Fiat Lancia Tester

The Fiat Lancia Tester made by Magneti Marelli (Fiat part no. 1806039000 , M.M. part no. 64890013) was the successor to the PR01 Electronic Analyzer (Fiat part no. 1806034000). The FLT was used by Fiat and Lancia dealers to check and adjust the ECU parameters for those vehicles fitted with a 3 pin diagnostic socket from the late 1980's until the mid 1990's when it was replaced by the Examiner system. Versions were also made for Alfa Romeo (Fiat part no. 1827014000) and Ferrari. The FLT is a hand-held computer with a LCD display and 4 X 5 keypad and is powered by a 12V or 24V supply from the vehicle's battery. It is able to work with multiple ECU types through the use of replaceable modules which are inserted into the base of the unit when the tester is not powered. When other components later became microprocessor controlled new modules were created to diagnose faults in these components. Examples of this are ABS and alarm systems.

The FLT uses the Hitachi 6303R CMOS microprocessor which is low power and upwards compatible with the Motorola 6802. It has a MK48Z02B non-volatile Zeropower RAM which is able to store diagnostic data safely while the FLT is not powered. The maximum life of the MK48Z02B internal battery is 11 years so it would now need replacement for this feature to work.

FLT modules

Each ECU or component type will require a specific module to be inserted into the tester before communication with it is possible. Below is a scan of the module list from January 1995.

Manual

Tester Module Application Guide Jan 1995

A module can contain 1, 2 or 3 EPROMs which unfortunately are not socketed, the type of EPROMs used depends on the revision of PCB. Early modules used PCBs which can have a 27C64 in the leftmost position and 27C256 or 27C512 in the centre and rightmost positions. Later modules used PCBs which have a 27C512 in all three positions. The EPROMs in the earlier modules were labelled from left to right with yellow, green and blue stickers but I have named the positions A, B and C.

PCB type identification

If the components are identified with legends such as 'IC4' then it is the later PCB. If there are no legends then it is the early type. All module firmware can use either PCB type if the correct size of EPROMs are used.

For those who are interested the difference is that the early PCB connects pin 1 of EPROM A (which is the Vpp pin for a 27C64) to +5V and the later PCB connects pin 1 of EPROM A (which is the A15 pin for a 27C512) to 0V. Using the wrong EPROM type in socket A will either cause the EPROM to malfunction or the wrong part of the EPROM contents to be accessed and the module won't work correctly.

Module PCB type 1 circuit diagram

Module PCB type 2 circuit diagram

The module on the left is the earlier type with 27C64 and 27C256 EPROMs.

The module on the right is the later type with only 27C512 EPROMs. Note how there are no labels covering the EPROM windows. If the cartridge cover was left off and the EPROMs exposed to sunlight, over time their contents would be erased.

After finding module EPROMs that were not protected by labels I built a module reader which can read the contents of any EPROMs in a module without desoldering them from the PCB. This has made it possible to backup the module EPROMs now before they malfunction as a result of data corruption. See the FLT module reader page.

Module type list

This is a list of module types with systems supported, known applications, the size of the dump for each EPROM if present and if adaptors are required.

Module versions

This is a list of the modules for which I have copies of the firmware. The module suffix indicates the language used for messages, a trailing X indicates translated by a third party.

For the 648nnnnX (with optional '000' suffix) style MM part no# the X denotes the language according to the following table.

For the later 5014nnnnXXnn style MM part no# the XX denotes the language according to the following table.

For the early PCB, EPROM A, if required, must be a 27C64 and EPROM B or C, if required, must be either a 27C256 (32K bytes) or 27C512 (64K bytes) depending on the size of the dump.

For the later PCB, EPROM A, if required, must be a 27C512 and EPROM B or C, if required, must be either a 27C256 (32K bytes) or 27C512 (64K bytes) depending on the size of the dump. Note that the modules built with the later PCB always seem to use 27C512s for EPROM B or C.

The dump size of EPROM A, if required, will always be 8K bytes as the FLT cannot access more than the first 8K bytes of EPROM A even if a 27C512 is fitted here in the later PCB.

e.g. The M6A module requires a 27C64 for the early PCB or 27C512 for the later PCB for A and two 27C256s for both B & C.

When programming EPROM A using a 27C512 for the later PCB you should fill the EPROM programmer RAM with FFh (hexadecimal) before loading the hex or binary dump. This ensures that, because the dump size is less than the size of the EPROM being used, the unused areas are set to a known value of FFh, This is the same value read from an EPROM which has been erased, and so the programming will be faster.

The EPROMs should be CMOS devices, normally indicated by the 'C' in the device type. Use of older NMOS devices, no 'C' in device type, is not recommended as it may cause malfunction of the tester.

For the later PCB, Winbond W27E512 or W27C512 EEPROMs can be used instead of 27C512 EPROMs and have the advantage of being electrically erasable which means that they do not require exposure to UV light to erase.

FLT module EPROM dumps

The file contains backup copies of all the EPROMs present in each module listed above.

Module data file (30/12/2018)

FLT accessories

Adaptor ADT101A

Adaptor (Fiat part no# 1806174000 , M.M. part no# 79607701) required by some modules and inserted in-line between the FLT and the FLT extension cable. The circuit is documented here.

Test resistances and sensors

Here is a list of test resistances and sensors with Fiat/Lancia part numbers

FLT extension cables

Here are the connections for the FLT extension cables (Fiat part no. 1806118000). There are two separate cables, power and data, using the same 9 way D-type female connector which is plugged into the 9 way male connector on the FLT.

Note that the screen on the data cable must only be connected at the diagnostic plug.

9 way D-type female connector

Note:
IN is input to FLT
OUT is output from FLT

3-pin Fiat/Lancia diagnostic plug (looking at pin end)