2003 FIAT PALIO fuel filter

5
Hydraulic power
steering
Do not exceed the max-
imum level of the fluid as indicated
on the tank. Use only the fluid pre-
scribed in the “Refueling” chapter.
PROHIBITION SYMBOL WARNING SYMBOLS
Battery
Do not expose to open
flames.
Battery
Keep children away.
Heat guards - belts -
pulleys - fan
Do not put hands.
Catalytic converter
Do not stay on inflam-
mable surfaces. Refer to
the “Safeguard of the device reduc-
ing the emissions” chapter.
INJECTION SYSTEM
FAILURE (red) (diesel
versions)
When there is a fault in the injection
system.
The warning light should come on
when the ignition key is turned to
MARand go out after a few seconds.
WATER IN DIESEL FU-
EL FILTER versions (am-
ber) (diesel version)
When there is water in the diesel fu-
el filter. have the condense drained out
by a Fiat Dealership.
GLOW PLUGS
(amber)
(diesel version)
When the ignition key is turned to
the
MARposition. The warning light
will go out when the glowplugs reach
the correct temperature
1-19 03/03/2003 05:44 PM Page 5

37
HEATING /CLIMATE CONTROL SYSTEM
1 -Windscreen defroster/demister
vents.
2 -Front side window
defroster/demister vents.
3 -Central and side directional vents.
4 -Side vents for sending air to
footwell.
P4E02020
fig. 27
WATER IN DIESEL
FUEL FILTER versions
(amber) (diesel version)
When there is water in the diesel fu-
el filter. have the condense drained
out by a Fiat Dealership.
GLOW PLUGS
(amber)
(diesel version)
When the ignition key is turned to
the
MARposition. The warning light
will go out when the glowplugs reach
the correct temperature.
The warning light has a diagnostic
function to signal pre-heating system
failures (cut-off or short-circuited
glow plugs, blown pre-heating control
unit power fuse, tripped pre-heating
control unit circuit surge and current
protections).
If the warning light flashes for 60 sec-
onds just before the engine is started,
the vehicle can still be started but a
Fiat Dealershipshould be contact-
ed as soon as possible to have the
anamoly rectified.
20-63 03/03/2003 06:02 PM Page 37















106
Thousands of kilometers 15 3045 6075 90105 120135 150165 180
SERVICE SCHEDULE
Check of conditions and weariness of tyres
Check front disc brake pad
Check of conditions and weariness of rear drum brake gasket
Visually inspect: underbody protection, pipes
(exhaust - fuel supply - brakes), rubber elements
(guards - sleeves - bushes - etc.), supply and brake system tubing
Voltage check and possible adjustment of trapezoidal belts
and/or poly-V
Inspect conditions of V belts and/or ploy v-belts
Tappet clearance check/adjustment (petrol version)
(excluding the versions with hydraulic tappets)
Check and adjust tappet clearance (diesel version)
Check/adjustment of the stroke of the lever hand brake
Check evaporation system (diesel version)
Visually inspect fuel evaporation system (connections, lines,
containers, seals and filler cap)
Fuel filter replacement (see “important” in the “Additional
interventions” in this chapter) (for diesel version replace the filter
every 7,500 km)
Replace air cleaner cartridge (diesel version) (see “important” in the
“Additional interventions” in this chapter)
Replace air cleaner cartridge (see “Additional checks” in this chapter)
104-127 03/03/2003 06:53 PM Page 106

109
IMPORTANT - Air cleaner
Using the car on dusty roads, replace
the air cleaner more frequently than
indicated in the Scheduled Servicing
Plan.
For any doubt on the air cleaner re-
placement, in relation to how the car
is used, contact the
Fiat Dealership.
The maintenance of the
car must be committed
to Fiat Dealership. For
those interventions of ordinary
and small maintenance, always
make sure to have the adequate
equipment, Fiat spare parts and
the consumption fluids; in any
event, do not perform such op-
erations, if you do not have any
experience. IMPORTANT - Fuel filter
Check the conditions of the fuel fil-
ter when changes (choking) are no-
ticed in the engine operation.
IMPORTANT - Battery
We suggest you to carry out the
check of the state of battery charge,
preferably at the beginning of the cold
season in order to avoid the possibil-
ity of freezing the electrolyte.
Such check must be carried out
more frequently if the car is mainly
used for short distances, or if it is
equipped with permanent absorption
users with disconnected key, above all
if applied in after market.
Please refer page no. 52 of 24
hours service assistance booklet
for BAT MOBILE service extend-
ed by M/s. Exide Batteries.You should check the battery fluid
(electrolyte) level more frequently
than shown in the service schedulein
this chapter if the car is used in hot cli-
mates or particularly demanding con-
ditions.
24 HOURS SERVICE
CALL - 9628 290 260
This single response num-
ber is available in 9 cities.*
AHMEDABAD - BANGALORE -
KOLKATA - CHENNAI - DELHI -
HYDERABAD - MUMBAI -
PUNE - LUCKNOW
* If you are not in, but near any of the above
cities; Dial city code followed by the single
response numberFor further information about Fiat Service Network please refer 24 Hours Service
AssistanceBooklet provided.
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116
AIR CLEANER
REPLACEMENT fig. 14
Release the clips A, remove the cov-
er
Band remove the filtering element
C.
fig. 14
P4E01442
The symbol π, present
on the container, indi-
cates synthetic brake flu-
ids distinguishing it from mineral
fluid. Using mineral type fluid
would damage the special rubber
braking system gasket beyond re-
pair.
Do not clean the filter-
ing element. You could
damage it and conse-
quently severely damage the en-
gine.
Replace the cleaner
more frequently than
shown in the Service
Schedule if the car is frequently
used on dusty roads. IMPORTANT
Brake fluid is hy-
groscopic (meaning it absorbs humid-
ity). This is why, the fluid should be
changed more frequently than shown
in the Scheduled Servicing Plan if the
car is mainly driven in areas with high
percentage of humidity in the air.
fig. 15 - 1.9 D versions
P4E02329
DIESEL FILTER
DRAINING THE
CONDENSATE
Drain the condense from the filter
every 5,000 km.
Loosen ring nut
A-fig. 15of some
turns and retighten it when fuel comes
out free from water.
You are however advised to have this
operation performed at a
Fiat deal-
ership.
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132
FUEL SUPPLY/ IGNITION
Integrated multipoint electronic in-
jection and ignition system: only one
electronic control unit controls both
functions. It processes both the time
the injection lasts (for petrol meter-
ing) and the ignition advance angle.
Type: Multipoint.
Air cleaner: dry, with paper filtering
element.
Fuel pump: by immersion, in the tank.
Injection pressure 3 barMixture metered by electronic pro-
cessing of the data picked up by the
engine speed sensor and absolute
pressure sensor in the intake manifold.
Petrol metering system : a “Closed
Loop” (information on the combus-
tion trend transmitted by the sensor
Lambda).
Ignition order: 1-3-4-2.
Spark plugs:
Modifications or repairs
to the fuel feed system
that are not carried out
properly or do not take the sys-
tem’s technical specifications in-
to account can cause malfunc-
tions leading to the risk of fire.
LUBRICATION
Forced-feed with gear pump with
pressure relief valve incorporated.
Oil purification through full-flow car-
tridge filter.
COOLING
Cooling system with radiator, cen-
trifugal pump and expansion tank.
Thermostat on the secondary circuit
for recirculating the water from the
engine to the radiator. “By-pass con-
trolled” thermostat.
Electrical fan for cooling the radiator
with connection/disconnection, con-
trolled by a thermostatic switch lo-
cated on the radiator.
Spark plug (type)
1.2
Champion RC7BMCChampion RC8BYC
1.6NGK BKR5EZ
Champion RC10YCC
Bosch FR8DE
Other equivalent Spark plug for 1.6 engine
is Champion RC10YCC.
128-143 03/03/2003 07:39 PM Page 132

1.2
litres kg
47 –
5.5-7.5 –
5.9 6.1
3.05 2.75
1.8 1.5
0.68 0.54
– 0.075
0.40
0.50
2.3 –
1.6
litre kg
47 –
5.5-7.5 –
6.6 6.8
3.88 3.5
1.8 1.5
0.68 0.54
– 0.075
0.40
0.50
2.3 –
140
Prescribed fuels
Recommended products
Super unleaded petrol 87 R.O.N.
Mixture composed by 70% distilled water
and 30% fluid
PARAFLU11
VS MAX PETROL(*)
ZC 80/S
GI/A
MRM 2
TOP 4
TOP 4
Mixture of distilled water and 10% of fluid DPI
CAPACITIES
(*) Do not top up with oil having specifications different from the oil present in the car.
47 –
5.5-7.5 –
4.8 3.9
43.3
2.0 1.73
0.68 0.54
– 0.075
0.40 –
0.50
2.3 –
1.9
litre kg
Fuel tank:
including a reserve of:
Engine cooling system:
– with manual climate control system
ngine sump:
Engine sump and filter:
Transaxle:
Hydraulic power steering:
CV joint cavities and boots :
Front and rear hydraulic brake circuit:
Hydraulic brake circuit with
ABS antilock device:
Windscreen/rear window washer
fluid reservoir:
128-143 03/03/2003 07:39 PM Page 140

FUEL CAPACITY (litres)
COLD TYRES PRESSURE [bar (kg/cm2) / lb/sq. in (P.S.I)]
ENGINE OIL CAPACITY
Print no.AS/STA 50167-03/2003 - 4thedition - Printed in India
Coordinamento Editoriale Satiz - Torino
24 HOURS SERVICE CALL - 9628 290 260
This single response number is available in 9 cities.*
AHMEDABAD - BANGALORE - KOLKATA - CHENNAI - DELHI - HYDERABAD - MUMBAI -
PUNE - LUCKNOW
* If you are not in, but near any of the above cities; Dial city code followed by the single response number
For further information about Fiat Service Network please refer 24 Hours Service AssistanceBooklet provided.
1.21.6 1.9-
litres kg litres kg litres kg
Oil sump and filter 3.05 2.75 3.88 3.5 4 3.3
Do not disperse used oil in the environment
1.21.6 1.9
Fuel tank 47 47 47
Reserve 5.5 - 7.5 5.5 - 7.5 5.5 - 7.5
Fill petrol run cars only with unleaded petrol with a minimum octane number of 87.
Tyre Average load Full load Spare
Front Rear Front Rear wheel
1.2EL-ELX165/80 R13 1.93/28.00 1.93/28.00 2.24/32.49 2.24/32.49 2.24/32.49
1.6 GTX175/65 R14 1.93/28.00 1.93/28.00 2.24/32.49 2.24/32.49 2.24/32.49
1.9 DEL-ELX165/80 R13 2.1 1.9 2.2 2.2 2.2
0.3 bar should be added to the values given if the pressure is measured while the tyre is hot.
144-150 03/03/2003 07:02 PM Page cop3