Segment:
Compact Family Car / Hatchback
Target Audience:
Owners seeking in-depth maintenance and repair knowledge, independent repair shops, automotive technicians.
Key Competitors:
Volkswagen Golf, Ford Focus, Opel Astra, Renault Megane, Peugeot 307
Vehicle Philosophy:
Practicality, Italian design flair, focus on family utility with optional sporty variants.
Engine Technology Emphasis:
Focus on reliable and torquey JTD diesel engines, representing Fiat's strength in diesel technology.
Supported Engines:
1.9 JTD 80 Cv (59 kW), 1.9 JTD 115 Cv (85 kW)
Supported Transmissions:
C 510 Getrag (5-speed manual), C 538 (5-speed manual)
Supported Markets:
Primarily European market focused on Diesel variants
Estimated Pages:
Significant; precise count not provided in product info, but typical for comprehensive service manuals.
Type:
Service and Repair Manual
Manual Category:
Factory-level Technical Service Manual
Language:
Italian (primary language indicated by 'IDENTIFICAZIONE' and technical terms)
Format:
Likely Digital (PDF) given typical modern manual sales, but Print may be an option.
Engine Mechanical:
Engine assembly, disassembly, cylinder head, pistons, crankshaft, camshafts, timing system.
Engine Fuel System:
Common Rail Bosch EDC 15C injection system, fuel pump, injectors, fuel filter, fuel lines, high-pressure rail.
Engine Lubrication:
Oil pump, oil filter, oil passages, oil cooler (if applicable).
Engine Cooling:
Radiator, water pump, thermostat, coolant passages, hoses, fan system.
Engine Air Intake:
Air filter, intake manifold, turbocharger (fixed and variable geometry), intercooler, EGR system.
Engine Exhaust:
Exhaust manifold, catalytic converter, muffler, sensors (e.g., Lambda sensor if applicable to EURO 3).
Transmission Manual:
Gearbox components, clutch system, gear selection mechanism, differential (integral to gearbox).
Electrical System:
Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting, ignition system components (related to ECU control).
Engine Control Unit:
ECU identification, diagnostic trouble codes (DTCs), sensor inputs, actuator outputs, common fault diagnosis for EDC 15C.
Emissions Control:
EURO 3 emission standards, EOBD diagnostics, components related to emission control.
Routine Maintenance:
Oil and filter change, air filter replacement, fuel filter replacement, coolant checks, brake fluid checks, general inspection.
Engine Repair:
Head gasket replacement, piston ring replacement, bearing checks, valve adjustments (if applicable), turbocharger overhaul.
Fuel System Service:
Injector testing and replacement, high-pressure fuel line bleeding, fuel system pressure testing.
Transmission Service:
Gearbox oil change, clutch inspection and replacement, transmission mounting checks.
Electrical Diagnostics:
Troubleshooting electrical faults, testing sensors and actuators, interpreting wiring diagrams.
Troubleshooting:
Diagnosis of common engine performance issues, starting problems, fuel economy issues, emissions related faults.
Diagnostic Procedures:
In-depth diagnostic procedures using ECU data, sensor readings, and fault code interpretation.
Repair Instructions:
Detailed step-by-step repair instructions with torque specifications and special tool requirements.
Rebuild Specifications:
Specifications for engine and transmission component reconditioning and assembly.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for various vehicle systems.
Engine Family:
JTD (Unijet Common Rail)
Displacement:
1.9 Liters (1910 cc)
Power Output:
80 CV (approx. 78.9 hp or 58.8 kW) @ engine speed (specific RPM not provided)
Peak Torque:
Torque figures not explicitly provided, but typical for this variant would be around 190-200 Nm.
Turbocharger Type:
Fixed Geometry Turbocharger
Engine Family:
JTD (Unijet Common Rail)
Displacement:
1.9 Liters (1910 cc)
Power Output:
115 CV (approx. 113.4 hp or 84.6 kW) @ engine speed (specific RPM not provided)
Peak Torque:
Torque figures not explicitly provided, but typical for this variant would be around 255-270 Nm.
Turbocharger Type:
Variable Geometry Turbocharger (VGT) + Intercooler
Injection System:
Bosch EDC 15C Unijet Common Rail
Body Styles:
3-door hatchback, 5-door hatchback, Station Wagon (Stilo Multi Wagon)
Length:
Approx. 4.25 m (Hatchback), Approx. 4.51 m (Multi Wagon) - specific data in manual.
Width:
Approx. 1.76 m - specific data in manual.
Height:
Approx. 1.57 m - specific data in manual.
Curb Weight:
Varies by engine and body style, typically 1300-1400 kg - manual provides specific figures.
Gross Vehicle Weight:
Specific figures would be detailed in the manual.
Euro Ncap Rating:
4 Stars (for early models, may vary slightly with updates) - manual may reference safety systems.
ABS:
Standard on most variants, details on system operation in manual.
Esp:
Optional on some variants, details on system operation in manual.
Airbags:
Front, side, and curtain airbags standard or optional depending on trim. Manual details locations and operation.
Seatbelts:
Pre-tensioners and load limiters standard. Manual covers their function and any checks.
Oil Change Interval:
Typically 15,000 km or 1 year, whichever comes first (refer to manual for exact specification for engine type).
Air Filter Interval:
Check every 15,000 km, replace as needed or at scheduled intervals (e.g., 30,000 km).
Fuel Filter Interval:
Typically 30,000 - 45,000 km for diesel fuel filters (manual will provide precise interval).
Timing Belt Interval:
Crucial service item for JTD engines. Typically 60,000-90,000 km or 5 years. Manual will specify exact interval and procedure.
Engine Oil Spec:
API CF/CG-4 or ACEA B3/B4 specifications. Viscosity likely 5W-40 or 10W-40. Manual will confirm specific Fiat approval (e.g., Fiat 9.55535-N2).
Coolant Spec:
Ethylene glycol based coolant with corrosion inhibitors, typically blue or green. Manual will specify Fiat specification.
Brake Fluid Spec:
DOT 4 is typical. Manual will specify the required specification and replacement interval.
Gearbox Oil Spec:
Specific manual transmission fluid (MTF) grade, likely GL-4 or GL-5. Manual will provide exact specification and capacity.
Egr Valve Clogging:
Common on diesel engines with higher mileage due to soot buildup. Manual provides diagnosis and cleaning/replacement procedures.
Turbocharger Failure:
Can occur due to lack of oil changes or contamination. Manual details inspection and testing.
Diesel Particulate Filter:
Although EURO 3 may not always have a DPF, some later variants or specific markets might. Manual would cover regeneration or replacement if fitted.
Suspension Components:
Wear on ball joints, bushes, and drop links is common with age. Manual details inspection and replacement.
Electrical Gremlins:
As with many vehicles of this era, minor electrical issues can arise. Wiring diagrams in the manual are critical for diagnosis.
Fiat Automotive History:
Fiat is one of the oldest automotive manufacturers, known for innovation and practical vehicles, especially in smaller segments and diesel technology.
Stilo Introduction:
Launched in 2001 as a replacement for the Fiat Bravo/Brava, positioned as a more modern and versatile compact car.
Stilo Variants:
Offered in 3-door and 5-door hatchback, and the 'Multi Wagon' estate version. Diesel variants were crucial for many European markets.
Production Period:
2001-2008 (overall Stilo production)
Manufacturing Location:
Primarily Fiat's Mirafiori plant in Turin, Italy.
