Fiat Doblo 2010-2021

Machine Translated by Google
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.
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.
Marketing since 2008 Position for lifting

Model code 223
Displacement (cm3) 1.598 1.956
Power (Kw) 66/77 135
Transmission type C510.5/C635 C635
Number of reports 5/6 6
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.
Location of tow hooks

B
Approval number
C
Vehicle type identification code
D Progressive chassis manufacturing number
AND
Maximum authorized weight of the vehicle when fully loaded
F
Maximum authorized weight of the vehicle when fully loaded plus the trailer
G Maximum authorized weight on the first axle (front)
H Maximum authorized weight on the second axle (rear)
I
Engine type
L Body version code
M Number for spare parts
N Correct value of the smoke coefficient (for diesel engines)
2
FIAT DOBLÒ
generality
MAINTENANCE FREQUENCY
Thousands of km 35 70 105 140 175
Check tire conditions/wear and adjust pressure if necessary x x x x x
Check the functioning of the lighting system (headlights, direction

x x x x x
indicators, emergency, passenger compartment, luggage compartment, instrument panel warning lights, etc.)
Check the operation of the windshield wiper/washer system x x x x x
Check positioning/wear of windshield/rear window wiper blades x x x x x
Check the condition and wear of the front disc brake pads and operate the pad wear indicator x x x x x
Check the condition and wear of the rear disc pads 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
Check and adjust the handbrake lever travel if necessary x x x x x
Exhaust emissions/smoke control x x x x x
Check the battery charge status and recharge if necessary x x x x x
Visually check the condition of the accessory drive belts x x
Check engine control systems functionality (via diagnosis socket) x x x x x
Replacing the timing belt x
Fuel filter replacement x x
Replacing the air filter cartridge x x
Brake fluid replacement (or every 24 months) x x
Pollen filter replacement (or every 15 months) x x x x x
Do you want diagnoses on every single ODB code?

Toll-free number 800-42-42
Editions
NEW 2012 www.semantica.it

Then purchase the Basic SUITE OBD Plus - 4 CDs
SEMANTICS
(1000 codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
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
1.6 Multijet 16v 2.0 Multijet 16v
Bore (mm) 79.5 83.0
Stroke (mm) 80.5 90.4
Total displacement (cm3) 1.598 1.956
Maximum power (kW EEC) 66/77 99
Maximum power (EEC CV) 90/105 135
Max. power regime (revolutions/1') 4.000 4.000
Maximum torque (Nm EEC) 290 320
Maximum torque (kgm EEC) 29.5 36.7
Maximum torque speed (revs/1') 1.500 1.750
Minimum speed (revs/1') 850 ± 20 850 ± 20
Compression ratio 16.5 : 1 16.5 : 1
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
FIAT DOBLÒ
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
Gasket Valve stem diameter - Exhaust (mm) 4.972 ÷ 4.990
VALVE SEATS
Locations reported in the header.
Size 1.6 16V Multijet Value
Valve seat band angle in contact with valves 45° 0’ +/- 1°
Valve seat external diameter - intake (mm) 28.355 ÷ 28.365
External diameter of valve seats - exhaust (mm) 26.100 ÷ 26.111
Size 2.0 16V Multijet Value
Valve seat band angle in contact with valves -

45° 30’ +/- 1°
Fit for 1.6 16V Multijet engine Value aspiration
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
Fit for 2.0 16V Multijet engine Value

protrusion VALVE SPRINGS
Cylinder head gasket thickness with protrusion +0.110 ÷ +0.230 Identical load valve springs for intake and exhaust valves.
maximum pistons (mm) thickness (no hole)
Measure Value
0.95 +/- 0.05
Valve spring free length (mm) 44.1
protrusion
Cylinder head gasket thickness with protrusion +0.231 ÷ +0.330

Valve spring length under load of 22.80 ÷ 25.20 Kg
34.0
maximum pistons (mm) thickness (one hole) (mm)
1.05 +/- 0.05 Valve spring length under load of 43.90 ÷ 48.10 Kg
25.5
(mm)
protrusion
Cylinder head gasket thickness with protrusion + 0.331 ÷ +0.425

HYDRAULIC TAPPETS
maximum pistons (mm) thickness (two holes)
For each valve a hydraulic tappet operated by a is used
1.15 +/- 0.05 balance wheel in turn moved by the camshaft.
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.

Editions

SEMANTICS
FIAT DOBLÒ
CYLINDER BLOCK Measure Value
< 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
CRANK DRIVE Main bearings
CRANKSHAFT Measure Value Validity

It is made of cast iron, rests on five main bearings and its axial play is
Main bearing half thickness - 1.831 ÷ 1.837 1.6 JTD 16v
regulated by two half rings housed in the rear main bearing. Class A (Red) (mm)
Eight counterweights give the crankshaft accurate balancing of the
rotating masses. Main bearing half thickness - 1.836 ÷ 1.844 1.6 JTD 16v
Class B (Blue) (mm)
A series of ducts runs internally along the crankshaft for the
lubrication of the main and connecting rod journals. The Main bearing half thickness - 1.843 ÷ 1.849 1.6 JTD 16v
tone wheel for the rpm sensor. Class C (Yellow) (mm)
Measure Value Validity

1.6 JTD 16v
Crankshaft axial clearance (mm) 0.049 ÷ 0.211 Increase in main bearing half-bearings - 0.127 1.6 JTD 16v
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)
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
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
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)
Main journal seat diameter (mm) 63.705 ÷ 63.718 2.0 JTD 16v Class A (brown) (mm)
Measure Value Validity Class B (green) (mm)
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 Class A (Red) (mm)
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
Connecting rod pin diameter - Class C (mm) 50.787 ÷ 50.793 2.0 JTD 16v
Class C (Yellow) (mm)
6
FIAT DOBLÒ
Measure Value Validity Measure Value Validity
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 - Class C 0.127 2.0 JTD 16v

(nero) (mm) Measure Value Validity
Increase in main bearing half-bearings (mm) 0.254 2.0 JTD 16v Allowable weight difference between connecting rods
+/- 2.5
complete (g)
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.
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)
PISTONS Measure Value Validity

The pistons in silicon aluminum alloy with autothermal inserts are divided Thickness of 1st cylinder compression seal ring
1.470 ÷ 1.495 2.0 JTD 16v
into three size classes. The chamber is located on the piston crown (mm)
“OMEGA' combustion to improve combustion efficiency. Thickness of 2nd cylinder compression seal ring
1.470 ÷ 1.495 2.0 JTD 16v
(mm)
Thickness of 3rd cylinder compression seal ring
1.970 ÷ 1.990 2.0 JTD 16v
Piston external diameter - Class A (mm) 79.440 ÷ 79.450 1.6 JTD 16v (mm)
Piston external diameter - Class B (mm) 79.450 ÷ 79.460 1.6 JTD 16v
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
Measure Value Validity 1.6 JTD 16v

2nd cylinder compression seal ring opening
0.60 ÷ 0.80
82.930 ÷ 82.940 2.0 JTD 16v (mm) 2.0 JTD 16v
Piston external diameter - Class A (mm)
Piston external diameter - Class B (mm) 82.940 ÷ 82.950 2.0 JTD 16v
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
1.6 JTD 16v

Allowable weight difference between pistons (g) +/- 5 Measure Value Validity
2.0 JTD 16v
Sealing ring seat on piston - 1st groove (mm) 1.620 ÷ 1.640 2.0 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
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)
Measure Value Validity Measure Value Validity

Pin seat diameter (mm) 29.985 ÷ 29.990 2.0 JTD 16v
29.975 ÷ 29.980 2.0 JTD 16v 0.125 ÷ 0.170 2.0 JTD 16v
Pin external diameter (mm)
cylinders (mm)
CONNECTING ROD
0.055 ÷ 0.100 2.0 JTD 16v
cylinders (mm)
The connecting rods are made of hardened and tempered steel, with a
copper bush inserted for coupling with the piston pin. Measure Value Validity
Measure Value Validity Axial play 1st compression seal ring

0.125 ÷ 0.170 2.0 JTD 16v
cylinders (mm)
Internal diameter of connecting rod small end bushings (mm) 26.006 ÷ 26.014 1.6 JTD 16v
0.055 ÷ 0.100 2.0 JTD 16v
Connecting rod head internal diameter (mm) 51.354 ÷ 51.366 1.6 JTD 16v cylinders (mm)
7
FIAT DOBLÒ
Measure Value Validity THEY FLY

0.125 ÷ 0.170 2.0 JTD 16v Dual mass flywheel, DVA (Double Shock Absorber Flywheel), one
cylinders (mm) integral with the crankshaft and one with the gearbox primary
Axial play 2nd compression seal ring shaft with an interposed torsional elastic damping system.
0.055 ÷ 0.100 2.0 JTD 16v
cylinders (mm)
The resonance points which, with the conventional system are located between 800 and
Measure Value Validity 2,200 rpm, are shifted towards lower rotation speeds,
1.6 JTD 16v out of range of use.
Engine piston oil scraper ring gap (mm) 0.25 ÷ 0.50
2.0 JTD 16v
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.
DISTRIBUTION CINEMATISM Measure Value Validity

Distribution via two overhead camshafts. 1.6 JTD 16v
First shaft pin diameter
The exhaust camshaft alone is driven by the timing belt 43.600 ÷ 43.615
distribution (mm) 2.0 JTD 16v
and drives the intake camshaft by a set of two
gears inside the head crankcase. Second shaft pin diameter
1.6 JTD 16v
43.400 ÷ 43.415
TIMING ANGLES
1.6 JTD 16v
Third timing shaft pin diameter
43.200 ÷ 43.215
1.6 Multijet 16v 2.0 Multijet 16v (mm) 2.0 JTD 16v
Timing Aspiration 0.50 0.50 1.6 JTD 16v

Fourth shaft pin diameter
43.000 ÷ 43.015
clearance (mm) I unload 0.50 0.50 distribution (mm) 2.0 JTD 16v
Opening (before PMS) - 1.6 JTD 16v

Fifth shaft pin diameter
30.000 ÷ 30.015
Aspiration Opening (after PMS) - 10° -10° distribution (mm) 2.0 JTD 16v
Closing (after PMI) 1.5° 1.5° 1.6 JTD 16v

First shaft support diameter
43.646 ÷ 43.671
40° distribution (mm) 2.0 JTD 16v
Opening (before PMI) 40°
I unload -9° 1.6 JTD 16v

Closing (before PMS) - Diameter Second shaft support
43.446 ÷ 43.471
9° distribution (mm) 2.0 JTD 16v
Closing (after PMS)
1.6 JTD 16v
Third shaft support diameter
43.246 ÷ 43.271
CAMSHAFTS distribution (mm) 2.0 JTD 16v
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
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.
Shaft axial play 1.6 JTD 16v TIMING BELT

0.100 ÷ 0.230 Toothed belt in synthetic materials.
Connect the crankshaft drive pulley to the tensioner roller
(proceeding in the direction of rotation), the high pressure pump
Measure Value Validity pulley and the camshaft pulley (exhaust shaft for the twin engine
Nominal cam lift 1.6 JTD 16v trees).
8.5
suction (mm) 2.0 JTD 16v
Visually check toothed belt and tensioner roller
Nominal cam lift 1.6 JTD 16v 50,000 km / 2 years
8.0 Maintenance frequency
exhaust (mm) 2.0 JTD 16v Belt and roller replacement 120,000 km / 8 years
8
FIAT DOBLÒ

LUBRICATION Oil pressure relief valve spring height
Forced lubrication by oil pump driven by the crankshaft, 36.0 1.6 JTD 16v
engine at a load of 8.78 ÷ 9.66 daN (mm)
pressure relief valves ensure the maintenance of the circuit a
Oil pressure relief valve spring height
adequate pressure values. 49.8 2.0 JTD 16v
free motor (mm)
Oil pressure relief valve spring height
MOTOR OIL 34.5 2.0 JTD 16v
engine at a load of 9.43 ÷ 10.29 daN (mm)
Radial clearance between pump body and gear 1.6 JTD 16v
0.080 ÷ 0.186
Name Classification Quantity (litres) duct (mm) 2.0 JTD 16v
SELENIA TURBODIESEL SAE 10W-40 - ACEA B3 - API CD 4,4

OIL FILTER AND HEAT EXCHANGER
SELENIA WR DIESEL SAE 5W-40 - ACEA B4 - API CF 4,4 Oil filter with liquid/liquid type heat exchanger for cooling the
engine oil.
OIL PUMP PRESSURE SWITCH

The engine oil is sucked from the sump via the vacuum created
by the rotation of the gears keyed onto the crankshaft. 1 bar at minimum
Engine at operating temperature and temperature
The depression is present starting from the separation bulkhead of the oil at 100°C
4 bar a 4.000 giri/min
gears up to the oil sump dip tube.
COOLING DOWN FUEL SUPPLY

Cooling by forced circulation of the refrigerant liquid The fuel supply system is divided into circuit
motor in hermetic circuit. low pressure and high pressure circuit.
The low pressure circuit consists of an auxiliary electric pump
COOLANT immersed in the tank; by a fuel filter; from a collector tube
fuel return and connecting pipes.
Name Classification The high pressure circuit consists of the pressure pump; from the tube
Paraflu Up CUNA NC 956-16, ASTM D3306
unique fuel manifold; from the electro-injectors and the pipes
Amount 7.2 liters
connection.
WATER PUMP LOW PRESSURE PUMP

Centrifugal vane type water pump with alloy pump body The electric fuel pump has an electric magnet motor
aluminum and phenolic resin impeller. Fixed to the engine base permanent which controls the pump impeller and a terminal
and driven directly via the timing belt. support cover which contains the electrical and hydraulic connections.
Immersed in the tank, accessible from the passenger compartment, via a cover
THERMOSTAT protection positioned under the rear seat cushion.
Mounted on the rear side of the cylinder head, with the function of
keeping the engine at the optimal temperature: HIGH PRESSURE FUEL PUMP
It is of the "radialjet" type with three radial pistons (total displacement 0.567 cm3) and is
temperature < 82 ± 2° controlled by the timing belt without timing requirements.
C the thermostatic valve (closed) diverts the liquid directly towards the pump The pressure pump must be powered with a pressure of at least
temperature > 82 ± 2° 0.5 bar; therefore the fuel system is equipped with an auxiliary
C the thermostatic valve (open) conveys the liquid towards the radiator electric pump immersed in the tank. The maximum delivery pressure
reaches 1400 bar. The pressure pump is lubricated and cooled
RADIATOR from the same fuel through appropriate pipelines.
It is composed of a radiant mass and two lateral trays for the inlet
and outlet of the coolant. The tubes and fins of the radiant mass FUEL FILTER
they are made of aluminium, the trays are made of plastic. The fuel filter is mounted in the engine compartment on the
firewall. It is of the cartridge type with a filter element consisting of a pack of
EXPANSION TANK paper discs with a filtering surface of 5300 cm2 and a filtering
In addition to its power function, the circuit absorbs volume variations degree of 4 ÷ 5 ÿm. The water presence sensor in the fuel filter is
of the coolant, as the engine temperature varies. mounted at the base of the cartridge.
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.

Editions

SEMANTICS
FIAT DOBLÒ
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.
SUPERCHARGING If the conditions of the particulate filter worsen (the

accumulation threshold of 250%) in addition to the "particulate trap
TURBOCHARGER clogged" warning light, the EOBD warning light also comes on and
It has variable geometry (fixed geometry for version 1.6 Multijet therefore forced regeneration using a diagnostic tool is essential.
105CV) and is connected to the exhaust manifold; is intended to increase theDuring the regeneration phase it is possible that some particulate matter
volumetric efficiency of the engine. pollutes the engine oil and therefore requires replacement earlier than
scheduled. This is signaled by the “minimum engine oil pressure”
INTERCOOLER warning light flashing.
Air/air type intercooler, allows the reduction of the temperature of the This signaling is carried out by the injection control unit based on:
air coming from the compressor wheel, giving a higher density
greater.
• number of regenerations
• 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
FIAT DOBLÒ
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
• Maximum inlet exhaust gas temperature = 350 °C

The advantages introduced by the new valve are:
• Maximum outlet exhaust gas temperature = 200 °C
• greater actuation force, therefore less sensitivity to blocking
• single plate, resulting in less sensitivity to leakage EGR cooling by-pass actuator
The actuator is pneumatic and works with the vacuum taken from the
• presence of a plate position sensor, which allows better control
tank integrated into the EGR heat exchanger.
and diagnosis on
The actuator has only two positions available, in the rest position
functionality • less dispersion of performance, with consequent consolidation of
the recirculated gases pass through the heat exchanger, when the by-
calibrations
pass is implemented, the deflector conveys the gases, through an
uncooled duct, directly to the exit of the EGR module.
Valve position sensor The engine control unit controls the by-pass position via
This sensor detects the real position of the valve plate, returning a an ONOFF pneumatic solenoid valve.
voltage information between 0.5 and 4.5V.
The engine control unit takes into account the aging of the position EGR by-pass actuator control solenoid
sensor and, every time the engine is switched off, learns the closing valve It is an electro-pneumatic switch that allows you to
position drift which is then memorized and used at the next start-up. control the movement of the by-pass actuator. The solenoid valve is con
engine control unit with an ON-OFF command.
To guarantee this functionality and avoid damage to the valve When powered, the vacuum reaches the actuator, while in
EGR at each replacement of the same or of the engine control unit, In the absence of power, the ambient pressure acts on the actuator
a specific learning procedure must be carried out. it then moves to the rest position.
MAINTENANCE COOLANT
MOTOR OIL Name Classification
Name Classification Quantity (litres)

Paraflu Up CUNA NC 956-16, ASTM D3306
SELENIA TURBODIESEL SAE 10W-40 - ACEA B3 - API CD 4,4
SELENIA WR DIESEL SAE 5W-40 - ACEA B4 - API CF

Amount 7.2 liters
4,4
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
1.6 JTD 16v

Cylinder head Quickly M12 65 +/- 3 + 90° + 90° + 90°
2.0 JTD 16v
1.6 JTD 16v

Engine oil drain plug Cork M14 18 ÷ 22
2.0 JTD 16v
1.6 JTD 16v

Engine oil sump Side screws M8 22 ÷ 27
2.0 JTD 16v
1.6 JTD 16v

Engine oil sump M6 distribution side and gearbox side screws 8 ÷ 10
2.0 JTD 16v
1.6 JTD 16v

Front shaft oil seal cover
Screw (to be replaced) M6 8 ÷ 10
motor 2.0 JTD 16v
1.6 JTD 16v

Rear crankshaft cover al
Screw (to be replaced) M6 0.8 ÷ 1.0
basement 2.0 JTD 16v
1.6 JTD 16v

Flywheel side oil seal cover Screw (to be replaced) M6 08 ÷ 10
2.0 JTD 16v
1.6 JTD 16v

Flywheel Screw (to be replaced) M12 144 ÷ 176
2.0 JTD 16v
1.6 JTD 16v

School hats Quickly M12 19 ÷ 21 + 100°
2.0 JTD 16v
1.6 JTD 16v

Connecting rod caps Quickly M9 24 ÷ 26 + 60°
2.0 JTD 16v
11
FIAT DOBLÒ

1.6 JTD 16v
Mobile tensioner of the distribution control Quickly M8 23 ÷ 28
2.0 JTD 16v
1.6 JTD 16v

Driven toothed pulley for distribution control Quickly M12 28 ÷ 31 + 40°
2.0 JTD 16v
1.6 JTD 16V

Toothed driving pulley Left-handed screw M16 323 ÷ 357
2.0 JTD 16v
1.6 JTD 16v

Fixed timing control tensioner Quickly M8 23 ÷ 28
2.0 JTD 16v
1.6 JTD 16v

Timing belt tensioner support Quickly M10 45 ÷ 55
2.0 JTD 16v
1.6 JTD 16v

Distribution shaft gears Quickly M12 29 ÷ 32 + 40°
2.0 JTD 16v
Fuel tank Quickly M8 32 ÷ 39
Fuel pump assembly fixing ring nut Ring -

54 ÷ 66
1.6 JTD 16v

Water presence sensor - fuel temperature
- -
2÷3
2.0 JTD 16v
1.6 JTD 16v

Electroinjector brackets Given M8 23 ÷ 28
2.0 JTD 16v
1.6 JTD 16v

Piping from pressure pump to fuel manifold - side
Connection M12 22 ÷ 24
pressure pump 2.0 JTD 16v
1.6 JTD 16v

Piping from pressure pump to fuel manifold - side
fuel collector 2.0 JTD 16v
Pipes from fuel manifold to electro-injectors - side 1.6 JTD 16v

fuel collector 2.0 JTD 16v
Pipes from fuel manifold to electro-injectors - side 1.6 JTD 16v

electroinjectors 2.0 JTD 16v
1.6 JTD 16v

Fuel pressure sensor - fuel manifold side - -
65 ÷ 75
2.0 JTD 16v
1.6 JTD 16v

Single fuel manifold pipe (rail) Quickly M8 23 ÷ 28
2.0 JTD 16v
1.6 JTD 16v

Pressure pump Nut (to be replaced) M8 23 ÷ 28
2.0 JTD 16v
1.6 JTD 16v

Pressure pump control pulley Given M14 45 ÷ 55
2.0 JTD 16v
1.6 JTD 16v

Engine water temperature sensor
-
M12 18 ÷ 22
2.0 JTD 16v
1.6 JTD 16v

Rpm sensor Quickly M6 8 ÷ 10
2.0 JTD 16v
1.6 JTD 16v

Cam angle sensor Quickly M6 8 ÷ 10
2.0 JTD 16v
1.6 JTD 16v

Throttle body Quickly M8 23 ÷ 28
2.0 JTD 16v
1.6 JTD 16v

Upper screw (pretreated with
Pressure pump support - crankcase side M8 x 1.25 x 110 23 ÷ 28
sealant - to be replaced) 2.0 JTD 16v
1.6 JTD 16v

Pressure pump support - crankcase side Quickly M8 x 1.25 x 35 23 ÷ 28
2.0 JTD 16v
1.6 JTD 16v

Pressure pump support - cylinder head side Quickly M10 x 1.25 x 40 45 ÷ 55
2.0 JTD 16v
1.6 JTD 16v

Turbocharger and exhaust manifold assembly - cylinder head side Nut (to be replaced) M8 22 ÷ 27
2.0 JTD 16v
12
FIAT DOBLÒ
1. engine > engine management
Engine oil pressure warning light switch

-
M14 29 ÷ 35
1.6 JTD 16v

Engine oil delivery pipe to the turbocharger - side
turbocharger 2.0 JTD 16v
1.6 JTD 16v

Engine oil delivery pipe to the turbocharger - upper cylinder head side
2.0 JTD 16v
1.6 JTD 16v

Engine oil return pipe from the turbocharger Quickly M10 45 ÷ 55
2.0 JTD 16v
1.6 JTD 16v
Engine oil filler neck Quickly M6 8 ÷ 10 1.9 JTD 16v
2.0 JTD 16v
1.6 JTD 16v

Engine oil filter cover
- -
25
2.0 JTD 16v
1.6 JTD 16v

Thermostat Quickly
-
8
2.0 JTD 16v
1.6 JTD 16v

Water pump Screw (to be replaced) M8 23 ÷ 28
2.0 JTD 16v
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

Editions

SEMANTICS
FIAT DOBLÒ
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
FIAT DOBLÒ
• 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.
(via CAN network) Preheating glow plugs 25. Throttle
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
FIAT DOBLÒ
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
Lambda measurement from 0.8 to infinity

Pin Color Signal Reference pin
range System tolerance ÿO2 /O2 = ± 4%
1 Signal 58 connector B
Discharge temperature ÿ 980 °C
2
Grey green Pasta 41 connector B
Exhaust pressure ÿ 2,5 bar
Diet ÿ 10.8V
Activation time ÿ 10 s Speed sensor

The task of the sensor is to detect the rotation speed of the engine and the
Potentiometer range 30 ÷ 300 Ohm
its angular position. It is a variable magnetic reluctance transducer,
mounted on the base and faces the tone wheel screwed to the shaft
Camshaft position sensor motor (60-2 teeth).
The sensor has the task of detecting the motor phase during
synchronization. 860 ÿ ± 10% at 20° C
Winding resistance
It is a Hall effect sensor, mounted on the cylinder head and facing out
to the welded ring (on which the window is made) on the keyed pulley
on the camshaft. Pin Color Reference pin
Signal
Pin Reference pin 1 Brown Signal 27 connector B

Signal
1 Pasta 11 connector B 2 White 12 connector B
Signal
2
Signal 50 connector B
3 Power supply (+5V) 20 connector B

Butterfly potentiometer
The sensor, positioned on the accelerator pedal, in an axial position, is
Intake air flow and temperature sensor consisting of a shaft connected to the two potentiometers, one main and
The flow meter has the task of measuring the maximum flow rate of air a safety one.
sucked in from the environment; this flow rate is used to control the EGR e On the shaft a helical spring guarantees the right resistance to pressure,
for limiting exhaust smoke during loading passages. while a second spring ensures the return when released.
It is a hot film meter, mounted on the downstream intake duct
from the air filter to the mount of the compressor, the digital signal in frequency Pin Signal Reference pin
is transmitted by the air temperature from the air temperature to the central motor. 1 46 connector A
Power supply 1 (+5V)
Passage section diameter 70 mm 2 Power supply 2 (+5V) 45 A connector
Diet 12V nominal 3 Mass 1 30 A connector
Range 10 ÷ 640 kg/h 4 9 connector A

Signal 1
Nominal flow rate 480 kg/h 5 Mass 2 8 A connector
Pin Color Reference pin 6 Signal 2 31 connector A

Signal
1 Orange/Black Power supply (+12V) 22 shunt control units
2 Purple 44 connector B Pasta
Overpressure sensor
3 Green Temperature signal 37 connector B The sensor is mounted in the center of the intake box and has the task
4 White green Air mass signal 42 connector B of informing the injection control unit to:
Coolant temperature sensor • adjust the injection pressure

It is mounted on the thermostat and measures the temperature of the
• adjust the duration of the injection
coolant to provide the control unit with an index of the thermal state of the engine.
16
FIAT DOBLÒ
OUTPUT SIGNALS Pin Out Motore 2.0 Multijet 16V
Pre-heating control unit Connector A (vehicle wiring)

The glow plugs are controlled via the pre-heating control unit, under the Pin Description
direct control of the injection control unit. 1 Battery positive
Inside the pre-heating control unit there is an "intelligent" relay which 2
Battery negative
sends a "feed-back" response to the injection control unit.
tion which is thus informed of any failure of the control unit 3 Battery positive
preheating or short circuit to ground of the glow plugs. 4

Battery negative
5 Battery positive
Pin Signal Reference pin
6
1 Battery negative
Power (+12) 4 Additional engine compartment control unit
7
2
- -
Turbo pressure actuator
3
Pilot signal 52 connector A 8
Potentiometer 2 on accelerator pedal (-)
4 Activation signal Cylinder glow plugs 1-2 9
Potentiometer 1 signal on accelerator pedal
5
Activation signal Cylinder glow plugs 3-4 10 Diesel temperature sensor (-)
6 Pasta Right/left front mass 11 Diesel temperature sensor signal
7 Power supply (+12V) Drums
12 Linear pressure sensor for air conditioner (-)
13 Linear pressure sensor signal for air conditioner
Injectors
14 Fuel level sensor (-)
The injector is a component that requires very high manufacturing
15 Fuel level sense signal
precision. The manufacturing tolerances between the needle shank and the plunger of
16 N.C.
high pressure are only 3ÿm.
This very high precision of the injectors necessarily requires the 17 Signal + Contact on brake pedal (NO)
maximum cleanliness during interventions on the Common Rail system. 18 N.C.
Dirt particles of the order of 1/1,000 mm can already be the cause
of a failure of the Common Rail system. 19 Alternator “L” signal
20 Low pressure pump relay control
Injector A 21 N.C.
22 Linear pressure sensor for air conditioner (+)
1
23 Power supply for 1 sensor 5V
2
24 Power supply for 2 sensors 5V
Injector B
25 K Line
1
Signal 2 connector B 26 Turbo pressure indicator signal
2
Signal 31 connector B 27 Fuel consumption signal
Injector C 28 Key signal
Pin Signal Reference pin 29 Negative signal for compressor activation relay control
1
30 Potentiometer 1 on accelerator pedal (-)
2
31 Potentiometer 2 signal on accelerator pedal
Injector D
32 Exhaust gas temperature sensor signal 2 (only versions with DPF)
33 Exhaust gas temperature sensor 2 mass (only versions with DPF)
1
2 33 connector B 34 Exhaust gas temperature sensor signal 1 (only versions with DPF)
Signal
35 Exhaust gas temperature sensor 1 mass (only for versions with DPF)
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.
Control unit and connectors 40 Reserved digital input

41 N.C.
42 Reserved digital input

46 60 45 51 73 94 72
43 Wake-up signal
31
44 Differential pressure sensor (DPF) (+) (only for versions with DPF)
45 Potentiometer 1 on accelerator pedal (+)
16
47 Immobilizer interface
1 15 30 29 7 28 50 48 Engine speed signal

49 Cruise Control warning light control
17

Editions

SEMANTICS
FIAT DOBLÒ
Connector A (vehicle wiring) Connector B (engine harness)

1 Cylinder 3 injector (+)
Pin Description
50 N.C.
3 N.C.
51 Lambda sensor heater control (only versions with lambda sensor) 4 Rail pressure regulator supply
52 Glow plug preheating control unit diagnosis

5 Reserved battery positive power supply
6 N.C.
53 Vehicle speed sensor (-)
7 Engine rpm sensor screen
54 Compressor activation request 8 Fuel pressure sensor (-)
55 Starter motor relay control 9 N.C.
56 SET + Cruise Control 10 Power supply for 3 sensors 5V

11 Phase sensor (+)
57 Reverse gear switch signal
12 Engine rpm sensor (-)
58 Trinary air conditioning signal/alternator “F” signal 13 Turbo pressure sensor (+)
59 N.C. 14 Power supply for 2 sensors 5V
60 N.C. 15 Turbo pressure actuator

61 CAN network (low channel)
62 CAN network (high channel) 18 N.C.
63 N.C. 19 Fuel pressure regulator (+)

20 Phase sensor (-)
64 Lambda sensor signal (only for versions with lambda probe)
21 Oil level sensor signal input
22 Reserved analog ground
66 Oil temperature sensor signal 23 Turbo pressure sensor (-)
67 N.C. 24 N.C.

68 Fuel heater relay control
26 EGR position sensor power supply
69 2nd level of engine cooling electric fan
27 Engine rpm sensor (+)
70 DPF warning light control (only for versions with DPF) 28 Fuel pressure sensor (+)
71 EOBD fault warning light 29 Power supply for 2 sensors 5V
30 Engine positive EGR
72 Main relay control negative signal
31 Cylinder 2 injector (-)
73 N.C.
32 N.C.
74 Water presence sensor signal in the diesel filter 33 Cylinder 4 injector (-)
75 Vehicle speed sensor signal from 34 to 36 NC
37 Air temperature sensor (air flow meter)

76 Oil temperature sensor (-)
38 N.C.
77 Cruise “off”
39 Throttle valve diagnosis ground
78 Cruise “Set/Decrease” 40 Turbo pressure sensor signal
41 Engine coolant temperature sensor (-)
79 Signal - Contact on clutch pedal
42 Air flow sensor signal
80 Brake pedal secondary switch signal
43 Rail pressure sensor signal
81 Quadrinary air conditioning signal
44 Mass (air flow meter)
82 N.C. 45 N.C.
83 CAN network (low channel) 46 Cylinder 3 injector (-)

84 CAN network (high channel)
48 N.C.
85 N.C.
49 Fuel pressure regulator (-)
86 Lambda sensor ground (only for versions with lambda probe) 50 Phase sensor signal
51 EGR position sensor ground
52 Throttle valve diagnosis signal
88 EGR exchanger actuator
53 Turbo air temperature sensor signal
89 Reserved analogue input N.C.
54
90 1st level of engine cooling electric fan 55 Intake air temperature sensor ground
56 Insufficient engine oil pressure
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
FIAT DOBLÒ
Pin Out Motore 1.6 Multijet 16V
Connector A (vehicle wiring) Pin Description
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.
11 Diesel temperature sensor signal

60 N.C.
12 Linear pressure sensor for air conditioner (-)
13 Linear pressure sensor signal for air conditioner
14 Fuel level sensor (-)
63 N.C.
15 Fuel level sense signal
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.

68 Fuel heater relay control
21 N.C.
69 2nd level engine cooling electric fan
22 Linear pressure sensor for air conditioner (+)
70 DPF warning light control (only for versions with DPF)
23 Power supply for 1 sensor 5V
24 Power supply for 2 sensors 5V 71 EOBD fault warning light
25 K Line 72 Main relay control negative signal
26 Turbo pressure indicator signal 73 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)
38 Resume Cruise Control
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)
43 Wake-up signal 88 EGR exchanger actuator
44 Differential pressure sensor (DPF) (+) (only for versions with DPF) 89 Reserved analogue input
90 1st level engine cooling electric fan
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
50 N.C. 94 Fan relay control 3
19
FIAT DOBLÒ
Pin Description
Connector B (engine harness)
Pin Description 29 Power supply for 2 sensors 5V
1 Cylinder 3 injector (+) 30 Engine positive EGR

32 N.C.
3 N.C.
4 Rail pressure regulator supply
from 34 to 36 NC
5 Reserved battery positive power supply
6 N.C.
37 Air temperature sensor (air flow meter)
38 N.C.
7 Engine rpm sensor screen
39 Throttle valve diagnosis ground
8 Fuel pressure sensor (-)
40 Turbo pressure sensor signal
9 N.C.
41 Engine coolant temperature sensor (-)
42 Air flow sensor signal
11 Phase sensor (+)
43 Rail pressure sensor signal
12 Engine rpm sensor (-)
44 Mass (air flow meter)
13 Turbo pressure sensor (+) N.C.
45
15 Turbo pressure actuator 47 Cylinder 1 injector (-)
16 Cylinder 1 injector (+) N.C.
48
17 Cylinder 4 injector (+) 49 Fuel pressure regulator (-)
18 N.C.
50 Phase sensor signal
19 Fuel pressure regulator (+) 51 EGR position sensor ground
20 Phase sensor (-) 52 Throttle valve diagnosis signal
21 Oil level sensor signal input 53 Turbo air temperature sensor signal
22 Reserved analogue ground 54 N.C.
23 Turbo pressure sensor (-) 55 Intake air temperature sensor ground
24 N.C. 56 Insufficient engine oil pressure
25 Power supply for 3 sensors 5V 57 EGR position sensor signal
26 EGR position sensor power supply 58 Engine coolant temperature sensor signal
27 Engine rpm sensor (+) 59 Throttle solenoid valve control
28 Fuel pressure sensor (+) 60 EGR solenoid valve
ENGINE MANAGEMENT DIAGRAMS K041 Air Flow Meter

K044 Air Pressure/Temperature Sensor
ELECTRICAL DIAGRAMS LEGEND K046 Rev Sensor
K047 Phase Sensor
A040 Preheating glow plugs
K055 Accelerator Pedal Potentiometer
B001 Engine Compartment Junction Control Unit
K083 Fuel Pressure Sensor
B099 Maxi Fuse Box on Battery
K100 Temperature Sensor and Heating Resistance
C020 Passenger side dashboard mass L030 Egr. solenoid valve
C030 Left Posterior Mass
L036 Variable Turbine Geometry Control Solenoid Valve
C060 Injection control unit ground
M001 Body Computer
D001 Front Junction / Dashboard M010 Engine Control Unit
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
I050 Inertia switch Sky blue Brown

A M
K030 Insufficient Engine Oil Pressure Sensor B White N Black

K031 Water Presence Sensor in the Diesel Filter C Orange R Red
K032 Engine Oil Level Sensor IN Green
H Grey
K036 Engine Coolant Temperature Sensor/Transmitter L Blu WITH
Viola
20
FIAT DOBLÒ
1. engine > wiring diagrams
Engine
21
FIAT DOBLÒ
Engine
22
FIAT DOBLÒ
Engine
23
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
Tool Name Function

1860804001 Tablet Disassembly/reassembly of valves
1860815000 Flange Crankshaft rotation
2000004100 Introducer Introduction of oil pump seal ring
1860833000 Key Unscrew/tighten crankcase cup screws on the distribution side and gearbox side
Unscrew/tighten engine upper head screws
1860834000 Key
Unscrew/tighten crankcase cup side screws
1860846000 Anti-couple Flywheel stopper
1860851000 Cross Powertrain support

1860854000 Extractor Extraction of the pressure pump control pulley
1860898000 Anti-couple Flywheel stopper
1870739000 Extractor Removal of electroinjectors

1870815000 Anti-couple Unscrew/tighten the distribution driven toothed pulley fixing screw
1870836000 Pegs Unscrew/tighten the distribution driven toothed pulley fixing screw
1870894000 Extractor Removing the valve guide oil seal
1870896800 Introducer Introduction of exhaust side timing shaft front oil seal
1870896900 Dime Engine timing
1870897100 Extractor/Introducer Removal/Introduction of valve guides Introduction of valve guide oil seal
1870897300 Adapter Removal of electroinjectors
1871000000 Review stand Engine overhaul
1871000000 Bracket Positioning the engine on the overhaul stand

1871000500 Introducer Introduction of front crankshaft oil seal
1871000600 Extractor/introducer Extraction/introduction of valve guides
1871000700 Extractor Extraction of the steering rod from the upright
1871001300 Vertical support Powertrain support

1871001700 Scale Removing/reattaching the powertrain
1871003100 Extractor/introducer Removing/reassembling the clutch mechanism
1871008500 Extractor/introducer Extraction/introduction of valve guides
2000001400 Cork Brake/clutch system depression
2000003000 Dima Engine timing
2000003200 Key Removing/reconnecting glow plugs
2000003900 Key Unscrew/tighten engine oil filter cover
2000004100 Introducer Introduction of front crankshaft oil seal
2000024900 Centrifugation kit Removing/reassembling the clutch mechanism
2000026800 Cage Disassembly/reassembly of valves
2000026900 Pressure pump removal/reconnection kit Removal/reconnection of pressure pump
2000032400 Extractor/introducer Extraction/introduction of valve guides and insertion of oil seal
24
FIAT DOBLÒ
operations without disconnecting the engine
DISTRIBUTION Assembly - In this position, tighten the M8 nut (14) of the

- Unscrew the screw of the front cover (5) tensioner to a torque of 23 ÷ 28 Nm.
BELT of the base. - Remove the timing tools.
- Temporarily fit the timing belt (6) on the - Make the engine complete two revolutions to
Disassembly toothed pulley. settle the belt.
- Place the car on the lift. ta presenter. - Unscrew the nut of the mobile distribution
- Disconnect the battery. tensioner and, working carefully, bring the
- Drain the air conditioning refrigerant system. Use: pointer of the tensioner (15) in correspondence
The arrow painted on the timing control toothed with the reference hole (16) and in this position
- Remove the protection underneath the engine. belt must respect the direction of rotation of the of correct tension, tighten the M8 nut (17) of
- Remove the timing side engine rigid support. engine. The strap must be fitted avoiding causing the tensioner to a torque of 23 ÷ 28 Nm.
sharp bends so as not to compromise the structure
- Remove the front wheels. of the strap itself. Belt tensioning
- Remove the additional wheel arches.
- Remove the service belt.
- Undo the screws and remove the engine - Mount the template (7) and secure it with the 9
flywheel protection cover. calibrated screw (8).
- Fit the flywheel holding tool.
- Undo the screws and remove the service Template assembly
pulley on the crankshaft.
- Remove the flywheel holder and the timing 6
10
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

Toll Free Number 800-42-42
Editions

SEMANTICS
FIAT DOBLÒ
- 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
- Remove the camshaft sensor.

- Loosen the two shaft drive gears a 8 3
cams. 5 6
- Use a pulley holder (1).

- Counteract the camshaft control gear (2). 10
9
1
2
- Loosen the shaft drive gear a

cams.
6 7 5 4
Gear removal
1
2 9
3 8
- Insert the roller drive levers with hydraulic

2
- Remove the cylinder head. tappets.
- Place the cylinder head on a suitable - Fit the coolant hoses to the thermostat
support for the overhaul. housing and radiator
- Place the contrasts to block the valves. exhaust gas recirculation.
- Remove the cotters with a suitable tool. - Tighten the fixing screw of the high pressure
pump support in the cylinder head.
- Remove the valve springs, valves and - Prepare to assemble the two camshafts.
- Remove the motor transport bracket. valve guides. - Moisten the bearing surfaces with engine
- Remove the small parts. - Check that all measurements correspond to oil.
- Remove the camshaft housing. those described in the technical data. - Insert the shaft drive gears a
cams.
Attention: Bench assembly - Fit - Adjust the two camshafts to the ignition
Loosen the screws gradually in a spiral from the valve guides (if necessary they are TDC of cylinder 1.
the outside towards the inside. Make sure that available with larger diameters). - Position the 2 camshafts.
the camshaft housing detaches evenly from the - Mount the valves and position the contrasts - Pay attention to the correct mounting
cylinder head. to block them. position.
- Fit the valve springs. - Fit the two camshaft control gears and
- Remove the gasket and remove the front - Remove the head from the support for review tighten the screws to a torque of 120 Nm.
camshaft control gear and the screw. it is. - Place the shaft housing a
cams.
- Remove the rear camshaft control gears. Assembly on the monobloc - Tighten the camshaft housing fixing screws
- Carry out a flatness check of the cylinder to a torque of 25 Nm.
- Remove the camshaft sealing ring. - Fit the intake camshaft cover.
head and monobloc with a knife ruler and feeler gauge.
- Bring the first cylinder to the TDC position.
Use: - Use a dial indicator (1) with adequate - Fit the shaft sealing ring a
Lift using a suitable tool. Don't give- support. cams.
protect the sealing surfaces. - Place the probe on the head and zero - Fit the shaft drive gear a
adjust it with a slight preload. cams.
- Remove the camshafts. - Rotate the engine in the direction of rotation. - Tighten the camshaft pulley fixing screw
to a torque of 120 Nm.
Use: Use: - Fit the camshaft sensor, tightening it to a
Eject the camshaft acting on the intake valves Determine the highest point of cylinder 1 by torque of 9 Nm.
with the cover. turning the crankshaft. - Fit the motor transport bracket and tighten
the screw to a torque of 50 Nm.
- Unscrew the screw from the high pressure - Measure the piston protrusion. - Mount the depressor and tighten the screws to
fuel pump support in the cylinder head. - Carry out the measurement on the remaining pistons. a torque of 9 Nm.
- Drain the coolant. - Perform the measurement on two different - Fit the oil filler neck and tighten the screws
- Remove the coolant hoses from the flat points. to a torque of 9 Nm with red threadlocker.
thermostat body and from the exhaust gas
recirculation radiator. Attention: - Connect the coolant temperature sensor
- Remove the sixteen roller drive levers with The calculated maximum piston protrusion is connector.
hydraulic tappets. decisive for the selection of the cylinder head - Insert the brake booster vacuum line so
gasket with the corresponding identifier. that the fitting locks audibly.
Note: - Fit the engine breather hose from the
Pay attention to the layout. - Replace the head gasket. engine oil filler neck.
26
FIAT DOBLÒ
- 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.
operations with engine disconnection
POWERTRAIN - Disconnect the electrical connections (13) and

(14) from the electronic injection system control
REMOVING THE ENGINE FROM - Unscrew the exhaust pipe support fixing nuts. unit.
CAR - Unscrew the nut (15) and disconnect the ground
- Unscrew the nuts and remove the exhaust pipe cable (16).
Disassembly connected to the engine complete with support
- Place the car on the lift. and relative elastic support. Removal of control unit connectors
- Remove the front wheels. - Unscrew the screw and disconnect the
16
- Disconnect the battery and remove it together compressor inlet pipe, compressor side.
with its basket. - Unscrew the screws (8) and move the clutch
15
- Remove the wheel arch dust covers. control operating cylinder (9) sideways without
13
- Remove the under-engine protection. disconnecting the relevant pipe.
- Unscrew the right and left dust cover screws on
the front suspension cross member reinforcement. Removal of operator cylinder
- Disconnect the lower coolant outlet hose from
the radiator, radiator side.
- Disconnect the upper coolant inlet hose from 8
the radiator, radiator side.

- Unclip the electrical wiring from its fixings and
move it away from the electric fans - Unscrew the
nut and remove the upper central radiator support. 14
- Unscrew the screw, loosen the clamps and

remove the air delivery hose from the heat - Unscrew the nut and move the glow plug control
9
exchanger to the throttle body. unit sideways.
- Loosen the clamps and remove the air delivery - Remove the wiring complete with electrical
hose between the turbocharger and the heat Loosen the clamp and disconnect the coolant connections from the engine compartment bulkhead.
exchanger. delivery pipe to the air conditioning system - Disconnect the quick coupling of the fuel return
- Unscrew the screw and disconnect the pipe from heater from the thermostat. pipe on the fuel return manifold pipe side and
the compressor to the condenser of the air - Loosen the clamp and disconnect the pipe disengage the pipe itself from the fastening.
conditioner, compressor side. exiting the air conditioning system heater from
- Unscrew the power steering system heat the T-connection of the thermostat. - Remove the caulking (17) and unscrew the nuts
exchanger fixing screw. - Disconnect the vacuum pipe for the vacuum securing the half-shafts to the wheel hubs.
- Disconnect the quick coupling of the return pipe, tank from the T-fitting.
heat exchanger side and drain the oil from the - Loosen the clamp and disconnect the vacuum Hub nut removal
power steering circuit. pipe from the depressor.
- Position a hydraulic jack (1) under the lower - Unscrew the nut and disconnect the power
radiator cross member. cable from the fuse/contactor box.
- Unscrew the screws (2) and remove the lower - Disconnect the gear engagement hose (10) and
radiator crosspiece assembly (3) complete with unscrew the screws (11) and move the gear
radiator (4), electric fans, air conditioner engagement/selection hose support (12) sideways.
condenser (5), power steering system heat
exchanger (6) and air-air heat exchanger (7). Removing the gear shift hose
Removal of radiator cross member
11
5
4 17
- Unscrew the nuts and disconnect the steering

tie rods from the front uprights with the tool.
2 7
3 - Unscrew the screws fixing the intermediate half-
1 2 10 12
shaft to the relative support.
27
FIAT DOBLÒ
- 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
Dust cover removal secure it with the relative nuts (6).

Using a hydraulic crane (7), support the powertrain
10
with suitable chains (8) fixed to the three points as
indicated in the figure.
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.
- Extract and remove the left half-shaft. Support bench positioning

- Place a hydraulic jack under the gearbox.
- 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
- Unscrew the fixing screw of the front support

elastic plug on the distribution side of the powertrain. 12
3 - Unscrew the nut securing the elastic plug to the

rigid support on the gearbox side of the power unit.
- Unscrew the fitting (9) and disconnect the pipe 11
from the pump to the power steering box (10), on

the power steering box side.
- Unclip the pipe from the pump to the power - Using the hydraulic crane equipped with suitable
steering box from the fastening clamp to the front chains as previously indicated, safely support the
suspension cross member. powertrain.
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
FIAT DOBLÒ
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
- Carry out 4 - 5 cycles of complete steering 9
wheel rotation (right and left).

- Connect the quick coupling of the fuel return - Restore the oil level in the tank.
pipe on the fuel collector pipe side and secure
the pipe itself. ENGINE OVERHAUL
7
- Position the wiring complete with electrical
connections through the passage on the engine Disassembly
compartment bulkhead. - Place the engine on a bench for overhaul.
- Tighten the cable gland fixing nuts. 6
8
- Place the glow plug control unit back in its seat - Unscrew the front, rear (2) and side (3) screws
and secure it with the relative nut. of the crankcase cup.
- Connect the ground cable and tighten the - Remove the gasket with a dedicated cutter (4)
relative nut. and remove the crankcase cup (5).
- Connect the electrical connections to the - Unscrew the screws and remove the distribution
electronic diesel injection system control unit. side powertrain support.
- Place the protection back in its seat and secure - Unscrew the screw and remove the fixed
Cup removal
it with the relative nuts. tensioner of the distribution control.
- Place the clutch/gear selection hose support in - Unscrew the screw and remove the automatic
its seat and secure it with the relative screws. belt tensioner for the auxiliary control belt.
- Unscrew the screws (10) and remove the front
- Connect the gear shift hose. crankcase cover with the integrated oil pump
- Connect the electrical connections to the fuse/ 3 (11) complete with suction tube (12).
contactor switch box and place it back in its place.
2
- Place the cover of the fuse/contact switch box
back in its seat. Oil pump removal
- Connect the power cable to the fuse/contactor
switch box and secure it with the relative nut.
12
- Connect the vacuum pipe to the depressor and

5
tighten the relative clamp.
- Connect the vacuum pipe for the vacuum tank
to the T-fitting.
4
- Connect the pipe exiting the air conditioning
system heater to the T-connection of the
thermostat and tighten the relative clamp.
- Connect the coolant delivery pipe to the air
conditioning system heater to the thermostat
10
and tighten the relative clamp. 11
- Place the clutch control operating cylinder back

in its seat and secure it -
Place the air delivery hose between the
turbocharger and heat exchanger in its seat and
tighten the relative clamps.
- Place the air delivery hose from the heat
exchanger to the throttle body in its seat and
tighten the relative clamps and screws.
- Place the upper central radiator support in its
seat and secure it with the relative nut.
- Place the electrical wiring in its place and
connect the electrical connections to the engine
cooling electric fans.
29

Editions

SEMANTICS
FIAT DOBLÒ
- 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
(9). - Fit the crankshaft.

- Remove the crankshaft (10). - Check that the external diameter of the piston pin - Apply the Plastigage calibrated wire to measure the
- Unscrew the screws and remove the tone wheel (11) falls within the value of 25.982 ÷ 25.988 mm. play of the main journals.
from the crankshaft. - Fit the caps onto the connecting rods and secure - Fit the main caps complete with half-bearings and
- Remove the upper main bearing halves (12). them with the screws, check with a bore gauge that tighten the screws to a torque of 24 ÷ 26 Nm + 90°.
the diameter of the connecting rod head falls within
- Remove the thrust half rings (13). the values of 53.883 ÷ 53.923 mm. - Remove the main caps and measure the pin play with
- Unscrew the screws and remove the jets (14) from the base - Check that the internal diameter of the connecting a special graduated meter.
ment. rod small end falls within the values of 26.006 ÷ 26.012 mm.
- Unscrew the screw and remove the rpm sensor (15). - Position the bands inside the cylinder and check with Use:
a feeler gauge that the elastic face gap values are If the value detected is not within tolerance, replace the
within the values shown below. main bearing halves with others of the appropriate size and
Crankshaft removal class.
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
- Fit the water/oil sealing caps on the crankcase.

7
14 - Lubricate all mechanical coupling components with

16
15 engine oil.
4
- Check that the cylinder head support surface has no
13
cracks or surface scratches.
- Determine the diameter of the cylinder liners according to the
scheme shown below.
Cylinder liners diameter Value (mm)
Class A 82,000 ÷ 82,010

- Unscrew the screws and remove the flange complete - Measure the clearance between the pin and the
with oil return pipe to the sump from the turbocharger. Class B 82,010 ÷ 82,020 bearings using a special meter, then tighten the
sore. connecting rod cap fixing screws in pairs according
Class C 82,020 ÷ 82,030
- Unscrew the fitting and remove the oil delivery pipe to the previously indicated procedure.
to the turbocharger. - Fit the rear crankcase cover with integrated oil seal
- Unscrew the screws and remove the turbocharger - Check that the conicity of the cylinder liners is within ring and tighten the M6 screws to a torque of 8 ÷ 10
support bracket. the value of ÿ0.005 mm. Nm.
30
FIAT DOBLÒ
- 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
pump support. engine oil level dipstick to the pressure pump

- Disconnect the electrical connection from support.
the fuel pressure regulator. - Place the fuel return manifold pipe complete
6
- Block the rotation of the pressure pump with the pipe from the electro-injectors to the
control pulley with two screws. fuel recovery manifold in its seat and secure it
- Unscrew the nut of the pressure pump control with the relative screws.
5
pulley. - Connect the fuel return pipe to the pressure

- Unscrew the two previously mounted screws pump, on the fuel return manifold pipe side
for blocking the rotation of the pressure pump and tighten the relative clamp. 8
control pulley. - Connect the quick coupling of the fuel return

- Remove the pressure pump control pulley pipe to the tank, fuel return manifold side.
with an extractor.
- Unscrew the nuts (3) and remove the pressure - Connect the quick coupling of the fuel return - Unscrew the fittings and remove the pipe
pump (4) from its support. pipe from the fuel filter, fuel return manifold from the pressure pump to the fuel manifold.
pipe side. - Disconnect the electrical connection from the
Pump removal fuel pressure sensor.
3 FUEL DISPENSER - Unscrew the screws and remove the single
fuel manifold pipe complete with fuel pressure
Removal - sensor.
Disconnect the battery.
- Remove the tappet crankcase cover. Assembly -
- Manually push the clips (5) and disconnect Tighten the M14 fittings on the fuel distributor
the pipe from the electro-injectors to the fuel to a torque of 23 Nm.
recovery manifold (6), on the electro-injector - Proceed with assembly in the reverse order
4
side and move it laterally. of disassembly.
31
FIAT DOBLÒ
LOW PRESSURE PUMP Pump removal Assembly

- Place the electric fuel pump in its seat.
Disassembly 1
- 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
- Connect the electrical connection to the

- Unscrew the fixing screws (1) and remove the electric pump.
protective cover (2). - Place the protective cover in its seat and
- Disconnect the electrical connection from the 4 secure it with the relative screws.
electric pump. - Place the floor covering back in its place.
- Disconnect the quick couplings of the fuel 5
delivery and return pipes from the electric fuel - Lower the rear seat cushion by fixing it to the
pump. relative anchoring hooks.
- Using the tool (3), unscrew the ring nut (4) and - Connect the (-) battery terminal.
remove the electric fuel pump (5). - Fit the electric fuel pump cover and tighten the
fixing screws.
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
the pump body and driven gear is between 14

the values of 0.080 ÷ 0.186 mm.
- Check that the axial clearance between the 12
15
pump cover support surface and the gear upper 16
side is between 0.025 ÷ 0.070 mm. 13
32
FIAT DOBLÒ
- 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.
the radiator from the thermostat. 10

- Disconnect the quick coupling of the radiator
re. water inlet pipe and move it to the side.
8
7
- Disconnect from the thermostat “T” fitting (2) - Unscrew the upper right radiator fixing screw.
the outlet pipe from the plant heater
11
air conditioning system (3) and the delivery pipe - Disconnect the electrical connection of the
to the rigid liquid inlet pipe to the water pump (4). electric fan.
- Separate the crosspiece (13) from the radiator (14).
- Disconnect the coolant delivery pipe (5) to the Assembly - - Unscrew the screws (15) and remove the
air conditioning system heater from the Place the water/exhaust gas heat exchanger for electric fan (16).
thermostat. the EGR system in its seat together with the
- Disconnect the coolant return pipe (6) to the thermostat complete with relative gasket. Removal of radiator with electric fan
engine cooling supply tank from the thermostat.
- Tighten the pin and the M8 screw securing the 16
thermostat to a torque of 23 ÷ 28 Nm.

Removing pipes from thermostat - Tighten the nut and the heat exchanger screws 14
to the cylinder head.

1
connect the electrical connections to the electro-
6
injectors.
- For subsequent assembly operations, proceed
in the reverse order of disassembly. 15
RADIATOR AND ELECTRIC FAN 13
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

Editions

SEMANTICS
FIAT DOBLÒ
Turbocharger removal
SUPERCHARGING
TURBOCHARGER
Disassembly
- Unscrew the screws and remove the lower
and upper exhaust manifold heat shield. 3
- Unscrew the front section fixing nuts 1
exhaust pipe to the catalytic converter

co.
- Disconnect the vacuum pipe from the variable 4
geometry control actuator

- Loosen the clamp and disconnect the sleeve
air delivery between turbocharger and heat
exchanger, turbocharger side.
- Unscrew the screws and nuts securing the 2
catalytic pre-converter support bracket.

- Unscrew the return pipe fixing screws
engine oil from the turbo, crankcase side.
- Unscrew the fitting and disconnect the pipe Assembly
engine oil delivery to the turbocharger, side Place the exhaust manifold gasket back in its seat.
engine base. - Tighten the M8 nuts of the exhaust manifold to a torque of 28 Nm.
- Loosen the collar and remove the catalytic - Connect the corrugated air inlet sleeve to the turbocharger, turbocharger side and tighten the
pre-converter. relative clamp.
- Unscrew the nuts (1) and remove the - Connect the air delivery hose between the turbocharger and the heat exchanger, turbo-
compressor
complete variable geometry turbo-compressor assembly (2). side and tighten the relative clamp.
of exhaust manifold (3) complete with gasket - Fit the exhaust manifold upper heat shield and secure it with the relative nuts.
(4). - For subsequent assembly operations, proceed in the reverse order of disassembly.
34
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
it is obtained through the pressure exerted by a diaphragm spring.

The clutch is released by means of a hydraulic system controlled by the Disc spring load (N) 5.000
pedal.
HYDRAULIC CIRCUIT Master cylinder csc

The system consists of: The clutch is disengaged by the action of the clutch master cylinder
which sends oil under pressure, through the pipe, into the expansion
• a clutch pump (master cylinder), which has the task of compressing the oil, chamber. The oil pressure causes the piston to move
fixed to the pedal it slides on the guide tube using wear-resistant plastic pads.
• a connection pipe between the pump and the clutch control cylinder The plunger is integral with the thrust bearing which presses on the
• a clutch control cylinder fixed to the gearbox pressure plate springs thus disengaging the clutch.
• a thrust bearing operating lever When the oil pressure ceases, the actuator returns to the rest position
• a thrust bearing through the thrust of the pressure plate springs.
• a clutch basket with diaphragm pressure plate springs The seal of any transmission oil leaks that may spill
• a clutch disc
inside the clutch bell is guaranteed by an oil seal ring and by
• a fluid reservoir shared with the brake system un O-ring.
As protection against the entry of external agents, a
The pump, controlled by the clutch pedal, puts pressure on the circuit rubber bellows held in place by a spring.
hydraulic and activates the clutch control cylinder. The latter acts on
operating lever, which "pulls" the thrust bearing, overcoming the action CSC secondary cylinder
of the pressure plate springs. This action causes the detachment of the The clutch release pump has been designed with the body
clutch disc from the flywheel. When the pedal is released, the action of and the plastic piston, for weight reduction, the operating rod is anchored
the diaphragm springs returns the mechanism to the initial position. to the piston (T interface).
Inside the body in the sliding area of the piston seals there is a steel
CSC SYSTEM cylinder to avoid wear and deformation
The CSC system is defined as coaxial because the disengagement actuator due to pressure. The piston coming out is prevented by a V-shaped stop
device is made up of an annular aluminum cylinder mounted inside fork, while a protective bellows prevents the accumulation of
of the clutch bell, placed between the gearbox and the clutch mechanisms, dirt inside the cylinder.
in a coaxial position with respect to the primary shaft. The upper and lower limit switches of the piston in the pump body also
The advantage of the CSC system, compared to the traditional system, determine the extreme positions, high and low, of the pedal.
lies in the absence of kinematic couplings and sliding, obtaining greater
reliability, functionality and ease of maintenance.
The system highlights the following particularities: MAINTENANCE
• constant adjustment of the clutch pedal height CLUTCH OIL
• effort applied to the pedal constant over time
Products TOP 4 PROTECTION - FMVSS n°116 DOT 4
• elimination of any difficulties in returning the clutch pedal
Capacity 1 liter
• reduction of noise and vibrations transmitted by the pedal by means of
Maintenance frequency drain replacement every 2 years
the action of a vibration damper placed in the oil pipe
cylinder command
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
FIAT DOBLÒ
2. clutch > 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.
HYDRAULIC PART Assembly Secondary cylinder removal

- Position the main cylinder and engage the
10
MASTER CYLINDER pipe retaining clips at the gearbox.
- Tighten the clutch main cylinder fixing screws
9
Disassembly to a torque of 12 ÷ 18 Nm.
- Act on the clip and remove the fitting a - Position the three-way fitting and secure it with the
three ways. relative retaining clip.
- Unscrew the screws (6), compress the clips
retainer (7) and remove clutch master cylinder SECONDARY CYLINDER
(8).
Disassembly
11
Master Cylinder Removal - Place the car on the lift.
- Disconnect the battery and remove it together
to his basket.
- Remove the left front wheel and the respective
wheel arch.
- Connect a suitable container to the valve
bleed the clutch control actuator and drain all the
7
brake/clutch fluid.
- Compress the upper clip of the retaining device
12
and disengage the cap of the
secondary cylinder from the clutch pedal.
8
- Act on the clips and remove the device
of retention from the tip.
- Loosen the clamp and disconnect the clutch
system feed pipe (9).
- Move the clip back and disconnect the vibration
damper from the secondary cylinder (10).
6
- Unscrew the nuts (11) and remove the secondary
cylinder (12).
36
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

Editions

Then purchase the Basic SUITE OBD Plus - 4 CDs (1000
SEMANTICS
codes, 500 diagnoses and 500 vehicle summary data sheets) DEMO PRESENT ON THE ATTACHED CD
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
14. Clutch housing

15. Differential support box
16. Gear box cover
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
FIAT DOBLÒ
3. C510.5 gearbox > technical data
C510.5 GEARBOX WHEELS Secondary tree
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
Component Fixing Ø Value (Nm)
Mechanical Gearbox/Differential Given M12 (Engine crankcase side) 72 ÷ 8
Mechanical Gearbox/Differential Quickly M10 (Engine oil sump side) 50 ÷ 60
Mechanical Gearbox/Differential Quickly M12 (Engine crankcase side) 72 ÷ 88
Internal Mech./Diff. Gearbox Controls Quickly M6 18
Internal Mech./Diff. Gearbox Controls Quickly M6 10
Rear cover Gearbox Mech./Diff. Quickly M8 25
Corona Differenziale Cambio Mecc. Quickly M11 13
Rear Cover Spacer M/D change Quickly M8 25
Gear selection lever Quickly M8 15
Reverse gear transmission Mech./Diff. Quickly M7 34
Reverse gear transmission Mech./Diff. Quickly M7 34
Mech./Diff. Gearbox Gearbox Quickly M8 25
Mech./Diff. Gearbox Caps Conical cap M22 x 1.5 36
39
FIAT DOBLÒ
3. gearbox C510.5 > maintenance operations
operations without detachment of the gearbox
Removing the fuel cap
LUBRICANT
GEARBOX OIL C510.5
Replacement - Place the car on the lift. 1
- 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.
- Clean the M22 filling cap and tighten it to a torque of 29 ÷ 43 Nm.
operations with gearbox detachment C510.5
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
Disassembly - Place the car on the lift.

- Remove the front wheels. Removal of radiator cross member
- Disconnect the battery and remove it together
with its basket. 9
- Remove the wheel arch dust covers.
- Remove the under-engine protection.

- Unscrew the right and left dust cover screws 6
on the front suspension cross member reinforcement.

- Disconnect the lower coolant outlet hose
from the radiator, radiator side. - Disconnect
the upper coolant inlet hose from the radiator, 5
radiator side.
- Unclip the electrical wiring from its fixings 10
and move it away from the electric fans - 7
Unscrew the nut and remove the upper central

radiator support.
- Unscrew the screw, loosen the clamps and
remove the air delivery hose from the heat 3 8
4
exchanger to the throttle body. 2

3
- Loosen the clamps and remove the air - Loosen the clamp and disconnect the
delivery hose between the turbocharger and coolant delivery pipe to the air conditioning
the heat exchanger. system heater from the thermostat.
- Unscrew the connections and disconnect the
pipe from the compressor to the condenser of the - Loosen the clamp and disconnect the pipe
air conditioner, compressor side. exiting the air conditioning system heater
- Unscrew the power steering system heat - Unscrew the exhaust pipe support fixing nuts. from the T-connection of the thermostat.
exchanger fixing screw. - Disconnect the vacuum pipe for the vacuum
- Disconnect the quick coupling of the return - Unscrew the nuts and remove the exhaust tank from the T-fitting.
pipe, heat exchanger side and drain the oil pipe connected to the engine complete with - Loosen the clamp and disconnect the vacuum
from the power steering circuit. support and relative pipe from the depressor.
- Position a hydraulic jack (2) under the lower elastic support - Unscrew the screw and - Unscrew the nut and disconnect the power
radiator cross member. disconnect the compressor inlet pipe, compressorcable
side. from the fuse/contactor box.
40
FIAT DOBLÒ
- 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
from the electronic injection system control unit.
- 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
- Remove the caulking (8) and unscrew the nuts

securing the half-shafts to the wheel hubs.
Hub nut removal
Unscrew the nuts, the screws and remove the rigid

engine support connection plate on the distribution
8
side to the air capacity box.
Fit the tool (13) on the pressure pump support and
secure it with the relative nuts (14).
Using a hydraulic crane (15), support the powertrain
with suitable chains (16) fixed to the three points
as indicated in the figure.
41

Editions

SEMANTICS
FIAT DOBLÒ
- 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.
for supporting the powertrain-

re. - Connect the vacuum pipe to the depressor and
- Place a hydraulic jack under the gearbox. tighten the relative clamp.
- Connect the vacuum pipe for the vacuum tank
- Place the powertrain reaction rod in its seat and to the T-fitting.
secure it with the bolt at a torque of 88 Nm and - Connect the pipe exiting the air conditioning
the screw at a torque of 114 Nm. system heater to the T-connection of the
thermostat and tighten the relative clamp.
- Tighten the intermediate half-shaft fixing - Connect the coolant delivery pipe to the air
2
screws to the relative support. conditioning system heater to the thermostat
- Connect the steering tie rods to the front and tighten the relative clamp.
uprights and tighten the relative nuts to a torque of 45 Nm.
Tighten the front wheel hub nuts to the half- - Place the clutch control operating cylinder back
shafts to a torque of 70 Nm + 55° using in its seat and secure it -
1
the angle tightening tool. Place the air delivery hose between the
Make two caulks (3) on the nut collar as shown turbocharger and heat exchanger in its seat and
in the figure. tighten the relative clamps.
- Place the air delivery hose from the heat
- Using the hydraulic crane equipped with Nut caulking exchanger to the throttle body in its seat and
suitable chains as previously indicated, safely tighten the relative clamps and screws.
support the powertrain. - Place the upper central radiator support in its
- Separate the engine from the gearbox. seat and secure it with the relative nut.
Assembly - connect the electrical connections to the engine
Disengage the chains of the hydraulic crane from cooling electric fans.
the powertrain. - Connect the upper coolant inlet hose to the
- Lower the car with the lift. 3
radiator, radiator side.
- Through the engine compartment, support the - Connect the lower coolant outlet hose from the
powertrain with the hydraulic crane equipped radiator, radiator side -
with suitable chains as previously indicated - - Connect the quick coupling of the fuel return re.
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
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
Insertion of left half-shaft bearing seal (mm) 144.4
TIGHTENING TORQUES
Semialberi Given M22 70 + 55°
Half-shaft Bearing Support Quickly M10 45 ÷ 55
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FIAT DOBLÒ
4. transmission > 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
- Tighten the M10X1.25 wheel hub fixing nut to

a torque of 60 Nm.
Wheel nut removal - Proceed to tighten the nut itself
following the illustration below.
2 Wheel hub nut caulking
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
FIAT DOBLÒ
4. transmission > maintenance operations
- Position the new protection guard on the Tripod removal

half-shaft.
- Fit the bearing on the half-shaft.
- Fill the protection cap and bearing with 3
suitable grease.
4
- Position the constant velocity joint and
with light pressure on it engage it with
the bearing. 2
- Fasten the protective cap to the joint

using two new clamps. 1
GEARBOX SIDE JOINT
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

Editions

SEMANTICS
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
1. Steering control and linkage 2.

Power steering
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
FIAT DOBLÒ
5. steering > maintenance operations
TIGHTENING TORQUES
Mechanical part
Component Fixing Ø The value of Nm
Fixing Elements Joints Shafts Com. Steering Screw M8 37
Steering Control Shaft Support Given M8 (On body) 28
Steering Control Shaft Support Given M8 8
Adjustable Steering Tie Rod Heads (CS) Given M14 x 1.5 (On steering box arm) 85
Steering wheel Given M16 x 1.5 50
Hydraulic part
Single stage power steering pump Quickly M8 (Support side) 23 ÷ 28
Single stage power steering pump Quickly M8 25
Single stage power steering pump Quickly M8 25
Power Steering Pump Control Pulley Screw M8 (Power steering pump side) 23 ÷ 28
Power Steering Fluid Reservoir Quickly M6 8,5
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 40
Power steering pump/box hose Connection M16 x 1.5 (On power steering pump) 40
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
- Remove the protection ring (2) and unscrew the

fixing nut (3).
Steering wheel removal

7
5
9
3 2
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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
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
1. Protective cover 2. 5. Buffer 6. 9. Shock absorber 13. Circlip 14.

Washer 3. Bellows 7. 10. Hub Arm support 15.
Dowel 4. Coil spring 8. Coil 11. Upright Swing arm 16. Bar/
Shock absorber support spring support plate 12. Bearing arm support
49

Editions

SEMANTICS
FIAT DOBLÒ
6. suspensions > technical data
Shock absorbers Posterior bridge

The shock absorbers are double-acting telescopic hydraulic ones
with axial bearing integrated into the elastic block.
6
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
Stabilizer bar attached to the lower arms.

1
Bar diameter 23,5 mm 5
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
The advantages of this solution are: 3. Shock absorber

4. Biscuit
• structural simplicity and therefore maintenance
5. Front support (for fixing to the body)
• the constructive economy 6. Rear support (for fixing to the body)
7. Anti-roll bar (only for some versions)
• the constancy of the wheel camber regardless of the acting load
WHEEL GEOMETRY Inclination
FRONT WHEELS Inclination value -20’
Convergence
REAR WHEELS
Convergence value -0,86 mm
Convergence
Convergence value 0 mm
Incidence
Inclination
Incidence value 2°50’

Inclination value 0°
TIGHTENING TORQUES
Front suspension
Front shock absorbers (SM) Given M12 x 1.25 85
Shock Absorbing Lower Attachment Ant. (SM) Given M12 x 1.25 (its amount) 120
Front Stabilizer Bar Given M6 (rear) 8
Front Stabilizer Bar Quickly M10 x 1.25 (rear) 70
Front Stabilizer Bar Quickly M8 (on swinging arm) 28
Front Lower Swing Arms Given M12 x 1.25 (front) 125
Front Lower Swing Arms Quickly M12 x 1.25 (rear) 125
Front Lower Swing Arms Quickly M6 (rear) 80
Front Shock Propeller Spring Support (SM) Quickly M8 (suspension on the cathedral) 32
Articulated Head Lower Swing Arms Ant. Given -

(on swinging arm) 24
Articulated Head Lower Swing Arms Ant. Given M10 x 1.25 60
Articulated Head Lower Swing Arms Ant. Given M12 x 1.25 (its amount) 60
Front Suspension Crossmember Quickly M10 x 1.25 (front) 70
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FIAT DOBLÒ
6. suspensions > maintenance operations
Rear suspension
Rear shock Fixing Ø The value of Nm
absorber component . (SM) Given M10 x 1.25 (upper) 49
Post Shocks (SM) Quickly M14 x 1.5 (lower) 11

Post Stabilizer Bar Joints Given M10 x 1.25 (Stabilizer bar) 52
Post Stabilizer Bar Joints Given M10 x 1.25 (Rear bridge) 52
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
Rear Leaf Springs (SM) Given M12 x 1.25 (central stand) 75
Rear Leaf Springs (SM) Given M12 x 1.25 (rear) 80
Rear Leaf Springs (SM) Given M16 x 1.5 (front) 180
Rear Stabilizer Bar Supports Given M8 16
Rear Stabilizer Bar Supports Quickly M8 16
Rear Suspension End Stop Pads. Quickly M10 29
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
2 7 on the vehicle: (incidence 3° 6' - hydraulic guidance).

11 9
- Using the tool and the appropriate hex wrench
to hold the shock absorber rod,
tighten the fixing nut of the upper block
re.
6
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
FIAT DOBLÒ
- 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
Assembly - Place the front wheel hub in a vice.

- Position the swinging arm. - Move the internal ring of the bearing away
- Position the rear fixing screws and the from the hub with a chisel so as to allow the
stabilizer bar U-bolt and tighten them until insertion of the extractor.
they stop, without tightening them. Assembly - Remove the internal bearing ring
- Insert the front fixing bolt of the swinging front hub using generic extractor type USAG
arm; if the operation is difficult, slightly Use: 472/3 and USAG 472A/3 or similar equipped
compress the swinging arm using a hydraulic The elastic blocks must not show signs of with the reaction part.
column ratchet. deterioration, like the stabilizer bar itself, under - Place the front upright in a vice.
- Approach, without tightening it, the front penalty of replacing the blocks and the bar itself. - Remove the front hub bearing snap ring.
fixing bolt of the swinging arm.
- Insert the head (conical) on the upright and - Remove the front hub bearing from the
screw the fixing nut. - Position the stabilizer bar. upright using a press and the beater.
52
FIAT DOBLÒ
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.
REAR SUSPENSION MOLLA Assembly

- Position the leaf spring, making the
SHOCK ABSORBER Disassembly projection on the lower part of the leaf
- Place the vehicle on a lift. coincide with the hole on the rear axle.
Disassembly - Place a hydraulic column jack under the re.
- 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.
1 Panorama version 175 kg (335 kg)

3
Van version 290 kg (506 kg)
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

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SEMANTICS
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
1. Electro-hydraulic control unit 6. System failure indicator

2. Master cylinder (on instrument panel)
3. Brake servo 7. Stop light switch
4. Brake fluid reservoir 8. Parking brake lever
5. Front rpm sensors 9. Rear rpm sensors
10. Rear drums
FRONT BRAKES REAR BRAKES

Self-ventilated disc brakes equipped with single-piston floating calipers.
Piston diameter 34,00 mm
Thickness of the discs 20,00 mm Drum diameter 228,50 mm
Minimum thickness of the discs 18,20 mm Maximum grinding diameter of the drums 230,00 mm
Minimum pad thickness 1,5 Minimum jaw thickness (including support) 5,5 mm
54
FIAT DOBLÒ
Self-recording device Jaw self-adjustment

Adjusting the clearance between the shoes (1) and the rear drum (2)
due to the wear of the braking material (3) is carried out automatically 4
and continuously at each braking, provided that at that moment it is 3
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
Automatic recording is active both during braking and braking

service and during the intervention phase of the parking brake thanks
to the action of the transmission of the latter which is also in contact 5
6
with the rear fork of the adjustment device. 11

7
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
contact with the drum.

The two ends of the device are kept in contact with the
jaws through the thrust of the ratchet (10) of the leaf spring (9) BRAKE PUMP
with the toothed ring nut (7). The brake master cylinder forms a single body with the brake booster.
This thrust and related rotation allows the system to extend. The reserve oil tank of the brake hydraulic system is press-fitted onto
In the release phase, the self-registering device is turned on again the upper part of the pump.
compression thanks to the action of the jaw return spring (12); there
toothed ring nut (7) stops in the angular position reached during the Diameter 7/8’’
braking phase.
This stop during rotation is due to the friction between the sleeve (8) and
the tie rod (5). BRAKE SERVO
If, with the ring nut locked, the wear of the braking linings is sufficient, The brake vacuum system consists of a vacuum pump, which supplies
the pawl (10) snaps one tooth, engaging the next one. the vacuum for the operation of the brake booster to which it is
The wear necessary for tooth skipping to occur is between connected via a pipe.
0.020 and 0.025 mm.
If overheating occurs following excessive braking PARKING BRAKE
brakes with temperature on the recording device between 70° and The mechanical control of the handbrake consists of a lever, located between
80°, the elastic blade (11) intervenes and, by bending, blocks the fork the two front seats, which operates a rocker to which two are anchored
(13). flexible tie rods connected to the parking brake levers, present on the
The toothed ring nut (7) during the braking phase is therefore not rear brakes.
subjected to the pushing action of the spring (9) and the relative pawl (10) and
therefore there will be no recovery of the slack actually due to the BRAKE FLUID
expansion of the drum.
In case of revision and/or replacement of braking linings, Product DOT 4 SAE J1703
before assembling them, it is necessary to bring the ends of the device
Capacity 1.0 liters
into contact with the jaws by unscrewing the toothed ring nut by half a turn.
TIGHTENING TORQUES
Braking system
Disc brake Column screw M8 12
Complete disc brake calipers Quickly M10 x 1.25 25 ÷ 30
Hose connection to the caliper Connection M10 x 1 14
Disc Brake Disc Shelter Quickly M6 5
Disc Brake Caliper Bracket Quickly M10 x 1.25 57
Drum Brake Cylinders Quickly M6 10
Drum Brake Shoe Holder Disc Quickly M10 x 1,25 50
Brake Drums Quickly

-
14
55
FIAT DOBLÒ
ANTIBLOCCAGGIO SYSTEM ELECTROHYDRAULIC GROUP

The TEVES MK20 anti-lock braking system (ABS) with EBD, integrated with:
DESCRIPTION the master cylinder (2), the brake booster (3), the front brake calipers (6),
The sizing of the braking system must take into account the weight of the the rear drums (12) of the traditional braking system of the vehicle is
fully loaded vehicle and the maximum ground/tyre adhesion coefficient that composed of:
can occur, with the aim of generating effective slowing down or stopping a control unit (1) which integrates an electronic control unit (A), the part
in the shortest space and in any driving conditions. electro-hydraulic (B) which modulates the braking pressure using eight
marcia. solenoid valves, two for each wheel and the recovery pump
However, it is oversized due to the most common conditions of partial load (C); a failure warning light (7) located on the dashboard which signals
and reduced adhesion. the effectiveness or failure of the
The application of maximum braking force, in such circumstances, leads system; four sensors, two front (5) and two rear (11), of the "active" type which
to the immediate blocking of the wheels with the consequent reduction of they detect the angular rotation speed of the wheels. a
adhesion-friction coefficient and a worsening of braking effectiveness. switch on the brake pedal (8) for detecting the condition
braking.
The objective of stopping the movement of a vehicle quickly and effectively The system is completed by the hydraulic system pipes and wiring
in any contingent situation it instead imposes the conservation of specific electrical socket and a diagnosis socket.
rolling state of the tyres, despite the fact that, due to design requirements, The presence of a fault determines the immediate deactivation of the ABS
the braking force applied on the friction linings is frequently excessive in system.
relation to the driving weight and the normal coefficients The information relating to the faults present can be read by connecting
of adhesion. the computerized diagnosis station to the diagnostic socket.
It is therefore necessary to prevent the wheel from locking by means of
an electronically controlled anti-lock braking system that integrates with ABS overall
the vehicle's braking system.
Since there is no possibility of evaluating the conditions in advance 1
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
of the ABS system, allows the two strategies to operate simultaneously;

6
therefore the system normally intervenes in order to maintain the "sliding"
of the rear wheels within values very close to
1. Electro-hydraulic control unit 7. Failure warning light
the ideal ones, with the possibility of intervening with the strategy
ABS when a rear wheel tends to lock (for example transit 2. Brake pump 8. Stop light switch
on a surface with less grip). 3. Brake servo 9. Parking brake

4. Brake fluid reservoir control lever
The following graph illustrates the braking pressure implementation
5. Front active sensors 10. Rear active sensors
strategy, controlled by the electronic control unit, based on the data in
6. Front disc brakes 11. Rear drum brakes
input, represented by the signal relating to the rotation speed of the
wheels on the two axles.
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
FIAT DOBLÒ
In the order in which they appear, the

DIAGNOSIS AND RECOVERY error type code and error counter.
The system is equipped with a self-diagnosis function which has the function of This parameter consists of the code of the last fault that occurred e
check for any anomaly status of the following components: from the relevant counter.
The latter is brought to 31 in the event of a failure and subsequently
• wheel speed sensors • decreased by 1 for each start-up and subsequent exceeding of 20
inlet solenoid valves
km/h which occurs without the presence of the fault.
• output solenoid valves

CONTROL UNIT
The electro-hydraulic control unit is connected to the brake pump and cylinders
If an operating malfunction is identified, the safety circuit of the control brake calipers via the braking system pipes and is integrated with
unit excludes the ABS system, still guaranteeing the the electronic control unit.
normal operation of the traditional system. Its task is to vary the pressure of the brake fluid in the cylinders
The deactivation of the ABS system is signaled to the driver by the warning of the brake calipers in correspondence with the control signals coming
light on the instrument panel coming on. from the electronic control unit.
In practice the electronic control unit for safety purposes is capable, for example
using the two microprocessors with which it is equipped, to control all the Pin out
logical functions, its software, as well as all the input signals.
By receiving identical input signals the microprocessors must provide, ABS control unit connector
during correct operation, identical output signals.
If there is a logical discrepancy between the input and output signals
output for a period of time exceeding a pre-set threshold, the system
detects the fault and deactivates.
The electronic control unit is also equipped with a safety circuit which
has the task of monitoring the efficiency of the system before each
departure as well as while the vehicle is traveling.
The safety circuit performs the following self-checks:
1. after inserting the ignition key and for approximately 2

seconds, checks the operation of the control unit, of the contactors which
they activate the solenoid valves and the connection of the
sensors; 2. after starting the engine, as soon as you exceed 5 km/h, start the
solenoid valves and recovery pump for operation control; it also checks
the presence of the 4 speed signals; 3. every time you Pin Description
exceed 20 km/h, starting with the car stationary, con- 1

Front left sensor signal
checks for the presence of the 4 speed signals; 2 Front left sensor power supply
4. while driving, the peripheral speed of the vehicles continues continuously
3 N.C.
wheels and compares it with the calculated reference speed, checks the
memory conditions and supervises the operation of the solenoid valve 4 N.C.
control contactors 5. while 5
Rear left sensor signal
driving, it constantly monitors the battery voltage.
6
Rear left sensor power supply
7
Checking the system using a diagnostic tool is only possible if the wheel Diagnostic tool connection
8
speed is less than 4 km/h, the battery voltage is greater than 7 Volts and Signal masses
the ABS system is not in operation. 9
Battery powered (+30)
10 N.C.
The complete diagnosis of the system consists of the following three phases: 11 N.C.
a) Display of the following functional parameters:
12 N.C.
speed of the individual
wheels engine status recovery 13
Power under lock and key (+15)
pump brake pedal switch status 14 N.C.
fault warning light status b) 15
Warning lights (ABS-EBD) system failure
Diagnostic procedures consisting of:
16 N.C.
fault detection error
17 N.C.
storage
deletion of errors c) Active 18
Brake pedal switch
diagnosis of the following details: 19
Front right sensor signal
input solenoid valves 20 Right front sensor power supply
output solenoid valves
21 N.C.
recovery pump engine
failure warning light 22
Right rear sensor power supply
23
Rear left sensor signal
Fault detection 24
Power mass
It is carried out during the execution of basic functions and diagnostic tests.
gnostics related to sensors/actuators.
25
Battery powered (+30)
57

Editions

SEMANTICS
FIAT DOBLÒ
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
ABS front mass M50 ABS control unit

C12
Q15 Driver's side dashboard mass
AND
COLOR CODES
E50 Instrument panel A Sky blue M Brown
I
B White N Black
I30 Brake pedal switch C Orange R Red
K H Grey IN Green
K70 Left front wheel sensor for ABS L Blu WITH

Viola
58
FIAT DOBLÒ
7. brakes > wiring diagrams
ABS
59
FIAT DOBLÒ
7. brakes > wiring diagrams
ABS
60
FIAT DOBLÒ
7. brakes > 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
- Release the rubber retainer (1) of the brake correctly.

pipe from the seat (2) on the shock absorber. - Fasten the brake pipe to its seat on the shock
- Remove the spring securing the brake caliper absorber.
to the bracket.
- Unscrew the screws (3), then remove the front 9
brake caliper (4). REAR BRAKES

- Remove the brake pads from the caliper and replace
them (5). CYLINDER AND JAWS
12
Removing brake pads Disassembly

11
13
- Remove the rear wheels.
- Disconnect the parking brake control cable
Assembly from the coupling on the drum.
2
- Fit the front brake caliper onto the disc. - Using the ring spanner, disconnect the rigid
- Fix the brake caliper by tightening the two rear fitting of the rear brake hose.
fixing screws. - Position the tool (16) on the jaw control
- Fit the caliper fixing spring, engaging it cylinder.
correctly. - Using the specific pliers, remove the jaw return
- Tighten the flexible hose fitting, then secure springs (17) and (18).
1
the hose to the shock absorber ring and - Remove the rear brake shoe retaining clips
engage the spring. (19).
brake hose fixing bracket. - Remove the slack recovery device (20) together
with the two rear brake shoes (21).
3 DISCS
5
- Unscrew the fixing screws (22) and remove
4
Disassembly the jaw control cylinder (23).
- Remove the front wheels. Removing brake shoes
- Release the rubber retainer of the brake pipe
Assembly from its seat on the shock absorber.
22
- Fit the new brake pads into the caliper. - Remove the spring securing the brake caliper
16
- Fix the brake caliper by tightening the two to the bracket.

rear fixing screws to the prescribed torque. - Unscrew the screws, then remove the complete
- Fit the caliper fixing spring, engaging it front brake caliper.
23
correctly. - Unscrew the two fixing pins (14) and remove 17
- Fasten the brake hose to the shock absorber - the front brake discs (15).
20
re.
Front disc removal
PLIERS
16
Disassembly
- Place the car on the lift. 21
- Remove the front wheels. 19

18
- Remove the fixing clip (6), using the tool (7)
unscrew the fitting (8) of the brake pipe.
- Release the rubber retainer (9) of the brake

pipe from the seat (10) on the shock absorber. Assembly
- Remove the spring (11) securing the caliper - Place on the new control cylinder
brake to the bracket. jaws the appropriate tool.
- Unscrew the screws (12), then remove the 14
- Tighten the fixing screws of the jaw control
15
complete front brake caliper (13). cylinder.
61

Editions

SEMANTICS
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
handbrake adjustment must be carried out only after

replacing the rear brake shoes, the rear brake cylinder 11
and the complete cable.
- With the vehicle on the bridge, proceed with

registration.
10
- Remove the cover from the central tunnel.

- Make a note of the position of the nut, then
15
loosen the adjusting nut of the handbrake flexible
cable by at least two or three turns, in order to
guarantee complete loosening of the cable.
- Start the engine.
14
- With the engine idling, press firmly on the brake

pedal at least 10 or 15 times.
- Screw the handbrake cable adjusting nut back Assembly
into its original position. 7 - Position the ABS control unit on the bracket
- Make sure that with the handbrake lever at rest support and fix it using the relative screws.
the rear wheels are free to rotate. - Position the ABS control unit complete with
- Check that the braking action of the brake a 8 support bracket in the car.
6
hand starts from the first shot. 9 - Tighten the fixing nuts of the ABS control unit
- At the end of the adjustment, check that the lever support bracket to the body.
does not engage more than five clicks of the toothed sector. - Connect the brake pipe fittings to the hydraulic
- Turn off the engine. control unit using the appropriate wrenches.
- Fit the cover on the central tunnel.
HYDRAULIC CIRCUIT
BRAKING SYSTEM Refueling and bleeding

- Extract the brake booster complete with master - Place the car on the lift.
BRAKE PUMP cylinder, taking care not to bend the brake lines. - Check that the brake and clutch fluid level is
between the MIN and MAX marks.
Disassembly - Remove the brake fluid reservoir cap and connect
- Place the car on the lift. Assembly the equipment to the reservoir itself.
- Disconnect the battery and remove it. - Working from the engine compartment, - Remove the protective cap of the bleed valve
- Using the wrench (1), disconnect the fittings (2) reposition the brake booster complete with located on the brake caliper.
of the brake lines on the master cylinder. pump in its housing. - Connect the recovery device (pipe and tank) to
- Unscrew the two nuts (3) securing the master - Working from inside the car, secure the brake the bleeder valve on the brake caliper.
cylinder (4) and remove it from the brake booster (5). booster to the body using the relative nuts, - Open the bleed valve.
tightening them to the prescribed torque. - Slowly open the fluid tank tap.
Removing the brake pump - Connect the brake servo tip to the brake pedal.
5
- Wait until the air contained in the hydraulic
- Working from the engine compartment, connect system has completely escaped.
the vacuum intake pipe to the brake booster. - Close the bleeder valve on the brake caliper.
- Connect the brake pipe fittings to the master
3
cylinder and tighten them using the appropriate - Repeat the above operations for the remaining
wrench. brake caliper and the two rear drums.
2
4
62
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.
Drums Assorbim. Max. Voltage Internal elements
48 Ah 350A 12V Number of plates: 6 positive - 6 negative
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
3. Zener diode bridge type

"press fit"
5
1
4. Voltage regulator typ
5. Battery
6. Ignition key
7. Body computer (M1)

3
STARTING THE ENGINE • detects and stores any anomalies

The starting system consists of the ignition switch
• recognizes the various components and the type of fault
controlled by the key and the starter motor that is connected
directly to the battery. occurred • signals the onset of such anomalies by means of the appropriate warning light on the panel
instruments
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
FIAT DOBLÒ
BODY COMPUTER FUSE AND RELAY CONTROL UNITS

The NBC is equipped with a microprocessor and static electronic components The car is equipped with two boxes containing fuses and relays located in the
who have the task of: engine compartment and passenger compartment.
• receive the control signal of the platform switches/deviator, steering switch Location of fuse and relay control units
• activate the users (direction indicators, ceiling light, etc) •

acquire, convert and transmit values on the CAN network (ABS, fuel level, etc) • 3
carry out and manage the diagnosis (of the nodes responsible for it) and transmit on the CAN network
Each input is protected by special filters against any electrostatic discharges

or radio frequency signals, which could compromise the proper functioning of
the device. Activation of external lights
is carried out via semiconductor switches or contactors which 1
they simultaneously perform the command and control of the function.

The failure of the lamps, of the position, mentioned above is reported to the
dashboard on CAN network.
The NBC comes into operation in the presence of these conditions:
• when it receives the door opening or transmitter key command
• when the ignition key is in the RUN position 2
1. Engine compartment side shunt control unit (B01)

The control unit remains in "waiting" function, i.e. it decreases the load 2. Passenger side shunt control unit (B02)
energy required by the vehicle, to the battery when the car is NOT being used 3. Control panel
and is awakened when one of the above-mentioned functions becomes active.
Engine compartment box N° Color Amperage Type Name

F14 Red 10 Mini Right high beam
View of the engine compartment control unit F15 Red 10 Mini left high beam
Engine control unit (below
key)
F16 Brown 7.5 Mini System remote switch
engine cooling
Engine control system contactor
Engine control unit
F17 Brown 7.5 Mini (diet)
Diesel pump solenoid valve assembly
Engine control unit (+ battery)
F18 Brown 7.5 Mini
F19 Brown 7.5 Manual mini air conditioning compressor

F20 Yellow 20 Heated mini diesel filter
Engine stop solenoid valve
F21 Light Blue 15 Mini
Fuel pump
F22 Yellow 20 Mini -
N° Color Amperage Type Name F23 Red 10 Mini Automatic Gearbox
Maxi Dashboard control unit power supply:
F01 Beige 70 F30 Light Blue 15 Mini fog lights
standard functions
40 Maxi Dashboard control unit power supply:

F02 Ambra N° Color Capacity (A) Type Name
optional functions
T02 Black 20 Micro High Beams
F03 Yellow 20 Maxi starter switch
T03 Black 20 Micro Horns
F04 Red 50 Maxi ABS system power supply
F05 Blu 60 Maxi preheating
T06 Red 20 Micro First speed radiator fan
F06 Green/Amber 30/40 Maxi single speed radiator fan
Maxi Second radiator fan speed
F07 Amber/Blue 40/60
T08 Red 20 Micro fan inside the car
F08 Green 30 Mini interior fan
Yellow 20 Mini Lavafari
F09
15
T10 Black 20 Micro fuel pump/electric stop
F10 Light blue Mini Horn (horn)
Steam recirculation solenoid valve
gas T17 Black 20 Micro Lavafari
F11 Light blue 15 Mini
Speedometer generator T02 Black 20 Micro High Beams
Lambda probes (oxygen sensors) T20 Black 20 Micro Automatic gearbox
64
FIAT DOBLÒ
Passenger box N° Color Capacity (A) Type Name
Passenger box F38 Yellow 20 Mini Door Locks
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
F41 Brown 7.5 Mini electric heated mirrors
F42 Brown 7.5 Mini ABS control unit (under key)
32 16
20 10
Pompa lavacristallo - lavalunotto

1
F43 Blue 30 Mini
Windscreen wiper
1. Spare fuses 2. Seat for tweezers
F44 Yellow 20 Mini Cigarette Lighter
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,
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
F53 Red 10 Mini
Instrument panel and warning lights (power
Automatic transmission system (function
F35 Red 10 Mini drums)
Traction control switch (function
N° Color Capacity (A) Type Name
Subwoofer system (non-function
F36 Blu 15 Mini T01 Black 20 Micro High Beams
Instrument panel and warning lights (power

T11 Red 30 Micro heated rear window
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
Component Fixing Ø Value (daNm)

Preheating glow plugs -
M12 14 ÷ 17
Complete starter motor Quickly M8 24 ÷ 30
Alternator Bolt M10 45 ÷ 55
Alternator Bolt M12 63 ÷ 77
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8. electrical system > maintenance operations
ELECTRICAL PART Assembly Removing the starter motor
- Check that the alternator is not 7 4
ALTERNATOR damaged. 6
- Position the car on the lift. - Position the alternator.

- Disconnect the negative battery terminal. - Connect the electrical connections of the
- Remove the Poli-V service belt. alternator and screw the fixing nuts. 5
- 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).
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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
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
C015 Driver's side dashboard mass

F010 Left headlight
H066 Driver's seat movement controls
C020 Passenger side dashboard mass F011 Right headlight H067 Passenger side seat movement controls
C030 Left rear mass F015 left fog light H075 LP Bag exclusion command
C031 Right rear mass H080 Air conditioning controls
F016 right fog light
C038 Mass on Central Tunnel Electric fan control
F020 Left side direction light H081
air conditioning
C050 Mass of Air System Bag F021 Right side direction light
C053 Massa Side Bag + Head Bag H090 Switch control group
F030 Left rear light Left control group (platform
C060 Injection control unit mass H091
F031 Right rear light left commands)
D
F032 Rear fog light H115 Auxiliary control panel
D001 Front / dashboard junction
F033 Reverse rear light H127 lights control device always on Drl
D004 Front / engine junction
F040 Additional rear light (Third H128 Fog light control
D006 Front / rear junction Stop)
H129 Restore lighting command
D007 Alternator Junction F050 Left license plate light Instrumentation
D008
Front/air conditioning junction - F051 Right license plate light H136 Convergence control panel
Heater
F052 License plate light unit I
D013 Front/Bumper Junction

F055 License plate light unit and external switch I011 Trunk opening switch
D020 Dashboard / rear junction trunk opening I016 Switch on the left front door. Switch
D021 Dashboard/air conditioner junction - F069 Additional left headlight I017 on the right front door.
Heater F070 Additional right headlight I018
D029
Junction of engine cables/service cable Switch on left rear door.
G
motor I019 Switch on the right rear door.
G010 Front ceiling light
D030 Driver's side front door joint Reverse light switch (bridle
I020
G020 Rear ceiling light (Central) change)
D031 Passenger side front door joint
G025 Left rear ceiling light Front door lock/unlock switch
D035 Left rear door junction I026
G026 Right rear ceiling light G side
D036 Right rear door junction
G030 Drawer light I030 Brake pedal switch
D042 Ceiling light junction
I030 Brake pedal switch
G031 Driver's side sun visor light
D045 Sunroof junction
I031 Clutch pedal switch
G032 Passenger side sunshade door light
D047 Spiral contact junction
I033 Switch on external trunk handle
D050 Fog light junction G039 Passenger side door light
G040 Trunk ceiling light I040 Handbrake switch engaged
D060 Air Bag junction
G045 Air conditioner/heater control light I045 Side seat belt warning light switch
D065 Electric guide junction
Left front door light (Anti - guide
D070 Driver's seat joint G051
I046 Driver's side seat belt switch
Puddle)
D071 Passenger side seat joint Right front door light (Anti - Side seat belt switch
G052 I047
D073 Trailer Preparation Junction Puddle) passenger
D075 Radiotelephone junction G065 Driver's side front door handle light I050 Inertia switch
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Side seat heating switch L030 EGR solenoid valve

I065 K055 Accelerator pedal potentiometer
guide K056 Throttle Position Sensor L031 PDA solenoid valve
Side seat heating switch
I066 K058 Steering Sensor
L036 Geometry control solenoid valve
passenger
K062 Volumetric sensor group for alarm Turbine variable
I115 Stability control system switch
K064 Exhaust gas presence sensor
L037 Waste-Gate solenoid valve
I143 Presence recognition switch
L062
Key in the ignition lock K065 Passenger presence sensor Solenoid valve Throttle body
J K066 Sensor for Side Air Bag, driver's side L064 Flow modifying solenoid valve
J010 K067 Sensor for Side Air Bag, side L102
Turbocharger by-pass solenoid valve
Main Injection Contactor
J015
passenger M
Remote control Fuel pump
K067 Side Air Bag Sensor, side
J017 Diesel preheating contactor M001 Body Computer
passenger
Compressor activation contactor K070 Left front wheel sensor. for Abs K071 M010 Engine control unit
J020
conditioner
Right front wheel sensor. for Abs K074 Yaw M015 Glow plug pre-heating control unit
Motor activation contactor
sensor (Vdc) (rear) M047 Tire pressure control unit
J033 cooling electric fan
capacitor K075 Left rear wheel sensor. for Abs M050 ABS control unit (rear)
Contactor 1. Electric fan speed K076 Right rear wheel sensor. for Abs K081 M051 Braking System Control Unit
J034
cabin air Fuel temperature sensor M054 Robotic gearbox control unit
J040 Fog light contactor K082 Boost sensor
M060 Centralina Air Bag
J062 Seat Heating Contactor K083 Fuel pressure sensor
M063 Trunk compartment control unit
J087 Robotic gearbox contactor K084 Tachometric sensor
M065 Infotelematic Switchboard (Night)
J147 Motorized Butterfly Valve Contactor K085 Rain sensor
K086 Antibrina Sensor M066 Driver's side door control unit
K
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
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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
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8. electrical system > electrical diagrams
High
70
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Electrical
71
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Electrical
72
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Wiring
73
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Low
74
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Car
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Wiring
76
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Door
77
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Door
78
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Wiring
79
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Wiring
80
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Fog
81
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Instrument
82
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Wiring
83
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Wiring
84
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Wiring
85
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Reverse
86
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Stop
87
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Electrical
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Navigator
89
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9. air conditioning > technical data
9. air conditioning
technical data
GENERALITY INTERIOR BOX COMPONENTS

The evaporator - heater - distributor assembly presents the main
The car can be equipped with climate control systems for the passenger component of the heating and air conditioning system at
compartment, both manual and automatically controlled. manual controls.
The air conditioning system allows the characteristics to be changed
temperature and humidity of the air introduced into the passenger compartment. Air conditioning box
fluid type R134a

D AND
Capacity (g) 600 ± 40
Oil type PAG ISO 46
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
Compressor support Quickly M10 (Engine crankcase side) 45 ÷ 55
Compressor/Condenser Piping Quickly M6 (Compressor side) 7 ÷ 11
Condenser/Filter Drier Piping Quickly M6 (Condenser side) 7 ÷ 11
Filter Dehydrator/Expansion Valve Pipe Given M6 (Expansion valve side) 7 ÷ 11
Evaporator piping Given M6 Compressor inlet side) 7 ÷ 11
Evaporator piping Given M6 (Expansion valve side) 7 ÷ 11
Compressor Inlet Pipe Quickly M6 (Compressor side) 7 ÷ 11
90
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9. air conditioning > technical data
AIR CONDITIONING MANAGEMENT K
K10 4-level pressure switch

N
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
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9. air conditioning > electrical diagrams
Air
92
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9. air conditioning > electrical diagrams
Air
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9. air conditioning > 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.
CRYOGENIC CIRCUIT Removal of pipes Assembly

- Check that the compressor is not damaged,
COMPRESSOR 3
then place it in place.
- Tighten the M8 fixing screws of the compressor
Disassembly and tighten them to a torque of 23 ÷ 27 Nm.
- Place the car on the lift. - Connect the electrical connection of the compressor
- Drain the refrigerant fluid sore.
4
- Act on the belt tensioner, insert the locking
pin and remove the single drive belt Use:
motor organs. 6
Replace the O-rings of the fittings. Use
- Unscrew the screws (1) and remove the protection exclusively green colored rings, resistant to
of the compressor belt (2). R134A refrigerant fluid. Lubricate the threads of the
- Unscrew the screws (3) and disconnect the fittings (4) of the fittings with antifreeze oil.
pipes from the compressor (5). 5
- Connect the pipe fittings to the compressor,

Use: then secure them with M6 screws per pair
Plug the fittings with appropriate sealing caps di 7 ÷ 11 Nm.
unplugged to prevent entry of moisture and - Position the compressor belt protection and
impurities in the system. secure it with the screws.
- Position the engine coolant tank in place,
- Disconnect the electrical connection (6). 2 making sure the lower retainer engages, then
1
- Unscrew the fixing screws and remove the tighten the screws.
compressor. - Refill the refrigerant fluid.
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10. air bag > technical data
10. air bag

technical data
GENERALITY • Driver's front Air Bag with dual activation

stage • Passenger's
The car is equipped with an electronically controlled system which, in the event front Air Bag • Front seat belts with pretensioner
of a frontal or side impact, commands the activation of specific restraint devices. and load limiter • Rear seat belts with pretensioner and load
The frontal protection system includes: limiter (optional) • Additional front crash detection sensor
Air Bag assembly
8
4
3 7
1. Pretensioners 2.
Guide bag 3.
Passenger bag 4.
1
Side bag 5.
Control unit 6.
4
RSU satellite unit
7. Passenger bag exclusion

switch 8.
6
Failure warning
10
light 9. Passenger bag

5 1
inhibition
warning light 10. K line connector
DRIVER 'S SIDE AIR BAG Spiral cable The

The driver's side bag system is made up of: spiral cable allows you to transfer the electrical signal of the controls on the
a cover, a bag, a gas generator, a clock spring. A support is steering wheel (horn and other optional controls) and to connect the Air Bag
fixed to the steering wheel containing: the pyrotechnic device with gas generator module without risk of breakage.
and the folded bag, a cover equipped with a pre-breaking area to facilitate the The device, made up of two plates, is fixed, via the lower plate, to the switch
exit of the bag. and is made integral with the steering wheel, through appropriate joints present
A spiral contact (Clock spring) is mounted in the lower part between the on the upper plate. Inside the two plates, the connection cables of the module
steering wheel and the light switch which guarantees the electrical connection of theand
steering
the horn
wheel
buttons are spirally wound, allowing the movements of the steering
with the ACU3. wheel to be followed.
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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.
AIR BAG MANAGEMENT Pin Out
AIR BAG CONTROL UNIT Air Bag control unit connector

Each control unit has its own identification stamped on the label. Yes
can find the following control units:
• ACU3-C03 control unit that manages front pretensioners/Air Bags
driver. •
ACU3-C05 control unit that manages front pretensioners/Air Bags
driver/passenger Air Bag. •
ACU3-R07 control unit that manages front pretensioners/Air Bags
driver/passenger Air Bag.
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
and memorize both fault and crash codes. The ignition 4 Nc 4 Nc

of the anomaly warning light, red on the dashboard, is of the intelligent type. 5 5 Nc
Passenger bag inhibition warning light
6 Failure 6 Nc
Up to three activations of the pretensioners or Side Bags do not require
replacing the control unit. 7
warning light + passenger manual 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 control unit is not 16 Nc 16 Nc

connected • one of the two pretensioners is not 17 Nc 17 + Side Bag sx
connected • the supply voltage is interrupted within the next two seconds 18 Nc 18
- Side Bag sx
an anomaly is detected during the check phase.
19 + Passenger bag (2) 19 + Side Bag dx
Attention: 20 - Passenger bag (2) 20
- Side Bag dx
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
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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
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
D Q21 Front passenger side seat belt pretensioner
D58 Right Head bag junction Q30 Driver's side air bag
Q31 Passenger side side air bag

D59 Left Head Bag junction
Q40 Head Bag on driver's side
D62 Driver side/rear side bag junction
Q41 Passenger side head bag
D63 Side-bag junction on passenger/rear side
D69 Rear junction/seat bridle
AND COLOR CODES

E50 Instrument panel
A Sky blue M Brown
H
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
K67 Side Air Bag sensor, passenger side L Blu WITH

Viola
97
FIAT DOBLÒ
10. air bags > wiring diagrams
Air
98
FIAT DOBLÒ
10. air bags > wiring diagrams
Vista
99
FIAT DOBLÒ
10. air bag > 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
preliminary operations: (1st) place the key Use:

ignition in “STOP” position; (2nd) disconnect e A new one is supplied together with the module
isolate the battery cables; (3rd) wait 10 minutes adhesive plate to stick on top of the existing one
before proceeding. present in the car. However, first it is necessary to
drill it in correspondence with the month and 10
- Remove the fixing covers (1) and unscrew the screws (2). years following the year in which the module is mounted
Air Bag module fixing. (e.g. 1999 will correspond to 2009).
1
- Remove the Air Bag in module from its seat
so that the electrical connectors can be disconnected. - Position the Air Bag module and connect the
- Place the Air Bag module in the appropriate Assembly electrical connectors.
cabinet by placing it on a free surface with - Fit the Air Bag module into place and secure it with
the pillow facing up. Attention: the relevant screws.
- Check the operation of the system used In case you install a new Air module - Check the operation of the system used
using the diagnostic tool. Bag, arrange the relevant labels. using the diagnostic tool.
100
FIAT DOBLÒ
11. bodywork > technical data
11. bodywork
technical data
GENERALITY re of the vehicle. These rigidity characteristics lead to a reduction

in noise while driving, thanks to the reduced vibrations of the
The monocoque bodywork with high torsional and flexural rigidity body, while offering greater resistance to breakage caused by
use of the car on very rough road surfaces.
ensures high safety in the event of an impact for the driver and passengers.
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

Editions

SEMANTICS
FIAT DOBLÒ
11. bodywork > 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
- Unscrew the upper screws (1) of the bumper.

- Raise the lift.
- Unscrew the screws (2) on the wheel arch and the
screws (3) on the body, on both sides of the bumper.
- Unscrew the lower screws (4) and remove the 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
Removing bumper fasteners Removal -

Disconnect the negative battery terminal.
3
- Remove the steering column cover.
2
- Remove the instrument panel cover.
- Unscrew the fixing screws (12) and remove
the dashboard (13) from its seat.
- Disconnect the electrical connector (14).
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
- Screw the side fixing screws to the wheel arch

and body on both sides. 12
- Lower the lift and tighten the upper screws.
- Close the bonnet and remove the car from the

lift. Use:
If the bumper is in the same color, be particularly
GO careful not to cause damage to the paint.
Assembly -
Disassembly - Unscrew the fixing screw (9), positioned inside Connect the electrical connector and place the
- Unscrew the fixing screws (5), and disconnect the car under the parcel shelf support, and the instrument panel in place.
the electrical connector (6). screws (10) and remove the bumper (11). - Tighten the fixing screws.
102

Fiat Doblo 2010-2021

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Machine Translated by Google

Marketing since 2008 Position for lifting

Displacement (cm3) 1.598 1.956

Power (Kw) 66/77 135

Transmission type C510.5/C635 C635

Number of reports 5/6 6

Location of tow hooks

D Progressive chassis manufacturing number

G Maximum authorized weight on the first axle (front)

H Maximum authorized weight on the second axle (rear)

L Body version code

M Number for spare parts

N Correct value of the smoke coefficient (for diesel engines)

Thousands of km 35 70 105 140 175

Check tire conditions/wear and adjust pressure if necessary x x x x x

Check the functioning of the lighting system (headlights, direction

Check the operation of the windshield wiper/washer system x x x x x

Check positioning/wear of windshield/rear window wiper blades x x x x x

Check the condition and wear of the rear disc pads x x x x x

Check and adjust the handbrake lever travel if necessary x x x x x

Exhaust emissions/smoke control x x x x x

Check the battery charge status and recharge if necessary x x x x x

Visually check the condition of the accessory drive belts x x

Check engine control systems functionality (via diagnosis socket) x x x x x

Replacing the timing belt x

Fuel filter replacement x x

Replacing the air filter cartridge x x

Brake fluid replacement (or every 24 months) x x

Pollen filter replacement (or every 15 months) x x x x x

Do you want diagnoses on every single ODB code?

NEW 2012 www.semantica.it

1.6 Multijet 16v 2.0 Multijet 16v

Bore (mm) 79.5 83.0

Stroke (mm) 80.5 90.4

Total displacement (cm3) 1.598 1.956

Maximum power (kW EEC) 66/77 99

Maximum power (EEC CV) 90/105 135

Max. power regime (revolutions/1') 4.000 4.000

Maximum torque (Nm EEC) 290 320

Maximum torque (kgm EEC) 29.5 36.7

Maximum torque speed (revs/1') 1.500 1.750

Minimum speed (revs/1') 850 ± 20 850 ± 20

Compression ratio 16.5 : 1 16.5 : 1

Gasket Valve stem diameter - Exhaust (mm) 4.972 ÷ 4.990

Size 1.6 16V Multijet Value

Valve seat band angle in contact with valves 45° 0’ +/- 1°

Valve seat external diameter - intake (mm) 28.355 ÷ 28.365

External diameter of valve seats - exhaust (mm) 26.100 ÷ 26.111

Size 2.0 16V Multijet Value

Valve seat band angle in contact with valves -

Fit for 2.0 16V Multijet engine Value

Cylinder head gasket thickness with protrusion +0.231 ÷ +0.330

Cylinder head gasket thickness with protrusion + 0.331 ÷ +0.425

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CYLINDER BLOCK Measure Value

CRANK DRIVE Main bearings

CRANKSHAFT Measure Value Validity