186003710 - INTRODUCTION

WARNINGS

Do not try and rotate the engine with the battery earth lead slack as this will cause serious damage to the wiring.Never pull the leads or wiring using force because this would result in the cables being disconnected from the connectors or terminals.Disconnect all the control units and electronic devices when carrying out arc welding operations on the bodyshell.Before replacing a fuse, check that the circuirt protected is not faulty.When replacing fuses, make sure that the new fuse is the correct amperage. Do not use higher or lower amperage fuses.

PRECAUTIONS

When working on electrical components always follow the precautions described below very carefully.

• Remove rings, wrist watches and other metal objects.
• Before working on the electrical system (connectors, electrical components, wiring, etc.) turn the ignition key OFF and DISCONNECT THE BATTERY.
• Take care over electrical arcs. Even if the voltage is 12V, the battery can produce high currents if there is a short circuit, creating arcs or sparks that can be dangerous to the mechanic or create a fire hazard;
• Take care over high tensions. The electronic ignition system produces voltages of 20,000V and more which could be very dangerous. Take great care when working on or near these components.
• Prevent fire risks. Do not smoke when working close to the battery or components which get hot during usage (e.g. halogen bulbs) or in the area of the engine compartment when the engine is still hot. Also take care to avoid damage to tools and components.

CODE - ALARM SYSTEM COMPONENT MANAGMENT

Data base for code and alarm system parts management

There is a centralized DATA BASE (for all markets) managed by the PARTS DIVISION for ordering all CODE system components and some of the alarm system components.The production plant transfers all the required data into this DATA BASE, together with the chassis no. of the new vehicle. This DATA BASE is then used for completing an order for replacement parts received from the Dealer Network.

The data base contains numerous pieces of information, such as:

• vehicle chassis no.;
• secret code;
• code for each key (transponder identification);
• remote control code (versions with alarm only);
• mechanical key code;
• programming data;

1. Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.2. Carry out the KEY PROGRAMMING for the remaining keys using the Examiner or other diagnostic equipment working on the CODE control unit. Keys which are not presented will never be able to be used again. A list of keys that are still valid will be printed out.3. Versions with alarm only. Carry out the REMOTE CONTROL PROGRAMMING for the remaining keys using the Examiner or other diagnostic equipment working on the alarm control unit. Keys which are not presented will never be able to be used again.4. Connect to the FIAT PARTS DIVISION giving the vehicle chassis no. and other information requested. Send an order using the V.O.R. procedure requesting one or more keys.5. By consulting the DATA BASE, the FIAT PARTS DIVISION is capable, through the chassis no., of producing a key which has:- the same shape (but indicating that it is a replacement).- A transponder with a new key code, but with the secret code for the CODE control of the vehicle in question.- the same mechanical code (metal insert).- remote control code (versions with alarm only).The DATA BASE will be updated with the new code key entered.6. The FIAT PARTS DIVISION will send the key to the Dealer Network within 24 - 48 hours.7. Carry out the KEY PROGRAMMING using the Examiner or other diagnostic equipment working on the CODE control unit entering both the new key(s) and the previous ones.8. Versions with alarm only. Carry out the REMOTE CONTROL PROGRAMMING using the Examiner or other diagnostic equipment working on the alarm control unit entering both the new key(s) and the previous ones.

the receiver PASSWORD must be entered to carry out this procedure. Ask the FIAT PARTS DIVISION for this password, always providing the chassis no. of the vehicle.

9. Carry out a final check on both the CODE system and the alarm system (if fitted) using the Examiner or other diagnostic equipment.If one of the CODE - alarm system components needs replacing and is being ordered, follow the procedures described below.New key requestProceed as described previously, "skipping" step 2 which is superfluous in this case. Versions with alarm: up to 8 keys (remote controls) can be stored in a receiver.Replacing the transponderThe transponder is pressed in the key shell. Therefore it cannot be replaced: this guarantees improved safety in the face of "transponder thefts".Replacing key lock barrels1. Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.2. Carry out the CANCELLATION OF THE PROGRAMMED KEYS using the Examiner or other diagnostic equipment working on the CODE control unit and not on the alarm control unit. These keys can never be used again.3. Connect to the FIAT PARTS DIVISION: giving the vehicle chassis no. and other information requested. Send an order using the V.O.R. procedure requesting a complete key kit.4. By consulting the DATA BASE, the FIAT PARTS DIVISION is capable, through the chassis no., of producing a complete key kit which has:- the same shape (but indicating that it is a replacement).- A transponder with new key codes, but with the secret code for the CODE control of the vehicle in question.- a new mechanical code (metal insert).- new remote control codes (versions with alarm only).A new CODE Card is also supplied containing the previous recovery code but with a new mechanical code. The DATA BASE will be updated with the new key codes and the new mechanical code entered.5. The FIAT PARTS DIVISION will send the key kit to the Dealer Network within 24 - 48 hours.6. Carry out the KEY PROGRAMMING using the Examiner or other diagnostic equipment working on the CODE control unit entering all the keys received.7. Versions with alarm only: Carry out the REMOTE CONTROL PROGRAMMING using the Examiner or other diagnostic equipment working on the alarm control unit entering all the keys received.

the receiver PASSWORD must be entered to carry out this procedure. Ask the FIAT PARTS DIVISION for this password, always providing the chassis no. of the vehicle.

8. Carry out a final check on both the CODE system and the alarm system (if fitted) using the Examiner or other diagnostic equipment.Code card mislaid1. Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.2. Connect to the FIAT PARTS DIVISION giving the vehicle chassis no. and other information requested. Send an order for a CODE Card using the V.O.R. procedure.3. By consulting the DATA BASE, the FIAT PARTS DIVISION is capable, using the chassis no., of producing a new CODE Card that is identical (emergency code and mechanical code) to the one that was mislaid. The card will then be sent to the Dealer Network.4. Hand it over the Customer, notifying them that it is a duplicate. Therefore, if the old card is found, it can be used for starting.Replacing the code control unitA possible fault in the CODE control unit should always be confirmed through a thorough check using the Examiner or other diagnostic equipment.1. Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.2. Connect to the FIAT PARTS DIVISION: giving the vehicle chassis no. and other information requested. Send an order using the V.O.R. procedure requesting A CODE control unit.3. By consulting the DATA BASE, the FIAT PARTS DIVISION is capable, through the chassis no., of producing a control unit which has the same secret code as the faulty one. The DATA BASE will also be updated by entering the operation that has taken place.4. The FIAT PARTS DIVISION will send the control unit to the Dealer Network within 24 - 48 hours.5. Fit the new control unit in place of the faulty one.6. Carry out the KEY PROGRAMMING using the Examiner or other diagnostic equipment working on the CODE control unit entering all the previously enabled keys.7. Carry out a final check on the CODE system using the Examiner or other diagnostic equipment.Replacing the engine management control unitA possible fault in the electronic injection control unit should always be confirmed through a thorough check using the Examiner or other diagnostic equipment.1. Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.2. Connect to the FIAT PARTS DIVISION giving the vehicle chassis no. and other information requested. Send an order using the V.O.R. procedure requesting an engine management control unit.3. The FIAT PARTS DIVISION will send a new unprogrammed control unit to the Dealer Network within 24 - 48 hours.4. Fit the new control unit in place of the faulty one.5. Turn the key to the ON position: the CODE control unit will initialize the new control unit sending the secret code.6. Carry out a final check on the engine management system using the Examiner or other diagnostic equipment.Receiver replacement (versions with alarm only)A possible fault in the receiver should always be confirmed through a thorough check using the Examiner or other diagnostic equipment.1. Ask the Customer for all the remaining keys in their possession. They should also prove that they are the owner of the vehicle by producing the registration document and identification data.2. Connect to the FIAT PARTS DIVISION: giving the vehicle chassis no. and other information requested. Send an order requesting a receiver.3. FIAT PARTS DIVISION should send a new, unprogrammed receiver.4. Fit the receiver in place of the faulty one.5. Carry out the REMOTE CONTROL PROGRAMMING using the Examiner or other diagnostic equipment working on the alarm control unit and not on the CODE control unit, entering all the keys present.

the receiver PASSWORD must be entered to carry out this procedure. Ask the FIAT PARTS DIVISION for this PASSWORD, always providing the chassis no. of the vehicle.

6. Carry out a final check on the alarm system using the Examiner or other diagnostic equipment.Alarm control unit replacement (versions with alarm only)A possible fault in the alarm control unit should always be confirmed through a thorough check using the Examiner or other diagnostic equipment.If the alarm control unit is being replaced, it is NOT necessary to carry out the REMOTE CONTROL PROGRAMMING using the Examiner or other diagnostic equipment, but simply to carry out the simplified "CONTROL UNIT PROGRAMMING" procedure which simply "passes" all the data and codes in the receiver onto the new control unit.If the control unit is being replaced, carry out a final check on the alarm system using the Examiner or other diagnostic equipment.