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2004 Fiat Stilo Service and Repair Manual

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🏷️ Basic Information Identification Make: Fiat Model: Stilo Year: 2004 Codes Engine Codes Likely Covered: 182B9000 (1.2L 16V), 192A4000 (1.4L 16V), 192B2000 (1.6L 16V), 192A1000 (1.9L JTD 8V), 192B1000 (1.9L JTD 16V), 32302 (2.4L 20V) Chassis Codes Likely Covered: 192 (Stilo Hatchback) 👋 Introduction Market Position Offering Value: Provides dealership-level diagnostic and repair information for Fiat Stilo owners and independent repair shops, enabling DIY repairs and reducing reliance on expensive dealership services. Competitive Analysis Advantage Over Generic Manuals: Vehicle-specific, factory-level detail, including all necessary diagrams, schematics, and specifications, unlike generic repair guides. Key Features Convenience: Single, easy-to-use PDF manual with the ability to print only needed pages, searchable content, and portability. User Experience: Enhances user knowledge and confidence in repairing their vehicle, turning repair into a potentially enjoyable activity. 📋 Manual Details Coverage Areas Primary Coverage: All Fiat Stilo models and all repairs A-Z Target Audience: Dealership technicians, DIY enthusiasts Page Count Estimated Page Count: Comprehensive (Exact count not specified, but implied to be extensive) Manual Type Type: Factory Service and Repair Manual Language Language: English Format File Format: PDF Delivery Method: Digital Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, emission control, cooling system, lubrication, ignition, starting & charging systems, manual transmission, automatic transmission, clutch, propeller shaft, drive shafts, differential, axle suspension Chassis: Brake control, parking brake, steering column, power steering, wheels, tires Body And Interior: Air conditioning, supplemental restraint system (SRS), seat belts, engine hood, doors, exterior/interior trim, windshield/glass/mirrors, instrument panel, seats, door locks Electrical And Electronics: Wiring schematics, electrical system, multiplex/CAN communication, engine immobilizer, cruise control, wiper & washer system, horn, meter/audio/visual systems Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Diagnosis: Troubleshooting guides, diagnostic procedures, fault code interpretation (implied) Repair: Step-by-step repair instructions for all covered systems and components Diagnostics: Detailed diagnostic strategies and procedures for electrical and mechanical systems. Engine Rebuild: Detailed procedures for engine disassembly, inspection, repair, and reassembly, including torque specifications and clearances for internal components. Suspension And Steering Repair: Comprehensive guide for replacing and servicing suspension components (shock absorbers, springs, bushings, ball joints) and steering system parts (tie rods, power steering pump). Brake System Overhaul: Detailed instructions for brake pad and disc replacement, caliper service, brake line repair, and bleeding the brake system. Electrical System Diagnosis: Extensive wiring diagrams for all circuits, troubleshooting guides for electrical faults, and procedures for diagnosing and repairing modules, sensors, and actuators. Technical Depth Depth: Vehicle-specific, factory-level detail with step-by-step instructions, diagrams, illustrations, and wiring schematics. Scope: Complete repair and maintenance information, not generic. Covers everything needed to maintain, service, diagnose, and repair the vehicle. 📊 Manual Specifications File Format Compatibility: Windows (Vista 32/64, XP, ME, 98, NT, 2000) and Mac compatible Software Requirements: Adobe PDF Reader, Winzip (free online) Print Quality Printability: All pages are printable, allows for enlarged copies of images Binding Type Digital Format Benefit: No physical binding, easy to select and print specific pages, avoids greasy/torn pages. Paper Type Digital Format Benefit: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Options For 2004 Stilo: 1.2L 16V (FIRE), 1.4L 16V (FIRE), 1.6L 16V (FIRE), 1.9L JTD (8V & 16V Diesel), 2.4L 20V (M-Jet) Performance 1.2L 16V Performance: Approx. 80 HP (59 kW), 114 Nm torque 1.4L 16V Performance: Approx. 95 HP (70 kW), 128 Nm torque 1.6L 16V Performance: Approx. 103 HP (76 kW), 145 Nm torque 1.9L Jtd 8V Performance: Approx. 115 HP (85 kW), 255 Nm torque 1.9L Jtd 16V Performance: Approx. 140 HP (103 kW), 305 Nm torque 2.4L 20V Performance: Approx. 170 HP (125 kW), 221 Nm torque Fuel System Petrol Engines: Multi-point fuel injection (MPI) Diesel Engines: Common Rail Direct Injection (JTD) 🔧 Transmission Standard Gearbox Options: 5-speed manual, 6-speed manual (for some 1.9 JTD 16V models) Optional Automatic Transmission: Selespeed (Automated manual gearbox) available on some petrol engines (e.g., 2.4L) Features Manual Transmission Details: Front-wheel drive (FWD) with various gear ratios depending on engine Automatic Transmission Details: Selespeed offers manual selection via steering wheel paddles or gear lever. 📐 Dimensions Exterior Body Styles: 5-door hatchback Length Approx: 4280 mm (168.5 in) Width Approx: 1755 mm (69.1 in) Height Approx: 1570 mm (61.8 in) Weights Curb Weight Range Approx: 1300 - 1500 kg (2866 - 3307 lbs) depending on engine and configuration 🛡️ Safety Features Ratings Euro Ncap Rating: 4 stars (for 2004 models) Active Features Braking System: ABS with EBD (Electronic Brakeforce Distribution), Brake Assist (BA) Traction Control: ASR (Anti-Slip Regulation) / Traction Control System available on higher trims or as an option Passive Features Airbags: Driver, passenger, side airbags, and window airbags as standard or optional depending on trim level and market. Seat Belts: Pre-tensioned seat belts with force limiters, ISOFIX child seat anchorages. 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player, optional multi-function display, steering wheel audio controls...
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Tipo: Car
Fabricante:
Sku: 165442
Coleções: ALL Fiat

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2004 Fiat Stilo Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Fiat
Model:
Stilo
Year:
2004
Codes
Engine Codes Likely Covered:
182B9000 (1.2L 16V), 192A4000 (1.4L 16V), 192B2000 (1.6L 16V), 192A1000 (1.9L JTD 8V), 192B1000 (1.9L JTD 16V), 32302 (2.4L 20V)
Chassis Codes Likely Covered:
192 (Stilo Hatchback)
👋 Introduction
Market Position
Offering Value:
Provides dealership-level diagnostic and repair information for Fiat Stilo owners and independent repair shops, enabling DIY repairs and reducing reliance on expensive dealership services.
Competitive Analysis
Advantage Over Generic Manuals:
Vehicle-specific, factory-level detail, including all necessary diagrams, schematics, and specifications, unlike generic repair guides.
Key Features
Convenience:
Single, easy-to-use PDF manual with the ability to print only needed pages, searchable content, and portability.
User Experience:
Enhances user knowledge and confidence in repairing their vehicle, turning repair into a potentially enjoyable activity.
📋 Manual Details
Coverage Areas
Primary Coverage:
All Fiat Stilo models and all repairs A-Z
Target Audience:
Dealership technicians, DIY enthusiasts
Page Count
Estimated Page Count:
Comprehensive (Exact count not specified, but implied to be extensive)
Manual Type
Type:
Factory Service and Repair Manual
Language
Language:
English
Format
File Format:
PDF
Delivery Method:
Digital Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, emission control, cooling system, lubrication, ignition, starting & charging systems, manual transmission, automatic transmission, clutch, propeller shaft, drive shafts, differential, axle suspension
Chassis:
Brake control, parking brake, steering column, power steering, wheels, tires
Body And Interior:
Air conditioning, supplemental restraint system (SRS), seat belts, engine hood, doors, exterior/interior trim, windshield/glass/mirrors, instrument panel, seats, door locks
Electrical And Electronics:
Wiring schematics, electrical system, multiplex/CAN communication, engine immobilizer, cruise control, wiper & washer system, horn, meter/audio/visual systems
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Diagnosis:
Troubleshooting guides, diagnostic procedures, fault code interpretation (implied)
Repair:
Step-by-step repair instructions for all covered systems and components
Diagnostics:
Detailed diagnostic strategies and procedures for electrical and mechanical systems.
Engine Rebuild:
Detailed procedures for engine disassembly, inspection, repair, and reassembly, including torque specifications and clearances for internal components.
Suspension And Steering Repair:
Comprehensive guide for replacing and servicing suspension components (shock absorbers, springs, bushings, ball joints) and steering system parts (tie rods, power steering pump).
Brake System Overhaul:
Detailed instructions for brake pad and disc replacement, caliper service, brake line repair, and bleeding the brake system.
Electrical System Diagnosis:
Extensive wiring diagrams for all circuits, troubleshooting guides for electrical faults, and procedures for diagnosing and repairing modules, sensors, and actuators.
Technical Depth
Depth:
Vehicle-specific, factory-level detail with step-by-step instructions, diagrams, illustrations, and wiring schematics.
Scope:
Complete repair and maintenance information, not generic. Covers everything needed to maintain, service, diagnose, and repair the vehicle.
📊 Manual Specifications
File Format
Compatibility:
Windows (Vista 32/64, XP, ME, 98, NT, 2000) and Mac compatible
Software Requirements:
Adobe PDF Reader, Winzip (free online)
Print Quality
Printability:
All pages are printable, allows for enlarged copies of images
Binding Type
Digital Format Benefit:
No physical binding, easy to select and print specific pages, avoids greasy/torn pages.
Paper Type
Digital Format Benefit:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Options For 2004 Stilo:
1.2L 16V (FIRE), 1.4L 16V (FIRE), 1.6L 16V (FIRE), 1.9L JTD (8V & 16V Diesel), 2.4L 20V (M-Jet)
Performance
1.2L 16V Performance:
Approx. 80 HP (59 kW), 114 Nm torque
1.4L 16V Performance:
Approx. 95 HP (70 kW), 128 Nm torque
1.6L 16V Performance:
Approx. 103 HP (76 kW), 145 Nm torque
1.9L Jtd 8V Performance:
Approx. 115 HP (85 kW), 255 Nm torque
1.9L Jtd 16V Performance:
Approx. 140 HP (103 kW), 305 Nm torque
2.4L 20V Performance:
Approx. 170 HP (125 kW), 221 Nm torque
Fuel System
Petrol Engines:
Multi-point fuel injection (MPI)
Diesel Engines:
Common Rail Direct Injection (JTD)
🔧 Transmission
Standard
Gearbox Options:
5-speed manual, 6-speed manual (for some 1.9 JTD 16V models)
Optional
Automatic Transmission:
Selespeed (Automated manual gearbox) available on some petrol engines (e.g., 2.4L)
Features
Manual Transmission Details:
Front-wheel drive (FWD) with various gear ratios depending on engine
Automatic Transmission Details:
Selespeed offers manual selection via steering wheel paddles or gear lever.
📐 Dimensions
Exterior
Body Styles:
5-door hatchback
Length Approx:
4280 mm (168.5 in)
Width Approx:
1755 mm (69.1 in)
Height Approx:
1570 mm (61.8 in)
Weights
Curb Weight Range Approx:
1300 - 1500 kg (2866 - 3307 lbs) depending on engine and configuration
🛡️ Safety Features
Ratings
Euro Ncap Rating:
4 stars (for 2004 models)
Active Features
Braking System:
ABS with EBD (Electronic Brakeforce Distribution), Brake Assist (BA)
Traction Control:
ASR (Anti-Slip Regulation) / Traction Control System available on higher trims or as an option
Passive Features
Airbags:
Driver, passenger, side airbags, and window airbags as standard or optional depending on trim level and market.
Seat Belts:
Pre-tensioned seat belts with force limiters, ISOFIX child seat anchorages.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player, optional multi-function display, steering wheel audio controls on some trims.
Driver Assistance
Cruise Control:
Available as an option on certain models and trim levels.
Connectivity
Multiplex Can Communication:
The manual covers the multiplex and CAN communication systems, crucial for diagnosing electronic module interactions.
Comfort Features
Climate Control:
Manual air conditioning and optional automatic climate control.
🔧 Maintenance
Service Intervals
Oil Change Interval Petrol:
Typically 15,000 km (9,300 miles) or 1 year, whichever comes first (refer to manual for specific engine and oil type).
Oil Change Interval Diesel
Oil Change Interval Diesel:
Typically 20,000 km (12,400 miles) or 1 year, whichever comes first (for JTD engines).
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity grades (e.g., Selenia K Pure Energy 5W-40 for petrol, Selenia WR Diesel 5W-40 for JTD) and API/ACEA specifications (e.g., ACEA A3/B4, ACEA C3 for diesel with DPF).
Coolant Type:
Paraflu UP (or equivalent ethylene glycol-based coolant with organic additives - OAT), typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4
Transmission Fluid Manual:
Refer to manual for specific SAE grade (e.g., SAE 75W-85 GL-4)
Transmission Fluid Automatic Selespeed:
Specific ATF (Automatic Transmission Fluid) and hydraulic fluid for the Selespeed system (refer to manual for part numbers and specifications).
Known Issues
Common Issues Reported:
Electrical gremlins (e.g., dashboard faults, window regulators), suspension components (e.g., ball joints, wishbones), clutch slave cylinder (especially on Selespeed), exhaust manifold cracks (on some diesel engines), minor bodywork corrosion.
Maintenance Tips:
Regularly check and top up all fluid levels, inspect suspension and braking components for wear, address electrical faults promptly to prevent escalation.
📚 Vehicle History
Brand Heritage
Fiat History:
Fiat, an Italian automotive manufacturer founded in 1899, has a long history of producing a wide range of vehicles, from city cars to commercial vehicles, known for innovation and style.
Model Evolution
Stilo Introduction:
The Fiat Stilo was introduced in 2001 as a replacement for the Bravo/Brava range, aiming to compete in the C-segment (compact family car) market with a focus on practicality, space, and comfort. The 2004 model represents an update or continuation within its production cycle.
Production
Production Years:
2001-2008
Manufacturing Locations:
Primary production in Fiat's plant in Montecchio Maggiore, Italy, and also at the Magna Steyr plant in Austria.
🏆 Awards & Recognition
Recognitions
Safety Award:
Achieved a 4-star Euro NCAP safety rating, indicating good occupant protection.
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