2008 FIAT ULYSEE Service and Repair Manual
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NUOVA BRAVO 1.4 16v POWER UNIT RIGID SUPPORT - GEARBOX
SIDE - R.R. 1008A42
Removing ( Refitting )
Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.
Op. 5530B10 BATTERY - R+R
Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R
Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) -
REPLACE
1. Undo the bolt fixing the air pipe to the rigid support.
2. Undo the bolts (2a) and remove the rigid support (2b).
Refitting ( Removing )
- Place the rigid mounting in its housing and tighten the bolts to the
recommended torque.
- Tighten the bolt fixing the air pipe to the rigid support.
Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) -
REPLACE
Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R
Op. 5530B10 BATTERY - R+R
Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.
Component Fastening dia
Value
(daNm)
Validity
Gearbox side
power unit
rigid support
Bolt (to be
replaced)
M10 5.0 ÷ 6.0
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NUOVA BRAVO 1.9 JTD 8v SINGLE CYLINDER HEAD OR (ONE) LEFT
OR RIGHT, REMOVED - GRINDING 1016E38
- Check that the planarity of the lower cylinder head plane corresponds
to the recommended values.
1. If the lower surface flatness of the lower cylinder head is not within
specified values, grind from the nominal head height and then fit a new
gasket with the number of notches determined as described below.
a - The head may be levelled to 0.1 m if starting from a gasket with no
references and using a new gasket with one reference.
b - The head may be levelled to 0.2 m if starting from a gasket with no
references and using a new gasket with two references.
c - The head may be levelled to 0.1 m if starting from a gasket with one
reference and using a new gasket with two references.
Measurement Value Validity
Engine cylinder head
lower surface flatness
(mm)
< 0.1
When within limit conditions (head gasket with 2 notches before
levelling), the lower cylinder head surface cannot be levelled.
Measurement Value Validity
Cylinder head nominal
height (mm)
107 +/- 0.05 1.9 JTD 16v
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NUOVA BRAVO 1.4 16v TOOTHED TIMING BELT - R + R FOR TIMING
ADJUSTMENT OR REPLACEMENT 1032B10
Removing ( Refitting )
- Position the vehicle on a lift.
Op. 4450B04 RIGHT FRONT WHEEL - R.R
Op. 1016A10 SOUND-PROOFING COVER - R.R
Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.
Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT
WHEEL ARCH - R.R.
Op. 1092G10 SINGLE ENGINE BELT - R.R
Op. 1092A10 CRANKSHAFT PULLEY - R + R
Op. 1092G14 ENGINE COMPONENT SINGLE BELT MOVING
TENSIONER - R + R
Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER
- R + R
Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R
1. Remove the front plug (1a) and fit the camshaft timing tool (1b) to
the camshaft housing.
Check that the tool is correctly inserted in the housing in the
exhaust side camshaft, rotating the crankshaft until the pin for the
tool can be heard engaging correctly in the housing in the
camshaft.
Tool Description Function Validity
1870896900 Templates Engine tuning 1.9 JTD 16v
1. Undo the bolt fixing the crankcase front cover shown in the diagram.
2. Fit the tool (2a) provisionally and fasten it using the calibrated screw
(2b) and the nut.
Tool Description Function Validity
1860905000 Template Engine tuning 1.9 JTD
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Tool Description Function Validity
1860905010 Calibrated screw Engine tuning 1.9 JTD
- Remove the timing tools positioned previously.
1. Loosen the nut retaining the timing belt moving tensioner.
2. Release and remove the toothed timing drive belt.
Refitting ( Removing )
1. Loosen the bolt securing the exhaust side timing belt toothed driven
pulley.
- Fit the timing drive belt on the drive gear, checking that the belt teeth
are correctly inserted in the gear grooves.
- Position the template for measuring TDC and fasten it using the
calibrated screw.
Tool Description Function Validity
1860905000 Template Engine tuning 1.9 JTD
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1. Fully fit the toothed timing drive belt.
2. Use a screwdriver on the tensioner (2a) tab for leverage until the
reference (2b) is in the maximum tension position, then lock the nut (2c)
fixing the moving tensioner in this position.
- Remove the timing tools.
3. Loosen the nut fixing hte moving tensioner and align the moving
reference (3a) with the opening (3b), i.e. adjust to nominal tension
position and then tighten nut (3c) securing the belt tensioner to torque.
4. Tighten the bolt fixing the exhaust side camshaft toothed driven pulley
to the recommended torque.
Tool Description Function Validity
1860905010 Calibrated screw Engine tuning 1.9 JTD
Component Fastening dia
Value
(daNm)
Validity
Timing
system
moving
tensioner
Nut M8 2.3 ÷ 2.8 1.9 JTD
Component Fastening dia
Value
(daNm)
Validity
Driven
timing
toothed
pulley
Bolt M12
2.8 ÷ 3.1 +
40°
1.9 JTD
- Rotate the crankshaft through two revolutions.
- Recheck the timing by refitting the timing tools.
- Check the moving timing belt tensioner references are aligned.
- Tighten the bolt fixing the previously removed crankcase front cover.
Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R
Only fit the exhaust side camshaft template because the intake side
template seat is not accessible.
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Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER
- R + R
Op. 1092G14 ENGINE COMPONENT SINGLE BELT MOVING
TENSIONER - R + R
Op. 1092A10 CRANKSHAFT PULLEY - R + R
Op. 1092G10 SINGLE ENGINE BELT - R.R
Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT
WHEEL ARCH - R.R.
Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.
Op. 1016A10 SOUND-PROOFING COVER - R.R
Op. 4450B04 RIGHT FRONT WHEEL - R.R
- Remove the vehicle from the lift.
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NUOVA BRAVO 1.4 16v LEFT FOG LAMP 5540D12
Removing ( Refitting )
Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.
Op. 5540D15 FOG LIGHT TRIM (ONE), LEFT OR RIGHT - R.R.
1. Detach the electrical connection.
2. Undo the bolts fixing the fog light.
3. Remove the fog light at the front of the vehicle.
Description Connector
1 LEFT FOG LIGHT
See F015 LEFT FOG
LAMP
Refitting ( Removing )
- Check that the fog light is not damaged.
- Position the fog light.
- Tighten the bolts.
- Attach the electrical connection.
Op. 5540D15 FOG LIGHT TRIM (ONE), LEFT OR RIGHT - R.R.
Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.
Op. 5540D38 FOG LIGHT BEAM - ADJUST
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NUOVA BRAVO 1.9 JTD 8v FRONT 12 (Right hand drive, Right hand
drive, Right hand drive)
Valid for versions with:Right hand drive
Full - size
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NUOVA BRAVO 1.4 16v ENGINE NOT FEELING ACCELERATOR PEDAL
PRESSURE D009
The customer complains that: The engine does not react when the accelerator pedal is operated
Test results
0 PRELIMINARY CHECKS All OK Problems encountered Operation
Check that the engine
oil level is correct
Op. 0010T11 ENGINE
OIL - CHECK LEVEL
AND TOP UP, IF
NECESSARY
Check that the air
intake/vacuum circuit
is working properly by
carrying out the
See Test 1048OA AIR
INTAKE/VACUUM
CIRCUIT CHECK
Check the condition of
the fuel supply circuit
and make sure that it
is working properly by
carrying out the
See Test 1040OA
Fuel supply circuit
check
Check the operation of
the low pressure
supply circuit by
carrying out the
See Test 1060OB
Low pressure fuel
supply circuit check
Move on to Step 1 Oil level incorrect
Restore the correct
engine oil level
Op. 0010T11 ENGINE
OIL - CHECK LEVEL
AND TOP UP, IF
NECESSARY
1
MODE PARAMETERS
CHECK
All OK Problems encountered Operation
Select the following
control unit at the
diagnostic equipment:
EDC16C39 Diesel
electronic injection
control unit.
Check the value of the
following parameters:
· Battery voltage
See Test 5530BB
BATTERY VOLTAGE
CHECK
· Accelerator pedal
· Accelerator position 1
AD/C
· Accelerator position 2
AD/C
See Test 1068AC
ACCELERATOR PEDAL
CHECKS
End of diagnosis
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· Target Diesel
pressure
· Measured Diesel
pressure
See Test 1060GH
DIESEL PRESSURE
CHECK
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- Maintenance
- Engine
- Control System
- Mechanical
- Fuel Service Specifications
- Emission Control
- Intake Exhaust Cooling
- Lube
- Ignition Starting Charging
- Auto Transmission Clutch
- Manual Transmission
- Transfer Propeller Shaft
- Drive Shaft
- Differential
- Axle Suspension
- Tire & Wheel
- Brake Control
- Brake
- Parking Brake
- Steering Column
- Power Steering
- Air Condition
- Suppl Restraint System
- Seat Belt
- Engine Immobilizer
- Cruise Control
- Wiper & Washer
- Door Lock
- Meter Audio/Visual
- Horn
- Windshield/Glass Mirror
- Instrument Panel
- Seat
- Engine Hood/ Door
- Exterior & Interior
- Electrical
- Multiplex/ Can Communication
- And much more...
These service repair manuals are compatible with all versions of Windows and Mac, and they are printable for your convenience. Language: English. Requirements: Adobe Reader and Win.
