INTRODUCTION

1.6 16v

WARNINGS

Do not try and crank the engine with the battery earth lead slack as this will cause serious damage to the wiring.

Never pull the leads or wiring using force because this would result in the cables being disconnected from the connectors or terminals.

Disconnect all the control units and electronic devices when carrying out arc welding operations on the bodyshell.

Before replacing a fuse, check that the circuirt protected is not faulty.

When replacing fuses, make sure that the new fuse is the correct amperage. Do not use higher or lower amperage fuses.

PRECAUTIONS

When working on electrical components always follow the precautions described below very carefully:

• Remove rings, wrist watches and other metal objects.
• Before working on the electrical system (connectors, electrical components, wiring, etc.) turn the ignition key OFF and DISCONNECT THE BATTERY.
• Take care over electrical arcs. Even if the voltage is 12V, the battery can produce high currents if there is a short circuit, creating arcs or sparks that can be dangerous to the mechanic or create a fire hazard;
• Take care over high tensions. The electronic ignition system produces voltages of 20,000V and more which could be very dangerous. Take great care when working on or near these components.
• Prevent fire risks. Do not smoke when working close to the battery or components which get hot during usage (e.g. halogen bulbs) or in the area of the engine compartment when the engine is still hot. Also take care to avoid damage to tools and components.

All versions

SAFETY INSTRUCTIONS TO BE FOLLOWED FOR OPERATIONS ON VEHICLES FITTED WITH AIR BAG SYSTEMS

The following instructions MUST BE FOLLOWED during any operation involving vehicles equipped with Air Bags.

PRELIMINARY INSTRUCTIONS

Before carrying out any repair operations to the bodywork, welding or operations that involve removing the Air Bag modules or the control unit:

• Turn the ignition OFF and remove the key.
• Always disconnect the battery, i.e.: disconnect the two leads from the pole and insulate them taping them carefully.
• Disconnect the electrical connection for the control unit waiting at least 10 minutes after disconnecting the battery.

Place the Air Bag modules that have been removed in a lockable metal cupboard with the cover facing upwards.

This cupboard, especially designed for this purpose, should not, under any circumstances, be used to store any other types of material, particularly if they are flammable.

The cupboard should be designed to store pyrotechnic charges (metal, impact resistant cupboard with grates to allow natural ventilation) and should have the markings required by law (DANGER EXPLOSIVES - NO NAKED FLAMES - NOT TO BE OPENED BY UNAUTHORIZED PERSONNEL).

All the connectors used and wired to the Air Bag modules contain a short circuit clip. Until the Air Bag modules are connected to an appropriate energy source there is no possibility of them being accidentally activated.

The continuity of the system components can only be measured after the modules have been replaced with specific simulation resistances.

A system component that has not been activated during an accident is considered to still be "active". Therefore unexploded components that have to be removed from the vehicle (on account of defects or the warranty has expired, etc.) should be returned to the special centre following the procedure described below.

Safety system components must ONLY be dismantled and reassembled by authorized, suitably qualified personnel. Failure to follow the instructions outlined could cause the accidental activation of the system resulting in personal injury or unnecessary repairs to the system. AIR BAG MODULES MUST NOT, UNDER ANY CIRCUMSTANCES, BE DISMANTLED..

All the system components have been specifically designed to work on a specific marque and type of vehicle, therefore Air Bags should not be adapted, reused or installed on other vehicles, only the ones for which they have been designed and produced.

Any attempt to resue, adapt or install one on a different type of vehicle could result in serious injury or even be fatal for the occupants of the vehicle in the case of an accident.

REPAIRS TO SYSTEM COMPONENTS

After every repair to the system it should be checked using the EXAMINER or other diagnostic equipment.

AIR BAG MODULE REPLACEMENT (ON ACCOUNT OF DEFECTS OR EXPIRY OF WARRANTY)

If an Air Bag module is being replaced because it is defective or the warranty has expired:

• Remove the detachable part of the adhesive label from the new module and place it in the special folder containing the vehicle details (model, registration date, chassis number) and the serial number of the old control unit. The file should be kept for future checks.
• A new adhesive lable is supplied together with the module that should be stuck on top of the existing one. Beforehand, however, it should be perforated at the month and 14 years after the year in which the module is being fitted (e.g. 1998 for 2012).

Similarly, if the clock spring or a pretensioner is being replaced, remember that the recommended life of these components is 10 years.

CONTROL UNIT REPLACEMENT

The electronic control unit should ALWAYS be replaced after an impact that results in the system being activated.

If the control unit is being replaced, the detachable part of the adhesive label must also be removed and placed the special file mentioned above.

CLOCK SPRING REPLACEMENT

A clock spring allows the connecting cables for the Air Bag module to follow the rotation of the steering wheel without danger of breaking.

A special internal safety device automatically locks the rotation of the two plates when the clock spring is removed from the steering wheel. This prevents the upper plate, now no longer secured to the steering wheel, from turning freely and unwinding or winding the coil inside the device and possibly causing it to break. The new device is therefore supplied with a safety key.

During procedures and operations where the clock spring has to be removed, observe the following precautions:

• always work with the car's wheels aligned straight ahead;
• lock the cable using a band before removint it from the steering wheel.

PAINTING OPERATIONS

There are no special safety regulations to follow for painting and subsequent drying operations in an oven because the modules in particular have been designed in such a way that the outside surfaces of the vehicle are not damaged when they get hot from normal paint drying systems.

It is forbidden to use naked flames near the modules.

All the electronic control units (including the Air Bag system) are always removed if the ambient temperature could reach or exceed 85°C.

REPAIRS FOLLOWING AN ACCIDENT

If any of the safety system components is damaged following an accident it SHOULD be replaced.

Do not attempt to repair the control unit, clock spring or Air Bag modules.

ACCIDENTS WITH OR WITHOUT THE ACTIVATION OF THE AIR BAGS

Several of the system components should always be inspected after an accident whether the system has been activated or whether it has NOT been activated. These components are:

• Steering column;
• Steering column supports;
• Electronic control unit and modules mounting area;
• Clock spring;
• Dashboard (the area of the passenger Air Bag module).

If the component shows signs of distortions, breaks or bends it should be replaced.

ACCIDENTS WITH THE ACTIVATION OF THE AIR BAGS

Several of the system components should be replaced if the vehicle is subject to an impact that has activated the system.

These components are:

• Air Bag modules.
• Electronic control unit.

As far as the wiring and connectors are concerned, they should be inspected for any signs of burning, melting of the outside insulation or damage from excessive heat.

Any signs of damage to the clock spring or in the area where the electronic control unit and Air Bag modules are mounted means that the damaged components should be replaced.

DANGERS TO HEALTH

The following precautions should be observed when handling activated Air Bag modules:

• wear polythene protective gloves and safety goggles;
• wash your hands and other parts of the body exposed with soap and water after touching exploded Air Bag units.

EFFECTS OF OVER EXPOSURE

There is no potential danger of exposure to the propellants as the system is completely sealed.

The propellant mixture is in a solid state therefore it is impossible to inhale it even if the gas generator cartridge is broken.

There is no danger to health (for people) if the gas escapes.

Contact with the skin should be avoided and the propellant should not be swallowed.

In the case of:

• Contact with skin: wash immediately with soap and water.
• Contact with eyes: wash eyes immediately with running water for at least 15 minutes.
• Inhalation: get the affected person into the open air immediately.
• Swallowing: make the person vomit if they are conscious.

A doctor should always be called in these situations.

SAFETY INSTRUCTIONS FOR HANDLING AIR BAG MODULES

It is important that the personnel who carry out repairs to devices fitted on the vehicle follow the safety regulations listed below.

The personnel working on the devices should be trained and should observe the following precautions:

• When removing and replacing open (exploded) Air Bags, only move the modules one at a time and wear protective gloves and goggles for the removal.
• Always rest the Air Bag module with the opening flap and the pre-breaking splining facing upwards. Never place anything on top of this flap.
• At the end of the operations wash your hands thoroughly with soap and, if there is any contact with the residual powder and your eyes, rinse immediately with plenty of running water.
• On all versions with Air Bags it is forbidden to work from the front seats before having rendered the system inoperative by disconnecting the two battery leads and waiting at least 10 minutes.
• The metal Air Bag components are very hot just after it has exploded. Avoid touching these components for several minutes (about 20 minutes) after the Air Bag has been activated.
• Never carry out repair operations on Air Bag modules. Send all defective modules to the supplier.
• Never heat the Air Bag module (e.g. through welding, striking, drilling, mechanical machining, etc.);
• Never fit Air Bag units that have been dropped or show signs of any type of damage.
• The storage of Air Bag modules together with flammable or combustible materials is prohibited.
• Gas generators should not come into contact with acid, grease or heavy metal: contact with these substances could cause the formation of gases that are poisonous or harmful or explosive compounds.

Replacement parts should be stored in their original packaging and the same procedures as for Air Bag modules that have not been activated and have been removed from the vehicle should be followed for their temporary storage, i.e. in a specially designed, locked, metal cupboard (impact resistant metal cupboard with grates for natural ventilation) The cupboard should have special warning signs (DANGER: EXPLOSIVES - NO NAKED FLAMES - NOT TO BE OPENDED BY UNAUTHORIZED PERSONNEL).

SCRAPPING AIR BAG MODULES

The Air Bag modules fitted on the vehicle should not be scrapped with the actual vehicle, but removed first.

The Air Bag units cannot be scrapped unless they have been activated first.

If the Air Bag module has not been activated during an accident it should be considered as still charged.

All the unexploded material SHOULD NOT BE ACTIVATED, but should be sent to a specialist centre (for ITALY to GEMCA in Chivasso) with a label that says: "AIR BAG CONTAINING PYROTECHNIC CHARGE TO BE DEACTIVATED".

The local laws in force should be followed in FOREIGN MARKETS.

The devices must be sent in the same packaging as replacement components and, if it is not available, the packaging only can be ordered from the PARTS DEPT.

Obviously, if Air Bags are being replaced, the original packaging should be kept intact for dispatching devices not activated.

Not following the procedures described here can cause the accidental activation of Air Bag units and result in personal injury. Air Bag units that have NOT been activated should be disposed of through normal methods. Air Bag units that have not bee activated contain substances that are dangerous to health and can cause personal injury if the sealed container is damaged during disposal. The disposal of Air Bag units not carried out in accordance with this procedure may be in violation of regulations in force on this subject.

ORDERING METHODS

If necessary, the devices can be ordered, from time to time, from the Aftersales Parts Department - Volvera through the V.O.R. procedure since the Network should not keep these parts in stock. In any case, a record should be kept of internal movements recording the module identification numbers and vehicle details (chassis number, registration date, model, etc.).

WARNINGS

Do not try and rotate the engine with the battery earth lead slack as this will cause serious damage to the wiring.

Never pull the leads or wiring using force because this would result in the cables being disconnected from the connectors or terminals.

Disconnect all the control units and electronic devices when carrying out arc welding operations on the bodyshell.

Before replacing a fuse, check that the circuirt protected is not faulty.

When replacing fuses, make sure that the new fuse is the correct amperage. Do not use higher or lower amperage fuses.

PRECAUTIONS

When working on electrical components always follow the precautions described below very carefully.

• Remove rings, wrist watches and other metal objects.
• Before working on the electrical system (connectors, electrical components, wiring, etc.) turn the ignition key OFF and DISCONNECT THE BATTERY.
• Take care over electrical arcs. Even if the voltage is 12V, the battery can produce high currents if there is a short circuit, creating arcs or sparks that can be dangerous to the mechanic or create a fire hazard;
• Take care over high tensions. The electronic ignition system produces voltages of 20,000V and more which could be very dangerous. Take great care when working on or near these components.
• Prevent fire risks. Do not smoke when working close to the battery or components which get hot during usage (e.g. halogen bulbs) or in the area of the engine compartment when the engine is still hot. Also take care to avoid damage to tools and components.

CODE - ALARM SYSTEM COMPONENT MANAGMENT

Data base for code and alarm system parts management

There is a centralized DATA BASE (for all markets) managed by the PARTS DIVISION for ordering all CODE system components and some of the alarm system components.

The production plant transfers all the required data into this DATA BASE, together with the chassis no. of the new vehicle. This DATA BASE is then used for completing an order for replacement parts received from the Dealer Network.

The data base contains numerous pieces of information, such as:

• vehicle chassis no.;
• secret code;
• code for each key (transponder identification);
• remote control code (versions with alarm only);
• mechanical key code;
• programming data;

1. Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.

2. Carry out the KEY PROGRAMMING for the remaining keys using the Examiner or other diagnostic equipment working on the CODE control unit. Keys which are not presented will never be able to be used again. A list of keys that are still valid will be printed out.

3. Versions with alarm only. Carry out the REMOTE CONTROL PROGRAMMING for the remaining keys using the Examiner or other diagnostic equipment working on the alarm control unit. Keys which are not presented will never be able to be used again.

4. Connect to the FIAT PARTS DIVISION giving the vehicle chassis no. and other information requested. Send an order using the V.O.R. procedure requesting one or more keys.

5. By consulting the DATA BASE, the FIAT PARTS DIVISION is capable, through the chassis no., of producing a key which has:

- the same shape (but indicating that it is a replacement).

- A transponder with a new key code, but with the secret code for the CODE control of the vehicle in question.

- the same mechanical code (metal insert).

- remote control code (versions with alarm only).

The DATA BASE will be updated with the new code key entered.

6. The FIAT PARTS DIVISION will send the key to the Dealer Network within 24 - 48 hours.

7. Carry out the KEY PROGRAMMING using the Examiner or other diagnostic equipment working on the CODE control unit entering both the new key(s) and the previous ones.

8. Versions with alarm only. Carry out the REMOTE CONTROL PROGRAMMING using the Examiner or other diagnostic equipment working on the alarm control unit entering both the new key(s) and the previous ones.

the receiver PASSWORD must be entered to carry out this procedure. Ask the FIAT PARTS DIVISION for this password, always providing the chassis no. of the vehicle.

9. Carry out a final check on both the CODE system and the alarm system (if fitted) using the Examiner or other diagnostic equipment.

If one of the CODE - alarm system components needs replacing and is being ordered, follow the procedures described below.

New key request

Proceed as described previously, "skipping" step 2 which is superfluous in this case.

Versions with alarm: up to 8 keys (remote controls) can be stored in a receiver.

Replacing the transponder

The transponder is pressed in the key shell. Therefore it cannot be replaced: this guarantees improved safety in the face of "transponder thefts".

Replacing key lock barrels

1. Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.

2. Carry out the CANCELLATION OF THE PROGRAMMED KEYS using the Examiner or other diagnostic equipment working on the CODE control unit and not on the alarm control unit. These keys can never be used again.

3. Connect to the FIAT PARTS DIVISION: giving the vehicle chassis no. and other information requested. Send an order using the V.O.R. procedure requesting a complete key kit.

4. By consulting the DATA BASE, the FIAT PARTS DIVISION is capable, through the chassis no., of producing a complete key kit which has:

- the same shape (but indicating that it is a replacement).

- A transponder with new key codes, but with the secret code for the CODE control of the vehicle in question.

- a new mechanical code (metal insert).

- new remote control codes (versions with alarm only).

A new CODE Card is also supplied containing the previous recovery code but with a new mechanical code. The DATA BASE will be updated with the new key codes and the new mechanical code entered.

5. The FIAT PARTS DIVISION will send the key kit to the Dealer Network within 24 - 48 hours.

6. Carry out the KEY PROGRAMMING using the Examiner or other diagnostic equipment working on the CODE control unit entering all the keys received.

7. Versions with alarm only: Carry out the REMOTE CONTROL PROGRAMMING using the Examiner or other diagnostic equipment working on the alarm control unit entering all the keys received.

the receiver PASSWORD must be entered to carry out this procedure. Ask the FIAT PARTS DIVISION for this password, always providing the chassis no. of the vehicle.

8. Carry out a final check on both the CODE system and the alarm system (if fitted) using the Examiner or other diagnostic equipment.

Code card mislaid

1. Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.

2. Connect to the FIAT PARTS DIVISION giving the vehicle chassis no. and other information requested. Send an order for a CODE Card using the V.O.R. procedure.

3. By consulting the DATA BASE, the FIAT PARTS DIVISION is capable, using the chassis no., of producing a new CODE Card that is identical (emergency code and mechanical code) to the one that was mislaid. The card will then be sent to the Dealer Network.

4. Hand it over the Customer, notifying them that it is a duplicate. Therefore, if the old card is found, it can be used for starting.

Replacing the code control unit

A possible fault in the CODE control unit should always be confirmed through a thorough check using the Examiner or other diagnostic equipment.

1. Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.

2. Connect to the FIAT PARTS DIVISION: giving the vehicle chassis no. and other information requested. Send an order using the V.O.R. procedure requesting A CODE control unit.

3. By consulting the DATA BASE, the FIAT PARTS DIVISION is capable, through the chassis no., of producing a control unit which has the same secret code as the faulty one. The DATA BASE will also be updated by entering the operation that has taken place.

4. The FIAT PARTS DIVISION will send the control unit to the Dealer Network within 24 - 48 hours.

5. Fit the new control unit in place of the faulty one.

6. Carry out the KEY PROGRAMMING using the Examiner or other diagnostic equipment working on the CODE control unit entering all the previously enabled keys.

7. Carry out a final check on the CODE system using the Examiner or other diagnostic equipment.

Replacing the engine management control unit

A possible fault in the electronic injection control unit should always be confirmed through a thorough check using the Examiner or other diagnostic equipment.

1. Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.

2. Connect to the FIAT PARTS DIVISION giving the vehicle chassis no. and other information requested. Send an order using the V.O.R. procedure requesting an engine management control unit.

3. The FIAT PARTS DIVISION will send a new unprogrammed control unit to the Dealer Network within 24 - 48 hours.

4. Fit the new control unit in place of the faulty one.

5. Turn the key to the ON position: the CODE control unit will initialize the new control unit sending the secret code.

6. Carry out a final check on the engine management system using the Examiner or other diagnostic equipment.

Receiver replacement (versions with alarm only)

A possible fault in the receiver should always be confirmed through a thorough check using the Examiner or other diagnostic equipment.

1. Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.

2. Connect to the FIAT PARTS DIVISION: giving the vehicle chassis no. and other information requested. Send an order requesting a receiver.

3. FIAT PARTS DIVISION should send a new, unprogrammed receiver.

4. Fit the receiver in place of the faulty one.

5. Carry out the REMOTE CONTROL PROGRAMMING using the Examiner or other diagnostic equipment working on the alarm control unit and not on the CODE control unit, entering all the keys present.

the receiver PASSWORD must be entered to carry out this procedure. Ask the FIAT PARTS DIVISION for this PASSWORD, always providing the chassis no. of the vehicle.

6. Carry out a final check on the alarm system using the Examiner or other diagnostic equipment.

Alarm control unit replacement (versions with alarm only)

A possible fault in the alarm control unit should always be confirmed through a thorough check using the Examiner or other diagnostic equipment.

If the alarm control unit is being replaced, it is NOT necessary to carry out the REMOTE CONTROL PROGRAMMING using the Examiner or other diagnostic equipment, but simply to carry out the simplified "CONTROL UNIT PROGRAMMING" procedure which simply "passes" all the data and codes in the receiver onto the new control unit.

If the control unit is being replaced, carry out a final check on the alarm system using the Examiner or other diagnostic equipment.