Vehicle Segment:
Compact family car / hatchback
Key Competitors At Launch:
Volkswagen Golf, Ford Focus, Opel Astra, Renault Mรฉgane, Peugeot 307.
Design Philosophy:
Spacious interior, comfort-oriented ride, distinct styling.
Engine Technology:
1.9 JTD 16V engine known for good torque and fuel efficiency.
Regions Covered:
Global (documentation provided in multiple languages)
Estimated Page Count:
Likely 500+ pages (typical for comprehensive service manuals)
Type:
Service and Repair Manual
Languages:
Italiano, English, German, Spanish, French, Dutch, Portuguese
File Format:
ISO (for download)
Engine:
Detailed diagnosis, repair, and overhaul of the 1.9 JTD 16V Multijet diesel engine.
Fuel System:
Common Rail, injectors, high-pressure pump, fuel filter, sensors.
Ignition System:
Glow plug system, engine control unit (ECU) related diagnostics.
Transmission:
Manual transmission (MT) maintenance, repair, and overhaul; clutch system.
Drivetrain:
Front-wheel drive system, driveshafts, CV joints.
Suspension:
Front McPherson struts, rear torsion beam, spring and damper replacement, alignment procedures.
Steering:
Power steering system, steering rack, linkages.
Brakes:
Front and rear disc brakes, ABS system, brake fluid service.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting, fuses, relays.
Body And Chassis:
Body panels, doors, hood, trunk, interior trim, structural components.
HVAC:
Heating, ventilation, and air conditioning system service and repair.
Emission Control:
Diesel Particulate Filter (DPF) system, EGR valve, emissions sensors.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks, brake pad replacement.
Troubleshooting:
Diagnostic flowcharts for common problems, fault code interpretation (where applicable).
Repair:
Step-by-step instructions for component removal, installation, and repair.
Overhaul:
Complete engine and transmission rebuild procedures.
Depth:
Comprehensive, from basic fluid changes to major engine and transmission overhauls, including electrical system diagnostics.
โ๏ธ Engine Specifications
Engine Type:
Inline 4-cylinder, turbocharged, common rail direct injection diesel
Displacement:
1910 cc (1.9 Liters)
Bore X Stroke:
82 mm x 90.4 mm (typical for this JTD family)
Compression Ratio:
18:1 (typical for this engine variant)
Valvetrain:
DOHC, 16 valves (4 valves per cylinder)
Horsepower Ps:
140 PS @ 4000 rpm (typical for 16V variant)
Torque Nm:
280 Nm @ 2000 rpm (typical for 16V variant)
Injection Type:
Bosch Common Rail Injection System
Engine Coolant Type:
Paraflu UP (or equivalent G12 type coolant)
Engine Oil Grade:
ACEA B4/C3 or API CF/CG-4 (check specific manual for exact spec, e.g., Selenia WR Pure Energy 5W-30)
Engine Oil Capacity:
Approximately 5.5 Liters (including filter)
Type:
Variable Geometry Turbocharger (VGT)
Type:
6-speed Manual Transmission (MTA - Manual Transmission Automated was also an option on some models, but this manual focuses on the standard manual)
Clutch Type:
Hydraulically operated dry single plate clutch
Final Drive Ratio:
Typically around 3.75:1 (varies by specific gearbox code)
Gearbox Oil Type:
API GL-4, SAE 75W-90 (e.g., Tutela Car Technyx)
Gearbox Oil Capacity:
Approximately 1.9 Liters
Body Styles:
3-door hatchback, 5-door hatchback, Wagon (Touring/Ulysse variant was a different model)
Length Mm:
4250 mm (3-door), 4280 mm (5-door)
Height Mm:
1550 mm (3-door/5-door)
Curb Weight Kg:
Approximately 1400-1500 kg (depending on body style and equipment)
Gross Vehicle Weight Kg:
Approximately 2000-2100 kg
Euro Ncap Rating:
4 Stars (for original Stilo model range)
Esp:
Optional on some trims/markets
Airbags:
Driver, passenger, side airbags, curtain airbags (depending on trim level)
Seatbelts:
Pre-tensioning seatbelts with load limiters
Engine Oil And Filter Change:
Every 15,000 km or 1 year, whichever comes first (check specific market recommendations)
Air Filter Replacement:
Every 30,000 km or 2 years
Fuel Filter Replacement:
Every 45,000 km or 3 years
Timing Belt Replacement:
Every 120,000 km or 5 years (critical component, consult manual for exact interval)
Coolant Replacement:
Every 60,000 km or 4 years
Egr Valve Fouling:
Common issue on diesel engines, leading to reduced performance and check engine lights.
Dpf Regeneration Issues:
Can occur with insufficient short journeys, leading to blockage.
Glow Plug Failure:
Can cause starting difficulties in cold weather.
Suspension Wear:
Commonly reported issues with ball joints and bushings on higher mileage vehicles.
Electrical Gremlins:
Reports of intermittent electrical faults affecting various systems.
Brand:
FIAT (Fabbrica Italiana Automobili Torino)
Production Years:
2001-2008 (Globally, various phases)
Platform:
Fiat Project 192 platform
Facelift:
Minor facelift around 2005/2006
Manufacturing Locations:
Primarily Italy (e.g., Cassino plant)
