| INTRODUCTION LANCIA pecenicel Date ENGINE CLUTCH GEARBOX DIFFERENTIAL PROPELLER SHAFT REAR DIFFERENTIAL | BRAKING SYSTEM STEERING a | susPENSION AND | WHEELS | AUXILIARY UNITS l ee a | Service | ELECTRICAL EQUIPMENT Manual | Le E | BODYWORK ea — >DELTA-PRISMA 4WD Preface This publication has been divided into sections headed by two figure numbers which appear in the parts mi- crofiches and in the repair time schedules. The section titled INTRODUTION and TECHNICAL DATA (00.) has a dual purpose of introducing the model and reinforcing the remaining part of the manual, It contains tables of technical data and information relating to the chapters in the remaining section of the manual. ‘The remaining sections (10. - 18. etc) include descriptions of the servicing operations. NOTE The operations involved in removing-refitting the power unit are illustrated in section 10. The procedure for overhauling the engine at the bench is described in a separate booklet which has its own print number. It should be inserted, according to the size of the engine, in the appropriate section, in either the “Overhauling petrol engines” or “Overhauling e@ Diesel engines” binder. This publication contains graphic representations and symbols in place of descriptions for mechanical com- ponents, operations and servicing techniques. The use of colour for a component or part of one serves to draw the opeartor's attention to the object to be measured or checked, Example: ‘Small end diameter Big end bearing housing Tighten to torque THIS PUBLICATION HAS BEEN PRODUCED IN A LOOSE LEAF FORMAT TO FACILITATE, THE OPERATION OF UPDATING THE MODEL. ANY SUBJECTS DEALT WITH IN THE SERVICE BULLETINS SHOULD BE INSERTED, FROM TIME TO TIME, UNDER THE APPROPRIATE SECTION. eo Copyright by Flat AutoForeword DELTA-PRISMA 4WD The DELTA HF 4WD is a 2 box saloon with a load car- rying structure; it has a 1995 cc 4 cylinder in line engine transversely mounted at the front which runs on super pe- ‘rol, has an electronic ignition/injection system, is super- charged by a turbocharger and develops a power output of 122 KW (165 bhp), Tt has permanently engaged four wheel drive Ferguson type viscous joints are fitted to the central differential. The rear differential is the Torsen self-locking type. THE PRISMA 4WD is a three box saloon with a load car- ying structure; it has a 4 cylinder in line 1995 cc engine transversely mounted at the front, runs on super petrol, is equipped with an electronic injection/ignition system and develops a power output of 84.5 KW (115 bhp). It has permanently engaged four wheel drive. Ferguson type viscous joints are fitted to the central diffe- rential. The rear differential has electro-pneumatic engage- ment for locking.DELTA-PRISMA 4WD Graphic representations and symbols Refit Connect vi oS Se a Prin Tolerance Difference in weight Remove Disconnect Operation Fitting Reassembly ay Tighten to torque Rolling torque Tighten to torque > Greater than << Smaller than j Maximum Minimum | Lubricate = - Grease of. aoe 4 Replacement @ Re NcA Ghee ue beast Temperature braking system BY O| ) * | be s SS Machined surface Temperature <0°C Finished surface Cold is Winter oe Interference Temperature >0°C Force fit Hot Summer Distance to be measured ‘Measurement - Check Thickness - Clearance ‘Windscreen wiper with electric washer pump Rearscreen wiper with electric washer pump @ & Exhaust i Engine Inlet ap Copyright by Fiat AutoDELTA-PRISMA 4WD Introduction and technical data INTRODUCTION ~ Car exterior features = Car interior features — Identification data - Location of identification data on vehicle ~ Dimensions Weights ~ Performance - Fuel consumption = Capacities ~ Characteristics of lubricants TECHNICAL DATA ENGINE, = Characteristics ~ Power curves — Cylinder blockjcrankease, crankshaft and associated components ~ Counter-balance shafts ~ Cylinder head and valve gear components - Lubrication = Cooling system - Fuel system - Supercharging CLUTCH GEARBOX AND DIFFERENTIAL, PROPELLER SHAFT REAR DIFFERENTIAL, BRAKING SYSTEM STEERING WHEELS FRONT SUSPENSION ELECTRICAL EQUIPMENT ~ Starting ~ Recharging = Electronic ignition/injection 00 page 34 35 36 37 38 39 42 44 Copyright by Fiat AutoDELTA-PRISMA 4WD Introduction Car exterior features e@ 00.0 3/4 front view of DELTA HF 4WD As an alternative air vents for cooling the front brakes are fitted in place of the driving lights @ 3/4 front view of PRISMA 4WD Copsright by Fiat Auto 1Introduction DELTA-PRISMA 4WD Car interior features 00.0 @ View of the dashboard on the PRISMA 4WD eDELTA-PRISMA 4WD Introduction Car interior features e 00.0 @ ‘View of the interior of the PRISMA 4WD Copyright by Fiat Auto 3Introduction Car interior features 00.0 Instrument panel on the DELTA HF 4WD 345 6789 10 1112 1314 1516 17 DELTA-PRISMA 4WD 1B | 22-23 24 1, Speedometer 2. Milometer 3. Left direction indicator signal 4, Main beam headlamps warning light 5. Dipped headlamps warning light 6. Lights warning lights 7. Fog lamps warning light 8. Starting go ahead signal 9. Rear fog lamps warning light Turbocharger pressure gauge . Heated rear windscreen warning light General warning light |. Handbrake warning light 14 15. 16. 17. 18. 19. 20. 21 22. 2 24. 25. 26. Brake pad wear warning light Hazard warning lights warning light Coolant overheating warning light Right direction indicator signal Rev counter Push button for zeroing trip meter Trip meter warning light (for specific markets) Volt meter Fuel reserve warning light Fuel gauge Coolant temperature gauge Overboost engaged warning light ® . Catalytic silencer maximum temperature @®DELTA-PRISMA 4WD Introduction Instrument panel on the PRISMA 4WD Car interior features 00.0 1. Speedometer 2. Milometer 3. Left direction indicator signal 4. Main beam headlamps warning light 5. Lights warning light 6. Dipped headlamps warning light 7. Rear fog lamps warning light 8. General warning light 9. Driving lights warning light @ 10. Engine oil pressure gauge 11. Heated rear windscreen warning light 12. Starting go ahead signal 13. Handbrake warning light oe 14. Spare warning light 15. Hazard warning lights warning light 16. Spare warning light 17. Right direction indicator signal 18. Rev counter 19. Push button for zeroing trip meter 20. Trip meter 21. Catalytic silencer maximum temperature warning light (for specific markets) 22. Volt meter 23. Fuel reserve warning light 24. Fuel gauge 25. Coolant temperature gauge 26. Spare warning light Copyright by Flat AuraIntroduction DELTA-PRISMA 4WD Car interior features 00.0 ‘Spare wheel housing on the DELTA HF 4WD_ Spare wheel housing on the PRISMA 4WD. NOTE. The spare wheel is smaller; in order to remove it from its housing undo the clip A and remove the cover B. This wheel should only be used for essential journeys to reach a garage where repairs can be carried out. Maximum speed 80 kph (50 mph) Engaging-releasing rear differential for the PRISMA 4wD Tn order to lock the rear differential press the lower section of switch D and LED E should come on. To release the differential press the upper section of switch D Diagram showing passenger compart- ment ventilation on the PRISMA 4WDIntroduction DELTA-PRISMA 4WD Dimensions 00.0 DELTA HF 4WD (9) Unladen vehicle Luggage compartment capacity with the rear seat_ backrest in its normal position: 200 litres (7.06 eu ft) Luggage compartment capacity with the rear seat folded down : 940 litres (33.19 cu ft) PRISMA 4WD ‘compartment capacity with rear seat backrest in upright position: 360 litres (12.71 cu ft). e@. compartment capacity with rear seat folded down to level of rear parcel shelf: 650 litres (22.95 cu ft).DELTA-PRISMA 4WD WEIGHTS (in kg) Introduction Weights 00.0 |e | 1190 1180 waige + 450 ahmam 1640 1630 | B I ; eee | 865 855 Kerb weight 718 715 @ om 1200Introduction DELTA-PRISMA 4WD Performance - Fuel consumption 00.0 ®@ | RS 65 35 | eae 105 90 Speed in kph BBe 155 130 @ = | es 208 184, | 28g 65 55 | ERS 58 42 Maximum climable gradient 37 23 wee * - - 8) ° ws i a Urban 10,8 (26.15) | 11 (25.68) EEC fuel consumption cyele (A) | figures ‘Constant (htres/100 km) (mpg) aac os | 50 Fee) 8 (36.21) § ‘Constant eed 10,2 (27.69) | 10 (28.24) 120 kph © “Average consumption ae b re 9,6 (29.42) 96 3 @DELTA-PRISMA 4WD Introduction 00.0 ‘on the PRISMA 4WD Arrangement of mechanical componentsIntroduction Capacities 00.0 DELTA-PRISMA 4WD ® Description [Quantity ‘a | (kg) BB ewcnom Taal ee Fc - Supermultigrade (GAE 15 Wi40) + Turbo Synthesis (SAE 15 W/40) capacity of cooling system T | - | 320 = B Partial capacity (periodic replacment) a= TUTELA C 80S TUTELA &= GIA as ea .. TUTELA W90/M DA = TUTELA aeb= TUT c= TUTELA W 90/M-DA d= K8s¢ TUTELA Dor i or I PRISMA 4wD. oS DELTA = 4wD * A Distilled water 2DELTA-PRISMA 4WD Introduction Characteristics of lubricants e 00.0 Name of Description a product International designation Usage “Temperature SAE 40 [OC = >35°C ys- SAE 30 | Low ash content detergent oil for petrol enignes Service API | Temperature Supers. SAE | SP Satshes standatd MILLGIS2. Eroesds: Busopeaa eS ae sionale SAE 20W | CCMC specifications oe carpw | Minimum temperature | SAE 10 W below — 15°C vs: Low ash content detergent oil for petrol engines. Service API Super- SAE 15 W/40 | “SE”. Satisfies standard MIL-L-46152. is European | Temperature ‘multigrade CCMC specifications | 7 1SC + >35C . ‘Synthetic based detergent oil for petrol engines VS Turbo Synthesis Service API “SE”. Satisfies standard MIL-L-#6132. Temperature SaEIs 2) Exceeds European CCMC specifications. = 19°C + >40°C SAE 40 aera ‘Temperature SAE 30 @ SAE | oto Des engiars eves APL“CD" TES He ee Satisfies standard MIL-L-2104 C. [Temperature SAE 20 W aS. Temperatare SAE 10W below — 15°C [YS Diesel Oil for Diesel engines. Service API “CD™ Temperature | ‘Supermaltigrade Satisfies standard MIL-L-2104 = 20°C = 40°C : Manual gearboxes TUTELA ZC 80S SAE SO/W oil. Satisfies standard MIL-L-2105 API GL4 ane eae | Non EP SAE 80 W/90 oil for manual gearboxes, containing | Gearboxes and non cue eee anti-wear additives. hypoid differentials ‘ 1+ normal and self-locking differentials. | Hypoid differentiais. | | rurea wooprpa — | EL SAP £0 6/90 cl for normal and self-locking differentials. |

) 04 | Difference in weight t5g | between pistons — | = | Piston-Cylinder bore | 0,050 = 0,070 Gudgeon pin ra 21,996 + 21,999 housing oF 22,002DELTA-PRISMA 4WD Engine: cylinder block/crankcase, crankshaft and associated components Technical data e 00.10 eer | eo 8. | DESCRIPTION { Values in mm ood 21,991 + 21,994 | 298 4 Fo} mmty ua 21,994 = 21,997 | ; tS as Gudgeon pin @ LANCIA > 02 143 GE Gudgeon pin-Housing 0,002. + 0,008, | e 1 1,535 + 1,555 Piston ring 7 3 Biston 2 2,030 = 2,050 3 3,967 + 3,987 1 1,478 = 1,490 | 2 iL) 2 1,978 ~ 1,990 si = | me (2) 3 3,925 + 3,937 Piston rings @ LANCIA | 04 | a 0,045 = 0,07 7 «Piston rings ae ~ e 53 2 Piston ring grooves fREs 2 Oma | 3] 0,030 = 0,062 1 = 0,45 pe 4s 1 0,30 + 0,45 51 2 0,30 = 0,45 Opening at end of rings in'cylinder bore 3 0,25 = 0,40 | 24,988 = 25,021 | Small end } | | @Le, bush housing 1 53,904 = 53,910 | y 6 | St Bigend = 2 | 53,898 + 53,904 | @ Te bearing housing A " 2 3 | 53,892 + 53,898 Copyright by Fiat AutoTechnical data DELTA-PRISMA 4WD Engine: cylinder block/crankcase, crankshaft and associated components 00.10 e@ 3 4 5 — => A= . ° DESCRIPTION Values in mm | 6 @:| 25,065 + 25,090 | 0 1 Sse nese ee ae sss ESSESEEEEEE| 7 fal 22,004 + 22,007 | Small end BA " O] oS A 2 22,007 + 22,010 |. e Gudgeon pin a 47 FE Small end bush O10: 9,018 Small end bush 16% pmallea | 0,044. 0,102 A 52,998 + 53,004 | Main A 5 | | journals 2 A B| 52,992 + 52,998 e “i a Cc} 52,986 + 52,992 8 1 50,799 = 50,805 | ‘Do | Crank 50,793 + $0,799 | pins | 3 50,787 + 50,793 | L 27,975 + 28,025 | Crankshaft bearings A 1,838 + 1,844 1,836 + 1,842 t AB 1,844 + 1,850 1,842 + 1,848 9 tn \ St ua | ™. \_/ Cc 1,850 = 1,856 1,848 = 1,854 3 @LANCIA << 0,254 ~ 0,508DELTA-PRISMA 4WD Technical data Engine: cylinder block/crankcase, crankshaft and associated components e@ 00.10 o- 8 - DESCRIPTION Values in mm 98 3 Crankshaft bearings-Main journals 0,025. + 0,049 | —_(0,029 + 0,053 A 1,527 + 1,533 Big end Li B 1,533 + 1,539 10 bearings SA c 1,539 + 1,545 ® ane @ LANCIA << 0,254 - 0,508 ® 08 2S Big end bearings-Pins 0,033 =. 0057 oo Thrust + 7 JU washers Ss 2,310 + 2,360 | ake S LANCIA >> 0,127 us 9o Crankshaft end float 0.055 - 0.305 Diagram showing connecting rod-piston assembly and direction of rotation in engine A = Area where number of cylinder bore to which connecting rod belongs is stamped. The arrow shows the direction of rotation of the engine as seen from the timing side. Imm = Gudgeon pin offset on the piston. e Copyright by Fiat Auto 19Technical data DELTA 4WD Engine: couter-balance shafts 00.10 e@ turbo DESCRIPTION Values in mm | 25 Couter-balance shafts w2 Shafts operated by toothed belt BS 36,920 = 36,940 OF Of Of 26 _ 25] 37,020 + 37,040 qa Oo | Bushes for counter- O35 38,020 + 38,040 ® balance shafts int housings Zi 36,850 ~ 36,870 OO 90 25 36,950 + 36,970 Counter-balance shaft bearings | 37,950 + 37,970 Bushes for shaft | | 26-1 a Housings 0,080 +.0,140 | 25:26 GE Shaft bearings - Bush: 6 | Ses arings - Bushes 0,080 + 0,090 |PRISMA 4WD Technical data Engine: counter-balance shafts 00.10 2 Oo 900 | 27 26 27 DESCRIPTION O——————— Values in mm 25 Counter-balance shafts ne? Shafts operated by toothed belt «OF | f-— e Ball bearings for counter-balance shafts 25 i @ Counter-halance shalt contral bearing i 2 37,020 + 37,040 Central bush for counter-balance shafts in housing Ob - Oo | 27 @ 19,990 + 20,000 36,945 + 36,960 + Counter-balance shaft bearings 19,980 = 19,993 | 2 Bushes for shaft ~ 210% Housings 0,080 = 0,140 25-26 2S Shaft bearings - Bushes 0,060 = 0,095 peg, Ball bearings ; 271 we Housings +0,011 + - 0,025 ° 26 Shaft bearings | @ Sol ec Ball bearings +0,020 = — 0,003 Copyright by Fiat Auto aTechnical data DELTA-PRISMA 4WD Engine: cylinder head and valve gear components 00.10 18 7 eee a ee 12 2 ae oi jes LANCIA > 0,05-0,10-0,25 | T 13-12 &_ Valve guide 2 | 0,063 + 0,108 Bore in cylinder head & | 0,021 = 0,066 063. + 0,108 2| 1,974 = 7,992 #4 2: 43,300 + 43,700 a 45° 30" +S ‘Valves 2 1,974 = 7,992 2:| 35,850 + 36,450 a 45° 30° + 5°DELTA-PRISMA 4WD Technical data Cylinder head and valve gear components @ 00.10 Se | turbo DESCRIPTION ‘Values in mm 1413 26 Valve-Valve guide | 0,030 = 0,066 Pi 14,13 + 15,11 daN ee ae Hi 31 sB tr 2 P: 26,39 + 28,74 daN Internal valve spring Hi: 21,5 : P, 36,68 + 39,6 daN @ 6 =~. = ae Hi 36 Hy 1 i" Me Pr 55,91 + 60,82 daN | External valve spring HE 26,5 a om 2 29,944 = 29,960 = 7 - i Q2 45,755 + 45,771 Ds 46,155 + 46,171 47 __Camshaft bearings at » 91 10,033, Cam lift = O SS 8.6 10,033, Camshaft bearings in cam- shaft housing 2 30,009 + 30,034 { { ea I in| |e Di 45,800 + 45,825 m@JIL rc a Ds 46,200 + 46,225 18 | Ce i HCBE T*pret housings @ 37,000 = 37,025 tS | Camshaft bearin; 5 0,049 + 0,090 17-18 2 © Camshaft housing ae 2 * supports D2-Ds 0,029 = 0,070 See, Sea 9 “So Tappet @ 36,975 + 36,995 e aah Copyright by Fiat AutoTechnical data DELTA-PRISMA 4WD Engine: cylinder head and valve gear components e 00.10 | | | i 2 6 43 = | a zy vi | |e eso eoes = fal | 15 DESCRIPTION Values in mm - 26 Tappet Housing in a i mame oylner head 0,005 + 0,050 » eS . (B 00s) 3,25 + 4,70 S=—"™ Shim | 8 Clearance for ae 0,30 timing check ot Y sy i \ 0,80 a o ‘iy ET | | operational = fw 0,35 + 0,04 0,40 + 0,04 clearance eS = & 0,40 + 0,04 0,48 + 0,03 TIMING ANGLES opens BTDC inlet closes ABDC s 42 opens BBDC are exhaust closes ATDC) DELTA-PRISMA 4WD Technical data Engine: lubrication 00.10 Oil pump Pump operated lobe gears by crankshaft Oil pressure relief valve incorporated in crank- shaft front cover | between pump casing housing and driven gear f f Ie f between upper side of gears and pump cover 0,025 = 0,056 | Full flow filter cartridge Insufficient oil pressure sender unit electrical O@ + Operating pressure at a temperature of 100°C 3.4 + 4,9 bar (3,5 + 5 kg/m’) 11,3 + 12,1 daN == P, Oil pressure relief valve spring 35,3 Copyright by Fiat AutoTechnical data DELTA-PRISMA 4WD Engine: cooling system-fuel system-supercharging 00.10 COOLING SYSTEM e Cooling circuit coolant circulation via ceitrifugal pump, radi tor and electric fan operated by thermostatic switch e Water pump operation through belt Thermal e@ 90° = 94°C switch to engage | fan a 85° + 89°C opens 81° = 85°C | Engine cooling water thermostat Pee 9PC | valve travel > 7,5 mm Clearance bewteen impeller S blades and pump casing 96 0821 mm Pressure for checking water tightness of 0,98 bar | system_ Pressure for checking overflow valve on expansion tank 0,98 bar FUEL SYSTEM Pump | electric Capacity ~ 120 litres/h SUPERCHARGING (with turbocharger operated by exhaust gases with wastegate valve) 7 Turbocharger type: KKK K26 | Garrett T3 - Maximum supercharging pressure | 0,9 bar - ‘Checking engine idle speed and carbon monoxide emissions Engine speed pm 800 + 900 (750 + 800)* | CO idle emissions (%) 15 +05 (%) With VAE valve disconnected 6DELTA-PRISMA 4WD Technical data Clutch 00.18 eS Values in mm Type @0d dry, single plate owe | Operating mechanism oO diaphragm spring |_ Lining Spring loading 575 daN @ 230 @: 155 Clutch pedal setting WH x 8 + 10 mm below the level of the brake pedal Clutch release mechanical Copyright by Fiat Auto 7Technical data DELTA-PRISMA 4WD Gearbox and differential 00.21-27 GEARBOX | spring En O {- (Porsche type) baulk ring ‘Synchronizers type wm toothed g oo Gears helical toothed | fee 3,500" 3,750 Re 2,235 2,235 eee eee 1,132 1,132 Kee 0,928 0,928 ey 3,583 3,583 b Crown wheel | @ Le and pinion 53/18 (2,944 65/19 3,421 1 reduction ae Xe) || | | Fee] 10,304 12,828 eee 6,580 7,645 =Ts 1 | 4468 | 5,193 “+b fi 1 T 3,332 3,872 Ratio at the wheels 2,732 3,174 10,548 12,257 ; | eo 28DELTA-PRISMA 4WD CENTRE DIFFERENT Technical data Gearbox and differential 00.21-27 hp Tv Differential internal casing bearing conical roller bearings + m# € Adjustment of bearing pre-loading ©& by shims Thickness of shims e S)? tance (F205) mm 1,00 = 1,60 L Interference to obtain exact bearing pre- mm loading bearings not pre-loaded = 0,12 bearings pre-loaded (350 daN) = 0,08 | FRONT DIFFERENTIAL 2 © Clearance bewteen satellite > _and planet gears <0,10 + oe Adjustment of clearance between planet and satellite gears no adjustment is carried out Copyright by Fias Auto 29Technical data DELTA-PRISMA 4WD Gearbox and differential 00.21-27 e- 6 IDLER GEAR | -t “s 43/19 +f =e. 263) Spur gear set ratio — g ~a. daNmn 0,18 = 0,20 | Ring gear bearing rolling torque 4+ om & Adjustment of ring gear bearings oy by shims SF iano ( B 002s) mm Thickness of shims 1,475 = 2,90 st GS e Clearance between pinion and ring gear Adjustment of idler gear bevel pinion by shims ES) + LANCIA ( A aon) mm 2,55 + 3,35 A Thickness of shims - | = daNm 0,08 + 0,12 Bevel pinion bearing rolling torque = mm 0,08. 0,15 fe [Adjustment of clearance between pinion and ring gear )) by shims GS LANCIA ( A oon) mm 1,475 = 2,90 Thickness of shims 30DELTA-PRISMA 4WD @ Technical data Propeller shaft 00.24 es 6 Type in three sections 1 on the centre section with a ball bearing on the support Supports 1 on the rear section with a ball bearing in- side the support dust cover | Sliding constant velocity joints 1, on the front section Universal joints 2, on the centre section 1, on the rear section Spider radial clearance O.0n = Gor Thickness of shims for adjusting spider radial clearance mm 1,30-1,53-1,56-1,59-1,62 Spline backlash 2.0175 =:0,350" Copyright by Fiat AutoTechnical data Rear differential unit DELTA-PRISMA 4WD 00. ® 205 The springs are divided into two categories | | | identifiable by a mark: | yellow (1) for 378 daN having a height of mm > 205 os those under a load of: 374 daN having a height of mm = >205 green (1) for 378 daN having a height of mm <205 - | those under a 1 load of: 374daN having a height of mm | = $205 o Springs of the same category must be fitted. Shock absorbers ‘Type: telescopic, hydraulic, double acting Way-Assauto | Travel mm 158 | Maximum extension mm 52,5 Copyright by Flat Auto a7Technical data Rear suspension 00.44 DELTA-PRISMA 4WD ® Rear suspension independent, Mac Pherson type with two transverse track control arms and a lower longitu- inal track control arm plus a damper comprising a double acting, telescopic, hydraulic shock absorber with an offset coil spring, Stabilizer bar a. Coil spring Diameter of wire mm 1194005 | —11,6+0,05 Number of turns 3,86 3,86 Direction of coil clockwise Height of spring released mm 316 331 Height of spring 258 daN mm 173 - under a load of: 268 daN mm = 1B The springs are subdivided into two cate- | gories identifiable by a mark: | yellow (1) for 258 daN having a height of mm >1B - those under a load of: 268 daN having a height of mm| 5 >12B green (1) for 258 daN having a height of mm| <173 - those under a load of: 268 daN having a height of mm_| = <173 (1) Springs of the same category must be fitted. Shock absorbers Type: telescopic, hydraulic, double acting Way-Assauto Travel 190 Maximum extension 590 8DELTA-PRISMA 4WD Technical data Electrical equipment 00.55 e- 8 STARTER MOTOR M. Marelli E95 - 1,1 kW - 12 V ALTERNATOR M. Marelli AAI25R - 14 V - 65 A. VOLTAGE REGULATOR M. Marelli RIT 119 AC BATTERY 12 V-45 Ah- 225A IGNITION SYSTEM Weber injection/ignition IGNITION DISTRIBUTOR DT 453 AX IGNITION COIL M. Marelli BAE 504 CK | IGNITION COIL WITH POWER M. Marelli AET 600 A MODULE Fiat V45 LSR M.Marelli F8 LCR SPARK PLUGS Bosch WR6 DC Champion RN7 YC @e Copyright by Flat Auto 39Technical data Starting 00.55 DELTA-PRISMA 4WD a 2 Motor: type M. Marelli E95 - 1,1/12 | Voltage v 12 Nominal power kw i Rotation, pinon side | clockwise No. of poles [ 4 | Field coil | series-parallel | Engagement free wheel Operation solenoid End float of armature shaft mm 0,15 + 0,45 | | Operating test (*): current Al 270 speed rpm | 1750 voltage Vv 92 torque developed daNm 0,65 2 | Engagement test (*): 3 current A 530 + 570 & voltage v 6,6 g torque developed daNm > 16 4 Free running test (*): current A 35 + 45 | voltage Ae 11,6 + 11,7 speed pm 8500 = 9500 pull in Q. 0,33 = 0,37 3 | Winding resistance (*) { ; holdin Q 113 + 127 = | Internal splines and . &) shait bushes Es | \2) 3 | Sleeve and intermediate disc ES) (*)_Data obtained at an ambient temperature of 20°C. NOTE When overhauling it is not necessary 10 undercut the insulator between the commutator barsDELTA-PRISMA 4WD Technical data Electrical equipment: starting e 00.55 STARTER MOTOR - TYPICAL CURVES M. Marelli E95 - 1,1/12 Wiring diagram showing M. Marelli E95 - @ 1,1/12 starter motor Copvright hy Flat Auto aTechnical data Hlectrical equipment: recharging 00.55 DELTA-PRISMA 4WD a | @ ALTERNATOR M. Marelli ‘Make and type AAI25R-14V-658, Nominal voltage v 12 Maximum current A 65 Cat in speed rpm 1050 = 1150 Current delivery on the batterty at 7000 4 >e 1pm = Field winding resistance, between the slip rings (*) a 26 + 28 Direction of rotation (as seen from the control side) clockwise Engine/alternator ratio 1:2 Rectifier diodes bridge (*) Data obtained at an ambient temperature of 25°C VOLTAGE REGULATOR = Built in electronic ype RTT 119 AC | Alternator test speed rpm 7000 Thermal stabilization current A 30 = 35 ‘Test current A 32 + 33 Regulation voltage (*) v 14 + 143 (*) Data obtained at an ambient temperature of 20°C BATTERY Nominal voltage < 2 Capacity (20 hour discharge) 45 2 @DELTA-PRISMA 4WD Technical data | Electrical equipment: recharging -@ 00.55 ALTERNATOR - TYPICAL OUTPUT CURVES (the data in these curves refer to outyut at a constant voltage of 13.5 V with bedded in brushes) > a 19 T | i @ oi. Maret asrase -14v- 65.4 a CX. Connectors 2, 7 Marelli alternator wiring diagram | + Ignition switch with key | Y = Alternator recharging warning light (12V - 3/SW) “$I | R = Electronic voltage regulator wo - Sb! FIMM RTT 119 AC voltage regulator typical curve A 200 20-40 “80 40 CoD @ Consright by Fiat Auto 43Technical data DELTA-PRISMA 4WD Electrical equipment: electronic injection/ignition 00.55 POWER MODULE ELECTRONIC IGNITION e e-| 6 Make and type M. Marelli AE 600A Firing order 1-3-4-2 DISTRIBUTOR | Make M. Marelli | Type DT 453 AX Built in rotor arm resistance 2 1000 sistance at 30°C Electro-magnetic impulse generator winding re- Q 758 + 872 com Make M. Marelli Type BAE 504 CK Primary winding resistance at 20°C 0,415 = 0,495 | Secondary winding resistance at 20°C 4320 = 5280 TDC AND RPM SENSOR Make and type | M. Marelli SEN 8 D | Sensor winding resistance a} 612 + 748 | pulley teed | Distance (gap) between sensor and crankshaft mm | 04+1 ENGINE ADVANCE | Minimum from 800 to 850 rpm at 0.43 bar (0,68 bar)* | 15° 4 2° 18° + 2° (*) Maximum at 4000 rpm at 0.43 bar (0,299 bar)* | 40° + 2° 39° + 2°(*) SPARK PLUGS Make and type Fiat V 45 LSR. Tock WREDE [Channa RAE] M Thread M 14x 1,25 Electrode gap 0,6 + 0,7 mmDELTA-PRISMA 4WD Technical data Electrical equipment: electronic injection/ignition IAW INJECTION SYSTEM COMPONENTS 00.55 S-- DESCRIPTION QUANTITY TYPE ELECTRONIC CONTROL UNIT 1 | WHAE.03/085-F6 |WH26.03/HAI-BB black label yellow label BUTTERFLY CASING 1 52. CFL 15 SOCFLI8. | e INJECTOR 4 TW 025/01 Tw 024/03 | ENGINE IDLE AUTOMATIC ADJUSTMENT SOLE: | VAE 02 PRESSURE REGULATOR 1 RP 1/3 bar | AiR TEMPERATURE SENSOR 1 ATS 04 WATER TEMPERATURE SENSOR 1 | WTS 05 ABSOLUTE PRESSURE SENSOR Ty] aps 0201 APS 03/01 | BUTTERFLY VALVE POSITION SENSOR ae PF 09/01 @ eve rite 1 F1.02/01 ELECTRIC FUEL PUMP 1 PI 022/2 | Copyright by Flat Awo 45Technical data DELTA 4WD Electrical equipment: electronic injection/ignition 00.55 e DIAGRAM SHOWING INJECTION/IGNITION CONTROL UNIT CONNECTIONS (CONCERNING ELECTRONIC IGNITION ONLY) The identification numbers for the components are the same as those given in the wiring diagrams eke Tee PEE y 16. Ignition coil with power module 5S. Connector 17. Connection 58. Rpm and TDC sensor 18. Anti-detonation sensor 109. Injection/ignition electronic control unit 19. HLT. distributor with built in timing sen- 128. Ignition switch sor ~ 40. Battery @ CHARACTERISTIC IGNITION ADVANCE CURVES FOR EIGHT VACUUM VALUES IN THE IN- LET MANIFOLD at an absolute pressure of 0,18 bar (135 mmHg) at an absolute pressure of 0,299 bar (225 mmHg) 2 ge 5 att ae 2 ¥ g oF ga z go 2 8 E Bat é Su 4 gu 2 = 7 = a 05 WW 3 WS 0 45 55 6085 opm 100 05 0 15 20 oH 15 A045 80:55 ODES opmx 100 eoDELTA 4WD Technical data Electrical equipment: electronic injection/ignition e@ 00.55 at an absolute pressure of 0,43 bar (321 mmHg) at an absolute pressure of 0,54 bar (405 mmHg) ge 2 g Po g PS 34 : Ea i z i a i SUT ESTE TTS 05 WW 2 B W035 0 5S ES cm 10 at an absolute pressure of 0,70 bar (525 mmHg) at an absolute pressure of 0,92 bar (690 mmHg) Z 24 & Sy g ¥ g e g g 5 ¢ 8 2 3 uh 2 7 5 W 15 2 25 30 95 49 45 5055 GO Gd rpmx 100 = 05 15 20 25 90 95 40 45 5055 GO G5 MPM x 100 at an absolute pressure of 1,38 bar (1035 mmHg) at an absolute pressure of 1,80 bar (1350 mmHg) 2 2 & zg a” » 2 8 Ea 5 S 5 a E ZW é€ g 2 05 1 15 20 25 30 35 40 45 99 55 0 6S pm x 100 = G5 0 15 20 25 90 95 40 45 5055 OO 6S mx 100 e Copyright by Fiat Auto a7Technical data Electrical equipment: electronic injection/ignition 00.55 DIAGRAM SHOWING INJECTION/IGNITION CONTROL UNIT CONNECTIONS (CONCERNING ELECTRONIC IGNITION ONLY) ‘The identification numbers for the components are the same as those used in the wiring diagrams PRISMA 4WD ® 128 16. Ignition coil with power module 17 19. HLT. distributor with built in timing sen- ‘onnection sor 40. Battery 35, 38, 128. Connector Rpm and TDC sensor 109. Injection/ignition electronic control unit Ignition switch ® CHARACTERISTIC IGNITION ADVANCE CURVES FOR EIGHT VACUUM VALUES IN THE IN- LET MANIFOLD at an absolute pressure of 0,17 bar (129 mmHg) ADVANCE DEGREES ON ENGINE Tolerance 22 5 M15 20 2 WW 40 45 30 55 60 6S rpm 100 ADVANCE DEGREES ON ENIGNE, BORDERS O 5 055 8 at an absolute pressure of 0,299 bar (225 mmHg) v TolerancePRISMA 4WD Technical data Electrical equipment: electronic injection/ignition @ 00.55 at an absolute pressure of 0,39 bar (294 mmHg) at an absolute pressure of 0,53 bar (399 mmHg) zg & 5 z 2 ab g S 5 I : 3 2 2 2 z th . & = EH 20 25 0 5 M0 4S 80 85 OES cpm tO 05 W 15 20 25 30 95 40 45 50 55 GD 65 rpm ute. at an absolute pressuré of 0,60 bar (450 mmHg) at an absolute pressure of 0,73 bar (549 mmHg) é g g y 8 S 3 zg 2 g - 05 10 15 20 25 30 35 40 45 S055 60 65 rpm x10, 05 18 15 2 25 30 35 40 45 50 55 80 65° rpm xi at an absolute pressure of 0,82 bar (615 mmHg) at an absolute pressure of 0,82 bar (619 mmHg) S zg 2g y 8 y 2 z 2 ¥ 05 1 15 20 25 a0 35 40 45 50 55 60 65 rpm x100 05 15 2 25 M0 45 40 45 5055 60 65 rpm x100 Coperight by Fier Auto 49Technical data DELTA 4WD Electrical equipment: electronic injeciton/ignition 00.55 eo Diagram showing 1AW injection/igni ion system Fuel tank 15. Injection/ignition relays Electric fuel pump 16. Additional air solenoid valve for automatic Fuel filter adjustment of engine idling Fuel inlet Coolant temperaiure sensor Fuel pressure regulator Absolute air pressure sensor HT distributor with injection timing sensor Butterfly valve position sensor Inlet air temperature sensor 10. Rpm and TDC sensor IL. Electronic control unit 12. Injector 13. Battery nition switch Spark plugs . Ignition unit Butterfly valve ~ Diagnostic socket . W.LL. system protective fuse Vehicle electrical system connector Overboost solenoid valve Detonation sensor OIA NAwEPRISMA 4WD Technical data Electrical equipment: electronic injection/ignition e 00.55 Diagram showing IAW injection/ignition system @ = 15. Injectionjignition relays 2. Electric fuel pump 16. Additional air solenoid valve for automatic ad- 3. Fuel filter justment of engine idling 4. Fuel manifold 17. Coolant temperature sensor 5. Fuel pressure regulator 18. Spark plugs 6. Inlet air absolute pressure sensor 19. Ignition unit 7. HT distributor with injection timing sensor 20. Butterfly valve 8. Butterfly valve position sensor 21. Diagnostic socket (located near injection con- 9. Inlet air temperature sensor trol unit connector) 10. Rpm and TDC sensor 22. IAW system protective fuse IL. Electronic contro! unit 23. Vehicle electrical system connector 12. Injectors 13. Battery 14. Ignition switch Copyright by Fiat Auta 51