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Abarth - 500 - Parts Catalogue - 2008 - 2014
Fiat - 500 Abarth - Miscellaneous Documents - 2009 - 2010
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Fiat - 500 Abarth - Owners Manual - 2015 - 2015
Abarth - 500C - Sales Brochure - 1949 - 1949 (German)
Abarth - 500C - Sales Brochure - 1949 - 2011
Fiat - Auto - fiat-500-abarth-2012-blue-and-me-user-s-manual-37201_5d8a7f6c3b0ca3a08410135
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Abarth - 500 - Owners Manual - 2008 - 2008 (Dutch)
Abarth - 500 - Workshop Manual - (2013) (8)
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Abarth - 500 - Sales Brochure - (2007) (4)
Abarth - 500 - Sales Brochure - (2007) (3)
Abarth - 500 - Owners Manual - (2015) (3)
Abarth - 500 - Owners Manual - (2014) (7)
Abarth - 500 - Sales Brochure - (1949)
Abarth - 500 - Owners Manual - 2009 - 2009 (French)
Abarth - 500 - Owners Manual - (2014) (4)
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Abarth - 500C - Owners Manual - (2014)
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Abarth - 500 - Workshop Manual - 2007 - 2014
Abarth - 500 - Owners Manual - (2010)
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Abarth - 500 - Sales Brochure - (2013) (4)
Abarth - 500 - Sales Brochure - 1949 - 2012
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Abarth - 500 - Owners Manual - (2012) (5)
Abarth - 500 - Owners Manual - (2014) (5)
Abarth - 500 - Sales Brochure - 2012 - 2012 (French)
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Abarth - 500 - Owners Manual - 2011 - 2011 (Italian)
Abarth - 500 - Owners Manual - (2010) (Italian)
Summary of Content
Contents INTRODUCTION ..................................................................................................................................... 2 DIMENSIONS .......................................................................................................................................... 3 TECHNICAL SPECIFICATIONS ............................................................................................................ 4 BACCI DOG RING GEARBOX (OPT) .................................................................................................... 5 MAIN SHAFT ............................................................................................................................................7 LAYSHAFT...............................................................................................................................................7 GEARS ....................................................................................................................................................7 GEARBOX RATIOS..................................................................................................................................12 DIFFERENTIAL AND FINAL DRIVE RATIO....................................................................................................12 Differential pre-loading check......................................................................................................... 15 PASSENGER COMPARTMENT GEAR LEVER FRAME ....................................................................................15 MATERIAL USED AND TREATMENTS .........................................................................................................18 Dog ring gearbox kit ....................................................................................................................... 18 Shim type self-locking differential................................................................................................... 19 FRONT SEATS ..................................................................................................................................... 19 LEXAN KIT (7UW) ................................................................................................................................ 19 INTERIOR HANDLES ........................................................................................................................... 20 ANTI-INTRUSION GRID AND REAR BAR .......................................................................................... 20 FRONT AND REAR SHOCK ABSORBER UNIT ................................................................................. 21 ADJUSTMENTS ......................................................................................................................................22 Extension ........................................................................................................................................ 22 Spring holders and pre-loading ring nuts ....................................................................................... 23 MAINTENANCE AND CHECKING ....................................................................................................... 23 STEM INSPECTION .................................................................................................................................23 REMOVAL OF FRONT SHOCK ABSORBERS ................................................................................................25 TRACK KIT ........................................................................................................................................... 25 DIGITAL DATA LOGGER AIM MXL2 LCD .....................................................................................................25 Description ..................................................................................................................................... 28 Connection with the control units ................................................................................................... 29 Engine RPM ................................................................................................................................... 30 Speed signal................................................................................................................................... 30 Connector pinout ............................................................................................................................ 30 Wiring diagram ............................................................................................................................... 31 4-POINT SABELT SEAT BELTS .................................................................................................................32 EXHAUST ............................................................................................................................................. 34 SPORT MODE ........................................................................................................................................34 Exhaust .......................................................................................................................................... 35 “SPORT” mode pneumatic actuator ............................................................................................... 36 Sport mode activation button ......................................................................................................... 36 Three-way valve ............................................................................................................................. 37 “Sport” mode control unit ................................................................................................................ 37 SCHEDULED SERVICING PLAN ........................................................................................................ 40 ENGINE MANAGEMENT WIRING DIAGRAM ..................................................................................... 41 ABARTH 695 BIPOSTO -1- REV. 1.0 INTRODUCTION 695 Biposto: the perfect blend of on-road performance and racing thrill. With a dry weight of just 997 kg (unladen weight 1020 kg) and the 190 HP 1.4 T-Jet engine, the 695 biposto is the vehicle with the best weight/power ratio (5.2 kg/HP) and the best 0–100 km/h acceleration in its category (5.9''), with a top speed of 230 km/h. Technological excellence, passion for extreme performance, an obsession with adrenaline and a dash of madness: this is the Abarth formula. Key: 1. Front bumpers with carbon fibre surround. 2. Aluminium bonnet. 3. Polycarbonate windows with sliding hatches (Racing Windows kit). Key: 1. Carbon fibre diffuser. 2. Titanium exhaust tailpipe. 3. Carbon fibre side skirt; ABARTH 695 BIPOSTO -2- REV. 1.0 DIMENSIONS DIMENSIONS ABARTH 695 BIPOSTO WIDTH 1647 HEIGHT 1485 WHEELBASE 2300 FRONT TRACK 1429 REAR TRACK 1422 -3- REV. 1.0 TECHNICAL SPECIFICATIONS NO. OF CYLINDERS, ARRANGEMENT 4 CYLINDERS IN LINE, 1368 CM POWER KW (HP) RPM 139 KW (190 HP) AT 5750 RPM MAX. TORQUE NM RPM 250 NM AT 2500 RPM (SPORT MODE) MAX. TORQUE NM RPM WITH DOG RING GEARBOX 270 NM AT 2500 RPM (SPORT MODE) TURBO GT1446 BORE X STROKE 72X84 COMPRESSION RATIO 9.0:1 ENGINE T-JET TOP SPEED (KM/H) 230 ACCELERATION 0-100 KM/H 5.9 DRIVE FRONT GEARBOX 5-SPEED MANUAL FRONT MACPHERSON LAYOUT AND ANTI-ROLL BAR REAR INTER-CONNECTED WHEEL SUSPENSION THROUGH TORSION BEAM WITH ANTI-ROLL BAR FRONT (mm) SELF-VENTILATING BRAKE DISCS Ø 305 MM X 28 MM REAR (mm) BRAKE DISCS Ø 240 MM X 11 MM STEERING TYPE DUALDRIVE ELECTRIC POWER STEERING WITH SPORT MODE URBAN (L/100 KM) 8.2 COMBINED (L/100 KM) 6.2 EXTRA-URBAN (L/100 KM) 5.1 CO2 EMISSIONS 145 EMISSIONS LEVEL EURO 6 WHEELS RIMS LIGHTENED 18” OZ ALLOY WHEEL RIMS 215/35 R18 ELECTRICAL SYSTEM BATTERY 250 A / 50 AH EXHAUST EXHAUST PIPE DUAL STAGE ABARTH BY AKRAPOVIC ENGINE 3 PERFORMANCE TRANSMISSION SUSPENSION BRAKES TM STEERING CONSUMPTION AND EMISSIONS LEVEL SHOCK ABSORBERS AIR CLEANER ABARTH 695 BIPOSTO HEIGHT-ADJUSTABLE EXTREME SHOX WITH SPORTS SPRINGS HEIGHT-ADJUSTABLE EXTREME SHOX WITH SPORTS SPRINGS FRONT (mm) REAR (mm) FILTER BMC OTA CLEANER -4- REV. 1.0 BACCI DOG RING GEARBOX (OPT) The gearbox has been designed to provide high performance content for an original C510 gearbox casing mod. 2013, fitted on the new Abarth 695 biposto. The gearbox features 5 forward gears plus reverse, with H scheme, without synchronisers, dog ring type (used in the sport - Motorsport gearbox types) and, thanks to its design, no adaptation of the original gearbox casing is required for fitting it. The specific and special quality of the dog ring gearbox is reducing the gear engagement time: since there is not a synchroniser to slow down the gear before engagement, the passage between one gear and the next one takes place very quickly, with the dog- ring (sliding sleeve) teeth and the relevant sliding gear appearing directly. Their engagement is guaranteed by the engagement teeth with a dovetail shape. The gearbox has a transverse configuration with 2 shafts in a cascade: it thus replicates the original configuration. Given the extreme conditions of use often undergone by this type of gearbox, the entire transmission requires more frequent overhauls. A dog ring gearbox always requires (as in the synchronised version) the clutch for changing gear (both for upshifting and down- shifting) and ideally the “double declutching” technique during downshifting. The gearbox lubricant operating temperature must be between 50°C and 105 °C; therefore it is highly recommended to warm up the gearbox oil without forcing the transmission too much, since the future Abarth 695 biposto will be used on the road and the lubricant cannot be warmed up before starting; this will cause the user to feel a "rough" behaviour with cold oil. Above 120°C, the transmission oil deteriorates and the internal expansion of the gearbox will start to become critical, changing the design tolerances considerably. In racing, where dog ring gearboxes are used, during a season the mileage is about 5000 km. The racing gearbox has been modified in order to approach the duration of a gearbox for road use, and therefore engine oil must be changed every 25000 km (or every year), and the self-locking differential pre-load must be checked every 20000 km. If the vehicle is used in demanding conditions the engine oil must be changed and the differential pre-load must be checked, as racing vehicles are set up after each race. ABARTH 695 BIPOSTO -5- REV. 1.0 ABARTH 695 BIPOSTO -6- REV. 1.0 Key: 1 – Main shaft 2 – 1st Sliding 3 – 2nd Sliding 4 – 3rd Sliding 5 – 4th Sliding 6 – 5th Sliding 7 – 3rd Fixed 8 – 4th Fixed 9 – 5th Fixed 10 – Dog Ring 1st - 2nd 11 – Dog Ring 3rd - 4th 12 – Dog Ring 5th 13 – Hub 1st - 2nd 14 – Hub 3rd - 4th 15 – Hub 5th 16 – Idler wheel 17 – Fork 3rd - 4th 18 – Fork 5th 20 – Adjustment 2nd - 3rd 21 – Sliding adjustment 4th 23 – Pinion 24 – Ring gear 25 – Shaft nut 26 – Fork 1st - 2nd 76 – Roller cage 1st - 2nd - 3rd - 4th 79 – Main bearing (cod. FIAT 55190691) 80 – Roller cage 5th (cod. FIAT 55210414) 81 – Pinion bearing (cod. FIAT 55229274) MAIN SHAFT The main shaft consists of: - st nd 1 , 2 speed and Reverse fixed gears directly on the shaft. rd th 3 and 4 speed fixed gears (removable) fitted on the main shaft through a splined profile. th 5 speed sliding gear and relevant dog ring hub. Ribbing for original clutch disc. The main shaft is supported by two (original) ball bearings. LAYSHAFT The layshaft (pinion) consists of: - Final reduction ratio gear obtained directly on the shaft. st nd rd th 1 , 2 , 3 and 4 speed sliding gears. st nd rd th Hubs (fitted with a splined profile) and dogrings for 1 - 2 speed and 3 - 4 speed. th 5 speed fixed gear. rd th The layshaft is supported by two ball bearings (as initially). During the design stage the 3 and 4 speed sliding gears have been moved from the main shaft to the layshaft, in order to make the gear solution as robust as possible (for reasons related to internal space). rd th th This required the 3 /4 and 5 gear forks to be remade. GEARS The gears have the following characteristics: - Forward gears are helical toothed. - Reverse is straight toothed. - Forward gears have a ground tooth. - Splined profiles have a ground tooth. All the material provided with the gearbox undergoes a surface superfinishing treatment to reduce roughness, after the thermal treatment. All the sliding gears rotate on roller cages, suitably sized for their use. ABARTH 695 BIPOSTO -7- REV. 1.0 Key: 1 – Main shaft 6 – 5th Sliding 7 – 3rd Fixed 8 – 4th Fixed 12 – Dog Ring 5th 15 – Hub 5th ABARTH 695 BIPOSTO 16 – Idler wheel 18 – Fork 5th 25 – Shaft nut 79 – Main bearing (cod. FIAT 55190691) 80 – Roller cage 5th (cod. FIAT 55210414) -8- REV. 1.0 Key: 2 – 1st Sliding 3 – 2nd Sliding 4 – 3rd Sliding 5 – 4th Sliding 9 – 5th Fixed 10 – Dog Ring 1st - 2nd 11 – Dog Ring 3rd - 4th 13 – Hub 1st - 2nd 14 – Hub 3rd - 4th ABARTH 695 BIPOSTO 17 – Fork 3rd - 4th 20 – Adjustment 2nd - 3rd 21 – Sliding adjustment 4th 23 – Pinion 25 – Shaft nut 26 – Fork 1st - 2nd 76 – Roller cage 1st - 2nd - 3rd - 4th 81 – Pinion bearing (cod. FIAT 55229274) -9- REV. 1.0 Key: 1 – Main shaft 2 – Main shaft rear bearing 3 – 4th speed gear 4 – 3rd speed gear ABARTH 695 BIPOSTO 5 – 2nd speed gear 6 – Reverse gear 7 – 1st speed gear 8 – Main shaft front bearing -10- REV. 1.0 Key: 1 – Layshaft 2 – Differential idler gear 3 – 1st speed gear 4 – 1st – 2nd speed selection sleeve 5 – 2nd speed gear ABARTH 695 BIPOSTO 6 – 3rd speed gear 7 – 3rd – 4th speed selection sleeve 8 – 4th speed gear 9 – Layshaft rear bearing -11- REV. 1.0 GEARBOX RATIOS The gearbox kit is provided with a global set of reduction ratios close to that currently on the Abarth 500. The main gearbox characteristics are summarised below: Gearbox specifications Dog ring gearbox (not synchronised) Gearbox family C510 Number of gears 5 + reverse Gearbox ratios Transmission ratios Differential ratio Ratios at the wheels 1st gear 3.455 10.973 2nd gear 2.133 6.776 3rd gear 1.474 4.681 3.18 4th gear 1.130 3.591 5th gear 0.923 2.932 Reverse 3.909 12.419 DIFFERENTIAL AND FINAL DRIVE RATIO The differential unit is located in the original position of that for the C510 casing, and supported by the same original tapered roller bearings. It comprises:    A final drive ratio (pinion + ring gear). A self-locking differential (sport- Motorsport type) with clutch fins, ramps and a Belleville preloading spring. After the tests have been carried out, the type of calibration chosen by Abarth is as follows: a. Acceleration ramp: 45°; b. Deceleration ramp: 30°; c. Operating clutch fins: one for each side; d. Pre-loading with new differential: 30- 40 Nm.  The left side housing (differential output driveshaft) with oversized shaft (ribbing Z=26 teeth) to guarantee that it is sufficiently reliable with respect to the additional stress due to the selflocking differential; the housing is still completely compatible with the original spider and boot of the Abarth 500. The right side differential output shaft will be original, with ribbing, Z=24 teeth, since it undergoes less torsional stress than that on the left side. The proposed mechanical self-locking differential type is that with clutch fins and ramps. This type of mechanical system is that most used in the world of racing. When the drive wheel grip on the road surface is not perfect, the self-locking differential guarantees that the torque available on the drive wheels is as balanced as possible, to achieve the most traction available. ABARTH 695 BIPOSTO -12- REV. 1.0 Key: 24 – Ring gear; 28 – Casing 29 – Differential cap 30 – Left planet gear 31 – Right planet gear 32 – Planet gear adjustment 33 – Satellite 34 – LH fastening hub ABARTH 695 BIPOSTO 35 – Cross 36 – Fin D.I.37 – Fin D.E.(outer teeth) 38 – Cup spring 39 – Housing D.A.(self-locking differential) (tulip) 44 – Circlip for left driveshaft 49 – RH fastening hub 50 – 10 x screw M10x1.25 L23 12.9 51 – 16 x screw M6x1 L20 12.9 -13- REV. 1.0 NOTE: the differential ring gear has a single assembly direction on the differential. It is advisable to make a sign to identify the correct positioning in the event of disassembly and refitting. The figure shows how the ring gear internal bevel must be positioned towards the differential cover. Key: 1 – Ring gear 2 – Bevel ABARTH 695 BIPOSTO 3 – Casing -14- REV. 1.0 Differential pre-loading check A specific tool (shaft with ribbing that couples with the planet gear) to be secured on a vice is used for the pre-loading check; the assembled differential is fitted on this tool. On the other side of the differential a torque wrench (equipped with a similar shaft with ribbing) is used to check that the differential pre-loading torque is as specified. PASSENGER COMPARTMENT GEAR LEVER FRAME An aluminium turret (frame), for supporting a high-resistance aluminium alloy gear lever, is provided with the dog ring gearbox and the self-locking differential. This gear lever kit is the ideal solution to complete a dog ring gearbox, since the reduced travel of the lever (compared to the gear lever of a road vehicle) allows the user to carry out extremely rapid gearshifting. The aluminium turret is obtained by shell casting, has been manufactured according to Abarth specifications to fit the tunnel of the Abarth 695 biposto, and is anodised. The remaining aluminium parts are obtained by turning and/or milling the solid material. ABARTH 695 BIPOSTO -15- REV. 1.0 The control Bowden cables connecting the lever inside the passenger compartment to the gearbox are original Abarth 500 components, and have been modified to adapt to the kit provided. These Bowden cables have various adjustment possibilities as far as the relative position of the lever and the gearbox is concerned, since the rod- ends are threaded on the control cable. The lower part of the frame includes a grid, which facilitates and allows perfect positioning of the lever during gearshifting. ABARTH 695 BIPOSTO -16- REV. 1.0 ABARTH 695 BIPOSTO -17- REV. 1.0 Key: 19 – Frame 22 – Lever 40 – Grid H 41 – Lever rocker 42 – Rocker L 45 – Low uniball spacer 46 – High uniball spacer 47 – Pin of grid H 48 – Pin cylinder of grid H 50 – Lever rocker shaft 51 – Cage HK L15 52 – Lever spacer 53 – Lever axle 54 – Knob 55 – Snap ring of grid H pin 56 – Lever axle snap ring 57 – Lever rocker tooth 58 – Grid H screw 59 – Pin of rocker L 60 – Cage HK L12 61 – Cap of rocker L 62 – Cap screw of rocker L 63 – Torx screw L25 64 – Torx screw L30 65 – Uniball nut 66 – Pivot head 67 – Threaded rod 68 – Shaft washer on Bowden side 69 – Shaft washer on rocker side 70 – Shaft washer cap 71 – Groover washer 72 – Lever shaft screw 73 – Angular joint D10 74 – Angular joint D13 75 – Bowden cable 82 – Spring (FIAT 775398D) MATERIAL USED AND TREATMENTS The kit components are produced with special steels and undergo casehardening and hardening thermal treatments. The gears are ground-tooth type and the grooves of the main shaft and pinion are ground as well; to reduce the remaining surface roughness effectively, all the components undergo surface superfinishing. Two of the three forks have been remade along with the gearbox kit. The left side housing with oversized shaft has a ribbing, Z=26 teeth, and is still compatible with the original spider. The steel used for the housing has been hardened and tempered. Dog ring gearbox kit Main shaft 1st sliding gear 2nd sliding gear 3rd sliding gear 4th sliding gear 5th sliding gear 3rd fixed gear 4th fixed gear 5th fixed gear Sleeve 1st - 2nd Sleeve 3rd - 4th Sleeve 5th Hub 1st - 2nd Hub 3rd - 4th Hub 5th Reverse idler gear Sliding adjustment 2nd- 3rd Casehardening and Vacuum hardening + Cryogenic + Surface superfinishing Sliding adjustment 4th Pinion Ring gear Fork 3rd- 4th Fork 5th Pinion and main shaft nuts Gearbox internal springs Roller cages ABARTH 695 BIPOSTO Induction + Burnishing Burnishing Standardisation ISO 3030 standard -18- REV. 1.0 Shim type self-locking differential Differential housing Differential cover Fastening hub Sun gear Planetary gear Cruising “Belleville” round washer Casehardening and Vacuum hardening + Cryogenic + Surface superfinishing Oil hardening + Tempering + Surface superfinishing Hardening and tempering + Surface superfinishing Hardening and tempering + Molybdenum coating Differential output housing Outer teeth clutch fin Inner teeth clutch fin FRONT SEATS The front seats are made of technical fabric and Alcantara, with composite material shell (carbon is available as option). LEXAN KIT (7UW) For vehicles equipped with the “Lexan kit” option, the driver and passenger front side windows are fixed, made of polycarbonate and equipped with sliding hatches. ABARTH 695 BIPOSTO -19- REV. 1.0 NOTE: Water penetration and wind noise from the side windows and the hatches must not be considered as fitting or design faults. INTERIOR HANDLES The vehicle is equipped with fabric bands for closing the doors from the inside. These are fitted on the driver side and passenger side internal door panels and provide a convenient handhold for closing the doors. Use the fabric band in the internal part of the tailgate to close it more easily. ANTI-INTRUSION GRID AND REAR BAR The vehicle is equipped with an anti-intrusion grid, which retains the luggage, secured to the rear titanium bar. ABARTH 695 BIPOSTO -20- REV. 1.0 FRONT AND REAR SHOCK ABSORBER UNIT The 695 Biposto features the EXTREMESHOX shock absorbers. The EXTREMESHOX shock absorbers have been designed to maintain the correct damping factor, regardless of temperature changes. The front shock absorbers feature interchangeable springs and height-adjustable spring holders. Key: 1 – Extension adjustment 4 – Helper 2 – Strut 5 – Main spring 3 – Pre-loading ring nuts 6 – Top Mounting ABARTH 695 BIPOSTO -21- REV. 1.0 Key: 1 – Nitrogen reservoir 3 – Extension adjustment 2 – End of travel buffer ADJUSTMENTS Extension To adjust extension of the rear shock absorber, rotate the adjustment (5-mm adjustment socket wrench) clockwise until it is locked (do not force it). Carry out the same procedure for the front shock absorber manually, using the red anodised knob located under the strut. ABARTH 695 BIPOSTO -22- REV. 1.0 This is the “fully closed” position and is called “0 click”. The maximum extension of the brake is obtained in this position. To soften the extension, rotate the adjustment anticlockwise for the relevant number of clicks. The fully open position is characterised by 18 clicks. Spring holders and pre-loading ring nuts The front spring holders and the pre-loading nuts are designed to be adjusted using pin wrenches, available commercially. MAINTENANCE AND CHECKING The shock absorbers are very important components of the vehicle. This is why they must always be kept in perfect condition, cleaning them and thoroughly checking any possible fault. Regularly check the condition of the chromed stem surface as a good preventive inspection measure. Check wear, dents or areas with scratches. The presence of a small amount of oil on the stem can be overlooked. If there is a constant leak of oil from the shock absorber, contact the assistance service as soon as possible. NOTE: overhaul by an Abarth service centre is recommended every 5000 km of road use or every 1000 km of racing use. STEM INSPECTION The external condition of the cartridge should be checked periodically, in particular the area of the stem and of the lower cap; carry out the following operations to do this:  Remove the spring pack.  Completely close the extension register (fully closed position).  Release the shock absorber cartridge, unscrewing the cap around the extension adjustment using a 14-mm wrench (blue Loctite is present). ABARTH 695 BIPOSTO -23- REV. 1.0  Undo the nut (21 size wrench) to release the strut cartridge, sliding it from the inner guides. ABARTH 695 BIPOSTO -24- REV. 1.0  Check the condition of the lower cap, looking for any trace of oil leak.  Check the condition of the buffer.  Refit the cartridge, taking care that the stem guide is fitted next to the housing inside the strut, before tightening the nut (correct positioning can be felt by hand). (Internal component welded to the strut) (Stem guide)  Retighten the nut (21 size wrench) with tightening torque of 65 Nm.  Retighten the extension adjustment cap with blue Loctite, without forcing it.  Restore the spring pack. NOTE: visual inspection is sufficient for the rear stem since it is exposed. REMOVAL OF FRONT SHOCK ABSORBERS The vehicle is equipped on the front with shock absorbers that are equivalent in terms of hydraulics, but different on the right/left for the strut attachments. TRACK KIT Includes:   Digital data logger AIM MXL2 LCD; front 4-point Sabelt seat belts. DIGITAL DATA LOGGER AIM MXL2 LCD ABARTH 695 BIPOSTO -25- REV. 1.0 The digital data logger AIM MXL2 LCD can be installed as an option. With its high contrast display, it has been developed to be installed on racing cars. The tool is completely configurable by the customer, for a maximum of 8 pages, and the data acquired are collected from a very wide range of sources, including the vehicle control units, the accelerometers and the internal gyroscopes. NOTE: Fitting of the telemetric device makes the vehicle NON-COMPLIANT with the typeapproval standards for road traffic; therefore it is subject to possible sanctions envisaged by the local laws. Abarth &C. S.p.a. shall not be liable for fitting and use of the 4-point seat belts in areas where these are forbidden. If the 4-point seat belts are removed the vehicle becomes compliant with the type-approval standards for road traffic again. The kit consists of:    1 telemetric device and relevant wiring (1) (pre-fitted on the suitable mounting); 1 mounting bracket for the dashboard crossmember (2) and relevant fixing screw; 1 connector for interface/diagnosis (3) and relevant cap and ring nut. The telemetric device mounting bracket must be installed, with the dedicated screw, inside the radio compartment, in the area where the dashboard is secured to the crossmember. ABARTH 695 BIPOSTO -26- REV. 1.0 Once the mounting has been fitted, the telemetric device is fitted in the vehicle as shown in the image below. The diagnosis connector will be fitted on the bracket inside the diagnosis socket compartment, drilling a 18.5-mm hole and fitting the interface/diagnosis connector, the cap and the ring nut in it. ABARTH 695 BIPOSTO -27- REV. 1.0 Description Key: 1 – 1-3 (configurable) alarm LEDs 3 – 4-6 (configurable) alarm LEDs 2 – Shifting lights 4 – Multifunction buttons The main unit (2) with 10 LEDs can be configured with great flexibility. There are also 6 different LED alarms - (1), (3) - that can be set to turn on or off, according to the digital or analogue input signals. ABARTH 695 BIPOSTO -28- REV. 1.0 Key: 1 – Motorsport connectors 2 – Aluminium body Connection with the control units The data logger can acquire data from the vehicle's control units and is compatible with the following connection systems:    CAN; RS232; K Line. Proceed as follows to manage the data from the Powertrain Control Module: 1. determine the hardware connection available for the control unit; 2. connect to the www.aim-sportline.com website and identify the suitable software driver; 3. use the software of the telemetric device to select the driver in the menu. ABARTH 695 BIPOSTO -29- REV. 1.0 Engine RPM The engine rpm signal can be received from different sources:    From the Powertrain Control Module. Through a square wave signal (8 V - 50 V). From the coil low voltage circuit (150 V - 400 V). Speed signal The speed signal can be received from different sources:    From the Powertrain Control Module. From the GPS receiver included into the kit. From the wheel speed sensors. Connector pinout Connection with the telemetric device is made through the bigger 37-pin connector. Key: 1 – 9 – 15 V power in 2 – battery earth 3 – CAN + Exp 4 – earth 5 – CAN batt power supply 6 – CAN - Exp 7 – + Vbext 8 – CAN 1 + ECU 9 – CAN 1 - ECU 10 – earth 11 – K line ECU 12 – USB D+ 13 – USB D14 – Earth 15 – RPM 16 – Earth 17 – + Vbatt 18 – Optical lap 19 – Speed 1 ABARTH 695 BIPOSTO 20 – Earth 21 – + Vbatt 22 – Ain 1 23 – analogue earth 24 – + Vbatt 25 – + Vref 26 – Ain 2 27 – analogue earth 28 – + Vbatt 29 – + Vref 30 – Ain 3 31 – analogue earth 32 – + Vbatt 33 – + Vref 34 – Ain 4 35 – analogue earth 36 – + Vbatt 37 – + Vref -30- REV. 1.0 Wiring diagram Key: 1 – BCM 2 – FIAT wiring side connection 3 – Telemetric device wiring side connection ABARTH 695 BIPOSTO 4 – MXL-2 tool 5 – Connector -31- REV. 1.0 4-POINT SABELT SEAT BELTS ABARTH 695 BIPOSTO -32- REV. 1.0 ABARTH 695 BIPOSTO -33- REV. 1.0 Both seats of the Abarth 695 Biposto are arranged for fitting the 4-point seat belts. Anchorage rods are fitted on its inner sides, while fitted on the outer side is a threaded ring screw on which the belt attachment shackle (in the figure) can be coupled. NOTE: Fitting of the 4-point seat belts makes the vehicle NON-COMPLIANT with the typeapproval standards for road traffic; therefore it is subject to possible sanctions envisaged by the local laws. Abarth &C. S.p.a. shall not be liable for fitting and use of the 4-point seat belts in areas where these are forbidden. If the 4-point seat belts are removed the vehicle becomes compliant with the type-approval standards for road traffic again. EXHAUST An Akrapovic, titanium exhaust with double outlet, with a pneumatic actuator installed on it, is fitted as standard. The actuator unit is welded on the exhaust. Key: 1 – Pneumatic actuator SPORT MODE The “sport mode” package includes the following components:  Titanium exhaust with double outlet (1) and pneumatic actuator for the “Sport” mode (2).  “Sport” mode (3) activation button, located on the central dashboard. ABARTH 695 BIPOSTO -34- REV. 1.0   One three-way valve, connected to the pneumatic actuator located on the exhaust (4). “Sport” activation control unit, located in the engine compartment, between the battery and the front driver side light cluster (5). Exhaust In titanium, as standard. Characterised by a double outlet. The pneumatic actuator is welded on the exhaust circuit and is next to the spring of the right rear shock absorber unit. ABARTH 695 BIPOSTO -35- REV. 1.0 “SPORT” mode pneumatic actuator The actuator is welded on the titanium exhaust, is vacuum controlled and is normally open. When the “Sport” mode is not requested, the three-way valve creates a vacuum on the head of the actuator, the pressure imbalance created inside the actuator head moves the control rod and the throttle closes. Sport mode activation button It is located in the central control dashboard, connected to the Body Computer. Once pressed, an activation request is sent to the Body, which will send the request status to the Sport mode control unit via CAN. ABARTH 695 BIPOSTO -36- REV. 1.0 Three-way valve The valve is in the engine compartment, on the engine compartment/passenger compartment partition. The route of the pipe that brings the vacuum to the pneumatic actuator is highlighted in the figure below. “Sport” mode control unit It is located in the engine compartment, between the battery and the front right light cluster; it is connected to the Body Computer via C-CAN. When the SPORT mode is requested (by pressing the button), the information reaches the Body, which makes it available on the C-CAN. The control unit reads the message and controls the three-way valve. ABARTH 695 BIPOSTO -37- REV. 1.0 Key: 1. 2. 3. 4. 5. 6. 7. “Sport” mode activation request message. Body Computer. C-CAN line connecting Body Computer – Sport control unit. Sport control unit. Pierburg three-way valve. Vacuum. Pneumatic actuator. ABARTH 695 BIPOSTO -38- REV. 1.0 Wiring diagram Key: 1 – Exhaust valve operating module side connector. 2 – Front wiring side connector for exhaust valve operating module 3 – + 15 V exhaust valve operating module 4 – BCM 5 – ECM 6 – Exhaust valve ABARTH 695 BIPOSTO 7 – Valve control (yellow/black) 8 – C CAN H (white) 9 – C CAN L (brown) 10 – Earth (black) 11 – +15 (red) -39- REV. 1.0 SCHEDULED SERVICING PLAN Servicing must be performed every 5,000 km or at the end of a race on track. Thousands of kilometres 5 10 15 20 25 30 35 40 45 50 Check tyre condition/wear and adjust pressure, if necessary. Check quick tyre repair kit recharge expiry date (if provided) Check operation of lighting system (headlights, direction indicators, hazard warning lights, luggage compartment, passenger compartment, glove compartment, instrument panel warning lights, etc.) Check and, if necessary, top up fluid levels (engine coolant, hydraulic clutch/brakes, windscreen washer, battery, etc.) ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Check exhaust emissions/smokiness ● ● ● ● ● Visually inspect condition of: exterior bodywork, underbody protection, pipes and hoses (exhaust – fuel system - brakes), rubber elements (boots, sleeves, bushes, etc.) ● ● ● ● ● Check windscreen/rear window wiper blade position/wear ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Check operation of windscreen washer system and adjust jets if necessary Check cleanliness of bonnet and luggage compartment locks, as well as cleanliness and lubrication of linkages Check handbrake lever travel and adjust, if necessary Visually inspect condition and wear of front disc brake pads and operation of pad wear indicator Visually inspect condition and wear of rear disc brake pads and operation of pad wear indication ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Check tension of accessory drive belt(s) and adjust if necessary ● ● Visually inspect conditions of toothed timing drive belt Check and, if necessary, restore the self-locking differential pre-loading (■) Visually inspect condition of the front and rear shock absorber stem (■) ● ● ● ● ● ● ● ● ● ● ● Gearbox oil change (■) (**) ● Change engine oil and oil filter (■) (**) ● ● ● ● ● ● ● ● Replace spark plugs (*) Replace toothed timing drive belt (▲) Replace accessory drive belt(s) (▲) ● Replace BMC air cleaner cartridge (■) ● (**) Change brake fluid (■) Once 50,000 km have been exceeded, the operations contained in the Scheduled Servicing Plan must be cyclically repeated restarting from the first interval, thus complying with the same time intervals fulfilled previously. (*) The following are essential to ensure correct operation and prevent serious damage to the engine: only use spark plugs of the same make and type specially certified for 1.4 Turbo petrol Abarth engines (see the information in the "Engine" paragraph); strictly comply with the spark plug replacement interval given in the Scheduled Servicing Plan; it is advisable to contact an Abarth Dealership. (**) To be replaced every 12 months regardless of the mileage. (■) It is recommended to carry out this operation immediately after each time the vehicle has undergone demanding use. (▲) Areas that are not dusty: advised maximum mileage 120,000 km. Regardless of the mileage, the belt must be replaced every six years. Dusty areas and/or demanding use (cold climates, town use, long periods of idling): advised maximum mileage 60,000 km. Regardless of the mileage, the belt must be replaced every 4 years. ABARTH 695 BIPOSTO -40- REV. 1.0 ENGINE MANAGEMENT WIRING DIAGRAM ABARTH 695 BIPOSTO -41- REV. 1.0 Key: 1 – 12-way connector 2 – Compressor 3 – Starter 4 – Dump valve (only turbo versions) 5 – Canister solenoid valve 6 – Engine oil pressure sensor 1 7 – Alternator D+ 8 – Knock sensor 9 – Cylinder 1 injector 10 – Cylinder 2 injector 11 – Cylinder 3 injector 12 – Cylinder 4 injector 13 – Cylinder 3 ignition coil 14 – Cylinder 4 ignition coil 15 – Cylinder 2 ignition coil 16 – Cylinder 1 ignition coil 17 – Turbo pressure sensor 18 – Air pressure and temperature sensor 19 – Timing sensor 20 – Engine coolant temperature sensor 21 – Motorised throttle 22 – Engine rpm sensor 23 – Downstream oxygen sensor 24 – Upstream oxygen sensor ABARTH 695 BIPOSTO -42- REV. 1.0 ABARTH 695 BIPOSTO -43- REV. 1.0 Key: 1 – Fuel pump 2 – Front/rear disconnection 3 – Fuel pump relay 4 – T09 Main relay 5 – T07 engine cooling solenoid valve high speed 6 – T07 engine cooling solenoid valve low speed 7 – Alternator D+ 8 – Ignition switch 9 – 12-way connector 10 – Wastegate solenoid valve 11 – BCM 12 – Brake light control (left hand drive) 13 – Brake light control (right hand drive) 14 – Battery negative pole engine earth 15 – Accelerator pedal potentiometer 16 – Clutch analogue sensor 17 – Linear pressure sensor for air conditioning system 18 – Reversing switch ABARTH 695 BIPOSTO -44- REV. 1.0