2016 FIAT FULLBACK maintenance

SERVICING AND MAINTENANCE
Correct maintenance permits the
performance of the car to be
maintained over time, as well as limited
running costs and safeguarding the
efficiency of the safety systems.
This chapter explains how.SERVICE PRECAUTIONS.......224
SCHEDULED SERVICING PLAN . .225
PERIODIC CHECKS..........240
DEMANDING VEHICLE USE.....240
CHECKING LEVELS..........241
CATALYTIC CONVERTER.......245
ENGINE OIL...............245
ENGINE COOLANT...........247
WASHER FLUID.............249
BRAKE FLUID..............249
CLUTCH FLUID.............250
POWER STEERING FLUID......251
BATTERY.................252
WIPER BLADE RUBBER
REPLACEMENT.............254
GENERAL MAINTENANCE......255
VEHICLE CARE PRECAUTIONS. . .255
CLEANING THE INTERIOR OF
YOUR VEHICLE.............256
CLEANING THE EXTERIOR OF
YOUR VEHICLE.............257
TYRES...................260
223

SERVICE
PRECAUTIONS
305) 306) 307) 308) 309) 310) 311)
Adequate care of your vehicle at regular
intervals serves to preserve the value
and appearance as long as possible.
Maintenance items as described in this
owner’s manual can be performed by
the owner.
We recommend you to have the
periodic inspection and maintenance
performed by a Fiat dealership or
another specialist.
In the event a malfunction or a problem
is discovered, we recommend you to
have it checked and repaired. This
section contains information on
inspection maintenance procedures
that you can do yourself. Follow the
instructions and cautions for each of
the various procedures.
WARNING
305)When checking or servicing the inside
of the engine compartment, make sure the
engine is switched off and has had a
chance to cool down.
306)If it is necessary to do work in the
engine compartment with the engine
running, be especially careful that your
clothing, hair, etc., does not become
caught by the cooling fan, drive belts, or
other moving parts.307)The cooling fan can turn on
automatically even if the engine is not
running. Turn the ignition switch to “LOCK”
position or put the operation mode in OFF
to be safe while you work in the engine
compartment.
308)Do not smoke, cause sparks or allow
open flames around fuel or battery. The
fumes are flammable.
309)Be extremely cautious when working
around the battery. It contains poisonous
and corrosive sulphuric acid.
310)Do not get under your vehicle with
just the body jack supporting it. Always use
automotive jack stands.
311)Improper handling of components
and materials used in the vehicle can
endanger your personal safety. We
recommend you to consult a specialist for
necessary information.
224
SERVICING AND MAINTENANCE

Thousand of miles9 182736455463728190
Thousand of kilometers15 30 45 60 75 90 105 120 135 150
Years12345678910
Replace spark plugs(3)
Check the carbon monoxide concentration
●●●●●●●●●●
Check the crank case ventilation system
condition●●●●●
Lubricate the appropriate points of the
transmission shaft●●●●●●●●●●
Visually inspect condition of: underbody
protection, pipes and hoses (exhaust, fuel
system), rubber elements (boots, sleeves,
bushes, etc.)
●●●●●●●●●●
Visually inspect the integrity of the steering
components and their fixings (including
gaskets and covers)
●●●●●●●●●●
Check windscreen/rear window wiper blade
position/wear●●●●●
Check operation of the windscreen
wiper/washer system and adjust jets, if
necessary
●●●●●
Check cleanliness of bonnet and luggage
compartment locks, cleanliness and
lubrication of linkage
●●●●●
(3) The spark plugs should only be replaced on a mileage basis every 40,000 km.
226
SERVICING AND MAINTENANCE

Thousand of miles9 182736455463728190
Thousand of kilometers15 30 45 60 75 90 105 120 135 150
Years12345678910
Check the brake and clutch pedal play●●●●●●●●●●
Visually inspect conditions and check the
tension of the accessory drive belts●●●●●●●●●●
Visually inspect conditions and check the
tension of the toothed timing drive belts●●●●● ●●●●
Visually check for any fluid leaks from the
front and rear differentials (if leaks are found,
check the oil level)
●●● ●●● ●●
Change front and rear differential oil (5)●●
Change rear limited slip differential oil
(where present) (6)●●●
Visually check for any fluid leaks from the
transfer case (if leaks are found, check the
oil level)
●●●●● ●●●●
Change transfer case oil (8)●
Change engine oil and replace oil filter●●●●●●●●●●
Replace accessory drive belts(7)
(5) To be done only on a mileage basis, independently of the time. In case of heavy use, it is recommended to change every 40,000 km.
(6) To be done only on a mileage basis, independently of the time. In case of heavy use, it is recommended to change every 20,000 km.
(8)To be done only on a mileage basis.
(7) The belt should only be replaced if damage/wear is found during the periodic inspection.
228
SERVICING AND MAINTENANCE

DIESEL ENGINE 4N15
Thousands of miles6 121825313743505662
Thousands of kilometers or10 20 30 40 50 60 70 80 90 100
Years12345678910
Check tyre conditions/wear and adjust
pressure, if necessary●●●●●●●●●●
Check operation of lighting system
(headlights, direction indicators, hazard
warning lights, boot, passenger
compartment, glove compartment,
instrument panel warning lights, etc.)
●●●●●●●●●●
Check and, if necessary, top up fluid levels
(1)●●●●●●●●●●
Check battery condition●●●●●●●●●●
Change engine coolant(7)
Adjust the tappet clearance (where there is
no hydraulic clearance adjustment) (8)
●
Check exhaust emissions/smokiness●●●●●●●●●●
Use the diagnosis socket to check
supply/engine management systems
operation, emissions and, for
versions/markets, where provided, engine
oil degradation
●●●●●●●●●●
(1) Always only use the liquids shown in the handbook for topping up after having checked that the system is not damaged.
(7) The engine coolant should be replaced after 8 years or 160,000 km, then every 5 years or 100,000 km
(8) to be done only on a mileage basis, independently of the time.
230
SERVICING AND MAINTENANCE

Thousands of miles6 121825313743505662
Thousands of kilometers or10 20 30 40 50 60 70 80 90 100
Years12345678910
Check cleanliness of bonnet and luggage
compartment locks, cleanliness and
lubrication of linkage
●●●●●
Visually inspect conditions and wear of front
disc brake pads and operation of pad wear
indicator
●●●●●●●●●●
Visually inspect condition and wear of the
rear drum brake lining●●●●●●●●●●
Check the front and rear wheel bearing
clearances●●●
Visually check for any fluid leaks from the
automatic transmission (if leaks are found,
check the oil level)
●●●●●●●●●
Change the automatic transmission oil (14)●
Visually check for any fluid leaks from the
manual transmission (if leaks are found,
check the oil level)
●●●●●●●●●
Change the manual transmission oil (8)●
Visually inspect the integrity of the
suspension system components and their
fixings
●●●●●●●●●●
(14) To be done only in case of heavy use, only on a mileage basis.
(8) to be done only on a mileage basis, independently of the time.
232
SERVICING AND MAINTENANCE

Thousands of miles6 121825313743505662
Thousands of kilometers or10 20 30 40 50 60 70 80 90 100
Years12345678910
Replace fuel filter cartridge(9)
Replace air cleaner cartridge(12)
Check the air filter cartridge for obstructions
or damage
●● ●● ●● ●
Change the brake fluid (6)●●●●●
Replace the passenger compartment
cleaner●●●●●●●●●●
(9) This should be done each year or every 20,000 km.
(12) The air cleaner should be replaced every two years or 40,000 km. If the vehicle is used in dusty areas, the cleaner must be replaced every year.
(6) The brake fluid replacement has to be done every two years, irrespective of the mileage.
234
SERVICING AND MAINTENANCE

Thousands of miles6 121825313743505662
Thousands of kilometers or10 20 30 40 50 60 70 80 90 100
Years12345678910
Perform the "Small Injection Quantity
Learning” procedure●●●●●●●●●●
Check the crank case ventilation system
operation●●●●●
Check the EGR (exhaust gas recirculation)
system●●●●●●●●●●
Lubricate the appropriate points of the
transmission shaft(9)
Visually inspect condition of: underbody
protection, pipes and hoses (exhaust, fuel
system), rubber elements (boots, sleeves,
bushes, etc.)
●●●●●●●●●●
Visually inspect the integrity of the steering
components and their fixings (including
gaskets and covers)
●●●●●●●●●●
Visually inspect the condition of the
turbocompressor flexible air intake
couplings and oil conduits (where present)
●●●●●
Check windscreen/rear window wiper blade
position/wear●●●●●
(9) This should be done each year or every 20,000 km.
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SERVICING AND MAINTENANCE