
special box, an intake manifold and an intercooler for the AIR FILTER
cooling of the compressed air exiting the turbine compressor wheels. Paper air filter with replaceable element.
THROTTLE BODY
PNEUMATIC THROTTLE The quantity of incoming air is regulated when the throttle is opened,
Pneumatically controlled throttle body. it is then conveyed into each combustion chamber. The control of
To reduce engine noise when turning off (noise idling speed does not occur with a solenoid valve but is performed by
generated by the DVA dual mass flywheel), was introduced before the throttle actuator when it opens/closes the throttle itself.
• kilometers travelled
ANTI-POLLUTION • number of engine starting cycles
DPF SYSTEM
• number of cold starts
It is a mechanical filter that "traps" the carbonaceous particles
(particulate matter) and the ash of the engine oil present in the exhaust gas of• the engine.
average value of engine oil temperature
this.
The action of the DPF allows for a reduction of up to a maximum of approximately 90%.
carbonaceous particles. EGR SYSTEM
EGR (Exhaust Gas Recirculation) is used on engines
Operation to reduce nitrogen oxide (NOx) emissions.
The operation of the DPF system is managed, with specific strategies, by The mass of the recirculated gases is essentially composed of air that has
engine control unit. The DPF system, in addition to the accumulation participated in the combustion process, and by the products of combustion
trap, consists of an exhaust gas temperature sensor and a pressure sensor (Carbon dioxide, water vapor).
differential pressure. These last two chemical species have a higher heat capacity than the
The differential pressure sensor, via special pipes, detects the air they replace, and therefore the average heat capacity of the
exhaust gas pressure downstream and upstream of the trap signaling charge will be higher.
the gradual accumulation of particulate matter to the control unit. With the evolution of regulations on harmful emissions, EGR technology
The process of particulate accumulation and relative increase in exhaust has also undergone a notable evolution: it has gone from the simple on-
gas pressure inside the trap depends on the engine load, the weight of off valve to the gas modulating valve, then the
the vehicle, the engine displacement and power. exchanger for lowering the temperature of the recirculated gases.
Therefore, it is necessary to occasionally remove the particulate, The use of the heat exchanger was necessary because the recirculated
regenerating the trap according to a procedure that uses multiple injections of
gases, being at a higher temperature than the sucked air,
fuel to raise the temperature of the exhaust gases (approximately 600 °C) they increase the temperature of the charge entering the combustion
and then burn the particulates. chamber, decreasing the volumetric efficiency.
The regeneration procedure is controlled by the injection control unit By conveying the burnt gases into a heat exchanger, it is lowered
which acts: on the dosage of the fuel (up to 5 injections into the same the temperature thus allowing for a greater mass flow rate
engine cycle per cylinder) and on air control (EGR and pressure and a lower temperature of the charge with obvious benefits for that matter
supercharging). concerns the containment of NOx emissions.
The regeneration phase takes place in a few minutes and does not
EGR module
affect the continuity of torque supplied by the engine compared to normal operation.
When the driving profile does not allow automatic regeneration, the The new EGR module mounted on this engine as well as having a new
after a few failed attempts, the injection control unit activates a modulating valve, allows you to choose whether to cool the exhaust
"particulate trap clogged" warning light on the dashboard. gases or exclude their cooling, by implementing a by-pass.
It is therefore advisable to keep the car running until the "particulate
trap clogged" warning light goes off. This functionality is completely managed by the control unit
If the "particulate trap clogged" light still remains on, it is essential to engine, allows you to optimize the operation of the EGR in terms of
carry out forced regeneration using the diagnostic tool. reduction of nitrogen oxides, without however penalizing hydrocarbon
(HC) and carbon monoxide (CO) emissions.
10
Machine Translated by Google
FIAT DOBLÒ
1. engine > technical data
EGR exchanger
EGR modulating valve Allows the cooling of exhaust gases. It can be traveled or not
The modulating valve used for this engine is based on a new one from the exhaust gases depending on the position of the EGR cooling
operating principle where the movement of the plate is implemented by-pass valve
with a direct current motor and a special sensor detects its position.
Technical features
MAINTENANCE COOLANT
MOTOR OIL Name Classification
TIGHTENING TORQUES
Component Fixing Ø Value (daNm) Validity
Quickly M6 8 ÷ 10
Tappet cover
1.6 JTD 16v
Engine upper cylinder head Quickly M8 23 ÷ 28
2.0 JTD 16v
11
Machine Translated by Google
FIAT DOBLÒ
1. engine > technical data
12
Machine Translated by Google
FIAT DOBLÒ
1. engine > engine management
engine management
GENERALITY • fuel temperature control
• engine coolant temperature control
The Common Rail EDC-16C39 is a high-performance electronic fuel injection system • control of injected fuel quantity
pressure for fast direct injection diesel engines. • idle speed control
• cutting of the fuel during the release phase (Cut-off)
The main features are: • cylinder balance control from idle to 3,500 rpm
• anti-serration control
• availability of high injection pressures (1600 bar) • exhaust smoke control during acceleration
• possibility of modulating these pressures between 150 bar up to the maximum value of • exhaust gas recirculation (EGR) control
operating at 1600 bar • maximum torque limitation control
• maximum speed limitation control
• regardless of rotation speed and engine load
• check glow plugs
• ability to operate at high engine speeds (up to 5000 rpm at full load)
• control of the air conditioning system coming into operation (where applicable)
• precision of the injection control (advance and duration of the injection)
• auxiliary fuel pump control
• reduction in consumption
• control of the position of the cylinders
• reduction of emissions • advance control of main and multiple injections
• closed cycle control of injection pressure
• control of the electricity balance
• IMA injector calibration
The main functions of the system are essentially the following:
13
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
1. engine > engine management
Components
3 14
6 18 17
5
35
2
7 8
36
15
1
19
9
20
39
22
16
21
37
29
23 27 25
24
38
32 33 30
28 11
12
31
10
34
26
13
1. Fuel tank 2. Electric 14. Throttle body 25. Glow plug control unit 32. Particulate filter (DPF)
fuel pump 3. Fuel filter 4. 15. EGR valve 26. Turbine 33. Exhaust gas temperature
Fuel return manifold 16. Heat exchanger for EGR 17. 27. Variable sensor
5. High pressure pump 6. Fuel Exhaust gas delivery pipe to the geometry turbocharger pneumatic actuator 34. Particulate filter differential pressure
pressure regulator 7. intake casing 18. Pressure 28. Variable geometry sensor 35.
Single fuel manifold (rail) - air temperature sensor 19. Engine rpm turbocharger pneumatic actuator Accelerator pedal potentiometer 36.
sensor 20. Timing control solenoid valve 29. Engine control unit 37. Exhaust
8. Fuel pressure sensor 9. sensor 21. Coolant Variable geometry gas cooling by-pass
Electroinjectors temperature sensor 22. Engine turbocharger pneumatic actuator EGR
10. Air filter oil pressure position sensor 30. Lambda 38. Pneumatic actuator for exhaust gas
11. Air flow sensor 23. Engine oil level sensor probe 31. Catalyst cooling by-pass control for EGR
meter 12. Air 24. Glow plugs 39. Deflector control actuator on
compressor 13. Intercooler suction box (SWIRL)
14
Machine Translated by Google
FIAT DOBLÒ
1. engine > engine management
• engine
COMPONENTS rpm • coolant temperature • boost
The Common Rail system allows a pre-injection (pilot injection) to be pressure • air temperature
carried out before TDC with the advantage of reducing the pressure • quantity of air
derivative in the combustion chamber, reducing the combustion noise
intake • battery
level, typical of direct injection engines. voltage
The control unit controls the quantity of fuel injected, regulating the
• diesel pressure
line pressure and injection times. The information that the control
unit processes to control the quantity of fuel to be injected is: • accelerator pedal position
Components
11 12
13
10
14
9 15
16
8
17
18
6
19
5
20
4
21
3 22
2
23
1 24
29 25
28 27 26
1. Auxiliary fuel electric pump 2. Supercharging 10. Fuel pressure sensor 11. Air flow meter 20. ALFA CODE (via CAN network)
pressure control solenoid valve 3. Air 12. Coolant 21. Diagnostic socket (via CAN network)
conditioning compressor temperature sensor 13. Fuel temperature sensor 14. Cruise 22. Pressure regulator 23.
4. EGR solenoid valve 5. Tachometer Control (where provided) (via CAN network) Electroinjectors 24.
15. Air pressure and temperature sensor 16. Phase solenoid valve (on throttle body)
6. Electric fans 7. sensor 17. Rev sensor 26. Glow plug preheating warning light (via CAN network)
Glow plug preheating control unit 8. 18. Speedometer (via 27. Injection warning light (via CAN network)
Accelerator pedal potentiometer 9. Brake - CAN network) 28. Max water temperature indicator light (via CAN network)
clutch pedal switch 19. Battery 29. Water in fuel warning light (via CAN network)
INPUT SIGNALS Having said this, we can express lambda as the ratio between the
quantity of air sucked in and the quantity of air necessary for the
Lambda probe combustion of the injected fuel. The lambda values range from 0.65
This sensor is used to measure the oxygen content and the Lambda (rich mixture, lack of oxygen) to infinite (percentage of oxygen equal
value (ratio between the quantity of air sucked in and the quantity of to the percentage present in the air, approximately 20.95%).
theoretical air necessary for complete combustion of the injected The value measured by the lambda probe is compared with the
fuel) in the exhaust gases of automotive engines. lambda value calculated by the engine control unit and, if necessary,
When the mass of oxygen present coincides with that necessary to changes are made to the mapping of the injectors and the air flow
burn all the fuel, the mixture is called stoichiometric and its ratio is meter in order to maintain the functionality of the engine and harmful
equal to 14.6. In this case lambda conventionally takes on a unitary emissions within legal limits; its function is therefore to monitor the
value. engine over time.
15
Machine Translated by Google
FIAT DOBLÒ
1. engine > engine management
The sensitive element is planar, the probe is made up of three layers It is an NTC sensor, whose active part is a negative coefficient resistor,
zirconium oxide, this particular geometry allows for a very compact obtained by sintering.
sensor, with low intensity pumping currents that The nominal resistance is between:
further decrease the power absorption of the sensor.
2,5 kOhm ± 6% a 20° C
Nominal heater supply voltage Power 7.5 V
0,186 kOhm ± 2% a 100° C
dissipation at 7.5 V 7.5W
16
Machine Translated by Google
FIAT DOBLÒ
1. engine > engine management
ENGINE CONTROL UNIT 36 DPF differential pressure sensor signal (only for versions with DPF)
Mounted in the engine compartment on the right side, the control unit is of the "flash" type37 DPF differential pressure sensor ground (only for versions with DPF)
eprom” i.e. reprogrammable from the outside without intervening on the 38 Resume Cruise Control
hardware. The injection control unit has integrated the absolute pressure sensor.39 N.C.
17
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
1. engine > engine management
51 Lambda sensor heater control (only versions with lambda sensor) 4 Rail pressure regulator supply
74 Water presence sensor signal in the diesel filter 33 Cylinder 4 injector (-)
90 1st level of engine cooling electric fan 55 Intake air temperature sensor ground
56 Insufficient engine oil pressure
91 Low pressure pump relay control
57 EGR position sensor signal
92 Preheating glow plug warning light control
58 Engine coolant temperature sensor signal
93 Activation of glow plug preheating 59 Throttle solenoid valve control
94 Fan relay control 3 60 EGR solenoid valve
18
Machine Translated by Google
FIAT DOBLÒ
1. engine > engine management
Pin Description
51
Lambda sensor heater control (only for versions with probe
1 Battery positive lambda)
2
Battery negative 52 Glow plug preheating control unit diagnosis
3 Battery positive
53 Vehicle speed sensor (-)
4
Battery negative
54 Request to insert compressor
5 Battery positive
55 Starter motor relay control
6
Battery negative
7
56 SET + Cruise Control
Turbo pressure actuator
8
Potentiometer 2 on accelerator pedal (-) 57 Reverse switch signal
9
Potentiometer 1 signal on accelerator pedal 58 Trinary air conditioning signal/alternator “F” signal
10 Diesel temperature sensor (-) 59 N.C.
16 N.C. 64 Lambda sensor signal (only for versions with lambda probe)
17 Signal + Contact on brake pedal (NO) 65 Lambda sensor signal (only for versions with lambda probe)
18 N.C. 66 Oil temperature sensor signal
19 Alternator “L” signal 67 N.C.
27 Fuel consumption signal 74 Water presence sensor signal in the diesel filter
28 Key signal
75 Vehicle speed sensor signal
29 Negative signal for compressor activation relay control
76 Oil temperature sensor (-)
30 Potentiometer 1 on accelerator pedal (-)
77 Cruise “off”
31 Potentiometer 2 signal on accelerator pedal
78 Cruise “Set/Decrease”
32 Exhaust gas temperature sensor signal 2 (only for versions with DPF)
79 Signal - Contact on clutch pedal
33 Exhaust gas temperature sensor 2 mass (only for versions with DPF)
34 Exhaust gas temperature sensor signal 1 (only for versions with DPF) 80 Brake pedal secondary switch signal
35 Exhaust gas temperature sensor 1 mass (only for versions with DPF) 81 Quadrinary air conditioning signal
36 DPF differential pressure sensor signal (only for versions with DPF) 82 N.C.
37 DPF differential pressure sensor ground (only for versions with DPF)
83 CAN network (low channel)
38 Resume Cruise Control
84 CAN network (high channel)
39 N.C.
85 N.C.
40 Reserved digital input
41 N.C. 86 Lambda sensor ground (only for versions with lambda probe)
42 Reserved digital input 87 Lambda sensor signal (only for versions with lambda probe)
44 Differential pressure sensor (DPF) (+) (only for versions with DPF) 89 Reserved analogue input
45 Potentiometer 1 on accelerator pedal (+)
90 1st level engine cooling electric fan
46 Potentiometer 2 on accelerator pedal (+)
91 Low pressure pump relay control
47 Immobilizer interface
92 Preheating glow plug warning light control
48 Engine speed signal
93 Activation of glow plug preheating
49 Cruise Control warning light control
19
Machine Translated by Google
FIAT DOBLÒ
1. engine > engine management
Pin Description
Connector B (engine harness)
D004 Front / Engine Junction M015 Glow plug preheating control unit
D029 Junction of Engine Cables / Engine Services Cable N040 Electric fuel pump and level meter
D097 Short-circuiting junction N070 Electroinjector
D154 Dashboard/Bridle Junction Brake Pedal Switch N075 Integrated Throttle Body Actuator
D213 Fuel Tank Junction N077 Fuel Pressure Regulator
N087 Fuel Pressure Regulator on Rail
E050 Instrument panel
I030 Brake Pedal Switch
Clutch Pedal Switch COLOR CODES
I031
20
Machine Translated by Google
FIAT DOBLÒ
1. engine > wiring diagrams
Engine
21
Machine Translated by Google
FIAT DOBLÒ
1. engine > wiring diagrams
Engine
22
Machine Translated by Google
FIAT DOBLÒ
1. engine > wiring diagrams
Engine
23
Machine Translated by Google
FIAT DOBLÒ
1. engine > maintenance operations
maintenance operations
such as: crankshaft position sensor, Attention:
PRECAUTIONS AND TOOLS camshaft position sensor and motorized The lack of the resetting procedure
throttle. of the engine management control unit can
CONTROL UNIT RESETTING cause malfunctions of the engine itself.
ENGINE MANAGEMENT Self-adaptive procedure
The engine management control unit requires a For the self-learning procedure you need to Important:
appropriate reinitialization procedure a use an appropriate diagnostic tool in For vehicles with ESP, every time the battery is
following interventions on the engine. so that the engine management control unit is ondisconnected, the steering angle sensor loses its
This procedure must be carried out after able to assimilate the physical characteristics of basic adjustment. It is therefore necessary to calibrate it again
replacement of engine components mounted sensors and actuators. using an appropriate diagnostic tool.
SPECIFIC TOOLS
24
Machine Translated by Google
FIAT DOBLÒ
1. engine > maintenance operations
cover.
- Rotate the crankshaft in the direction of rotation
until the notch on the driven toothed pulley (1)
corresponds to the notch on the tappet cover
(2), thus bringing the first cylinder to TDC.
12 13 15 16
17
14
Phase points
5
11
7 8
- Check the collimation of the phase marks- - Fit the flywheel holding tool.
2
tura (9). - Place the service pulley on the crankshaft
- Fit the timing control toothed belt (10) back in its seat and secure it with the relevant
1
completely. M8 screws at a torque of 23 ÷ 28 Nm.
- Lever with a screwdriver in the hole (11) until - Remove the flywheel holding tool.
the tensioner index (12) is in the maximum - For subsequent assembly operations,
tension position (13). proceed in the reverse order of disassembly.
- Loosen the distribution control mobile
tensioner fastening nut (3).
- Remove and remove the timing control
toothed belt (4). ENGINE HEAD ASSEMBLY - Extract the vacuum hoses.
- Place the depression duct to the side.
Timing belt removal - Remove the fuel recovery pipe.
HEADING - Place the car on the lift. - Loosen the four retaining clips.
- Disconnect the battery. - Extract the fuel recovery pipe.
- Remove the timing belt. - Remove the high pressure duct and remove
- Detach the cable harness for motor management- the injectors.
re.
4 - Extract the compressor and catalyst Use:
temperature sensor connectors. Respect the cylinder 1, 2, 3, 4 sequence and note
- Remove the engine management module the positions.
cable harness.
3
- Remove the cable harness strip. - Remove the pressure accumulator by
- Remove the fixings and place the cable harness to loosening the clamp from the return hose.
the side. - Remove the supply air hose from the butterfly
- Disconnect the vacuum duct. valve.
25
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
1. engine > maintenance operations
- Remove the engine breather hose from the - Loosen the head. - Fix the head.
engine oil filler neck. - Tighten the head fixing screws to a torque
- Remove the brake servo vacuum line. Use: of 65 Nm + 90° + 90° + 90° in the sequence
Loosen the screws in the sequence shown. indicated below.
- Remove the depressor.
- Remove the oil filler neck. Screw removal sequence Tightening sequence
- Disconnect the coolant temperature wire
4 7
10
harness connector. 1
cams. 5 6
Gear removal
1
2 9
3 8
26
Machine Translated by Google
FIAT DOBLÒ
1. engine > maintenance operations
- Fit the supply air hose and tighten the clamps to - Tighten the M12 union nuts to a torque of 22 Nm. - Tighten the M14 union nuts to a torque of 33 Nm.
a torque of 3.5 Nm.
- Mount the pressure accumulator and tighten the - Tighten the M14 union nuts to a torque of 30 Nm. - Fit the oil recovery pipe and secure the retaining
fixing screws to a torque of 25 Nm. clips.
- Fit the injectors and replace the sealing rings. - Fit the high pressure pipe, taking care to replace - Fit the vacuum pipe and tighten the fixing screws
- Insert the four injectors with support. the delivery pipes. to a torque of 9 Nm.
- Fit high pressure ducts, taking care to replace - Tighten the M12 union nuts to a torque of 23 Nm. - Fit the engine management cable harness.
the delivery pipes. - Fit the toothed belt.
11
5
4 17
27
Machine Translated by Google
FIAT DOBLÒ
1. engine > maintenance operations
- Extract and remove the right half-shaft (1) complete Unscrew the nuts, the screws and remove the rigid Removal of power steering pipe
with intermediate half-shaft (2) and remove the engine support connection plate on the distribution
dust cover. side to the air capacity box.
Fit the tool (5) on the pressure pump support and 9
Crane assembly
2
8
7
- Place a suitable work bench (11) under the power
unit (12), then slowly lower the latter with the
1
hydraulic crane until the bench itself is resting on
it.
- Unscrew the screw, the bolt and remove the tie rod
6
reaction powertrain.
- Position the bracket (3) and secure it with the
screw (4) positioned in place of a clutch control
operator cylinder fixing screw.
Bracket assembly 5
Assembly -
Disengage the chains of the hydraulic crane from Tighten the nut securing the elastic plug to the rigid for supporting the powertrain-
the powertrain. support on the gearbox side of the powertrain to a re.
- Lower the car with the lift. torque of 99 Nm. - Place a hydraulic jack under the gearbox.
- Through the engine compartment, support the - Place a hydraulic jack under the engine.
powertrain with the hydraulic crane equipped with - Place the powertrain reaction rod in its seat and
suitable chains as previously indicated - Slowly lift - Disengage the chains of the hydraulic crane from secure it with the bolt at a torque of 88 Nm and the
the powertrain with the hydraulic crane until it is the powertrain. screw at a torque of 114 Nm.
repositioned in its seat in the engine compartment. - Unscrew the nuts and remove the tool from the
pressure pump support. - Tighten the intermediate half-shaft fixing screws
- Connect the pipe from the pump to the power - Place the rigid engine support connection plate to the relative support.
steering box, power steering box side and tighten on the distribution side to the air capacity box in its - Connect the steering tie rods to the front uprights
the relative fitting to a torque of 36 Nm. seat and tighten the screws and nuts. and tighten the relative nuts to a torque of 45 Nm.
Secure the pipe from the pump to the power - Remove the hydraulic jack previously positioned Tighten the front wheel hub nuts to the half-shafts
steering box to the fastening clamp to the front under the engine. to a torque of 70 Nm + 55° using the angle tightening
suspension cross member. - Unscrew the screw and remove the bracket from the gearbox tool.
28
Machine Translated by Google
FIAT DOBLÒ
1. engine > maintenance operations
Make two caulks (1) on the nut collar as shown - Connect the upper coolant inlet hose to the - Fit the flywheel holding tool.
in the figure. radiator, radiator side. - Unscrew the screws (6) and remove the clutch (7).
- Connect the lower coolant outlet hose from the - Undo the screws and remove the crankshaft
radiator, radiator side - Bleed the air from the pulley.
Removal of power steering pipe
power steering system as described below. - Remove the timing belt.
- Unscrew the left-hand screw (8) and remove the
- With the front wheels raised from the ground, toothed driving pulley (9).
with the engine off, carry out 4 - 5 cycles of
complete steering wheel rotation (right and left). Timing belt removal
- Check and if necessary top up the oil level in
the tank.
- Place the car on the ground and start the engine.
1
29
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
1. engine > maintenance operations
- Unscrew the screws (1) and remove the connecting Dismantling the piston and - Check that the cylinder liners ovality is within the
rod cap (2). connecting rod - Remove the snap rings. value of ÿ0.05 mm.
- Remove the lower connecting rod bearing half - Remove the pin by removing the snap rings and
(3). separate the connecting rods from the pistons. Use:
- Remove the connecting rod/piston assembly (4). - Remove the piston rings with the dedicated If the barrels have values that differ from those of the
- Remove the upper connecting rod bearing half (5). extractor. project, ream them according to the increase of 0.1 mm.
- Unscrew the screws (6) and remove the rear crankcase Checking and recomposing pistons
cover (7) with the integrated oil seal ring. - Check the squaring of the connecting rods - Tighten the M12 screws of the main caps to a torque
using suitable equipment; in case of imperfect of 24 ÷ 26 Nm + 90° of further angular tightening.
- Check that the crankshaft axial play is within the squaring, replace the connecting rod.
values of 0.049 ÷ 0.211mm, using a magnetic base - Check that the weight difference between the pistons - Check that the diameter of the main journal seats
equipped with a dial indicator. does not exceed 5 grams. falls within the values of 63.691 ÷ 63.732 mm.
- Check that the difference in weight between the - Visually check the conditions of the main and
Use: connecting rods is within the value of 2.5 grams. connecting rod half-bearings and, if necessary, replace
If the value of the axial clearance of the crankshaft does - Check that the diameter of the bushings in the pistons them.
not fall within the prescribed values, upon assembly, grind is within the value of 25.999 ÷ 26.004 mm. - Check that the thickness of the main bearing halves
the seat on the engine crankcase and use appropriately - Check that the external diameter of the pistons is within the values given below, if not, replace them.
oversized thrust half rings. corresponds to the values shown below.
- Check that the thickness of the connecting rod
External diameter (mm) bearing halves is within the values given below, if not,
- Unscrew the screws and remove the main caps (8). Class A Class B Class C replace them.
- Fit the upper main bearing halves onto the crankcase.
- Remove the lower main bearing halves 81,783 ÷ 81,797 81,793 ÷ 81,807 81,803 ÷ 81,817
Luce (mm) - Fit the main caps and tighten the M12 screws to a
Oil torque of 24 ÷ 26 Nm + 90°.
1st ring 2nd ring
scraper ring - Fit the pistons into the cylinder block.
- Fit the upper connecting rod bearing halves onto the
0,25 ÷ 0,40 0,25 ÷ 0,50 0,25 ÷ 0,50 connecting rod head.
11
8
- Apply the Plastigage calibrated wire to measure the
- Fit the piston rings on the piston and check that the clearance of the connecting rod pins.
9
1 axial clearance between the second ring and the - Tighten the M9 screws (16) to a torque of 24 ÷ 26 Nm
relative seat on the piston is within the value of 0.002 + 60°.
2 10
÷ 0.006 mm.
Tightening connecting rod caps
6 3 12 Checking and reassembling the monobloc
- Carefully wash all the dismantled components.
5
30
Machine Translated by Google
FIAT DOBLÒ
1. engine > maintenance operations
- Fit the front crankcase cover with integrated - Fit the anti-torque tool. - Position the cylinder head centering bushes
oil pump complete with suction tube and - Mount the flywheel and apply Loctite 573 on the crankcase.
gasket and tighten the M6 screws to a torque threadlocker to the M12 screws and tighten - Fit the chosen cylinder head gasket.
of 8 ÷ 10 Nm. them to a torque of 136 ÷ 168 Nm.
- Fit the seal ring onto the oil pump using the - Fit the toothed driving pulley and tighten the Use:
introducer. left-handed M16 screw to a torque of 306 ÷ 378 The cylinder head gasket is of the Astadur type.
- Apply the silicone sealant around the entire Nm. The material it is made of undergoes a
perimeter of the crankcase cup. - Fit the power steering pump complete with polymerization process during engine operation,
- Fit the crankcase cup. support bracket. so that it hardens considerably during use.
- Tighten the side screws (1) of the cup to a - Fit the fixed timing control tensioner.
torque of 21 ÷ 26 Nm.
- Tighten the front screws e in a crisscross pattern - Fit the powertrain support on the distribution - Tighten the head screws to a torque of 65 Nm
rear (2) from M6 of the cup to a torque of 7 ÷ 9 side. + 90° + 90° + 90° of further angular tightening.
Nm. - Fit the automatic belt tensioner for the - Fit the coolant manifold.
auxiliary control belt. - Connect the oil inlet and return pipes to the
Oil sump assembly - Mount the heat exchanger and secure it with turbocharger.
the relative pin. - Fit the protection of the oil return pipe into
- Measure the protrusion of the pistons on two the sump from the turbocharger.
points, at 180° on the piston pin axis and - Tighten the exhaust manifold bracket nut to the
2
average the two values measured for each piston. crankcase.
- Choose the thickness of the head gasket to - Fit the gasket.
use, based on the maximum value between the - Connect the exhaust gas recirculation pipe.
averages of the protrusion of each single - Fit the exhaust gas recirculation pipe heat
plunger. shield and tighten the bracket screw.
1
- Fit the turbo-compressor heat shield.
Piston Number of Gasket
protrusion holes thickness - Connect the condensed oil recovery hose to
- 0,020 ÷ 0,100 0 0,82 ± 0,05 the crankcase sump.
- Connect the oil vapor recovery hose to the
0,101 ÷ 0,200 1 0,92 ± 0,05 crankcase and the head.
0,201 ÷ 0,295 2 1,02 ± 0,05 - For subsequent assembly operations,
proceed in the reverse order of disassembly.
FUEL SUPPLY - Unscrew the fittings (7), (8) and remove the
pipes from the fuel manifold to the electro-injectors
HIGH FUEL PUMP Assembly - (9).
PRESSURE Place the pressure pump in its seat and tighten
it with the M8 nuts (1b) to a torque of 25 Nm. Removal of pipes
Disassembly
- Place the car on the lift. - Tighten the M14 pressure pump control pulley
7
- Disconnect the battery and remove the Poly- nut to a torque of 50 Nm.
V belt and the timing belt. - Connect the electrical connection to the fuel
- Unscrew the screw securing the guide tube pressure regulator.
for the engine oil level dipstick to the pressure - Tighten the guide tube fixing screw for the 9
31
Machine Translated by Google
FIAT DOBLÒ
1. engine > maintenance operations
- Make sure the ignition key is in - Fix the electric fuel pump with the relative ring
STOP position, then disconnect the (-) terminal 2
nut using the tool for tightening the latter.
of the battery.
- Using the levers, lift the rear seat cushion, - Connect the quick couplings of the fuel delivery
move aside the floor covering so as to be able and return pipes to the electric fuel pump.
to access the fuel pump protection cover. 3
LUBRICATION - Fit the oil pressure relief valve and tighten the Assembly
relative cap. - Place the water pump complete with O-
OIL PUMP - Fit the driven gear and the driving gear. Ring in its seat and secure it with M8 screws
The oil pump can only be removed from the at a torque of 23 ÷ 28 Nm.
engine block with the engine positioned on the - Fit the oil pump cover. - Place the phase sensor back in its seat.
bench for overhaul. - Tighten the M12 screw securing the driven
toothed pulley to a torque of 108 ÷ 132 Nm.
Disassembly COOLING DOWN - For subsequent assembly operations, proceed
- Unscrew the screws (6) with an impact in the reverse order of disassembly.
screwdriver and remove the oil pump cover (7). WATER PUMP
- Remove the drive gear (8). THERMOSTAT
- Remove the driven gear (9). Disassembly
- Unscrew the cap (10) and remove the oil - Place the car on the lift. Disassembly
pressure relief valve (11). - Disconnect the battery. - Place the car on the lift.
- Remove the crankshaft front oil seal. - Remove the protection underneath the engine. - Disconnect the battery.
- Remove the timing side engine rigid support. - Remove the protection underneath the engine.
Oil pump breakdown - Unscrew the screws and remove the rigid pipe
- Remove the front wheels. from the EGR solenoid valve to the throttle body.
6
- Remove the additional wheel arches. - Disconnect the electrical connection from the
- Remove the service belt. EGR system solenoid valve.
7 - Remove the timing belt - Unscrew the - Unscrew the screws (15) and disconnect the
8
driven toothed pulley screw using a lever as an water/exhaust gas heat exchanger (16) from the electro-
anti-torque. EGR valve.
9
- Unscrew the screws and move the phase sensor - Unscrew the screws (17) and remove the EGR
without disconnecting the relative electrical connection.solenoid valve (18).
- Unscrew the screws (12) and remove the water - Remove the bracket (19).
11 pump (13) complete with O-Ring (14).
EGR exchanger removal
Water pump removal
18
19
10
Reassembly -
Check that the radial clearance between 17
32
Machine Translated by Google
FIAT DOBLÒ
1. engine > maintenance operations
- Unscrew the screws and remove the throttle body. Thermostat removal - Remove the front bumper and the intercooler.
- Disconnect the electrical connection from the - Suitably secure the condenser of the air
turbocharger vane position actuator control 12 conditioning system, unscrew the fixing screws
solenoid valve. and compress the clip to disconnect it from the
- Disengage the turbocharger vane position 9 radiator.
actuator control solenoid valve from the protection - Disconnect the quick coupling of the water
on the gearbox. outlet pipe from the radiator and move it to the side.
- Disconnect the electrical connection (1) from - Loosen the clamp and disconnect the system
the engine coolant temperature sensor. supply pipe from the radiator.
- Disconnect the electrical connection of the resistor-
- Disconnect the upper coolant inlet sleeve to re.
Disassembly
- Place the car on the lift.
2
Assembly - Close the air bleed screw.
- Mount the electric fan and secure it with the - Top up the liquid further until the tank level
3
relative screws. reaches the MAX mark.
4 - Place the radiator on the support crosspiece.
- Connect the electrical connection of the electric - Fit and screw firmly the cap on the expansion
fan. tank.
- Connect the system supply pipe to the radiator - Start the engine and leave it at idle for
- Disconnect the engine coolant inlet pipe from and tighten the relative clamp. approximately two minutes.
the exhaust gas heat exchanger for EGR - Fit and connect the water outlet pipe from the - Bleed the circuit of residual air by carrying out
radiator with the relative quick coupling. periodic and gradual accelerations (every 30
- Disconnect the engine coolant outlet pipe from - Tighten the upper radiator fixing screws. seconds) up to a speed of approximately 3,000 rpm
the exhaust gas heat exchanger for EGR. - Connect the electrical connection of the resistor. minutes.
- Fit and connect the water inlet pipe to the
- Disconnect the electrical connections from the radiator with the relative quick coupling. Use:
electro-injectors and move the electrical wiring to - Proceed with refueling and bleeding the cooling If during this phase you observe a drop in the coolant
the side. system. inside the expansion tank, proceed with refueling until
- Unscrew the fixing screws of the water/exhaust the MAX mark is reached.
gas heat exchanger for the EGR system REFUELING AND BLEEDING
cylinder head.
- Unscrew the nut (7) of the water/exhaust gas Refueling and Bleeding - Stop the engine and let it cool.
heat exchanger for the EGR system at the head - Close the liquid drain cock and keep the air - Top up if necessary with coolant until reaching
cylinders. bleed screw open. the MAX mark.
- Unscrew the pin (8), the screw (9) and remove - Proceed to fill the circuit with the prescribed - At the end of the aforementioned operations,
the thermostat (10) together with the EGR heat liquid through the expansion tank filler, until the make sure you have introduced a quantity of
exchanger (11). liquid comes out of the air bleed screw. liquid into the system at least equal to that
- Remove the thermostat gasket (12). recovered during the emptying phase.
33
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
1. engine > maintenance operations
Turbocharger removal
SUPERCHARGING
TURBOCHARGER
Disassembly
- Place the car on the lift.
- Unscrew the screws and remove the lower
and upper exhaust manifold heat shield. 3
34
Machine Translated by Google
FIAT DOBLÒ
2. clutch > technical data
2. clutch
technical data
GENERALITY
Driven disc external diameter (mm) 230
The clutch is of the single dry disc type, with the release bearing always in
contact with the pressure plate spring. The dragging of the driven disk Driven disc internal diameter (mm) 155
The connection of the pipe to the actuator is carried out via a quick TIGHTENING TORQUES
coupling with integrated bleeding.
The absence of a crank mechanism in the traditional system, the adoption of Component Fixing Ø The value of Nm
a clutch pump with the body and piston made of plastic material and the Clutch mechanism Quickly M8 25 ÷ 31
use of plastic materials also for the construction of the pedals has also Hydraulic clutch actuator Quickly M8 18 ÷ 22
allowed a notable reduction in noise and the overall weight of the system.
Clutch master cylinder (pump). Given M8 12 ÷ 18
35
Machine Translated by Google
FIAT DOBLÒ
2. clutch > maintenance operations
maintenance operations
- Unscrew the handwheel of the tool until the Assembly
MECHANICAL PART diaphragm spring of the clutch mechanism is released.
- Position the clutch disc on the flywheel
it is.
CLUTCH DISC - Remove the previously mounted tools. Use:
When assembling the clutch disc, observe the
Disassembly - Remove the clutch mechanism (5) and the disc assembly direction identified by the writing “side
clutch. engine” or “gearbox side”.
Use:
Operation to be carried out with the gearbox removed. - Position the clutch mechanism and rotate the
Removing the clutch assembly
handwheel of the tool until the pins are brought to
- Fit the flywheel anti-torque tool contact with the disc.
(1). 5 - Unscrew the handwheel of the tool until the
- Unscrew three clutch mechanism fixing screws diaphragm spring of the clutch mechanism is released.
by 120 degrees. it is.
- Fit the extractor tool (2) and the tool - Remove the previously mounted tools.
centering (3) by screwing the pins into the seats
screws previously removed. - Tighten the remaining fixing screws by hand
- Rotate the handwheel of the tool until the pins clutch device.
are in contact with the disc. - Progressively tighten the screws diagonally
4
- Unscrew the remaining clutch mechanism fixing 1 2
fixing the clutch device until the torque of 12 ÷
3
screws (4). 15 Nm is reached.
36
Machine Translated by Google
FIAT DOBLÒ
2. clutch > maintenance operations
Assembly
- Position the secondary cylinder and tighten the relative nuts to a torque of 12 ÷ 18 Nm.
- Connect the vibration damper to the master cylinder with the relative retaining clip.
- Connect the clutch system supply hose and tighten the relative clamp.
- Fit a new holding device on the clutch pedal.
- Press connect the master cylinder tip to the retaining device on the clutch pedal.
- Bleed the clutch/brake hydraulic system.
HYDRAULIC CIRCUIT
Bleeding
- Remove the brake-clutch fluid reservoir cap and connect suitable equipment to the reservoir itself.
Use:
To prevent impurities from entering the brake-clutch fluid reservoir, before unscrewing the cap, carefully clean it and the entire upper surface of the
reservoir adjacent to the filler.
- Remove the protective cap and connect the recovery device (pipe and tank) to the drain fitting of the coaxial actuator.
- Lift the clip one click and move the hose back to the bleeding position.
- Slowly open the equipment tank tap.
- Wait until the air contained in the clutch release hydraulic system has completely escaped.
- Connect the flexible hose to the coaxial actuator and secure it with the relative retaining clip.
- Remove the recovery device (pipe and tank).
- Remove the brake-clutch bleeding equipment.
- Check correct clutch release and gear engagement.
- Check the correct fluid level in the brake/clutch reservoir.
37
codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
3. C510.5 gearbox > technical data
3. change C510.5
technical data
GENERALITY I'm in sync. The external controls are double flexible. The gearbox
configured with a "closed bottom" with the elimination of the rear
Five-speed transverse gearbox (C510.5) with two shafts supported by cover. This contains and supports the primary and secondary shafts, the rods a
tapered bearings and additional shaft for the double idler RM with clutch the gear engagement forks and the gear selection/engagement device.
Gearbox 510.5
4 6 7 14
2 3 5
12
1
11
16
1. Primary shaft
2. 5th speed drive gear
9
3. 4th speed drive gear
4. 3rd speed drive gear 10
8
5. 2nd speed drive gear
6. 1st speed drive gear
7. RM drive gear 13
8. Secondary tree
9. Satellites
10. Planetarium
11. Ring gear
12. Coaxial clutch control device
13. Gear box 15
TRANSMISSION RATIOS
Type C510.5
I
3,909
II 2,238
III 1,444
Transmission reports
IV 1,029
IN 0,838
RM 3,909
38
Machine Translated by Google
FIAT DOBLÒ
3. C510.5 gearbox > technical data
PRIMARY SHAFT
The primary shaft consists of the gears of the 1st speed, RM and 2nd
speeds obtained from the piece and from the gears of the 3rd, 4th and 5th speed,
mounted on needle bearings, with the relevant synchronizers.
The shaft rotates on two ball bearings.
Primary tree
DIFFERENTIAL
The differential consists of a cylindrical reduction pair and a
differential box made in a single piece which integrates planetary gears and
satellites.
The differential housing is supported by two tapered bearings and has fixed
the cylindrical crown using screws.
Differential
Synchronizers
1
The synchronizers of the 3rd, 4th and 5th speeds, mounted on the main shaft 1. Gearbox differential internal box
allow to reduce the clutch loads during the synchronization phase and the mechanical
gearbox noise in neutral. 2. Differential planetaries/ satellites
The control device is keyed onto the end of the primary shaft mechanical gearbox
2
coaxial clutch 3. Gearbox differential planetary carrier
mechanical shoulder rings
SECONDARY SHAFT mechanical gearbox differential
The secondary shaft consists of the gears of the 1st and 2nd speed, 4. Gearbox differential crown 5
mechanical
mounted on needle bearings, with the relative synchronizers and by the 3rd,
4th and 5th speed gears keyed onto the shaft. 5. Internal shaft bearing 4
3
The shaft is supported by a roller bearing on the pinion side and by a ball mechanical gearbox differential
bearing on the cover side.
TIGHTENING TORQUES
39
Machine Translated by Google
FIAT DOBLÒ
3. gearbox C510.5 > maintenance operations
maintenance operations
operations without detachment of the gearbox
Removing the fuel cap
LUBRICANT
GEARBOX OIL C510.5
- Remove the filler cap from the gearbox and check that the oil level touches the lower edge of
the filler hole (1).
- If necessary, top up the level with specific transmission oil through the filler hole.
GEARBOX GROUP - Unscrew the screws (3) and remove the lower - Unscrew the screws (9) and move the clutch
radiator cross member (4) complete with control operating cylinder (10) sideways
REMOVING GEARBOX FROM radiator (5), electric fans, air conditioner without disconnecting the relevant pipe.
CAR condenser (6), power steering system heat
exchanger (7) and air-air heat exchanger (8 ). Removal of operator cylinder
radiator side.
- Unclip the electrical wiring from its fixings 10
40
Machine Translated by Google
FIAT DOBLÒ
3. gearbox C510.5 > maintenance operations
- Disconnect the gear engagement hose (1) and - Unscrew the nuts and disconnect the steering tie Crane assembly
unscrew the screws (2) and move the gear rods from the front uprights with the tool.
engagement/selection hose support (3) sideways. - Unscrew the screws fixing the intermediate half-
shaft to the relative support.
Removing the gear shift hose - Extract and remove the right half-shaft (9)
complete with intermediate half-shaft (10) and
remove the dust cover.
16
15
2 Dust cover removal
14
3
13
- Disconnect the electrical connections (4) and (5) 10
- Unscrew the nut (6) and disconnect the ground 9 - Unscrew the fixing screw of the front support
cable (7). elastic plug on the distribution side of the powertrain.
Removal of control unit connectors - Unscrew the nut securing the elastic plug to the
7
rigid support on the gearbox side of the power unit.
6
4
- Extract and remove the left half-shaft. - Unscrew the fitting (17) and disconnect the pipe
- Place a hydraulic jack under the gearbox. from the pump to the power steering box (18), on
the power steering box side.
- Unscrew the screw, the bolt and remove the tie rod - Unclip the pipe from the pump to the power
reaction powertrain. steering box from the fastening clamp to the front
- Position the bracket (11) and secure it with the suspension cross member.
screw (12) positioned in place of a clutch control
operator cylinder fixing screw. Removal of power steering pipe
5 Bracket assembly
17
- Unscrew the nut and move the glow plug control 12
unit sideways.
- Remove the wiring complete with electrical
connections from the engine compartment bulkhead.
18
- Disconnect the quick coupling of the fuel return
pipe on the fuel return manifold pipe side and
disengage the pipe itself from the fastening.
11
41
codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
3. gearbox C510.5 > maintenance operations
- Place a suitable work bench (1) under the - Place a hydraulic jack under the engine. - Place the protection back in its seat and secure
powertrain (2), then slowly lower the latter with it with the relative nuts.
the hydraulic crane until it rests on the bench - Disengage the chains of the hydraulic crane - Place the clutch/gear selection hose support in
itself. from the powertrain. its seat and secure it with the relative screws.
- Unscrew the nuts and remove the tool from the
Support bench positioning pressure pump support. - Connect the gear shift hose.
- Place the rigid engine support connection plate - Connect the electrical connections to the fuse/
on the distribution side to the air capacity box in contactor switch box and place it back in its place.
its seat and tighten the screws and nuts. - Place the cover of the fuse/contact switch box
- Remove the hydraulic jack previously back in its seat.
positioned under the engine. - Connect the power cable to the fuse/contactor
- Unscrew the screw and remove the bracket from the gearbox switch box and secure it with the relative nut.
Slowly lift the powertrain with the hydraulic pipe on the fuel collector pipe side and secure - Bleed the air from the power steering system
crane until it is repositioned in its seat in the the pipe itself. as described below.
engine compartment. - Position the wiring complete with electrical - With the front wheels raised from the ground,
- Connect the pipe from the pump to the power connections through the passage on the engine with the engine off, carry out 4 - 5 cycles of
steering box, power steering box side and tighten compartment bulkhead. complete steering wheel rotation (right and left).
the relative fitting to a torque of 36 Nm. - Tighten the cable gland fixing nuts. - Check and if necessary top up the oil level in
- Fasten the pipe from the pump to the power - Place the glow plug control unit back in its seat the tank.
steering box to the fastening clamp to the front and secure it with the relative nut. - Place the car on the ground and start the engine.
suspension cross member. - Connect the ground cable and tighten the
- Tighten the nut securing the elastic plug to the relative nut. - Carry out 4-5 cycles of complete steering wheel
rigid support on the gearbox side of the - Connect the electrical connections to the rotation (right and left).
powertrain to a torque of 99 Nm. electronic diesel injection system control unit. - Restore the oil level in the tank.
42
Machine Translated by Google
FIAT DOBLÒ
4. transmission > technical data
4. transmission
technical data
GENERALITY
The half-shafts, with constant velocity joints on the wheel side and tripod joints on the differential side, constitute the "transmission" assembly which has the task of transmitting
transfer the motion from the gearbox to the driving wheels.
Semiassi
1
2
1. Wheel side constant velocity joint
3
2. CV joint retaining ring
3. Protective cap
4. Semialbero
4
5. Protective cap
6. Tripod joint
7. Tripod joint retaining ring
8. Gearbox side joint
TIGHTENING TORQUES
43
Machine Translated by Google
FIAT DOBLÒ
4. transmission > maintenance operations
maintenance operations
OPERATIONAL PRECAUTIONS - Do not use open flames. During disassembly, check that the parts that
All operations must be carried out with the - Make sure that a fire extinguisher is available must be marked bear the reference marks.
utmost attention and care to avoid injury to near the work area.
people. Upon reassembly, lubricate the parts, where
The engine compartment contains many moving All operations must be carried out with the necessary, to prevent meshing or seizures
parts, high temperature components and live utmost attention and care to avoid damage to during the initial period of operation.
electrical cables. the components. When reassembling it is essential to respect
Scrupulously follow the following precautions To loosen solidly adherent parts, give light the tightening torques and adjustment data.
blows using an aluminum or lead hammer if
when carrying out operations in the engine compartment. At each reassembly, replace the seals, oil seals,
- Turn off the engine and wait until it has cooled dealing with ferrous materials; use a wooden elastic washers, safety plates, self-locking nuts
down. or resin hammer for light alloy parts. and all parts that are damaged.
- Not smoking.
HALF SHAFTS AND JOINTS - Fold the brake disc/wheel hub assembly WHEEL SIDE JOINT
downwards.
DRIVE SHAFT - Remove the half-shaft from the coupling on the Disassembly
wheel hub. - Place the half-shaft in a vice.
Disassembly - Open the clamp securing the half-shaft to the - Remove the fixing band and move the
- Place the car on the lift. differential. protective cover back.
- Remove the front wheels. - Remove the half-shaft complete with constant - Remove the constant velocity joint from the half-shaft
- Unscrew the cap on the gearbox and drain the velocity joint and tripod joint. ro.
gearbox oil - Clean the internal bearing housing area from
Assembly - grease, then using the tools (5), (6) and
Use: Check that the half-shaft is intact. simultaneously acting with pliers on the
The removal and reattachment of the left half-shaft - Check that the boots are not damaged and retaining ring located inside the joint, remove
is described and illustrated below; operate in a that there is lubricating grease inside. the fixing ring ( 7) of the constant velocity joint
similar manner also for the removal/ reconnection - Engage the tripod joint on the differential. bearing
of the right half-shaft, keeping in mind, however, - Lock the half-shaft to the flange with a new tico.
that it connects to the intermediate half-shaft rather clamp. - Then remove the protective cap (8) by
than to the internal differential half-shaft. - Fit the constant velocity joint onto the wheel removing the fixing strap (9).
hub.
- Using a hammer and a suitable chisel, loosen - Reposition the brake disc/wheel hub assembly
and then unscrew the nut in its seat. Joint breakdown
(1) fixing the wheel hub. - Tighten the M10X1.25 fixing bolts of the shock
- Unscrew the fixing bolts (2) of the upright absorber strut to a torque of 120 Nm.
of the shock absorber. 5
- Unscrew the fixing nut (3) and using the tool - Place the steering tie rod head pin in place.
(4) remove the steering head from the upright. 6
9
3
1
Assembly
4
- Check that the half-shaft does not show any
deformations or runout in the engagement area.
of the joint and that the area in contact with the
sealing gasket is not worn.
44
Machine Translated by Google
FIAT DOBLÒ
4. transmission > maintenance operations
Disassembly
- Place the half-shaft in a vice.
- Remove the snap ring (1) and remove
the tripod joint (2) from the half-shaft. Assembly
- Remove the fixing band (3) and move - Replace the boot and the sealing bearing.
the protection guard (4) back. - Position the sealing boot-bearing assembly on the half-shaft.
45
codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
5. steering > technical data
5. steering
technical data
GENERALITY
The steering assembly is equipped with a telescopic steering column and power steering for all versions. This type of system guarantees
safety and driving precision at high speeds, easy handling and limited effort during parking maneuvers and at low speeds.
Steering assembly
STEERING GEAR
The mechanical rack guide box is of the traditional type and characterized by a fixed ratio of 32 mm/rev.
POWER STEERING a distribution valve. The latter is controlled according to the effort
detected by a torsion device located at the end of the worm screw,
VANE PUMP The on the steering column side.
vane pump is driven directly by the engine via belt and is able to
supply the system with a supply pressure varying between 3.5 and POWER STEERING BOX
85 bar. Depending on the torque transmitted from the steering wheel to the
torsion device, the pressurized oil is sent to the tank (recirculated),
POWER STEERING BOX or into one of the two chambers of the operating cylinder.
The power steering box is of the rack type; an operating cylinder The force generated by the oil pressure on the surface of the plunger
has been created inside it, in which a double-acting piston slides, determines the power assistance provided by the device, particularly
integral with the rack rod. In the seat of the worm screw there is for the vehicle in question.
46
Machine Translated by Google
FIAT DOBLÒ
5. steering > maintenance operations
TIGHTENING TORQUES
Mechanical part
Component Fixing Ø The value of Nm
Adjustable Steering Tie Rod Heads (CS) Given M14 x 1.5 (On steering box arm) 85
Hydraulic part
Component Fixing Ø The value of Nm
Power Steering Pump Control Pulley Screw M8 (Power steering pump side) 23 ÷ 28
Power Steering Box Tie Rods (S) Given M10 (Wheel upright side) 45 ÷ 55
Power steering pump/box hose Connection M14 (Power steering box side) 36 ÷ 44
Power steering pump/box hose Connection M16 (Power steering pump side) 36 ÷ 44
Power steering pump/box hose Connection M14 x 1.5 (On power steering box) 40
Power steering pump/box hose Connection M16 x 1.5 (On power steering pump) 40
maintenance operations
COCKPIT SIDE - Remove the column covering. - Unscrew the fixing screw and disconnect the coupling
Disconnect the electrical connectors (4) of the switch cardan of the steering column.
STEERING WHEEL AND COLUMN and. - Remove the Code antenna from the switch
- Loosen the fixing screw (5) of the collar (6), start-up.
Disassembly which fixes the switch to the column. - Disconnect the electrical connectors of the
- Disconnect the negative battery terminal. - Open the retaining clip (7) and position a ignition switch and place the
- Position the front wheels perfectly side of the cable harness. wiring.
straight and mark the position of the steering wheel - Remove the steering switch (8) from the column. - Unscrew the fixing nuts (9) and remove the
with the upper half-box. steering control shaft support.
- Disconnect the electrical connection (1) of the starter Removal of steering column
acoustic viewer. Column removal
6
47
Machine Translated by Google
FIAT DOBLÒ
5. steering > maintenance operations
Assembly - Connect the universal joint of the steering - Position the steering wheel in the appropriate
- Position the steering control shaft support column and tighten the fixing screw to a torque seat, checking that the marks previously made on the
and tighten the fixing nuts to a torque of 28 Nm. of 37 Nm. steering wheel and on the half box coincide.
- Mount the switch on the column and screw - Tighten the steering wheel fixing nut to a torque
- Fit the antenna on the ignition switch. the collar fixing screw. of 50 Nm.
- Fasten the electrical wiring to the clamp - Position the protection ring and connect the
- Connect the electrical connectors of the ignition restraint. electrical connection of the horn.
switch. - Connect the electrical connectors of the switch. - Connect the negative terminal of the battery.
ENGINE COMPARTMENT SIDE POWER STEERING PUMP - Connect the delivery pipe from the pump to
power steering box, power steering pump side e
STEERING GEAR Disassembly screw without tightening the relevant fitting.
- Place the car on the lift. - Place the power steering pump back in its seat
Disassembly - Remove the front wheels. tighten the relative fixing screws to the torque
- Place the car on the lift. - Remove the drive belt 23 Nm.
- Remove the front wheels. re. - Tighten the valve fitting to a torque of 36 Nm
- Unscrew the bolt securing the lower steering - Remove the service pulley and the tensioner delivery pipe from pump to power steering box,
column shaft to the pinion on the power steering mobile. power steering pump side.
box; place the lower shaft to the side - Remove the fixed tensioner of the service belt. - Connect the supply pipe from
steering column. fluid tank to the power steering pump, tank side
- Unscrew the fixing screws of the support - Remove the liquid return pipe and tighten the relative clamp.
bracket of the flexible control transmissions e cooling to the cooling supply tank - Place the power steering fluid reservoir in its
gear engagement. engine cooling after disconnecting the seat and secure it with the relative screws.
- Place a container underneath the vehicle pipes and unscrewed the relative fixings. - Place the upper support back in its seat
for liquid recovery, then disconnect on Unscrew the lower tube fixing screw alternator and secure it with the relative screws
steering gear the liquid inlet pipe (1). engine oil dipstick. to the engine base.
under pressure from the pump and the pipe (2). - Remove the fuel filter and valve - Tighten the upper alternator fixing bolt to a
liquid return to the tank. EGR. torque of 45 Nm.
- Release the pipes from the retaining clamp - Disengage the electrical wiring from the fixings - Fix the electrical wiring to the relative fixings on the
(3). on the pressure pump support. pressure pump support.
- Unscrew the upper bolt securing the alternator - Place the dipstick tube back in its seat
Removal of pipes to its support. complete engine oil and tighten the upper screw.
- Unscrew the power steering fluid reservoir - Tighten the lower tube fixing screw
3
fixing screws. engine oil dipstick.
1
- Raise the power steering fluid reservoir as - Place the return pipe back in its seat
necessary, loosen the clamp and disconnect the coolant to the engine cooling supply tank, then
supply line from fluid tank to power steering secure it
2
pump, tank side. and connect the relevant pipes.
- Loosen the connection of the delivery pipe - Place the power steering pump pulley back in
from the pump to the power steering box, pump side its seat and secure it to the pair with the relative screws
power steering. di 23 Nm.
- Unscrew the screws then lift it as much as necessary - Connect the quick coupling of the hose
power steering pump. return, heat exchanger tube side.
- Completely unscrew the previously loosened - Refill the power steering circuit with TUTE oil -
fitting and disconnect the pipe LA GI/A for a quantity of 1.3 litres.
- Unscrew the fixing nut of the articulated heads delivery from pump to power steering box, side
of the steering tie rods (right and left). power steering pump. Bleeding
- Using the extractor tool, remove the - Remove the power steering pump complete with - With the front wheels raised from the ground,
tie rod heads from the seats on the uprights. supply line from fluid tank to power steering with the engine off, carry out 4 - 5 cycles of
- Lower the central tie rod to access pump. complete steering wheel rotation (right and left).
attach to the fastening of the power steering box. - Check and if necessary restore the
Assembly oil level in the tank.
Assembly - Position the power steering pump complete with - Place the car on the ground and start the engine.
- Fit the power steering box in its relative position supply pipe from fluid tank to power steering - Carry out 4-5 cycles of complete rotation
seat by passing it between the front cross member pump near its steering wheel (right and left).
and the differential box. site. - Restore the oil level in the tank.
- Rotate the power steering box and insert the
pinion of the box in the appropriate hole obtained
on the body.
- Tighten the bolts securing the power steering
box to the front crossmember.
- Fix the fitting to the power steering box
of the liquid return pipe from box a
reservoir.
48
Machine Translated by Google
FIAT DOBLÒ
6. suspensions > technical data
6. suspensions
technical data
GENERALITY telescopic, double acting. For the people transport versions there
is also a solution with a rear torsion bar which, tied to the frame
Front suspension with independent wheels, McPherson type with and connected at the ends to the wheel hubs, allows, during the
forged steel swinging arms anchored to an auxiliary cross member. compression phase of the leaf spring, to reduce the rolling effect improving tr
Offset coil springs and double-acting telescopic hydraulic shock The front and rear wheel hubs of the equipped versions have an
absorbers. Anti-roll torsion bar. The rear suspension is of the "rigid instrumented bearing for active sensors that replaces the tone
axle" type with single leaf springs and hydraulic shock absorbers, wheel of previous systems.
FRONT SUSPENSION The The swinging arms, made of forged steel, have horizontal axis
vehicle is equipped with independent wheel suspension at the bushings. The joint heads located at the end of the swinging arms
front, McPherson type with stabilizer bar. The front suspension are riveted and can be replaced if necessary by replacing the rivets
attachment crossbar is of the box type of the attachment sections with the suitable fixing systems (Screw-Nut-Washer) supplied together with t
to the bodywork in order to stiffen the structure and allow better The front upright is made of steel and an oblique ball bearing is
filtering of the noise entering the passenger compartment. fitted in the wheel hub.
Front suspension
11
1
6 8
12
13
10
3
16
15
4
14
5
49
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
6. suspensions > technical data
4
Molle
The springs used are "side-load" type helical springs and allow for a 3
6
better reduction of tangential forces on the shock absorber rod,
resulting in better absorption of small roughnesses in the surface 2
4
road.
2
Stabilizer bar 3
REAR SUSPENSION
The rear suspension is of the rigid axle type connected to the body
by means of longitudinal leaf springs equipped with end stop pads 1. Rear axle
Cellasto. 2. Crossbow 5
Convergence
REAR WHEELS
Convergence value -0,86 mm
Convergence
Convergence value 0 mm
Incidence
Inclination
TIGHTENING TORQUES
Front suspension
Component Fixing Ø The value of Nm
Shock Absorbing Lower Attachment Ant. (SM) Given M12 x 1.25 (its amount) 120
Front Shock Propeller Spring Support (SM) Quickly M8 (suspension on the cathedral) 32
Articulated Head Lower Swing Arms Ant. Given M12 x 1.25 (its amount) 60
50
Machine Translated by Google
FIAT DOBLÒ
6. suspensions > maintenance operations
Rear suspension
Rear shock Fixing Ø The value of Nm
Rear leaf spring biscuits. (SM) Given M12 x 1.25 (lower than leaf spring) 80
Rear leaf spring biscuits. (SM) Given M12 x 1.25 (on body) 80
maintenance operations
FRONT SUSPENSION Breakdown at the counter Recomposition
- Place the front shock absorber (4) on the
SHOCK ABSORBER AND SPRING pneumatic tool (5) for compression Attention:
molle. Before assembling the front shock absorber
Disassembly - Block the shock absorber with the locking device components, check that the spring does not show
- Place the car on the lift. fastening (6) for the upright block and with the any cracks or deformations that could compromise its
- Remove the front wheels. brackets (7) suitable for compressing the spring. efficiency. Also check the integrity
- Operating with the wheels resting on the ground, - Connect a hose (8) to the tool with of the cap, if there are cuts or cracks
remove the pad and unlock by unscrewing only compressed air and blow in using the lever (9). superficial, replace the cap itself.
some threads, the shock absorber rod fixing nut pressurized air and compress the shock absorber
using the shock absorber rod tool and the spring. - Refit the stop ring and the boot on the front
appropriate hexagonal wrench to hold the shock - Using the tool (10) and a hex wrench (11) to lock shock absorber.
absorber rod. the shock absorber rod, unscrew the fixing nut - Refit the spring on the shock absorber.
- Remove the brake caliper oil pipe from the (12) and remove the - Reposition the shock absorber assembly
support on the shock absorber after removing the dowel and the flange (13) of the shock absorber. on the pneumatic tool.
safety clip. - Position the spring against the relative limit
- Unscrew the bolts fixing the shock absorber to Spring/shock absorber assembly disassembly switch ring.
the upright. - Block the shock absorber with the locking device
- Unscrew the screws (1) securing the top attachment fixing for the upright block and with the brackets
rear shock absorber to the body and remove the 13
suitable for compressing the springs and
bracket (2). compressing the spring.
12 10
- Remove the front shock absorber (3). - Mount the flange orienting the grooves on the axis
with the spring.
Shock absorber removal 4 - Fit the block complete with bearing
orienting it according to the desired incidence
1
Assembly
- Close by acting on the lever on the tool
5 8 the delivery of pressurized air then wait for the
complete release of the spring.
- Remove the front shock absorber from the
pneumatic spring compression tool.
- Close by acting on the lever on the tool - Place the shock absorber on the vehicle.
3
the pressurized air delivery, wait for the spring to - Position the bracket and screw the fixing screws
release and remove the particular components of of the upper shock absorber block to
the front shock absorber from the tool. it pops.
- Remove the spring and the boot complete with buffer- Tighten the bolts securing the shock absorber
and the shock absorber stop ring. to the upright to a torque of 120 Nm.
51
Machine Translated by Google
FIAT DOBLÒ
6. suspensions > maintenance operations
- Fit the brake caliper hose onto the groove Use: - Tighten the fixing screw to the body of the
on the shock absorber and reposition the The definitive tightening of the swinging arm elastic buffer attachment bracket for the
safety clip. and stabilizer bar fixings must be carried out drain pipe.
- Block the shock absorber rod using under theoretical design load conditions. The - Place, without tightening, the screws and
hex wrench and tighten to a torque of 85 design load condition on the front axle is the fixing nut of the right and left stabilizer
Nm the fixing nut of the upper block by obtained by appropriately ballasting the vehicle bar retaining U-bolts to the front cross member.
interposing the appropriate tool. (an operation which must be carried out with the - Bring the stabilizing bar fixing screws close
Like this.
wheels mounted and the vehicle on the ground to the swinging arms without tightening them.
or a specific bridge).
LOWER ARM Use:
- Place a load of 70 kg on the right and left The definitive tightening of the swinging arm and
Disassembly on the car floor in the area in front of the stabilizer bar fixings must be carried out under
- Place the car on the lift. front seats, then tighten them in pairs. theoretical design load conditions. The design load
- Remove the front wheels. condition on the front axle is obtained by
- Loosen the nut securing the swinging arm appropriately ballasting the vehicle (an operation
jointed head to the front hub strut. STABILIZER BAR that must be carried out with the wheels mounted
and the vehicle on the ground or a specific bridge).
- Separate the swinging arm joint from the Disassembly
front hub strut using the tools. - Place the car on the lift. - Place a load of 70 kg on the right and left
- Remove the front wheels. on the car floor in the area in front of the
- Unscrew the fixing screws of the stabilizer - Unscrew the fixing screws (4) of the stability bar front seats, then tighten them in pairs.
bar to the swinging arm, then remove the lizer with swinging arms.
nut that fastened the articulated head to the - Unscrew the screw (5), the screw (6) and
swinging arm. the nut (7) on the right and left sides securing WHEEL HUB BEARING
- Unscrew the front fixing bolt (1) of the the U-bolts (8) of the stabilizer bar to the
swing arm to the front cross member. front cross member. Disassembly
- Unscrew the rear fixing screws (2) of the - Unscrew the fixing screw (9) on the body - Place the hub upright assembly on the
swinging arm and the stabilizer bar support of the elastic pad fastening bracket to press by placing it on suitable plates so that
U-bolt. support the exhaust pipe. it is flat.
- Remove the swinging arm (3). - Remove the stabilizer bar (10). - Remove the front hub (11) from the upright
(12) using the press (13).
Swing arm removal Removing the stabilizer bar
Front hub removal
1
8
12
4
5 13
67
11
2
10
52
Machine Translated by Google
FIAT DOBLÒ
6. suspensions > maintenance operations
Assembly
- Fit the front hub bearing into the upright, using a press interposing the tool.
- Fit the front hub bearing retaining snap ring.
- Fit the front wheel hub into the upright with a press, interposing a cylinder of suitable diameter and supporting the bearing race using the
beater.
- Place the car on the lift. rear axle, in correspondence with the leaf - Screw, without tightening, the front leaf
- Remove the rear wheels. spring to be removed, to support the axle. spring fixing bolt to the body.
- Place a column jack under the rear axle, - Screw, without tightening, the rear leaf
in correspondence with the shock absorber - Unscrew the lower fixing screw of the spring fixing bolt to the shackles.
to be replaced and slightly compress the shock absorber to the rear axle. - Fit the bracket and the leaf spring retaining
rear shock absorber. - Lower the hydraulic jack slightly to relieve U-bolts to the rear axle.
- Unscrew the lower fixing screw (1) of the the load on the rear suspension. - Screw, without tightening, the fixing nuts
shock absorber to the rear axle. of the leaf spring retaining U-bolts.
- Unscrew the upper fixing bolt (2) - Unhook the parking brake cable support - Hook the parking brake cable support
shock absorber on the body. bracket from the leaf spring. bracket to the leaf spring.
- Remove the rear shock absorber (3). - Unscrew the bolt (4) securing the rear leaf - Slightly compress the shock absorber and
spring to the shackles (5). tighten the lower fixing screw -
Rear shock absorber removal - Unscrew the front fixing bolt (6) The final tightening of the rear leaf spring
of the leaf spring to the body. fixings must be carried out under theoretical
- Unscrew the nuts (7) securing the U-bolts design load conditions.
(8) and the bracket (9) retaining the leaf - The design load condition on the rear axle
spring to the rear axle. is obtained by appropriately ballasting the
- Lower the hydraulic jack slightly and vehicle (an operation that must be carried
remove the leaf spring (10). out with the wheels mounted and the vehicle
2
on the ground or on a specific bridge)
Leaf spring removal arranging the loads in the rear part of the
vehicle according to what is reported in following.
6
The loads are to be understood without the
end stop pad; the values in brackets indicate
4 5 9 8
10 the loads to be applied with the end stop
pad mounted.
Assembly
- Position the shock absorber. Van version 440 kg (656 kg)
- Fix the rear shock absorber to the top of 7 (increased capacity)
the body.
- Slightly compress the shock absorber and
fix the shock absorber to the rear axle at
the bottom.
- Tighten the shock absorber fixing bolt to
the body
- Tighten the shock absorber fixing screw
to the rear axle.
53
codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
7. brakes > technical data
7. brakes
technical data
GENERALITY automatic recovery of the game. The service brakes are controlled by
pedal, with a 9" vacuum brake booster combined with a
The car is equipped with ventilated front disc brakes with 7/8". The hydraulic system is of the split type with two independent
floating calipers and rear drum brakes with self-centering shoes and crossed circuits.
Brake assembly
6
1
4 7
9
2 10
Minimum pad thickness 1,5 Minimum jaw thickness (including support) 5,5 mm
54
Machine Translated by Google
FIAT DOBLÒ
7. brakes > technical data
12
necessary, using a mechanical device (4).
The device consists of a tie rod (5) made of two parts whose 2
fork ends are kept in contact with the brake shoes by the action of a
leaf spring (9). 1
The two parts of the tie rod (5) are connected to each other via a screw-
13
nut system (6) placed inside and equipped externally with a toothed
ring nut (7).
In the rest position, the jaw return spring (12) maintains the 8
compression device. 9
During the braking action the two jaws move apart and enter 10
TIGHTENING TORQUES
Braking system
Component Fixing Ø The value of Nm
55
Machine Translated by Google
FIAT DOBLÒ
7. brakes > technical data
grip, you are forced to check the braking effectiveness only after having it
any effects of initial sliding of the tire caused by an excessive braking force
in relation to the grip coefficient present have been detected.
This measurement, carried out by special sensors, causes the modulation of the
7
braking force through the action of a series of solenoid valves and pumps
recovery which, driven by a control unit, act on the circuit
braking. 10
4
9
1
8
EBD function
As can be seen, the EBD function of the ABS system is able to adapt to the
ideal pressure curve, always exploiting the grip available in all braking
conditions. 11
2
The integration of the EBD function into the normal operating logic 3 5
COMPONENTS
• improve the detection capacity of the sensor at low speeds (up to zero km/
h)
Active sensors
The Teves MK20 ABS system uses "active" sensors to detect wheel speed. • reduce weight and dimensions on the vehicle
These sensors are mounted on the wheel hub at the front and at the rear
on the drum casing, are electrically powered by the ABS control unit. The prescribed distance (air gap) between the sensor end and the multi-
pole ring, to ensure correct signals, must be between:
The use of active sensors allows the following advantages to be obtained
compared to the traditional magnetic induction sensor:
0.4 and 1.5 mm for the front wheels
• improve the negative effects of the distance between the sensor and the magnetic ring
0.4 and 1.2 mm for the rear wheels
• improve immunity to electromagnetic fields
56
Machine Translated by Google
FIAT DOBLÒ
7. brakes > technical data
57
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
7. brakes > technical data
WIRING DIAGRAMS K
ELECTRICAL DIAGRAMS LEGEND K71 Front right wheel sensor for ABS
B
K75 Left rear wheel sensor for ABS
B1 Engine compartment shunt control unit K76 Right rear wheel sensor for ABS
M
B2 Junction control unit under the dashboard
C
M1 Body computer
AND
COLOR CODES
I
B White N Black
K H Grey IN Green
58
Machine Translated by Google
FIAT DOBLÒ
7. brakes > wiring diagrams
ABS
59
Machine Translated by Google
FIAT DOBLÒ
7. brakes > wiring diagrams
ABS
60
Machine Translated by Google
FIAT DOBLÒ
7. brakes > maintenance operations
maintenance operations
FRONT BRAKES Caliper removal Assembly -
Position the brake discs and secure them with
8 6
SKATES REPLACEMENT the fixing pins.
- Fit the front brake calipers on the discs.
Disassembly 7
- Fix the brake calipers by tightening the two
- Place the car on the lift. rear fixing screws.
- Remove the front wheels. - Fit the caliper fixing spring, engaging it
10
12
re.
Front disc removal
PLIERS
16
Disassembly
- Place the car on the lift. 21
61
codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
7. brakes > maintenance operations
- Position the slack recovery device together with Assembly ELECTROHYDRAULIC ABS UNIT
the rear brake shoes. - Reposition the master cylinder and secure
- Position the rear brake shoe retaining clips. it using the relative nuts to the prescribed torque. Disassembly
- Connect the brake pipe fittings to the master - Place the car on the lift.
- Position the shoe return springs using the cylinder using the appropriate wrench. - Disconnect the battery and remove it.
appropriate tool - Using the - Disconnect the electrical connectors from the
ring spanner, screw the rigid fitting of the rear BRAKE SERVO ABS electronic control unit.
brake hose. - Unscrew the brake pipe fittings (11) on the
- Connect the parking brake control cable to the Disassembly - hydraulic control unit using the wrench (12) and
seat on the drum. Remove the brake master cylinder. the fittings (13) using a 13 mm spanner.
- Disconnect the brake servo tip (7) from the brake - Unscrew the nuts (14) securing the ABS control
PARKING BRAKE pedal (6), acting on the tabs (8) of the retaining unit support bracket (15) to the body, then remove
device (9). the control unit complete with bracket.
Adjustment - Unscrew the four nuts (10) (the same ones that
secure the pedal) securing the brake booster. ABS control unit removal
Use:
12
The recovery of the gap due to wear is automatic; the Removing the pedal connection 13
2
4
62
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > technical data
8. electrical system
technical data
GENERALITY
DRUMS
Depending on the type of setup and engine, three types of battery can be installed on the vehicle.
ALTERNATOR A voltage regulator, always located inside, keeps the voltage supplied
The alternator shaft (rotor) is rotated by the shaft constant at around 14Volts for all ranges of variation in load and engine
engine through a belt. The rotor generates a magnetic field which speed.
induces an alternating current on the fixed winding (stator). Two small internal radial fans provide cooling for the alternator. When
A diode rectifier bridge, located on the back of the alternator, transforms placing the ignition key on position
the alternating current into direct current which is sent for charging GEAR, through the Body Computer, reaches the D+ pole of the alternator
of the battery and the power supply of the various devices. a power signal under key.
Alternator diagram
6
7
1. Alternator rotor
2. Alternator stator
2
IMMOBILIZER
The Code and engine control ECUs 'dialogue' via a CAN network. The control unit then recognizes anomalies in all system components:
The CODE section in the NBC has a direct CAN diagnosis line,
dependent on that of the engine control unit. • NBC • antenna • Transponder in the key • CAN network
Once the related faults have been repaired, it is then possible to delete them
The control unit carries out a continuous self-diagnosis of the operation of the
system. In particular: anomalies stored by the control unit.
63
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > technical data
• receive the control signal of the platform switches/deviator, steering switch Location of fuse and relay control units
carry out and manage the diagnosis (of the nodes responsible for it) and transmit on the CAN network
64
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > technical data
Trunk
17 1
Ceiling light
F39 Red 10 Mini
2 Services + 30 (car radio, cell phone,
siren, diagnosis taken)
11
F40 Green
1
30 Mini heated rear window
32 16
20 10
N° Color Capacity (A) Type Name F45 Blue 15 Mini heated seat
F12 Red 10 Mini Right high beam
Sunroof (function not
Left dipped beam F46 Natural 25 Mini
F13 Red 10 Mini
implemented on this vehicle)
Headlight alignment corrector
F47 Green 30 Mini front left electric window
Reverse light power supply
Air conditioner activation command F48 Verde 30 Mini right front electric window
Electric fan system contactor
F31 Brown 7.5 Mini
Services + 15 (car radio, telephone
internal passenger compartment heater
mobile phone, lighting controls on
Headlight washer contactor (non-function F49 Marrone 7.5 Mini
dashboard, electric mirrors, trailer,
implemented on this vehicle)
heated seat control lighting)
F32 Blu 15 Mini lighting system
F50 Brown 7.5 Mini Air Bag
Rear left window regulator
F33 Verde 30 Mini (feature not implemented on this F51 Brown 7.5 Mini License plate light power supply, lighting
vehicle) dashboard users
F52 Light blue 15 Mini Tergilunotto
Rear right window regulator (function
F34 Green 30 Mini
not implemented on this vehicle)
Emergency
Electric driving (function not Direction indicators
implemented on this vehicle)
F53 Red 10 Mini
Instrument panel and warning lights (power
Automatic transmission system (function
F35 Red 10 Mini drums)
not implemented on this vehicle)
Traction control switch (function
not implemented on this vehicle)
N° Color Capacity (A) Type Name
Subwoofer system (non-function
F36 Blu 15 Mini T01 Black 20 Micro High Beams
implemented on this vehicle)
locked up)
F37 Rosso 10 Mini T12 Black 20 Micro Exhaust wrench base
Stop (brake lights)
Third stop (additional) T13 Black 50 Maxi key exhaust OPT
TIGHTENING TORQUES
65
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > maintenance operations
maintenance operations
ELECTRICAL PART Assembly Removing the starter motor
- Check that the alternator is not 7 4
ALTERNATOR damaged. 6
- Unscrew the lower fixing screw of the - Engage the alternator with the upper 8
alternator. anchor bracket.
- Unscrew the upper fixing screw of the - Tighten the M12 screw of the anchoring
alternator. bracket and the M12X1.75X90 screw
- Loosen the fixing screw of the anchoring securing the alternator to a torque of 70 Nm.
bracket. - For subsequent assembly operations, 9
- Unscrew the nuts (1) and disconnect the proceed in the reverse order of disassembly.
electrical connections (2) and (3) of the
alternator by removing the latter. STARTER MOTOR
Alternator removal Assembly
Disassembly - Place the car on the lift. - Check that the starter motor does not
3
1
- Working on the left side of the engine, is damaged.
unscrew the upper fixing screw of the - Position the starter motor in its seat.
starter motor.
- Open the starter motor electrical - Tighten the lower fixing screw of the
connection protection cover (4) and starter motor to a torque of 24 ÷ 30 Nm.
1 unscrew the nut (5). - Connect the electrical connections of the
- Disconnect the electrical connections (6, 7) of thestarter motor; screw the nut and close the
starter motor. protective cover.
- Unscrew the lower fixing screw of the - Tighten the upper fixing screw of the
starter motor (8). starter motor to a torque of 24 ÷ 30 Nm.
2
- Remove the starter motor (9).
66
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > maintenance operations
D079 Gearbox Sensor Junction G066 Side front door handle light
WIRING DIAGRAMS D081 Injector junction passenger
G067 Rear left door handle light
D085 Rear junction / Tailgate
ELECTRICAL DIAGRAMS LEGEND
D089 Parking sensor junction G068 Right rear door handle light
H
A D097 Short-circuiting junction
H001 Ignition switch
A001 Battery D105 Rear potentiometer junction
Headlight alignment corrector H005 Devioguida
A010 Alternator
D106 Rear junction/crossbar H007 Cruise Control Command
A020 Starter motor
D107 Dashboard-rear/Services junction H015 Headlight trim control
A030 Ignition coil motor
H016 Radio controls on steering wheel
A040 Preheating glow plugs D110 Coiled Cable and Assembly Junction
B steering wheel controls H020 Emergency light switch
B001 Engine compartment shunt control unit D168 Coaxial cable junction for Antenna H030 Adjustable Mirror Control
Car radio H035 Group of Switches on Tunnel
B002 Junction control unit under the dashboard
D187 Front Junction/Bridle Switch Side front window switch
B016 Mirror Defrost Fuse H042
Reverse gear
guide on
B037 Fuse (Maxi Fuse) Glow plugs D212 Bumper/rear junction dashboard Side front window switch
H043
B045 Trunk compartment shunt control unit (Cvb) D213 Fuel tank junction passenger on
B098 Additional fuse box D215 Power socket/cigarette lighter junction H044 dashboard Window control unit on door
B099 Maxi Fuse Box on Battery front driver's side
D216 Third Stop Junction
H050 Window switch on front door
B106 Additional shunt control unit D217 Rear wiring/ceiling light junction
engine compartment passenger side
D219 Preheating glow plug junction Window switch on door
C H053
D259 Instrument panel bridle joint rear left
C001 Battery ground
AND
H054 Window switch on door
C010 Left front mass rear right
E050 Instrument Panel
C011 Right front mass H060 Sunroof switch
F
67
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > maintenance operations
Mixed air temperature sensor M067 Passenger side door control unit
Front trim corrector potentiometer K087
K001 inferior M070 Climate control unit
Go
K088 Mixed air temperature sensor M072 Fan speed variator
K002 Rear corrector potentiometer
Headlight alignment
superior M075 Additional heater control unit
K089 Passenger compartment air temperature sensor
K013 Longitudinal Acceleration Sensor M080 Door lock control unit
K090 Solar sensor
K015 Lambda Probe on Pre-Catalyst
M084 Parking sensor control unit
K097 Parking sensor group
K017 Lambda Probe on Catalyst
K098 electromagnet Phase variator M086 Electric steering control unit
K018 Lambda probe on Catalyst -2 M091 Control unit yaw
K100 Temperature sensor and resistance
K019 Anti-crush sensor on the door Heating Co
M092 Steering angle control unit (Nas)
rear left Fuel temperature sensor e
K101 M093 Flying node control unit
K020 Brake pad wear sensor (switch). presence of water in the fuel filter
left M094 Radio Receiver Node
K110 Air distribution temperature sensor
K022 Anti-crush sensor on the door upper D M095 Sunroof control unit
anterior Lat
K111 Air distribution temperature sensor M172 Multifunctional screen node
K023 Anti-crush sensor on the door Lower D
anterior Lat M183 Cabin air blower protection diode
K112 Air distribution temperature sensor
Anti-crush sensor on the door superior St M184 Luggage compartment light protection diode
K024
rear De Air distribution temperature sensor
N
K113
K025 Brake Fluid Level Sensor (Switch). Lower S Cooling electric fan motor
N013
K028 Engine oil pressure sensor K120 Linear sensor for electric fans Capacitor
K030 Oil pressure sensor (switch). K125 Rain and twilight sensor N015 Windshield wiper motor
motor Sensor for front side Air Bag
K175 N016 Rear window wiper motor
K031 Water presence sensor in the diesel filter driver
N020 Windshield washer electric pump motor
K032 Engine Oil Level Sensor K187 Fap differential pressure sensor
N021 Rear window washer electric pump motor
Temperature sensor/transmitter K189 Particulate filter temperature sensor
K036 Electric pump motor
(Dpf) a Monte N022
Engine coolant lavacristallo/Lavalunotto
K190 Particulate filter temperature sensor
K039 Front Air-Bag Sensor
(Dpf) a Valle N025 Headlight washer electric pump motor
K040 Probe Lambda
K195 External air temperature sensor N030 Headlamp trim adjustment motor
K041 Air flow meter K204 Pda Position Sensor left
K043 Integrated air temperature sensor L N031 Headlamp trim adjustment motor
right
K044 Air pressure/temperature sensor L010 Vapor recovery solenoid valve
fuel N035 Sunroof motor
K046 Speed sensor
K047 Phase sensor Compressor activation electromagnet N038 Side seat lumbar adjustment motor
L020
conditioner guide
K048 Absolute pressure sensor electric fuel pump and meter
L021 Compressor activation solenoid valve N040
K050 Knock sensor conditioner Level
68
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > maintenance operations
N050 Front door lock gearmotor N127 Seat sliding adjustment motor P049 Rear center speaker Woofer
driver's side driver's side
P050 Cigarette lighter / power socket
N051 Front door lock gearmotor N129 Front height adjustment motor
right front seat P051 Additional power socket
passenger side
Rear door lock gearmotor N130 Seat sliding adjustment motor P052 Rear power socket
N055
left passenger side P055 Heated rear window
Rear door lock gearmotor N132 Side seat backrest adjustment motor
N056 P060 Driver's side external rear-view mirror
right guide
Side seat lumbar adjustment motor P061 External side rearview mirror
N057 Trunk lock gearmotor N133
passenger passenger
Door lock gearmotor P065 Electrochromic internal rear-view mirror
N058
N135 Side seat backrest adjustment motor
fuel
passenger P070 Hifi Radio Amplifier
N059 Tailgate lock gearmotor O
P075 CD Player / Changer
N060 Driver's side front window regulator motor Electric fan adjustment resistance
O030 P092 Subwoofer
Side front window lift motor cabin air
N061
O040 Left seat heater resistance Antenna for alarm device e
passenger P093
door lock receiver
N065 Rear left window regulator motor Side seat heater resistance
O041 P110 Antenna Gps/Gsm
N066 Rear right window regulator motor passenger
Windscreen washer defrost resistor Q
N070 Electroinjector O050
left Q009 Driver's side air bag
N074 Minimum actuator Windscreen washer defrost resistor
O051 Q011 Air Bag on dashboard (passenger side)
N075 Integrated throttle body actuator right
Q014 Driver's side knee air bag
N076 Phase variator actuator P
Front side seat belt pretensioner
Q020
N077 Fuel pressure regulator P005 Monotone horn guide
Air mixing door actuator P011 Low tone horn Front side seat belt pretensioner
N078 Q021
left passenger
P012 Pressure control unit antenna
N079 Air mixing door actuator tyres Q022 Left rear seat belt pretensioner
right
P020 Autoradio Q023 Right rear seat belt pretensioner
N080 Air distribution door actuator
P025 Antenna power supply/amplifier Q030 Driver's side side air bag
N081 Air mixing door actuator
P030 Rear left speaker Q031 Passenger side side air bag
N082 External air intake door actuator /
recirculation P031 Rear right speaker Q040 Window Bag on driver's side
Air distribution door actuator - P035 Speaker on driver's side front door Q041 Window Bag passenger side
N083
Defrost
P036 Speaker on right front door
N085 Cabin air electric fan
P040 Speaker on left rear door COLOR CODES
N086 Electronic thermostat
P041 Speaker on right rear door
N087 Fuel pressure regulator on A Sky blue M Brown
Rail P044 Parking sensor buzzer
N095 Electric drive motor P045 Driver's side front tweeter speaker B White N Black
N112 Right air distribution actuator P046 Front side tweeter speaker C Orange R Red
passenger
N113 Left air distribution actuator H IN Green
P047 Rear left tweeter speaker Grey
N126 Front height adjustment motor
P048 Rear right tweeter speaker
L Blu Viola
left front seat
WITH
69
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
High
70
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Electrical
71
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Electrical
72
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Wiring
73
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Low
74
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Car
75
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Wiring
76
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Door
77
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Door
78
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Wiring
79
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Wiring
80
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Fog
81
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Instrument
82
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Wiring
83
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Wiring
84
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Wiring
85
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Reverse
86
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Stop
87
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Electrical
88
Machine Translated by Google
FIAT DOBLÒ
8. electrical system > electrical diagrams
Navigator
89
Machine Translated by Google
FIAT DOBLÒ
9. air conditioning > technical data
9. air conditioning
technical data
A
Oil quantity (cm3) 135 ± 10
COMPRESSOR
The compressor is driven directly by the crankshaft via the service
belt, and is the same for both the manual and automatic versions.
CAPACITOR
C
The condenser is a heat exchanger located in front of the engine
cooling radiator.
Its task is to condense, i.e. transform the refrigerant fluid from a
gaseous state to a liquid state. F
EXPANSION VALVE
The thermostatic expansion valve, mounted on the ducts A. External air inlet D. Defroster air diffusion door
evaporator inlet/outlet has the task of regulating the flow and expansion B. Internal air inlet (recirculation) E. Front air diffusion door
(pressure drop) of the R134a refrigerant before entering the evaporator. C. Control group F. Foot air diffusion door
TIGHTENING TORQUES
90
Machine Translated by Google
FIAT DOBLÒ
9. air conditioning > technical data
B
N85 Cabin air electric fan
B1 Engine compartment shunt control unit N86 Electronic thermostat
B2
Junction control unit under the dashboard O
C
O30
Cabin air electric fan adjustment resistance
Q10 Left anterior mass
Q15
Driver's side dashboard mass COLOR CODES
D
D8
A Sky blue M Brown
Front/air conditioner - heater junction
G B White N Black
G45
Air conditioner/heater control light C Orange R Red
H
H
Grey
IN Green
H80 Climate controls
H81 Air conditioning electric fan control L Blu WITH
Viola
91
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
9. air conditioning > electrical diagrams
Air
92
Machine Translated by Google
FIAT DOBLÒ
9. air conditioning > electrical diagrams
Air
93
Machine Translated by Google
FIAT DOBLÒ
9. air conditioning > maintenance operations
maintenance operations
PRECAUTIONS - The R134a refrigerant fluid cannot be mixed - Avoid prolonged contact with the skin of the
- Before carrying out disassembly on the circuit with Freon R12 used in the air conditioning R134a fluid in the evaporation phase as
air conditioner refrigerant is necessary systems of previous cars; therefore for i the low temperature (-26.5C) reached at the end
empty the system with air conditioners operating with R134a, never, expansion, can cause "burns" due to excessive
recovery of the refrigerant fluid. under any circumstances, use Freon R12. cold. It is therefore appropriate to use
- During operations, when the system - The air conditioner circuit uses leather or thick fabric gloves.
components are disconnected, close with The ecological fluid R134a is used as refrigerant. - It is essential to protect your eyes from contact
appropriate sealing caps for disconnected fittings - When working on the circuit, scrupulously with the refrigerant fluid: the excessive and
avoid the entry of humidity and impurities into respect the following safety regulations: instantaneous low temperature can cause serious injuries.
the system itself. - R134a fluid leaking from the system - The discharge of the fluid into free air constitutes
- Before reconnecting the pipes, provide the of air conditioning or the equipment for the danger to the environment. To empty the system
replacement of O-rings on fittings. emptying/recovery/recharging can become of R134a, use exclusively
- Use only color rings toxic if very close to open flames or in the the appropriate equipment.
green, resistant to the refrigerant fluid presence of certain metals (for example magnesium -orWhen the engine is hot, the cooling system
R134a. aluminium) in the form of fine or powdery of the engine itself is under pressure. Wait a
- Lubricate the threads of the fittings with oil particles. It is therefore advisable to operate in absence
few minutes before working on components of the
antifreeze and tighten the fittings to torque of open flames and in ventilated environments cooling circuit, making sure that the pressure
prescribed. with the extraction system activated. has dropped.
94
Machine Translated by Google
FIAT DOBLÒ
10. air bag > technical data
8
4
3 7
1. Pretensioners 2.
Guide bag 3.
Passenger bag 4.
1
Side bag 5.
Control unit 6.
4
RSU satellite unit
95
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
10. air bags > technical data
PASSENGER AIR BAG electric control. The electronic negative acceleration sensor (or
The passenger side Air Bag module is the passive safety device which, deceleration) is placed inside the control unit and it manages the
in the event of a frontal collision, it protects the front passenger, via a intelligent anomaly warning light.
cushion that is placed between the occupant and the dashboard of the car. The pyrotechnic activation system is an integral part of the reel
and thus creates a single component which is fixed in the upright of the
AIR BAG LATERAL vehicle.
To increase the protection offered by the body in the event of a side impact,
two side Air Bag modules are available inside the front seats. Operation
This arrangement allows you to always have the Air in the optimal position When a certain sufficiently severe longitudinal negative acceleration (or
Bag relative to the occupant, regardless of the adjustment of the deceleration) of the vehicle occurs, an electromechanical sensor located in
seat or the size of the occupant. The Side Bag provides protection for the the control unit records this condition, and
thoracic and pelvic areas, and guarantees, together with the door panels, the sends a command via the power circuit from pins 21-22 to the driver's
protection of critical areas of the body such as ribs and abdomen. pretensioner, and from pins 23-24 to the passenger's pretensioner.
Its position on the seat always guarantees maximum effectiveness regardless The electrical control triggers the pyrotechnic charges of the gas generators.
of its position, even if the seat occupant is not sitting correctly, as the The combustion of the propellant develops a chemical reaction forming
dynamics of of the (inert) gas whose pressure generates a force that pushes the piston a
opening the cushion minimizes the risk of damage to the body caused by rack upwards.
impact with the body. The upward movement of the rack piston rotates the wheel
serrata, which is connected to the serrata. The same toothed wheel, engaging
Pretension with the toothed bushing, changes the rotary movement of the spindle,
The car is equipped with a system consisting of front seat belts with reel, in the opposite direction to the unwinding of the belt, rewinding it
pyrotechnically activated pretensioner with same as a few centimetres.
The functionality of the system for the vehicle in question depends exclusively
on the type of electronic control unit used.
The ACU3-R07 control unit is supported by two satellite units or sensors A Connector A (Orange) B Connector B (Orange)
negative transverse accelerations (or decelerations). Both positive and Pin Description Pin Description
negative acceleration sensors send a signal to the control unit. 1 1
Nc Nc
The control unit records the decelerations and commands the triggering of the charges
2 Nc 2 Nc
pyrotechnics.
All ACU3 control units manage the energy accumulation for the front bags 3 Nc 3 Nc
When activating the front bags, the control unit must always be replaced. 8
deactivation 7 - passenger manual deactivationNc8
9 Nc 9 + R.S.U dx
Control Unit Self-Test 10 k line 10 - R.S.U dx
The failure warning light on the dashboard comes on when Key-on is activated for a period of time
11 Dough 11 + RSU sx
4 sec. to highlight the self-test phase of the control unit and the warning light
itself. After 4 seconds, the control unit continuously diagnoses the system. 12 + 12V under key 12 - RSU sx
13 Nc 13 Nc
The AIR BAG failure warning light remains on after 4 seconds of the recovery phase14 Nc 14 Nc
check when:
15 Nc 15 Nc
The vehicle must never be delivered to the customer with the fault warning light on. 21 - Passenger bag (1) 21 + Guide pretensioner
the ground cable is a dedicated cable, it must not have joints and/ or branches of 22 + Passenger bag (1) 22
- Guide pretensioner
any kind between pin 5 of the control unit and the body stud, the length of the cable
23 - Bag guide 23 + Passenger pretensioner
must be 200 mm. The resistance between the electrical ground
24 + Bag guide 24
of the vehicle and pin 11 of the control unit must be 100 mOhm. - Passenger pretensioner
96
Machine Translated by Google
FIAT DOBLÒ
10. air bags > technical data
Component Name
Component Name
M
B
M1 Body computer
B1 Engine compartment shunt control unit
M60 Air Bag control unit
B2 Junction control unit under the dashboard
Q
C
Q9 Driver's side Air Bag
Q15 Driver's side dashboard mass
Q10 Spiral cable on steering wheel
C50 Mass of the Air Bag system Q11 Air Bag on dashboard (passenger side)
C53 Massa Side bag + Head bag Q20 Driver's side front seat belt pretensioner
D58 Right Head bag junction Q30 Driver's side air bag
B White N Black
H75 Passenger Air Bag disabling switch
C Orange R Red
K
H Grey IN Green
K66 Side Air Bag sensor, driver's side
97
Machine Translated by Google
FIAT DOBLÒ
10. air bags > wiring diagrams
Air
98
Machine Translated by Google
FIAT DOBLÒ
10. air bags > wiring diagrams
Vista
99
Machine Translated by Google
FIAT DOBLÒ
10. air bag > maintenance operations
maintenance operations
AIR BAG SAFETY RULES - Always disconnect the battery, i.e. disconnect the natural ventilation inside) and must
two terminals from the respective pole and isolate thembe equipped with the markings required by the
Use: taping them carefully. current laws.
Please remember that the Air Bag modules are devices for - Disconnect the electrical connection of the
handle with caution. Use, transport and storage are control unit, waiting at least 10 minutes after All connectors used and wired on the modules
regulated by the procedures for disconnected the battery. Air Bags have a short-circuit clip inside them.
the manipulation of these components below Until the moment the Air Bag modules
illustrate. Store the devices with the cover upwards, are not connected to an energy source with
in a locked metal cabinet. Said suitable characteristics, there is no possibility
Before starting to carry out body repair work, wardrobe, intended exclusively for this of undue activation of the units.
welding work, work purpose, it must not be used under any circumstances
for which the Air Bag modules must be removed to store other types of materials especially Attention:
or the control unit is needed: if flammable. It is forbidden to carry out continuity measurements on
The wardrobe must meet the requirements for system components unless the modules have been
- Remove the key from the ignition switch accommodate pyrotechnic charges (shock- replaced with the specific resistors
power on. resistant metal cabinet with grates to allow simulation.
feel the unlocking “click” of one side of the dossier site reporting the car's data
AIR BAG SYSTEM module. (model, registration data, chassis number) ed
- Carry out the same operations on the hole the serial number of the old module. The dossier
DRIVER AIR BAG located on the opposite side of the steering must be kept for possible checks.
wheel camber.
Disassembly - Move the Air Bag module slightly and Use:
disconnect the electrical connections. A new one is supplied together with the module
Use: - Place the Air Bag module in the appropriate adhesive plate to stick on top of the existing one
Before removing and reconnecting the cabinet, placing it on a free surface with present in the car. However, first it is necessary to
Air Bag module strictly perform the the pillow facing up. drill it in correspondence with the month and 10
following preliminary operations: (1st) place the years following the year in which the module is mounted
ignition key in “STOP” position; (2nd) Assembly (e.g. 1999 will correspond to 2009).
disconnect and isolate the battery cables; (3rd) wait
10 minutes before proceeding. Attention: - Connect the electrical connectors.
In case you install a new Air module - Close the protection tab of the driver's side Air
- Introduce a generic screwdriver, or similar, Bag, arrange the relevant labels. Bag electrical connector.
in the hole located on the side of the steering - Fit the Air Bag module until you hear it
wheel camber. - Remove the removable part of the adhesive “click” to lock the module itself.
- Push the screwdriver all the way in until label from the new module and place it in a suitable place.
- Connect the battery electrical cables.
PASSENGER AIR BAG Removing the Air Bag module fixing - Remove the removable part of the adhesive
label from the new module and place it in a container
Disassembly specific dossier reporting the vehicle data
(model, registration data, chassis number) ed
Use: the serial number of the old module. The dossier
Before removing and reconnecting the Air Bag must be kept for possible checks.
module, perform the following absolutely 2
100
Machine Translated by Google
FIAT DOBLÒ
11. bodywork > technical data
11. bodywork
technical data
DIMENSIONS
Vehicle dimensions
AND
A B C G
M L H
A B C D AND F I L M
G (°) H (°)
758 2.566 835 4.159 2.236 1.800*/1.820** 1.490 1.496 1.714 454 2.581
(°) Depending on the size of the rims there may be minimal differences in measurement
(*) For Fiat Doblò ELX – SX versions (high roof and low roof) - Fiat Doblò Combi (high roof and low roof)
(**) For Fiat Doblò Cargo and Cargo SX versions (high roof and low roof)
101
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
Machine Translated by Google
FIAT DOBLÒ
11. bodywork > maintenance operations
maintenance operations
VEHICLE EXTERIOR Headlight removal Removal of side fixings
FRONT BUMPER 5
9
Removal -
Place the car on the lift and open the bonnet. 10
bumper.
Bumper removal 5
6 10
11
1
Assembly - Assembly -
Assemble the light unit by centering the pins in Check that the bumper is not damaged.
the relative seats on the body. - If necessary, touch up the paint.
- Connect the electrical connector of the light - Position the bumper and secure it with the relative
unit. screws.
REAR BUMPER
VEHICLE INTERIOR
Removal -
4
Unscrew the screws (7) and remove the bumper (8). DASHBOARD
7
Removal of instrument panel
14 13
Assembly -
Check the bumper for damage.
- Position the bumper and screw the lower
screws to the body.
8
102