Fiat Stilo Diesel Service Repair Manual

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🏷️ Basic Information Identification Make: Fiat Model: Stilo Generation: First Generation (192) Product Type: Service and Repair Manual Codes Engine Code 1: 192A3.000 Engine Code 2: 192A1.000 👋 Introduction Market...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Stilo

Generation:

First Generation (192)

Product Type:

Service and Repair Manual

Codes

Engine Code 1:

192A3.000

Engine Code 2:

192A1.000

👋 Introduction

Market Position

Segment:

Compact Family Car / Hatchback

Target Audience:

Owners seeking in-depth maintenance and repair knowledge, independent repair shops, automotive technicians.

Competitive Analysis

Key Competitors:

Volkswagen Golf, Ford Focus, Opel Astra, Renault Megane, Peugeot 307

Key Features

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.

📋 Manual Details

Coverage Areas

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

Page Count

Estimated Pages:

Significant; precise count not provided in product info, but typical for comprehensive service manuals.

Manual Type

Type:

Service and Repair Manual

Manual Category:

Factory-level Technical Service Manual

Language

Language:

Italian (primary language indicated by 'IDENTIFICAZIONE' and technical terms)

Format

Format:

Likely Digital (PDF) given typical modern manual sales, but Print may be an option.

📖 Manual Coverage

Systems Covered

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.

Procedures Included

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.

Technical Depth

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.

📊 Manual Specifications

File Format

Digital Format:

PDF (assumed)

Print Quality

Print Quality:

High-resolution for clear diagrams and text (assumed for digital format).

Binding Type

Binding:

N/A (for digital format) or Perfect Bound/Spiral Bound (for physical format).

Paper Type

Paper Type:

N/A (for digital format) or Glossy/Matte coated paper (typical for technical manuals).

⚙️ Engine Specifications

Primary Engine 80Cv

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

Primary Engine 115Cv

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

Fuel System

Injection System:

Bosch EDC 15C Unijet Common Rail

Fuel Type:

Diesel

Emission Standard

Euro Standard:

EURO 3

🔧 Transmission

Standard Transmission

Type:

5-Speed Manual

Manufacturer 1:

Getrag

Model 1:

C 510

Manufacturer 2:

Fiat (or supplier)

Model 2:

C 538

Features

Clutch Type:

Hydraulically actuated dry single-plate clutch (typical for this era).

Gear Ratios:

Specific ratios not provided in product info, but the manual would detail these.

📐 Dimensions

Exterior

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.

Weights

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.

🛡️ Safety Features

Ratings

Euro Ncap Rating:

4 Stars (for early models, may vary slightly with updates) - manual may reference safety systems.

Active Features

Standard on most variants, details on system operation in manual.

Optional on some variants, details on system operation in manual.

Passive Features

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.

💡 Technology Features

Infotainment

Radio System:

Factory fitted radio/CD players, details on operation and potential upgrades might be inferred from general manual sections.

Driver Assistance

Cruise Control:

Optional on some models. Manual would cover system operation and checks.

Connectivity

Diagnostics Port:

OBD-II (On-Board Diagnostics) port, typically located under the dashboard. Manual details diagnostic procedures and common P-codes.

🔧 Maintenance

Service Intervals

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.

Fluid Specifications

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.

Known Issues

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.

📚 Vehicle History

Brand Heritage

Fiat Automotive History:

Fiat is one of the oldest automotive manufacturers, known for innovation and practical vehicles, especially in smaller segments and diesel technology.

Model Evolution

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

Production Period:

2001-2008 (overall Stilo production)

Manufacturing Location:

Primarily Fiat's Mirafiori plant in Turin, Italy.

🏆 Awards & Recognition

Recognitions

Industry Awards:

The Fiat Stilo received mixed reviews, but Fiat's JTD diesel engines generally received praise for their efficiency and refinement.