2009 FIAT BRAVO engine

3
FIAT BRAVO LPG
This supplement is about the Fiat Bravo
LPG version (Petrol-LPG).
For anything not included in this supple-
ment, refer to the enclosed Owner Hand-
book.CONTENTS
KNOWING YOUR CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SYSTEM FUNCTIONAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LPG TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SOLENOID VALVES AND SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REGULATION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PAPER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LPG INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRONIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LPG/PETROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL CUT-OFF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REFUELLING THE CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REPLACING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SCHEDULED SERVICING PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FUEL CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CO
2EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
603_97_467 BRAVO GPL EN 24-11-2009 12:29 Pagina 3

4
FIAT BRAVO LPG
KNOWING YOUR CAR
INTRODUCTION
The LPG version of the car features two
fuel systems, one for petrol and one for
LPG.
Like the petrol system, the LPG system
is timed, sequential multipoint type with
special injectors.LPG MULTIPOINT
INJECTION SYSTEM
This product is produced by working clo-
sely with qualified suppliers in the LPG sec-
tor. The injection system used on the car
is an efficient system in terms of engine
performance and is based on the injection
of LPG in a gaseous state.
In this system with four injectors, one for
each intake manifold, the fuel is injected
directly into the engine heat transfer ducts,
thereby metering the LPG very precisely.
This improves combustion and, at the sa-
me time, excludes any possibility of back-
draught.
By adapting the electronic control tech-
nology of petrol engines to meet the spe-
cifications of LPG, it has been possible to
achieve significant results in terms of dri-
veability and controlling exhaust emissions.
Engines running on LPG have almost the sa-
me torque/power specifications as when
running on petrol and, as a result, the
performance of the car is also comparable.
The system operates at tem-
peratures are between −20 °C
and 100°C.
WHAT IS LPG?
LPG (which stands for “liquefied petro-
leum gas”) is a gas mixture used as an eco-
nomical and safe primary energy source.
Its main components are: propane gas and
butane gas mixed in various proportions.
These gases are a product of petroleum
refinement and are also present naturally
in oil fields and methane-producing depo-
sits.
In its natural state this mixture is in a ga-
seous state but, as the pressure increa-
ses at ambient temperature, it can easily
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.
603_97_467 BRAVO GPL EN 24-11-2009 12:29 Pagina 4

5
FIAT BRAVO LPG
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 petrol
with an automatic shift to LPG after about
40 seconds at the first significant accele-
ration.
This is the time required to reach opti-
mum conditions (engine coolant tempe-
rature, minimum revs level) for the swit-
ch to LPG. Therefore, there must
always be some petrol in the tank (at
least 1/4 full)in order not to compro-
mise the operation of the fuel pump. When running on LPG, when
the last red LED on the gas
gauge (visible on the switch)
comes on, refuelling is advisa-
ble. If the LPG runs out when in LPG mo-
de, the system automatically switches to
petrol mode. This is indicated by: the
amber LED staying on and the green
LED flashing, the fuel level LEDs going
out and an audio signal from the switch.
In addition, it is advisable to periodically
use up the petrol in the tank (until the re-
serve warning light comes on) in order to
ensure that the petrol does not become
old and possibly deteriorate.
The petrol/LPG switch fig. 1, located on
the central tunnel (next to the gear lever)
allows the driver to select petrol or LPG
operation as they see fit.
fig. 1F0Q0804m
Remember that, once LPG re-
fuelling is complete, it is ne-
cessary to switch again by
pressing the button fig. 1 to
run the car on gas.
The LPG supply system is
equipped with a “consump-
tion” function linked to the
LED display of LPG level on
the switch; this function activates only
after a consistent variation in fuel level
has been detected. You are therefore
advised to fill up with fuel at the first
LPG refuelling to obtain a more preci-
se indication of the “level”.
603_97_467 BRAVO GPL EN 24-11-2009 12:29 Pagina 5

6
FIAT BRAVO LPG
When painting in an oven, the
LPG tank should be removed
from the car and later care-
fully refitted by a Fiat Dea-
lership. Although the LPG system has
numerous safety features, it is advisa-
ble to close the manual tap on the tank
every time the car is not in use for a
long period, transported on other vehi-
cles or moved in an emergency as a re-
sult of a breakdown or accident.
Active safety
The car has the same active safety speci-
fications as other versions. The LPG tank complies with the national
standards in force in countries where the
version illustrated in this supplement is sold.
The car is equipped with a ga-
seous LPG injection system de-
signed specifically for it: it is
therefore absolutely forbidden
to alter the configuration of the system
or its components. The use of other
components or materials could cause
malfunctions and lead to a reduction
in safety. Therefore, in the case of pro-
blems, go to a Fiat Dealership. To pre-
vent damage to the LPG system parts
when towing or raising the car, follow
the instructions in the “Towing the car”
chapter of the Owner Handbook.
It should be pointed out that
in some countries (including
Italy) there are legal restrictions in
force for parking/garaging motor
vehicles with gas that has a higher
density than air; LPG comes under
this category.
IMPORTANT
PASSIVE SAFETY/ACTIVE
SAFETY
Passive safety
The car has the same passive safety spe-
cifications as other versions. In particu-
lar, the cylinder mountings (located in the
spare wheel housing) have been designed
to exceed the Fiat safety standards for im-
pact tests.
When running on LPG, the flow of gas (in
a liquid state) leaving the cylinder passes
through the dedicated pipe to the pres-
sure regulator where there is a safety so-
lenoid valve that stops the flow of LPG
when the key is removed or when a chan-
ge of fuel is selected by the driver (deci-
sion to run on petrol).
Together with the regulator solenoid val-
ve, a second solenoid valve, in the tank,
closes the LPG pipe at the tank outlet.
The two solenoid valves are closed in the
case of an impact after the engine is swit-
ched off by the fuel cut-off system.
603_97_467 BRAVO GPL EN 24-11-2009 12:29 Pagina 6

9
FIAT BRAVO LPG
SOLENOID VALVES
AND SAFETY DEVICES
The system has a solenoid valve located
on the pressure reduction unit and a so-
lenoid valve fitted inside the multiple val-
ve assembly on the tank.
The main function of these solenoid val-
ves is to interrupt/allow the flow of LPG
to the supply circuit.
The solenoid valves are open when:
– a request to run on LPG has been made;
– the optimum engine running conditions
are satisfied (engine coolant temperature,
minimum revs level) for running on LPG;
– there is enough LPG in the tank for
operation.The multivalve assembly fitted on the tank
includes:
– a valve that automatically stops the sup-
ply of LPG when the maximum permitted
filling level is reached (80% of the total
tank capacity);
– a flow limiter which, if a pipe is broken,
prevents the complete and sudden escape
of LPG;
– a one-way valve, located on the gas re-
turn pipe in the tank, which prevents LPG
reflux;
– a safety solenoid valve on the LPG sup-
ply which, either permits or prevents the
escape of gas to the pressure reduction
unit; – a manual tap, upstream of the solenoid
valve, that separates the tank from the
LPG system to allow maintenance opera-
tions;
– a fuse pad which, in the event of
overheating (temperature above 120 °C),
totally eliminates the danger of excess
pressure by making the LPG in the tank
flow out as quickly as possible in a con-
trolled manner;
– an analogue gauge showing the level of
LPG in the tank.
603_97_467 BRAVO GPL EN 24-11-2009 12:29 Pagina 9

10
FIAT BRAVO LPG
REGULATION UNIT
The regulation unit fig. 4includes:
– cut out solenoid valve with gauze filter;
– pressure regulator.
The cut out solenoid valveopens or
closes together with the solenoid valve on
the tank. It closes all flows of LPG when
the engine is not running on gas.
It also acts as a safety device that prevents
the flow of LPG if the fuel cut-off system
intervenes.
fig. 4F0Q0810m
The pressure regulatorallows the
change of the LPG from a liquid state to
a gaseous state through an expansion
chamber and maintains the pressure re-
quired for the operation of the system at
a preset value.
PIPING
The piping for the LPG in a liquid state
(from the filler to the tank and from the
tank to the pressure regulator) is made
from copper and coated in plastic.
The piping for the LPG in a gaseous state
(from the pressure regulator to the LPG
injectors) is made from rubber.
603_97_467 BRAVO GPL EN 24-11-2009 12:29 Pagina 10

12
FIAT BRAVO LPG
ELECTRONIC CONTROL
UNIT
The car has a dedicated electronic control
unit for the LPG system fig. 7; it uses the
incoming signals from the petrol injection
control unit and converts them into signals
for the injection of the LPG.
The control unit for the injectors has the
same strategy as the petrol control unit
(timed, sequential, multipoint).
LPG/PETROL SWITCH
The LPG/petrol switch fig. 8is located on
the central console near the handbrake
and includes:
A. LPG/petrol operating mode request
button;
B. LPG gauge: 5 LEDs (4 green and 1 red
to indicate the reserve). The red LED only
comes on when the last green LED goes
out.
The red LED indicates the reserve status;
ON. LPG operating mode indicator: green
LED on continuously, located under but-
tonA;
OFF. petrol operating mode indicator:
amber LED on continuously, located abo-
ve buttonA.
IMPORTANT When the ignition key is
turned to the MAR – ONposition, the
LEDs on the switch come on as follows:
– with petrol operation mode selec-
ted: amber OFFLED on;
– with LPG operation mode selected:
all LEDs on the switch are on continuou-
sly and the green ONLED flashes.
To select the type of fuel system desired
(LPG or petrol), press button A-fig. 8.
To change the type of fuel system, it is ad-
visable to operate the button with the car
stationary and the engine running or, whil-st driving, after having released the acce-
lerator.
If switching takes place during acceleration
or pick-up, there may be a brief flat spot
(drop in power).
Do not switch between the two operating
modes when starting the engine.
fig. 8F0Q0805m
fig. 7F0Q0813m
603_97_467 BRAVO GPL EN 24-11-2009 12:29 Pagina 12

13
FIAT BRAVO LPG
SWITCHING FROM PETROL
TO LPG
With petrol fuel supply: press the button
A-fig 8, the switch to LPG will take pla-
ce automatically at the first significant ac-
celeration.
During switching:
– the LPG gauge Bcomes on;
– the amber OFFLED goes out (petrol
operating mode);
– the green ONLED comes on, switching
from intermittent to on constantly (LPG
operating mode);
There are 5 LEDs B(1 red and 4 green)
on the left of the switch that display the
amount of LPG in the tank.
When the amount of LPG remaining goes
below about 1/5 of the capacity of the
tank, only the red (reserve) LED remains
on to signal the need for refuelling.
IMPORTANT When starting up at outsi-
de temperatures of below −10
°C, the
switching times from petrol to LPG in-
crease to allow the pressure regulator to
heat up.Running out of LPG
If the LPG runs out, switching to petrol
takes place automatically with:
– the amber OFFLED on constantly;
– the green ONLED flashing;
– an acoustic signal from the switch (high
frequency).
IMPORTANT The acoustic signal warns
the driver that the engine is running on pe-
trol; therefore, they must refuel with LPG
before it runs out.
THE acoustic signal can be deactivated by
pressing the switching button A.
Do not switch between the
two operating modes whilst
starting the engine.
Switching from LPG to petrol
With LPG supply: press the buttonA-fig.8.
During switching:
– the LPG gauge Bgoes out;
– the amber OFF LED comes on and
stays on (petrol operating mode);
– the green ONLED goes out (LPG ope-
rating mode).
603_97_467 BRAVO GPL EN 24-11-2009 12:29 Pagina 13