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L P G
F I A T B R A V O
604.39.936 BRAVO GPL GB 7.0 3-12-2008 9:16 Pagina 1
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The Fiat Bravo LPG version (Petrol- LPG)is dealt with in this appendix.
For anything not included in this Supple-ment, refer to the Owner Manual en-closed.
INDEX
KNOWING YOUR CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4SYSTEM FUNCTIONAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7LPG TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8SOLENOID VALVES AND SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10REGULATION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10PAPER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11LPG INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11ELECTRONIC CONTROL UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12LPG/PETROL SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12FUEL CUT OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14REFUELLING THE CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15FUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16SCHEDULED SERVICING PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21FUEL CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22CO2 EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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GKNOWING YOUR CAR
INTRODUCTION
The LPG version of the car features twofuel systems: one for petrol and one forLPG.
Like the petrol system, the LPG systemis the phased, sequential multipoint typewith special injectors.
LPG MULTIPOINT INJECTIONSYSTEM
This product is produced in strict collab-oration with prestigious suppliers in theLPG sector. The injection system used onthe car is an efficient system in terms ofengine performance and is based on theinjection of LPG in a gaseous state.
In this system with four injectors, one foreach intake manifold, the fuel is injecteddirectly into the engine heat transfer ductsthereby metering the LPG very preciselyimproving combustion and, at the sametime, excluding any possibility of flame re-turn.
By adapting the electronic control tech-nology of petrol engines to meet the spec-ifications of LPG, it has been possible toachieve important results in terms of dri-veability and controlling exhaust emissions.
Engines running on LPG have almost thesame torque/power specifications as whenrunning on petrol and, as a result, the per-formance of the car is also comparable.
The system extreme operat-ing temperatures are between–20°C and 100°C.
WHAT IS LPG?
LPG (the abbreviation of liquefied petro-leum gas) is a mixture of gas used as aneconomical and safe primary energysource.
Its main components are: propane gas andbutane gas mixed.
These gases are a product of petroleumrefinement and are also present naturallyin oil fields and methane-producing de-posits.
In its natural state this mixture is in agaseous state but, as the pressure in-creases, at ambient temperature, it caneasily be turned into a liquid state.
LPG is a fuel with a low environmental im-pact because it reduces the pollution pro-duced by vehicle exhaust gases.
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SELECTING THE TYPE OF FUEL SUPPLY
The car is configured for running inde-pendently on either petrol or LPG.
The engine is always started on petrolwith an automatic shift to LPG after about40 seconds at the first significant acceler-ation.
This is the time required to reach opti-mum conditions (engine coolant temper-ature, minimum revs level) for the switchto LPG. As far as what has been saidis concerned, there must always besome petrol in the tank (at least 1/4full) in order not to compromise the op-eration of the fuel pump.
When running on LPG, whenthe last red LED on gas quan-tity indicator (visible on theswitch) comes on, refuelling is
advisable. If the LPG runs out duringLPG operation, the system automati-cally switches to running on petrolshown by: the amber LED coming onconstantly and the green LED flashing,the fuel level LEDs going out and abuzzer in the switch.
In addition, it is advisable to periodicallyuse up the petrol in the tank (until the re-serve warning light comes on) in order toensure that the petrol does not becomeold and possibly deteriorate.
The petrol/LPG switch fig. 1, located onthe centre tunnel (next to the gear lever)allows the driver to select petrol or LPGoperation at their discretion.
fig. 1 F0Q0804m
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When painting in an oven, theLPG tank should be removedfrom the car and later care-fully refitted by a Fiat Deal-
ership. Although the LPG system hasnumerous safety features, it is advis-able to close the manual tap on thetank every time the car is not in use fora long period, transported on other ve-hicles or moved in an emergency as aresult of a breakdown or accident.
Active safety
The car has the same active safety speci-fications as other versions.
The LPG tank meets the legal safety stan-dards of the countries in which the ver-sion illustrated this Supplement is mar-keted.
The car is equipped withgaseous LPG injection systemdesigned specifically for thecar: it is therefore strictly
prohibited to alter the configuration ofthe system and components. The useof other components or materials couldcause malfunctions and lead to a re-duction in safety therefore, in the caseof problems, go to a Fiat Dealership.When towing or raising the car, to pre-vent damage to the gas system parts,follow the instructions in the OwnerHandbook in the “Towing the car”chapter.
It should be pointed out thatin some countries (including
Italy) there are legal restrictions inforce for parking/garaging motor ve-hicles with gas that has a higher den-sity than air; LPG comes under thiscategory.
WARNING
PASSIVE SAFETY/ACTIVE SAFETY
Passive safety
The car has the same passive safety spec-ifications as other versions. In particular,the canister mountings (located in thespare wheel housing) have been designedto exceed the Fiat safety standards for im-pact tests.
When running on LPG, the flow of gas (ina liquid state) leaving the canister, passesthrough the dedicated pipe to the pres-sure regulator where there is a safety so-lenoid valve that stops the flow of LPGwhen the key is turned off or when achange of fuel is selected by the driver (de-cision to run on petrol).
Together with the regulator solenoidvalve, a second solenoid valve, in the tank,closes the LPG pipe at the tank outlet.
The two solenoid valves are connected tothe inertia switch (Fire Protection Sys-tem).
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SYSTEM FUNCTIONAL DIAGRAMDESCRIPTION OF THE SYSTEM FUNCTIONAL DIAGRAM fig. 21 LPG tank - 2 Multivalve assembly and safety devices - 3 LPG refuelling filler - 4 LPG piping - 5 Pressure regulator - 6 LPG injec-tors - 7 LPG in gaseous state filter element - 8 LPG injection system electronic control unit - 9 LPG-petrol switch and LPG gauge10 Petrol tank.
10
F0Q0808mfig. 2
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GLPG TANK
The vehicle has a (pressurized) tank A - fig. 3 for LPG in a liquid state that istoroidal in shape and located in the hous-ing for the spare wheel with suitable pro-tection.
The LPG in the tank A is always in a liquidand gaseous state, in physical equilibriumconditions.
The liquid, which cannot be compressed,dilates by around 0.25% for each increasein temperature of one degree. For thisreason a suitable space allowing the in-crease in volume of the liquid for allforseeable temperature increases is guar-anteed (e.g. car parked in the full sun insummer) without compromising the in-tegrity of the tank.
In effect, there is a safety valve that auto-matically limits the refilling of the tank(during refuelling) to a maximum level of80% (liquid) of its total capacity.
Periodically (at least onceevery six months) it is advis-able to let the LPG in the tankrun out and, at the first refu-
elling, check that it does not exceed themaximum capacity of 41 litres (see in-structions in “Capacities” paragraph inthis Supplement). If the value is above41 litres, go to a Fiat Dealer immedi-ately.
LPG TANK CERTIFICATION
The LPG tank is certified in accor-dance with the regulations in force.
In Italy the tank has a life of 10 yearsfrom the registration date of the car.If the car has been registered in a dif-ferent country from Italy, the life ofthe LPG tank and test/inspectionprocedures may vary depending onthe laws in force in that particularcountry. In any case, when the timelimit in the individual country has runout, go to a Fiat Dealer to have thetank replaced.
There is a plate on the tank B - fig. 3 con-taining the following information:
– homologation country identification andhomologation number;
– type of gas designed for (LPG);
– name of canister manufacturer;
– canister test pressure (30 bar);
– maximum refilling percentage (80%);
– tank dimensions;
– nominal tank capacity in litres;
– canister manufacture date (month/year);
– canister serial number.
fig. 3
A
B
F0Q0801m
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SOLENOID VALVESAND SAFETY DEVICES
The system has a solenoid valve locatedon the pressure reduction unit and a so-lenoid valve fitted inside the multivalve as-sembly on the tank.
The main function of these solenoid valvesis to interrupt/allow the flow of LPG tothe supply circuit.
The solenoid valves are open when:
– a request to run on LPG has been made;
– the optimum engine running conditionsare satisfied (engine coolant temperature,minimum revs level) for running on LPG;
– there is enough LPG in the tank for op-eration;
– the inertia switch has not been triggered.
The multivalve assembly fitted on the tankincludes:
– a valve that automatically stops the sup-ply of LPG when the maximum permittedfilling level is reached (80% of the totaltank capacity);
– a flow limiter which, if a pipe is broken,prevents the complete and sudden escapeof LPG;
– a one-way valve, located on the gas re-turn pipe in the tank, which prevents LPGreflux;
– a safety solenoid valve on the LPG sup-ply, which either gives the go ahead orprevents the escape of gas to the pressurereduction unit;
– a manual tap, upstream of the solenoidvalve, that separates the tank from theLPG system to allow maintenance opera-tions;
– a fuse pad which, in the case of overheating (temperature above 120°C),totally eliminates the danger of excesspressure making the LPG in the tank flowout as quickly as possible in a controlledmanner;
– an analogue gauge showing the level ofLPG in the tank.
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GREGULATION UNIT
The regulation unit fig. 4 includes:
– cut out solenoid valve with gauze filter;
– pressure regulator.
The cut out solenoid valve opens orcloses together with the solenoid valve onthe tank. It closes each flow of LPG whenthe engine is not running on gas.
It also acts as a safety device that preventsthe flow of LPG if the inertia switch is ac-tivated.
fig. 4 F0Q0802m
The pressure regulator allows thechange of the LPG from a liquid state toa gaseous state via a dilation chamber andmaintains the pressure required for theoperation of the system at a preset val-ue.
PIPING
The piping for the LPG in a liquid state(from the filler to the tank and from thetank to the pressure regulator) is madefrom copper and coated in plastic.
The piping for the LPG in a gaseous state(from the pressure regulator to the LPGinjectors) is made from rubber.
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PAPER FILTER
The filter fig. 5, located on the pressureregulator outlet pipe, has the task of fil-tering the LPG in a gaseous state duringthe LPG injectors supply stage.
fig. 5 F0Q0803m
LPG INJECTORS
There are four injectors fig. 6, speciallydesigned for LPG, mounted on the intakemanifold near the cylinder head, one foreach inlet duct; they are supplied with LPGin a gaseous state at a constant pressureand are controlled by a specific electron-ic control unit.
A gas pressure and temperature sensorthat sends an appropriate electrical signalin order to determine the LPG injectiontime is fitted on the injectors.
fig. 6 F0Q0806m
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GELECTRONIC CONTROL UNIT
The vehicle has a dedicted electronic con-trol unit for the LPG system; it uses theincoming signals from the petrol injectioncontrol unit and converts them into sig-nals for the injection of the LPG.
The control unit for the injectors has thesame strategy as the petrol control unit(phased, sequential, multipoint).
LPG/PETROL SWITCH
The LPG/petrol switch fig. 7 is located onthe centre console near the handbrakelever and includes:
A. LPG/petrol operating mode requestbutton;
B. LPG gauge: 5 LEDs, 4 green and 1 redto indicate the reserve. The red LED on-ly comes on when the last green LED goesout.The red LED indicates the reserve con-dition;
ON. LPG operating mode indicator:green LED, located under button A, onconstantly;
OFF. petrol operating mode indicator:yellow LED, located above button A, onconstantly.
IMPORTANT When the ignition key isturned to the MAR position the LEDs onthe ignition switch come on in accordancewith the following logic:
– with the petrol operating mode se-lected: yellow OFF LED on;
– with the LPG operating mode se-lected: all the LEDs in the switch are onconstantly and the green ON LED is flash-ing.
To select the type of fuel system desired(LPG or petrol), press the button A - fig. 7.
To change the type of fuel system, it is ad-visable to operate the button with the ve-hicle stationary and the engine running or,whilst driving, after having released the ac-celerator.
If the switching takes place during accel-eration or pick-up, there may be a briefflat spot (fall in power).
Do not switch between the two operat-ing modes whilst starting the engine.
fig. 7 F0Q0805m
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SWITCH FROM PETROL TO LPG
When running on petrol: press the buttonA - fig 7, the switch to LPG will take placeautomatically at the first significant accel-eration.
During switching:
– the LPG gauge B comes on;
– the yellow OFF LED goes out (petroloperating mode);
– the green ON LED comes on switch-ing from intermittent to on constantly(LPG operating mode);
There is a series of 5 LEDs B (1 red and4 green) on the left side of the switch thatdisplay the amount of LPG in the tank.
When the amount of LPG remaining goesbelow about 1/5 of the capacity of thetank, only the red (reserve) LED remainson to signal the need for refuelling.
IMPORTANT In the case of starting atoutside temperatures of below -10°C, theswitching times from petrol to LPG in-crease to allow the pressure regulator tobecome warm enough.
LPG used up
If the LPG runs out, switching to petroltakes place automatically with:
– the yellow OFF LED on constantly;
– the green ON LED flashing;
– an acoustic warning from the switchbuzzer (fast frequency).
IMPORTANT The buzzer warns the dri-ver that the engine is running on petrol;therefore they must refuel with LPG be-fore it runs out.
IT IS possible to deactivate the buzzer bypressing switching button A.
Do not switch between thetwo operating modes whilststarting the engine
Switching from LPG to petrol
When running on LPG: press the buttonA - fig. 7.
During switching:
– the LPG gauge B goes out;
– the yellow OFF LED comes on con-stantly (petrol operating mode);
– the green ON LED goes out (LPG op-erating mode).
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GFUEL CUT OFF SWITCH
In the case of LPG operation as well, thesafety switch is triggered if the car is in-volved in an impact immediately cutting offthe supply (safety solenoid valve closed)and causing the engine to cut out.
For further information, see the “Fuel cutoff switch” paragraph in the “Controls”chapter in the Owner Handbook.
STARTING THE ENGINE
The engine is always started on petroleven with the switch in the LPG position(green LED flashing, yellow LED on con-stantly) and switches automatically soonafter.
There must always be some petrol in thetank to protect the petrol pump.
To carry out the starting manoeuvre, seethe warnings and advice in the OwnerHandbook under the chapter “Starting theengine”.
In this condition it is possibleto continue driving running onpetrol (excluding the LPG fu-el system). To stop the
buzzer, press button A: the green ONLED will go out and the yellow OFFLED will remain on constantly. Go to aFiat Dealer as soon as possible to havethe system checked.
SYSTEM FAILURE SIGNALLING
The car has an autodiagnostic system ca-pable of signalling any malfunctions in theLPG fuel system through the green ONLED fig. 7 flashing. In the case of faultsthat could affect the correct operation ofthe engine, the LPG control unit will au-tomatically switch from LPG operation torunning on petrol.
This condition will be shown by:
– the yellow OFF LED on constantly;
– the green ON LED flashing;
– an acoustic warning from the switchbuzzer (slow frequency).
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REFUELLING THE CAR
LPG FILLER
The gas filler is located next to the petrolfiller cap. It has a one-way valve, locatedin the actual filler body.
To access the filler B - fig. 8, open the ac-cess flap A and undo the cap C.
Observe the following precautions duringthe refuelling operation:
– switch off the engine;
– apply the handbrake;
– turn the ignition key to the STOP po-sition;
– do not smoke;
– hand the special adaptor over to thequalified LPG refuelling personnel.
IMPORTANT Before refuelling with LPG,the qualified personnel should make surethat the adapator is correctly tightenedonto the filler fitting.
IMPORTANT Depending on the country,there are two types of adaptors for refu-elling pumps. The adaptor that comes withthe car in a special case is specifically de-signed for the country in which the car issold. If you are in a different country, findout what type of adapator is used there.
WHEELS
The car does not have a spare wheel buta tool box that contains the “Fix&Go au-tomatic” quick tyre repair kit, the towhook and a screwdriver. The box is lo-cated in the luggage compartment, behindthe rear seat backrest.
To use the “Fix&Go automatic” kit, seethe instructions in the Owner Handbookthat this supplement is an appendix of.
fig. 8 F0Q0807m
fig. 9 F0Q0281m
IMPORTANT Only use LPG for mo-tor vehicles.
IMPORTANT Look after the LPGadapator carefully so that it does notget damamged.
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30 60 90 120 150 180
� � � � � �
� �
� � � � � �
� � � � � �
� � � � � �
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GFUSE REPLACEMENT
The LPG system components are protected by the following fuses:
– Additional 20A fuse located to the outside of the engine compartment junction unit: LPG control unit power supply (batterypositive);
– 7.5A F16 fuse located in the engine compartment junction unit: LPG control unit power supply (ignition-controlled positive) andcoil relay for gas solenoid valve power supply.
For all the other fuses, consult the Owner Handbook that this supplement comes with.
SCHEDULED SERVICING PLAN
Additional operations to the Servicing Plan in the Owner Handbook.
Thousands of kilometres
Visually inspect the condition of: LPG piping and connectors andLPG tank fastening
Replacement of filter inside the pressure regulator
Paper filter replacement (LPG in gaseous state)
Check operation and parameters of fuel supply system using autodiagnostic socket
Check mechanical tappet clearance and restore if necessary
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ENGINEENGINE CODE - BODYWORK VERSIONS
Engine code Bodywork version
1.4 16V 192B2000 198AXA1B G00C
IDENTIFICATION PLATE(STAGE 2)
Following the installation of the LPG sys-tem components, a plate (Stage 2) is fittedto the engine compartment front cross-member, that contains the following in-formation:
– Name of manufacturer;
– Homologation number (Stage 2);
– Vehicle type identification codes;
– Vehicle weights;
– Engine type;
– Bodywork version code.
INTRODUCTION 1.416V
Engine identification code 192B2000
Cycle Otto
Number of cylinders and position 4 in line
Piston diameter and stroke mm 72 x 80.4
Total capacity cm 1368
Compression ratio 11
LPG Petrol
Max power CEE kW 66 66HP 90 90
at a speed of rpm 5500 5500
Max torque CEE Nm 128 128kgm 13 13
at a speed of rpm 4500 4500
Spark plugs NGK DCPR7E-N-10
Fuel LPG Unleaded petrol95 RON
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GIGNITION
Static advance, electronic, integrated withthe injection.
LPG FUEL SYSTEM
Electronic injection with special LPG injec-tors.
Type: Phased, sequential, multipoint.
Stoichiometric metering of the air/gas mix-ture.
Engine idle speed: 750 ± 50 rpm
The LPG injection system is controlled bya dedicated control unit (connected to thepetrol one) using the sensors already onthe car.
Modifications or repairs tothe fuel feed system that are
not carried out properly or do nottake the system’s technical specifica-tions into account can cause mal-functions leading to the risk of fire.
WARNING
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WEIGHTS
(1) If special equipment is fitted (sun roof, trailer towing equipment, etc.) the unladen weight will increase and consequently thepayload will decrease in relation to the maximum permitted loads.
(2) Loads not to be exceeded. The user is responsible for arranging goods in the luggage compartment and/on load carrying plat-form within the maximum permitted loads.
(3) Lineaccessori Fiat range roof racks, maximum capacity: 50 kg.
Weights (kg)
Unladen weight (with all fluids, fuel tank filled to 90% and without optional equipment):
Payload including the driver (1):
Maximum permitted loads (2)– front axle:– rear axle:– total:
Maximum permitted load on the roof (3):
1.4 16V
1205
510
10008601715
80
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F0Q0003m
DIMENSIONS
fig. 10
A B C D E F G H
4336 974 2600 762 1498 1538 1792 15321530 (�) 1524 (�)
Small variations in size are possible depending on the dimensions of the rims
(�) with optional 18” alloy wheels
Dimensions are expressed in mm and re-fer to the vehicle equipped with its origi-nal tyres.
Height is measured with vehicle unladen.
Luggage compartment volume
Capacity with vehicle unladen (V.D.A. standards): . . . . . . . . . 365 dm3
Capacity with rear seat backrest folded over: . . . . . . . . . 1139 dm3
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CAPACITIES
Petrol
Petrol . . . . . . . . . . . . . . . . . litres 57
– including a reserve of . . . . 8-10 litres
LPG
– maximum refuellingcapacity (*) . . . . . . . . . . . . . . litres 41
(*) The figure already takes into accountthe 80% tank filling limit and the residualfluid required for the pump and the max-imum permitted capacity. There may beslight variations to this figure as a re-sult of: differences between networkpump supply pressures, pumps withdifferent supply/stop specifications,tank not completely in reserve con-ditions.
It should be remembered that when usinga fuel like LPG, the range is very variablebecause, in addition to the vehicle drivingand maintenance conditions, it also de-pends on the different composition of thegas which may vary, not only seasonally,but also from supplier to supplier. LPG is,in effect, a composition of gas (butane andpropane) mixed in a way that may not bestandardized.
During LPG operation, the “Instant con-sumption” and “Average consumption”readings are not significant, but remainvalid for all other functions.
IMPORTANT Only use LPG for mo-tor vehicles.
If, when refuelling with LPG,the tank is filled with morethan the 41 litres, seek assis-tance immediately from a Fi-
at Dealer. Periodically (at least onceevery six months) it is advisable to letthe LPG in the tank run out and, at thefirst refuelling, check that it does notexceed the maximum capacity of 41litres.
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GFUEL CONSUMPTION
The fuel consumption figures given in the table below are determined on the basis of the homologation tests laid down by specificEuropean Directives.
FUEL CONSUMPTION ACCORDING TO DIRECTIVE 2004/3/CE (litres x 100 km)
CO2 EMISSIONS
The CO2 emission figures refer to combined consumption.
CO2 EMISSIONS ACCORDING TO 2004/3/CE DIRECTIVE
LPG: 134 g/km
Petrol: 156 g/km
Petrol LPG
Urban 8.6 10.6
Extraurban 5.5 7.0
Combined 6.7 8.3
The range (when running on LPG), referring to combined consumption, is 494 km.
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NOTES
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Fiat Group Automobiles S.p.A. - Customer Services - Technical Services - Service EngineeringLargo Senatore G. Agnelli, 5 - 10040 Volvera - Torino (Italia)
Print no. 604.39.936 - 01/2009 -1st Edition
604.39.936 BRAVO GPL GB 7.0 3-12-2008 9:16 Pagina 24