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2001-2007 Fiat Stilo Workshop Service Repair Manual (EN-DE-ES-FR-IT-NL-PT)

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Basic Information Identification Make: Fiat Model: Stilo Production Years Covered: 2001, 2002, 2003, 2004, 2005, 2006, 2007 Engine Variants Covered: 1.2 16V, 1.4 16V, 1.6 16V, 1.8 16V, 1.9 JTD 8V, 1.9 JTD 16V, 2.4 20V Introduction Market Position Target Audience: DIY mechanics, auto enthusiasts, and professional workshops servicing the Fiat Stilo. Key Features Value Proposition: Provides comprehensive, step-by-step instructions and technical data to empower owners to perform repairs and maintenance independently, saving time and money. Competitive Analysis Manual Advantage: Offers multi-language support and detailed coverage for all Stilo variants, making it a versatile resource for a broad user base. Manual Details Coverage Areas Languages: English (EN), German (DE), Spanish (ES), French (FR), Italian (IT), Dutch (NL), Portuguese (PT) Page Count Estimated Page Count: Likely over 1000 pages (typical for comprehensive workshop manuals) Manual Type Type: Workshop Service Repair Manual Format Digital Format: ISO (typically indicates an image file that can be mounted or extracted, containing the manual content) Accessibility Viewing Compatibility: Any computer with Windows operating system Features Zoom And Print Capability: Yes Manual Coverage Systems Covered Powertrain: Engine Overhaul and Rebuilding, Engine Performance, Timing Belt Replacement, Firing Orders, Serpentine Belt Routings with Diagrams, Timing Belt Service Procedures Chassis: Brakes, Front End and Alignment Procedures and Specifications, Suspension, U-Joint and CV-Joint Service Procedures Transmission: Transmission Removal and Installation, Transmission In-Car Servicing Electrical And Electronics: Wiring Diagrams, Computer Diagnostic Trouble Tree Charts, Computer Diagnostic Codes Comfort And Convenience: Sunroof HVAC: Air Conditioning Service and Capacities Procedures Included Diagnostics: Troubleshooting and Diagnostics, Trouble Codes Repair And Rebuild: All repair procedures covered A-Z, Detailed step-by-step instructions Technical Depth Depth: Comprehensive: From basic maintenance to complete engine and transmission overhaul, including detailed technical data and exploded diagrams. Documentation Quality Illustrations: Detailed illustrations, exploded diagrams, drawings, and photos Completeness Content Guarantee: 100 percent complete and intact, no missing/corrupt pages/sections Manual Specifications File Format Format Detail: ISO Image File (Requires software like Daemon Tools or direct mounting in newer Windows versions to access content) Print Quality Printability: Printable (individual pages or sections can be printed) Binding Type Physical Binding: Not Applicable (Digital Format) Paper Type Physical Paper: Not Applicable (Digital Format) System Requirements Operating System: All Versions of Windows Engine Specifications Primary Engine 1 2 16V Engine Code Example: 182B2.000 Displacement: 1242 cc Bore X Stroke: 70.8 mm x 78.9 mm Power Output: Approx. 80 PS (59 kW; 79 hp) at 5800 rpm Torque Output: Approx. 114 Nm (84 lb-ft) at 4600 rpm Primary Engine 1 4 16V Engine Code Example: 182B6.000 Displacement: 1370 cc Power Output: Approx. 95 PS (70 kW; 94 hp) at 6300 rpm Torque Output: Approx. 128 Nm (94 lb-ft) at 4300 rpm Primary Engine 1 6 16V Engine Code Example: 182B3.000 Displacement: 1596 cc Power Output: Approx. 103 PS (76 kW; 102 hp) at 6200 rpm Torque Output: Approx. 145 Nm (107 lb-ft) at 4000 rpm Primary Engine 1 8 16V Engine Code Example: 182B7.000 Displacement: 1747 cc Power Output: Approx. 133 PS (98 kW; 131 hp) at 6300 rpm Torque Output: Approx. 164 Nm (121 lb-ft) at 4300 rpm Primary Engine 1 9 Jtd 8V Engine Code Example: 182B9.000 Displacement: 1910 cc Power Output: Approx. 100 PS (74 kW; 99 hp) at 4000 rpm Torque Output: Approx. 200 Nm (148 lb-ft) at 1500 rpm Primary Engine 1 9 Jtd 16V Engine Code Example: 192A5.000 Displacement: 1910 cc Power Output: Approx. 115 PS (85 kW; 113 hp) at 4000 rpm Torque Output: Approx. 275 Nm (203 lb-ft) at 1750 rpm Primary Engine 2 4 20V Engine Code Example: 182A1.000 Displacement: 2446 cc Power Output: Approx. 170 PS (125 kW; 168 hp) at 6000 rpm Torque Output: Approx. 220 Nm (162 lb-ft) at 3500 rpm Fuel System Fuel Delivery: Multi-point fuel injection (MPI) for petrol engines, Common Rail Direct Injection (CRDI) for JTD diesel engines. Ignition System Ignition Type: Electronic ignition (coil-on-plug for some variants) Cooling System Type: Liquid-cooled Transmission Standard Transmission Gearbox Options: 5-speed manual, 6-speed manual (for some variants), Selectronic (automated manual transmission - AMT) Optional Transmission Automatic Options: Selectronic (AMT) on certain models, no traditional torque converter automatic widely offered. Features Clutch Type: Hydraulically operated single dry plate clutch Dimensions Exterior Body Styles: 5-door hatchback, 3-door hatchback Length: Approx. 4287 mm (5-door) Width: Approx. 1755 mm Height: Approx. 1565 mm Weights Curb Weight Range: Approx. 1250 kg - 1450 kg (depending on engine and configuration) Gross Vehicle Weight Rating: Varies by engine and configuration, detailed in manual. Cargo Cargo Volume: Approx. 370 liters (rear seats up), expandable with seats folded. Safety Features Ratings Euro Ncap Rating: 3 Stars (initial testing for the 5-door version; safety standards and testing methods evolve) Active Features Braking System: Front: Ventilated discs; Rear: Solid discs. ABS with EBD is standard or optional depending on market and trim. Stability Control: Optional ESP (Electronic Stability...
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2001-2007 Fiat Stilo Workshop Service Repair Manual (EN-DE-ES-FR-IT-NL-PT)
Basic Information
Identification
Make: Fiat
Model: Stilo
Production Years Covered: 2001, 2002, 2003, 2004, 2005, 2006, 2007
Engine Variants Covered: 1.2 16V, 1.4 16V, 1.6 16V, 1.8 16V, 1.9 JTD 8V, 1.9 JTD 16V, 2.4 20V
Introduction
Market Position
Target Audience: DIY mechanics, auto enthusiasts, and professional workshops servicing the Fiat Stilo.
Key Features
Value Proposition: Provides comprehensive, step-by-step instructions and technical data to empower owners to perform repairs and maintenance independently, saving time and money.
Competitive Analysis
Manual Advantage: Offers multi-language support and detailed coverage for all Stilo variants, making it a versatile resource for a broad user base.
Manual Details
Coverage Areas
Languages: English (EN), German (DE), Spanish (ES), French (FR), Italian (IT), Dutch (NL), Portuguese (PT)
Page Count
Estimated Page Count: Likely over 1000 pages (typical for comprehensive workshop manuals)
Manual Type
Type: Workshop Service Repair Manual
Format
Digital Format: ISO (typically indicates an image file that can be mounted or extracted, containing the manual content)
Accessibility
Viewing Compatibility: Any computer with Windows operating system
Features
Zoom And Print Capability: Yes
Manual Coverage
Systems Covered
Powertrain: Engine Overhaul and Rebuilding, Engine Performance, Timing Belt Replacement, Firing Orders, Serpentine Belt Routings with Diagrams, Timing Belt Service Procedures
Chassis: Brakes, Front End and Alignment Procedures and Specifications, Suspension, U-Joint and CV-Joint Service Procedures
Transmission: Transmission Removal and Installation, Transmission In-Car Servicing
Electrical And Electronics: Wiring Diagrams, Computer Diagnostic Trouble Tree Charts, Computer Diagnostic Codes
Comfort And Convenience: Sunroof
HVAC: Air Conditioning Service and Capacities
Procedures Included
Diagnostics: Troubleshooting and Diagnostics, Trouble Codes
Repair And Rebuild: All repair procedures covered A-Z, Detailed step-by-step instructions
Technical Depth
Depth: Comprehensive: From basic maintenance to complete engine and transmission overhaul, including detailed technical data and exploded diagrams.
Documentation Quality
Illustrations: Detailed illustrations, exploded diagrams, drawings, and photos
Completeness
Content Guarantee: 100 percent complete and intact, no missing/corrupt pages/sections
Manual Specifications
File Format
Format Detail: ISO Image File (Requires software like Daemon Tools or direct mounting in newer Windows versions to access content)
Print Quality
Printability: Printable (individual pages or sections can be printed)
Binding Type
Physical Binding: Not Applicable (Digital Format)
Paper Type
Physical Paper: Not Applicable (Digital Format)
System Requirements
Operating System: All Versions of Windows
Engine Specifications
Primary Engine 1 2 16V
Engine Code Example: 182B2.000
Displacement: 1242 cc
Bore X Stroke: 70.8 mm x 78.9 mm
Power Output: Approx. 80 PS (59 kW; 79 hp) at 5800 rpm
Torque Output: Approx. 114 Nm (84 lb-ft) at 4600 rpm
Primary Engine 1 4 16V
Engine Code Example: 182B6.000
Displacement: 1370 cc
Power Output: Approx. 95 PS (70 kW; 94 hp) at 6300 rpm
Torque Output: Approx. 128 Nm (94 lb-ft) at 4300 rpm
Primary Engine 1 6 16V
Engine Code Example: 182B3.000
Displacement: 1596 cc
Power Output: Approx. 103 PS (76 kW; 102 hp) at 6200 rpm
Torque Output: Approx. 145 Nm (107 lb-ft) at 4000 rpm
Primary Engine 1 8 16V
Engine Code Example: 182B7.000
Displacement: 1747 cc
Power Output: Approx. 133 PS (98 kW; 131 hp) at 6300 rpm
Torque Output: Approx. 164 Nm (121 lb-ft) at 4300 rpm
Primary Engine 1 9 Jtd 8V
Engine Code Example: 182B9.000
Displacement: 1910 cc
Power Output: Approx. 100 PS (74 kW; 99 hp) at 4000 rpm
Torque Output: Approx. 200 Nm (148 lb-ft) at 1500 rpm
Primary Engine 1 9 Jtd 16V
Engine Code Example: 192A5.000
Displacement: 1910 cc
Power Output: Approx. 115 PS (85 kW; 113 hp) at 4000 rpm
Torque Output: Approx. 275 Nm (203 lb-ft) at 1750 rpm
Primary Engine 2 4 20V
Engine Code Example: 182A1.000
Displacement: 2446 cc
Power Output: Approx. 170 PS (125 kW; 168 hp) at 6000 rpm
Torque Output: Approx. 220 Nm (162 lb-ft) at 3500 rpm
Fuel System
Fuel Delivery: Multi-point fuel injection (MPI) for petrol engines, Common Rail Direct Injection (CRDI) for JTD diesel engines.
Ignition System
Ignition Type: Electronic ignition (coil-on-plug for some variants)
Cooling System
Type: Liquid-cooled
Transmission
Standard Transmission
Gearbox Options: 5-speed manual, 6-speed manual (for some variants), Selectronic (automated manual transmission - AMT)
Optional Transmission
Automatic Options: Selectronic (AMT) on certain models, no traditional torque converter automatic widely offered.
Features
Clutch Type: Hydraulically operated single dry plate clutch
Dimensions
Exterior
Body Styles: 5-door hatchback, 3-door hatchback
Length: Approx. 4287 mm (5-door)
Width: Approx. 1755 mm
Height: Approx. 1565 mm
Weights
Curb Weight Range: Approx. 1250 kg - 1450 kg (depending on engine and configuration)
Gross Vehicle Weight Rating: Varies by engine and configuration, detailed in manual.
Cargo
Cargo Volume: Approx. 370 liters (rear seats up), expandable with seats folded.
Safety Features
Ratings
Euro Ncap Rating: 3 Stars (initial testing for the 5-door version; safety standards and testing methods evolve)
Active Features
Braking System: Front: Ventilated discs; Rear: Solid discs. ABS with EBD is standard or optional depending on market and trim.
Stability Control: Optional ESP (Electronic Stability Program) on some higher-trim models.
Passive Features
Airbags: Front airbags for driver and passenger, optional side airbags and window airbags.
Seatbelts: 3-point seatbelts with pre-tensioners and load limiters for front seats, 3-point seatbelts for rear seats.
Technology Features
Infotainment
Audio System: Factory fitted radio/CD player with basic sound system. Higher trims might offer enhanced audio or an in-dash CD changer.
Navigation: Optional satellite navigation system ('Connect Nav Plus') was available on some models, often integrated into the dashboard.
Driver Assistance
Cruise Control: Available on higher trim levels and with specific engine options.
Connectivity
Auxiliary Input: Early models generally lack modern USB or Bluetooth connectivity; aftermarket solutions are common.
Maintenance
Service Intervals
Oil Change Interval: Typically 15,000 km (approx. 9,000 miles) or 12 months for petrol engines, 20,000 km (approx. 12,500 miles) or 12 months for diesel engines, whichever comes first. Specifics vary by oil type and driving conditions.
Timing Belt Replacement: Typically around 100,000 - 120,000 km (60,000 - 75,000 miles) or 5 years for most engines. Crucial to follow manual's recommendation due to potential for severe engine damage if it fails.
Fluid Specifications
Engine Oil Specification: Refer to manual for specific API/ACEA ratings and viscosity grades (e.g., 5W-40, 10W-40 for petrol; 5W-30, 5W-40 for diesel common rail). Fiat's own specifications like Selenia are often recommended.
Coolant Specification: Paraflu Up or equivalent with antifreeze and anti-corrosion properties, typically a 50/50 mix with deionized water.
Brake Fluid Specification: DOT 4
Transmission Fluid Specification: Manual: API GL-4, SAE 75W-85 or 75W-90. Automatic (Selectronic): Specific automatic transmission fluid (ATF) for automated manuals, consult manual.
Known Issues
Common Problems: Examples include: Suspension component wear (e.g., ball joints, bushings), electrical gremlins (e.g., issues with body computer modules, dashboard lights), EGR valve issues on diesel engines, gearbox synchromesh wear on manual transmissions, A/C system leaks, power steering pump issues.
Recommended Maintenance
Preventative Checks: Regular checks of fluid levels, tire pressures, brake pad wear, and visual inspection of suspension and exhaust components are essential for longevity.
Vehicle History
Brand Heritage
Manufacturer: Fiat Automobiles S.p.A., an Italian automotive manufacturer.
Model Evolution
Launch Year: 2001
Facelift: Received a minor facelift in 2004, introducing updated styling, interior trim, and features.
Production
Manufacturing Location: Primarily produced at Fiat's Mirafiori plant in Turin, Italy. Also produced in Poland and Brazil.
Discontinuation Year: Production ended around 2007 in most European markets, succeeded by the Fiat Bravo (second generation).
Awards & Recognition
Recognitions
European Car Of The Year: Shortlisted for European Car of the Year 2002.
Ratings
Owner Satisfaction Trends: While innovative for its time with features like 'My Car Manager' and advanced climate control options, owner satisfaction varied, often linked to specific electrical or mechanical issues depending on engine choice and production date.
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