Fiat Barchetta: Auxiliary Units

Fiat barchetta Auxiliary units
Heater with manual controls
P3WO17HO1 P3WO17HO2
1. Remove central console side fastening

3
strip from tunnel.
F~- 2. Disconnect connection for passenger side
@---
air bag.
/~ "" 3. Remove the distributor heater assembly
after unscrewing nuts retaining top of unit
to body and disconnecting connector (4)
4. Detail of left side of distributor heater as-
sembly.
5. Detail of rear part of distributor heater as-
sembly. Thiis is made up of fan unit (A),
which is connected to heater distributor
" fJ --
" \
unit (C) through duct (B). Both heater ra-
diaotr inlet and outlet ducts are indicated
by the number (2).
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P3WO17HO3
P3WO17H04
Copyright Fiat Auto 17

Auxiliary units Fiat barchetta
Disassembly
-
- working on left side surface of heater dis-
tributor unit, release sheaths of cables (8
and C) from clips (1) and withdraw coils at
cable ends from cylindrical ridges on lever
(2) and rack (3) controlling mixer flap and
distribution flap;
- working on left side of the air intake

shroud, undo sheath of cable (A) from clip
(4) and withdraw terminal coil of cable
from cylindrical ridge on air intake flap lever
(5);
P3WO18HO1
- disconnectconnectors (6 and 7) from pas-

senger compartment ventilation fan speed
selector (8) and connector (9) for front
control grille symbol lighting bulb wiring;
move clip (10) on control mount sideways

(in arrowed direction) so that it emerges
from its seat on the heater distributor unit:
P3WO18HO2
P3WO18HO3
1P. Publication no. 506.586

- unscrew screw (11) retaining connector

(12) to left side surface of heater distributor
unit (13);
- disconnect connector (14) of resistor (15)
and connector (16) from mount (17) of fan
(18);
- release electrical wiring from clips indicat-
ed by small arrows, which retain wiring to
assembly;
- unscrew screws indicated by large arrows
in figures, which retain duct (19) to fan as-
sembly (20) and heater distributor unit
(13).
'3WO19H04
DISMANTLING FAN ASSEMBLY
- unscrew screws (21) joining both case halves

(22 and 23) making up the fan assembly;
- unscrew screws (24 and 25) retaining mount
(17) of fan (18) and resistor (15) to lower case
half (23);

P3WO20HO1
Details of lower fan assembly case half

23. Lower case half 1. Diaphragm of air duct to fan
P3WO20HO3 P3WO20HO5
Details of upper fan case half
- working through arrowed slot on air intake flap (2), undo fin (3) with toothed profile of lever (4) in
order to withdraw from flap (2) and upper case half (22);
- position air intake flap (2) to release pivot pin from moulded ridges (5) press-fitted on upper case half
(22).
Detail of air intake flap and operating lever

P3WO20HO6
20 Publication no. 506.586

P3WO21 HO:
P3WO21 HI
DISMANTLING HEATER-DISTRIBUTOR
UNIT
- unscrew screws (1) retaining front of
heater radiator (2) to lower rear surface of
heater distributor unit;
- remove radiator (2) from seat on above as-
semblv;
unscrew arrowed screws and screw at the
bottom of hole (3), which joins the two
case halves making up the heater distribu-
tor unit:
P3WO21 H04 P3WO21 HO5

Detail of right case half Detail of left case half
- unscrew screws arrowed in bottom central figure, retaining square levers with toothed sector (4 and
5) operating distribution flaps (upper (A) and lower (8» to left side surface of left hand case half;
- firstly withdraw the two levers with toothed sector (4 and 5) from the cylindrical ridges press-fitted on
the above surface, then remove rack (6);
- unscrew screw (7) and withdraw intermediate return lever (8) operating lower distribution flap (8)
from cylindrical ridge on above surface;
- unscrew screw (9) and withdraw square lever (10) operating mixer flap (C) from cylindrical ridge on
above surface:
P3WO22H04
P3WO22HO5
P3WO22HO6 P3WO22HO7

View of left hand case half without square

flap control levers
P3WO23HO3
- undo tooth (arrowed in upper, right hand

figure) of lever (11) so that it disengages
from notch (arrowed in second figure on
right) on upper distribution flap spindle
(12) and withdraw flap from left hand case
half;
- repeat the last operation described for lever
P3WO23HO4 (13) and lower distribution flap (14), then
for lever (15) and mixer flap (16).
P3WO23HO5
P3WO23HO7
Detail of left hand case half (without

flaps)
~
Reassembly
Reverse disassembly operations, noting that

inner sliding surfaces of square levers with
toothed sectors (1 and 2) must be lubricated
with vaseline before fastening to left side sur-
face of heater distributor unit so that indexes
(arrowed) are aligned with the triangles on
rack (3).
After connecting coils of cables to cylindrical
ridges on rack (3) and levers (4 and 5), fit ca-
bles to clips arrowed in the second and third
figures on the right so that distribution and
mixer flaps move through their full travel.
'3WO24HO1
Refitting
To refit the distributor heater assembly, re-
verse operations described for removal. Note
that pipe (6) identified by a green stripe must
be connected to left duct of heater radiator
marked with a raised green dot. Pipe (7)
identified by a white stripe must be connect-
ed to heater radiator duct identified by a
raised white dot.
P3WO24HO3
P3WO24HO4

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P3WO25HO1
PASSENGER COMPARTMENT VENTILATION FAN
To remove the passenger compartment ventilation fan, sim-

ply work from the rear of the instrument facia (as indicated
by the arrow in the upper figure), remove bulkhead shown
in colour and unscrew screws (1) which fasten (2) to lower
part of distributor heater assembly. Then withdraw connec-
tor (3) before disconnecting supply leads.
Disassembly
- disconnect both terminals of leads (7) supplying motor
(8) from connector (9) fitted onto base (2);
- undo plastic moulded blocks (10) fitted on adaptor ring
(11) in order to release from base (2);
- withdraw motor (8) with impeller (12) and adaptor ring
(11) from base (2);
- use a drift to withdraw impeller (12) from shaft of motor
(8), to which it is press-fitted;
- expand toothed tabs of adaptor

ring (11) so that they can be
withdrawn from motor (8).
~
PASSENGER COMPARTMENT FAN SPEED RE-

SISTOR
To remove resistor (4) (see top right hand figure on

previous page), simply work on bottom right hand
part of instrument facia to withdraw screws (5) that
retain it to the bottom part of the distributor heater
assembly. After withdrawing from assembly, discon-
nect connector (6) of supply leads.
HEATER RADIATOR
Removing
- drain engine cooling system
- remove the instrument facia as described in
section 70 of this manual and place on front
seats;
- remove distributor heater assemblyas de-
scribed previously;
- after removing the distributor heater as-
sembly from the vehicle, withdraw the ar-
rowed screws that fasten front part of
heater radiator (1) to vehicle.
A strip of adhesive foam rubber (2) is applied
round the heater radiator and a second seal
(3) of the same material is applied behind the
P3WO26HO2
front part to which are applied the two input
and outlet ducts. Lastly, a thoroid seal (4) of
the same material is applied round the base of
these ducts.
Refitting
To refit, carry out removal operations in re-

verse order. Take into account previous notes
on connecting pipes to heater radiator ducts.

P3WO27HO2
HEATER CONTROL PANEL - Removing-re-

fitting
P3WO27HO1
1. Remove radio by inserting extractor s

1860861000 into holes provided to re-
3 lease retaining clips. Disconnect supply
connectors and aerial lead, then remove
radio.
2. Lift gear lever trim, unscrew the screws in-
dicated and remove panel after discon-
necting the electrical connectors.
3. Remove central fan speed control knob,
then unscrew screws to remove front con-
trol panel.
4. Unscrew screws and remove heater con-
trol unit.
5. Disconnect cables (A,B,C) from control
unit by undoing screws (1,2,3) and dis-
connect electrical connectors (4 and 5).
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P3WO27HO3
5 (B)
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P3WO27H04 P3WO27HO5

Air conditioner with manual controls
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P3WO28HO2
Before carrying out any operation

that could lead to loss of coolant R
134 A, drain air conditioning system
as described at the end of this sec-
tion. Whendraining the system,wear
gloves and goggles to protect against
harmful contact with jets of R 134 A.
To help drain coolant from the vehi-
cle air conditioning system more ef-
fectively, operatesystem(and car en-
gine) for 10-15 minutes.
COMPRESSOR - Removing-refitting
1. Drain air conditioning system, then work
from top of engine bay to unscrew screw
-
4 retaining pipe fitting to compressor drain
~\ " duct (A).
.l) 2. Disconnect compressor supply connector
(1), then remove upper compressor re-
~4
1~f/
taining screws.
3. Lift axle, remove right front wheel and
then take off plastic guard in wheel arch to
allow access to air conditioner compres-
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sor belt tensioner.
4. Move compressor drive belt tensioner
bearing in the arrowed direction to prise
belt off the air conditioner pulley.
~
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50.
P3WO29HO1
1. Unscrew screw retaining line fitting to in-

take duct (B) of compressor, then remove
lower air conditioner retaining screws and
remove from engine bay.
2. A. Outlet duct
B. Inlet duct (located on right front side
of compressor)
Reverse removal instructions to refit, en-
suring that air conditioner compressor
drive belt tension is properly adjusted.
CONDENSER - Removing-refitting
3. Drain air conditioning system, then re-
move resonator by undoing screws shown
in the figure.
4. Remove air duct by undoing clip and fas-
tenings shown in figure.

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P3WO30HO1
""
1. Unscrew nuts retaining the car alarm con-
3 rJl
~ trol unit/siren and position siren to one
side in engine bay without disconnecting
electrical connections.
2. Disconnect bracket retaining battery to
holder, then remove battery from engine
0 -I bay.
3. Disconnect battery holder by undoing fas-
tenings shown in figure.
nT fd 4. Disconnect air intake duct by undoing
fastenings shown in figure.
6. Unscrew screws retaining air cleaner
bracket and nut retaining line connecting
compressor to evaporator.
P3WO30HO5

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P3WO31 HO2
P3WO31 HO1
3
1. Unscrew upper screws retaining fans to
radiator unit and disconnect connections.
2. Raiselift and work on lower part of engine
bay. Loosen screw (1) retaining radiator
) ' ~ support beam so that radiator is slightly
lowered and air cleaner assemblycan be
'L-!-
removed after releasing electrical leads
from the unit.
3. Unscrew both screws retaining compres-
sor connection line to evaporatorfrom ra-
diator assemblybeam.
4. Unscrew lower fan retaining screws,then
take out assembly.
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Copyright Fiat Auto
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P3WO32HO1
1. Disconnectline (A) connecting compres-

sor to condenserfrom compressor(1).
2. Disconnect bracket for line connecting
compressor to condenser from radiator
unit.
3. Disconnect line connecting condenserto
dehydrating filter from condenser.
NOTE In order to prevent the dehydrating
filter from absorbing moisture, which
would impair its efficiency, seal fit-
ting of filter hose that has been dis-
connected from condenser with a
watertight plug.
4. Unscrew lower screws retaining con-
denser to radiator unit.
5. Remove lower air duct retaining screws.
P3WO32HO3
~
Auxiliary units
1. Lower the lift, then remove upper screws

retaining condenser to radiator assembly.
2. Move the radiator unit, withdraw lines
connecting compressor to condenser and
remove condenser.
3. Arrows indicate fastening points for con-
denser to radiator unit.
Reverse removal instructions to refit the
condenser. Note that fins should not be
blocked or deformed because this would
drastically reduce the heat exchange area
and system efficiency.
1. Working from inside the engine bay, un-

screw nuts (1) and (2) retaining heater/e-
vaporator assembly to bulkhead between
passenger compartment and engine bay.
Nut (1) is located near the power steering
fluid reservoir (which must be moved to
gain access to the nut), while nut (2) is lo-
cated near the evaporator unit connection
lines.
2. Unscrew interior ventilation central outlet
retaining screws, then take unit out.
3. Disconnect central outlet for front win-
dow ventilation
4. Remove central console side retaining
strip from tunnel.
5. Disconnect passenger side air bag con-
nection.
P3WO17HO1

P3WO35HO2
1-2. From inside the engine bay, unscrew

nuts retaining heater/evaporator assem-
P3WO35HO1 bly, disconnect connectors (11 and 12)
located on left hand side of unit, then re-
move assembly from passenger com-
partment.
Disassembly
- withdraw the end spirals of the two cables
(3) from the cylindrical ridges on rack (1)
and lever (2) and release the ends of the
cable sheaths from the clips arrowed in the
central figure;
- disconnect the supply cable connectors of
passenger compartment ventilation fan
speed selector (4), from socket (5) on
printed circuit of compressor activation
switches and passenger compartment air
intake selection and lastly from switch (6)
connected to control symbol light bulbs;
- move clip (7) of

control support
(8) in arrowed di-
rection so that it
emerges from its
seat on the distrib-
utor heater evapo-
rator assembly;
P3WO35HO5

P3WO36HO2
- disconnect the two connectors (9);

- disconnect connector (10) from connector
of terminal leads of electric actuator (mo-
tor) responsible for operating air intake
flap;
- disconnect connectors (11 - 12 and 13)
from fan base, resistor and compressor
ECU respectively;
- unscrew screws (14 - 15 and 17) that fas-
ten the two connectors (16) and bracket
with blocks to which the two relays (18)
are connected to the left side surface of the
assembly;
P3WO36HO3
release electrical wiring from hook clips (indicated by small arrows) applied to the above assembly;
unscrew screw (19) that fastens bracket (20) retaining the two pipes (21) connected to the expan-
sion valve and evaporator outlet duct to rear assembly surface;
unscrew screws indicated by large arrows in the various figures on this page that fasten the central
evaporator unit (A) to fan (8) and distributor heater (C).
P3WO36HO4

P3WO37HO2 P3WO37HO3
- unscrew screws (1 and 2) that fasten support (5) of fan

(6) and resistor (7) to lower case half (3);
- unscrew arrowed screws that fasten lower (3) and upper
Detail of lower case half (4) fan unit case halves together;
A. Diaphragm carrying air to fan - unscrew screws (8) that fasten bracket (9)
with electric actuator (10) to top case half
(4);
- release link (11) connected to actuator
(10) from lever (12) operating air intake
flap;
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P3WO37HO6

- working through the

slots arrowed in the
two details, undo
tabs with toothed
profile on shank of
lever (12) and shaft
that are fitted to the
end of pivot pin of air
intake flap (13) so
that they can be
withdrawn from the
flap and from the top
case half;
position air intake

flap (13) to release
pivot pin from pro-
filed ridges (14)
press-fitted to top
case half:
P3WO38HO3
DISMANTLING EVAPORATOR ASSEMBLY

unscrewscrews indicated by arrows in the figure below that fasten the two evaporator case halves to-
gether;
P3WO38HO5 P3WO38HO6

Auxiliary units
P3WO39HO2 P3WO39HO3
P3WO39HO1
- release the top case half (1,

from bottom half (2) and re-
move evaporator assembly
from the bottom half (shown
in top middle figure);
- remove evaporator support
plane (3) from bottom case
half (2);
- unscrew the two fittings (4
and 5) that join expansion
valve (6) and pipe (7) to in-
put duct (8) and output
duct (9) of evaporator (10); r"""v"""VO
- partly detach adhesive foam rubber strip that fastens the two
pipes (7 and 12) connected to outlet duct (9) and expansion
valve (6) to the side of evaporator (10);
P3WO39HO7

- withdraw clip (13) retaining sensor

(14) from the evaporator surface op-
posite the surface facing ducts;
P3WO4OHO1
- unscrew fitting (15) of equalization
pipe (16) of expansion valve (6)
from pipe (7) previously connected
to evaporator output duct;
- partly release adhesive foam rubber
trim (17) from above pipe (7) and
remove the two clips (18) that retain
sensitive bulb (19) of expansion
valve (6) in contact with pipe;
- unscrew fitting (20) of pipe (12)
connected to expansion valve.
DISMANTLINGHEATER-DISTRIBUTORUNIT
- unscrew screws (1) that fasten front part of heater radiator (2) to bottom rear surface of distributor
heater unit;
- remove radiator (2) from seat on the above unit;
P3WO40H04 P3WO21 HO2

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Fiat barchetta Auxiliary units

Heater with manual controls

1. Remove central console side fastening

Copyright Fiat Auto 17

- working on left side of the air intake

- disconnectconnectors (6 and 7) from pas-

move clip (10) on control mount sideways

1P. Publication no. 506.586

- unscrew screw (11) retaining connector

DISMANTLING FAN ASSEMBLY

- unscrew screws (21) joining both case halves

Copyright Fiat Auto 19

Details of lower fan assembly case half

Details of upper fan case half

Detail of air intake flap and operating lever

20 Publication no. 506.586

P3WO21 H04 P3WO21 HO5

Copyright Fiat Auto 21

Detail of right case half Detail of left case half

22 Publication no. 506.586

View of left hand case half without square

- undo tooth (arrowed in upper, right hand

Detail of left hand case half (without

Copyright Fiat Auto 23

Reverse disassembly operations, noting that

24 Publication no. 506.586

PASSENGER COMPARTMENT VENTILATION FAN

To remove the passenger compartment ventilation fan, sim-

- expand toothed tabs of adaptor

Copyright Fiat Auto 25

PASSENGER COMPARTMENT FAN SPEED RE-

To remove resistor (4) (see top right hand figure on

To refit, carry out removal operations in re-

26 Publication no. 506.586

HEATER CONTROL PANEL - Removing-re-

1. Remove radio by inserting extractor s

Copyright Fiat Auto 27

Before carrying out any operation

28 Publication no. 506.586

1. Unscrew screw retaining line fitting to in-

Copyright Fiat Auto 29

30 Publication no. 506.586

Copyright Fiat Auto

Auxiliary units Fiat barchetta

1. Disconnectline (A) connecting compres-

32 Publication no. 506.586

1. Lower the lift, then remove upper screws

1. Working from inside the engine bay, un-

34 Publication no. 506.586

1-2. From inside the engine bay, unscrew

- move clip (7) of

Copyright Fiat Auto 35

- disconnect the two connectors (9);

36 Publication no. 506.586

- unscrew screws (1 and 2) that fasten support (5) of fan

Copyright Fiat Auto 37

- working through the

position air intake

DISMANTLING EVAPORATOR ASSEMBLY

38 Publication no. 506.586

- release the top case half (1,

Copyright Fiat Auto 39

- withdraw clip (13) retaining sensor