Get Knowing Your Vehicle -> Version with Methane System (Natural Power) Guide for Fiat Fiorino SUV Third Generation (2015-2026)

the addition of special accessories, can

be used to carry various objects (e.g.

skis, surfboards, etc.).

The Methane Multipoint

Injection System

VERSION WITH

METHANE SYSTEM

(Natural Power)

It is an original product of Fiat research

in the field of alternative fuels, that

comes from close co-operation with

major suppliers in the methane sector.

By adapting the sophisticated

electronic control technology of petrol

engines to meet the specifications

of methane, it has been possible to

achieve important results in terms of

driveability, exhaust emissions and

consumption.

With the methane Multipoint injection

system, the engine features the same

driveability as a petrol fuelled system.

It should be borne in mind that,

under all driving conditions, methane

operation offers engine power

40) 41)

(for versions/markets, where provided)

5) 6)

42) 43) 44)

INTRODUCTION

WARNING

The "Natural Power" version features

two fuel systems, one for petrol and

one for natural gas (methane).

The two systems are independent of

each other and the CNG system is of

the Phased Sequential Multipoint type.

The starting system is the petrol

system in common to all versions.

40) Fully comply with the regulations in

force concerning maximum clearance.

41) After travelling for a few kilometres,

check to ensure that the fixing screws for

the attachments are well tightened.

IMPORTANT

What is natural gas?

Natural gas is a mixture of gas used as

a primary energy source.

Its main component is methane and

for this reason it is usually known as

"methane" in Italy but it contains small

amounts of other hydrocarbons and

inert gases.

It is extracted in a gaseous state

and transported to where it is used

through gas pipelines; world reserves

are plentiful and widely distributed.

Methane is a fuel with a low impact on

the environment, since it significantly

reduces the contribution of exhaust

gases to the greenhouse effect and

pollution.

5) Distribute the load evenly and pay

attention to side winds when driving.

6) Never exceed the maximum permitted

loads; see chapter "Technical Data".

and torque specifications 10%

lower than with petrol operation.

Petrol operation is therefore

recommended if a lot of power is

required (e.g. driving uphill with a

laden car, steep hill starts).

Selecting the type of

fuel supply

The vehicle is configured to run

normally on methane.

When the methane is running out and

the pressure in the cylinder is close

to the correct operating limit, the

55

system automatically switches to petrol

operation.

In particular, the cylinder location and

attachments are designed to pass the

impact tests in accordance with Fiat

safety standards. The flow of methane

from the cylinders is governed by a

solenoid valve that is open only during

methane operation.

The solenoid valve unit includes

protections against excess flows (if

the high pressure system breaks, the

flow of methane is restricted to values

that are not dangerous), overheating

(melting pad that allows the methane to

drain off if the temperature exceeds

110°C) and a pressure calibrated

device that intervenes if the pressure

goes above 300 bar ensuring the

methane escapes in a controlled

manner and as quickly as possible.

The solenoid valve is connected to

the Fire Protection System (fuel cut-off

system).

WARNING

The engine always starts up on petrol,

with automatic switching to methane

when the best conditions are achieved

(engine water temperature, minimum

engine rpm limit) for switching to

methane.

Therefore, there must always be some

petrol in the tank (at least 1/4 full), in

order not to compromise the operation

of the fuel pump.

42) The vehicle is equipped with a high-

pressure methane system designed to

operate at 200 rated bar. It is dangerous

to stretch the system with higher

pressures. To prevent damage to the

methane system parts when towing or

lifting the vehicle, follow the instructions

shown in the "Towing the vehicle" section.

If there is a problem with the methane

system, only contact a Fiat Dealership. Do

not modify configuration or components

of the methane system; they have been

designed exclusively for this vehicle. The

use of other components or materials

could cause malfunctions and prejudice

safety.

43) When oven painting, the cylinders

must be removed from the vehicle and

refitted by a Fiat Dealership. Although the

methane system has numerous safety

features, it is advisable to close the

manual tap on the cylinders whenever the

vehicle is not in use for a long period,

transported on other vehicles or moved in

an emergency as a result of a breakdown

or accident.

For this reason there must always

be petrol in the tank.

The petrol/methane switch fig. 109,

amongst the controls in the dashboard,

makes it possible to select petrol

operation. The system does not switch

automatically to methane operation if

the petrol runs out.

Active safety

The vehicle has the same active safety

specifications as other versions.

44) If gas is smelt, switch from methane

operation to petrol operation and

immediately go to a Fiat Dealerships to

have the vehicle checked and possible

system faults supply excluded.

WARNING If gas is smelled, switch

from methane operation to petrol

operation and immediately go to a Fiat

Dealership to have the vehicle checked

and possible system faults excluded.

109

F0T0343

Passive safety

The vehicle has the same passive

safety specifications as other versions.

56

SYSTEM FUNCTIONAL DIAGRAM

110

F0T0344

1. Methane cylinders 2. Methane filler 3. Methane pipes 4. Pressure regulator/reduction unit 5. Methane injector holder manifold

6. Petrol tank

57

methane cylinders comply with the

legislation in that country. In any

case, it should be remembered that

the life of the cylinders is 20 years

from the production date as set out

in ECE Regulation no. 110.

CYLINDERS

The vehicle has two cylinders (total

capacity about 77 litres) located under

the floor and protected by two special

guards.

The cylinders fig. 111 and fig. 112

are the tank that contains methane in

compressed gaseous state (200 rated

bar at 15°C).

The methane, stored in the canisters

at high pressure, flows through a

dedicated pipe to reach the pressure

regulator/reduction unit which supplies

the 4 methane injectors at low pressure

(about 6 bar).

SOLENOID VALVES /

SAFETY DEVICES

The solenoid valves fig. 113 and

fig. 113 are screwed directly onto the

methane cylinders: their main function

is to interrupt the flow of methane to

the supply circuit.

112

F0T0356

Cylinder certification

The methane cylinders are certified in

accordance with ECE Regulation no.

110.

The cylinders must be inspected, in

accordance with ECE Regulation

Procedure no. 110, every 4 years

from the vehicle registration date

or in accordance with specific

regulations in individual countries.

The other plates provided by the

Dealership with the vehicle documents

show the date when the first cylinder

inspection/test is due.

113

F0T0347

111

F0T0345

Methane refuelling stations are not

authorised to refill the cylinders

when the inspection date has

expired.

IMPORTANT If the vehicle has

been registered in a country other

than Italy, the certification and

identification data and the control

/ inspection procedures for the

114

F0T0348

58

The solenoid valves are open when:

the switching button is in the

methane position;

the pressure in the cylinder is

sufficient for operation;

This separates the cylinder from the

methane system to allow maintenance

operations.

The taps are accessible from outside

the vehicle and are located, in the case

of the lengthwise middle cylinder, at the

rear of the cylinder and, in the case of

the transverse rear cylinder, towards

the wheel right side.

PIPES

The methane piping from the filler to

the pressure regulator/reduction unit

is made from galvanised steel and

covered in plastic (high pressure) and

is located outside the passenger

compartment; the piping from the

pressure regulator/reduction unit to the

methane injectors is in stainless steel.

the engine is running;

The solenoid valve assembly is

equipped with the following safety

devices:

To close the taps (D) fig. 115: turn the

knob in the direction (1) shown by the

arrow (clockwise OFF).

To open the taps (D) fig. 115: turn the

knob in the direction (2) shown by the

arrow (anticlockwise ON).

1) Fuse pad: in the event of

overheating (temperature above 110

°C), it totally eliminates the danger of

excess pressure making the methane

in the cylinder flow out as quickly as

possible in a controlled manner.

2) Mechanical excess pressure

device (Burst Disk): in the event of

excess pressure (above 330 bar), it

ensures that the methane escapes

as quickly as possible in a controlled

manner.

PRESSURE

REGULATOR/REDUCTION

UNIT

The pressure reduction unit fig. 116 is

installed in the engine compartment.

It reduces the pressure of the methane

from the value in the cylinder to the

supply value for the methane injectors

(about 6 bar) and keeps it constant in

all operating conditions.

2

1

3) Excess flow device: intervenes

if the pipes break and limits the flow

of methane exiting to non dangerous

levels.

D

115

F0T0349

The flow restrictor valve is located to

allow it to operate even if the solenoid

valve casing is broken due to an

impact.

5) Check valve, this prevents the

methane from flowing back to the filler.

116

F0T0350

4) Manual tap: positioned upstream of

the solenoid valve.

59

of the capacity of the cylinders, the

first level and the edges of the bars of

the other 3 levels flash until the next

methane refuelling. A specific message

will appear on the display in addition to

an acoustic warning.

METHANE INJECTORS

There are four dedicated Methane gas

injectors (A) fig. 117, fitted on the intake

manifold near the cylinder head, one for

each intake duct; they are supplied at

a constant pressure (about 6 bar) and

operated by the electronic control unit.

119

F0T0382

118

F0T0462

117

F0T0351

If the methane has run out, switching

to petrol takes place automatically.

In this case, the display shows the

icon just above the CNG wording and

all the bars of the edges for the empty

notches light up constantly, regardless

of the type of supply; see fig. 119 or

fig. 120.

PETROL/METHANE

SWITCH

120

F0T0383

This engine normally runs on methane

except during starting when it runs on

petrol. Switching to methane takes

place automatically and is shown

on the instrument panel display by

switching off the signal in the

display.

If you want the car to run on petrol,

press the button fig. 121 located

between the controls in the dashboard.

The LED on the button switching on

indicates that the request for switching

has taken place correctly.

7)

METHANE FUEL RESERVE

The level of methane in the cylinders is

indicated by the four vertical bars near

the word CNG on the instrument panel

display fig. 118. When the residual

amount of methane is lower than 1/5

60

9)

PROTECTING THE

ENVIRONMENT

CNG SYSTEM FAILURE

In case of CNG system failure, all the

CNG fuel levels will turn off on the

display and the symbol "!" will appear

together with a dedicated message. In

this case, contact a Fiat Dealership as

quickly as possible.

The following devices are used for

reducing petrol fuel engine emissions:

three-way catalytic converter

Lambda sensors

evaporation control system.

In addition, do not let the engine run,

even for a test, with one or more spark

plugs disconnected.

The following devices are used for

reducing diesel fuel engine emissions:

oxidising catalytic converter;

exhaust gas recirculation system

(EGR);

121

F0T0343

IMPORTANT

The actual change to the chosen fuel

system takes place depending on the

vehicle usage conditions to guarantee

switching in absolute safety and will

be confirmed by the warning light

in the instrument panel display coming

on/going off.

Manual switching of the operating

mode from petrol to methane and

vice versa only occurs if the engine

speed is below 2000 rpm.

7) Regardless of the last fuel system used,

at the following engine starting, after

the initial petrol stage, the system will

automatically switch to methane.

8) When switching is requested, metallic

noise from the valves which pressurise

the circuit can be heard. For the switching

logic described above, a delay between

the valve ticking and the switching off the

indication on the instrument panel display.

9) Do not switch between the two

operating modes whilst starting the

engine.

particulate filter (DPF) (for

versions/markets, where provided).

DIESEL PARTICULATE

FILTER (DPF)

(for versions/markets, where provided)

The Diesel Particulate Filter is a

mechanical filter, integral to the exhaust

system, that physically traps carbon

particles present in the exhaust gases

of diesel engines.

8)

In addition, in the case of starting at

outside temperatures of below around

-10°C, the switching times from Petrol

to Methane increase to allow the

pressure regulator/reduction unit to

become warm enough.

The diesel particulate filter has been

adopted to eliminate almost all

particulates in compliance with current

/ future legal regulations.

During normal use of the vehicle, the

Powertrain Control Module records a

set of data (travel time, type of route,

temperatures reached etc.) and

WARNING If switching takes place

during acceleration or pick-up, there

may be a brief flat spot (drop in power).

61

Knowing Your Vehicle -> Version with Methane System (Natural Power) for Your Fiat Fiorino SUV Third Generation (2015-2026)

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