2016 FIAT FULLBACK maintenance

Thousands of miles6 121825313743505662
Thousands of kilometers or10 20 30 40 50 60 70 80 90 100
Years12345678910
Visually inspect the integrity of the
suspension system components and their
fixings
●●●●●●●●●●
Check handbrake lever travel and adjust, if
necessary●●●●●●●●●●
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 (10)●
Change rear limited slip differential oil
(where present) (11)●●
Visually check for any fluid leaks from the
transfer case (if leaks are found, check the
oil level)
●●●●●●●●●
(10) 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.
(11) 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.
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SERVICING AND MAINTENANCE

PERIODIC CHECKS
Before long journeys, check and, if
necessary, restore:
engine coolant level;
brake fluid level;
windscreen washer fluid level;
operation of lighting system
(headlamps, direction indicators, hazard
warning lights, etc.);
tyre inflation pressure and condition;
tyre alignment;
operation of screen washer/wiper
system and positioning/wear of
windscreen/rear window wiper blades.
To ensure that the vehicle is always
efficient and well maintained, it is
advisable to make sure that you carry
out the above operations regularly
(approximately every 1000 km and
every 3000 km for checking and
topping up engine oil is advisable).
DEMANDING
VEHICLE USE
If the vehicle is mostly used in one of
the following conditions:
towing a trailer or caravan;
dusty roads;
short, repeated journeys (less than
7-8 km) at sub-zero outside
temperatures;
engine often idling or driving long
distances at low speeds or long periods
of inactivity;
the following checks must be carried
out more often than indicated in the
Scheduled Servicing Plan:
check front disc brake pad
conditions and wear;
check cleanliness of bonnet and
boot locks, cleanliness and lubrication
of linkage;
visually inspect conditions of: engine,
gearbox, transmission, pipes and hoses
(exhaust - fuel system - brakes) and
rubber elements (boots - sleeves -
bushes - etc.);
check battery charge and battery
fluid level (electrolyte);
visually inspect condition of the
accessory drive belts;
check and, if necessary, change
engine oil and replace oil filter;
check and, if necessary, replace
pollen filter.
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SERVICING AND MAINTENANCE

4D56 Diesel-powered vehicles
Check items of engine compartment are located as shown in the figure below.
1. Engine coolant reservoir 2. Brake fluid reservoir 3. Engine oil level gauge 4. Engine oil cap 5. Battery 6. Power steering
fluid reservoir 7. Washer fluid reservoir
A— RHD versions
312) 313)
1
42
23
756
A
389VANOMOTORE25DIESEL01
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SERVICING AND MAINTENANCE

WARNING
312)Never smoke when performing operations in the engine compartment. Flammable gases and fumes may be present and risk igniting.
313)Be very careful when working in the engine compartment when the engine is hot: you may get burned. Remember that the fan may start
up if the engine is hot: this could injure you. Scarves, ties and other loose clothing might be pulled by moving parts.
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SERVICING AND MAINTENANCE

The engine oil used has a significant
effect on the engine’s performance,
service life and startability. Be sure to
use oil of the recommended quality and
appropriate viscosity. All engines
consume a certain amount of oil during
normal operation. Therefore, it is
important to check the oil level at
regular intervals or before starting a
long trip.
1. Park the car on a horizontal surface.
2. Switch off the engine.
3.Wait a few minutes.
4. Remove the dipstick and wipe it with
a clean cloth.
5. Reinsert the dipstick as far as it
goes.
6. Remove the dipstick and read the oil
level, which should always be within the
range indicated.
7. If the oil level is below the specified
limit, remove the cap located on the
cylinder head cover and add enough oilto raise the level to within the specified
range. Do not overfill to avoid engine
damage. Be sure to use the specified
engine oil and do not mix various types
of oil.
8. After adding oil, close the cap
securely.
9. Confirm the oil level by repeating
step 4 to 6.
NOTE Check or refill the oil according
to the following manner.
When the oil level is checked in step
6 above, check it on a low side of the
dipstick because it is different in
appearance of oil level in the two sides
of the dipstick.
On vehicles without diesel particulate
filter (DPF), the oil level should be within
the range (A) to (B) on the dipstick.
On vehicles with DPF, the oil level
should be within the range (A) to (C) (oil
replacement indication mark) on the
dipstick. If the oil level is beyond the oil
replacement indication mark (C),
replace the oil as soon as possible.
Then, the oil should be refilled to the
maximum level (B).
On vehicle with DPF, the engine oil
will be increased due to a few of the
fuel gets mixed in the engine oil when
the DPF regenerates to burn away the
PM (particulate matter). However, it
does not indicate a malfunction.
The engine oil will deteriorate rapidly ifthe vehicle is subjected to severe
conditions, requiring earlier oil
replacement. Please refer to the
maintenance schedule.
Selection of engine oil —
Petrol-powered and Diesel-
powered vehicles
Refer to “Refill capacities” under
Technical Specifications.
WARNING
315)If the engine oil is being topped up,
wait for the engine to cool down before
loosening the filler cap, particularly for
vehicles with aluminium cap (where
provided). WARNING: risk of burns!
394AHA102654
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SERVICING AND MAINTENANCE

Ambient temperature
(minimum) °CPetrol-powered vehicles
Anti-freeze concentration %Diesel-powered vehicles
Anti-freeze concentration %
-15 30
50 -20 35
-25 40
-30 45
-35 50
-50 60 60
During cold weather
If the temperatures in your area drop below freezing, there is the danger that the coolant in the engine or radiator could freeze
and cause severe damage to the engine and/or radiator. Add a sufficient amount of antifreeze to the coolant to prevent it from
freezing.
The concentration should be checked before the start of cold weather and anti-freeze added to the system if necessary.
WARNING
316)Do not open the radiator cap (B) while
the engine is hot. The coolant system is
under pressure and any hot coolant
escaping could cause severe burns.
IMPORTANT
148)Do not use alcohol or methanol
anti-freeze or any engine coolants mixed
with alcohol or methanol anti-freeze. The
use of an improper anti-freeze can cause
corrosion of the aluminium components.149)For effective anti-corrosion and
anti-freeze performance, keep the
anti-freeze concentration within the range
of 30 to 60 %. Concentrations exceeding
60 % will result in a reduction of both the
anti-freeze and cooling performance thus
adversely affecting the engine.
150)Do not top up with water only. Water
by itself reduces the rust-protective and
anti-freeze qualities of the coolant and has
a lower boiling point. It can also cause
damage to the cooling system if it should
freeze. Do not use tapwater, as it can
cause corrosion and rust formation.151)PARAFLU UP anti-freeze is used in
the engine cooling system. Use fluid of the
same type as that contained in the cooling
system for any top-ups. PARAFLU UP
cannot be mixed with any other type of
fluid. If this happens, do not start the
engine under any circumstances and
contact a Fiat Dealership.
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SERVICING AND MAINTENANCE

Fluid type
Use brake fluid conforming to DOT3 or
DOT4. The brake fluid is hygroscopic.
Too much moisture in the brake fluid will
adversely affect the brake system,
reducing the brake performance.
In addition, the brake fluid reservoir is
equipped with a special cap to prevent
the entrance of air, and this cap should
not be removed.
319) 320) 321) 322)
152) 153) 154)
WARNING
319)Take care in handling brake fluid as it
is harmful to the eyes, may irritate your skin
and also damage to painted surfaces.
320)Use only the specified brake fluid. Do
not mix or add different brand of brake fluid
to prevent chemical reaction. Do not let
any petroleum-based fluid touch, mix with,
or get into the brake fluid. This will damage
the seals.
321)Clean the filler cap before removing
and close the cap securely after
maintenance.
322)Brake fluid is poisonous and highly
corrosive. In the event of accidental
contact, immediately wash the affected
parts with water and mild soap. Then rinse
thoroughly. Call a doctor immediately if
swallowed.
IMPORTANT
152)Keep the reservoir tank cap closed to
prevent the brake fluid from deteriorating
except maintenance.
153)Prevent brake fluid, which is highly
corrosive, from coming into contact with
painted parts. Should it happen,
immediately wash with water.
154)The symbol
, on the brake fluid
container indicates if a brake fluid is
synthetic or mineral-based. Use of mineral
type fluids will damage the special rubber
seals of the braking system beyond repair.
CLUTCH FLUID
To check the fluid level
The clutch fluid in the master cylinder
should be checked when performing
other underhood service. In addition,
the system should be checked for
leakage at the same time.
Check to make certain that the clutch
fluid level is always between the “MAX”
and “MIN” level markings on the fluid
reservoir.
A rapid fluid loss indicates a leak in the
clutch system which should be
inspected by a Fiat Dealership or
another specialist and repaired
immediately.
MAX
MIN
398AHA106519
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SERVICING AND MAINTENANCE

BATTERY
155) 156)
4)
The condition of the battery is very
important for quick starting of the
engine and proper functioning of the
vehicle’s electrical system. Regular
inspection and care are especially
important in cold weather.
Battery precautions
325) 326) 327) 328) 329) 330) 331) 332) 333) 334) 335)
Checking battery electrolyte level
The electrolyte level must be between
the specified limit on the outside of the
battery. Replenish with distilled water as
necessary. The inside of the battery is
divided into several compartments;
remove the cap from each
compartment and fill to the upper mark.
Do not top up beyond the upper markbecause spillage during driving could
cause damage.
Check the electrolyte level at least once
every four weeks, depending on the
operating conditions. If the battery is
not used, it will discharge by itself with
time.
Check it once every four weeks and
charge with low current as necessary.
During cold weather
The capacity of the battery is reduced
at low temperatures. This is an
inevitable result of its chemical and
physical properties. This is why a very
cold battery, particularly one that is not
fully charged will only deliver a fraction
of the starter current which is normally
available.
We recommend you to have the battery
checked before the start of cold
weather and, if necessary, have it
charged or replaced. This does not only
ensure reliable starting, but a battery
which is kept fully charged also has a
longer life.
Disconnection and connection
157) 158) 159) 160)
To disconnect the battery cable, stop
the engine, first disconnect the negative
(-) terminal and then the positive (+)
terminal. When connecting the battery,
first connect the positive (+) terminal
and then the negative (-) terminal.NOTE Open the terminal cover (A)
before disconnecting or connecting the
positive (+) terminal of the battery.
NOTE Loosen the nut (B), and then
disconnect the battery cable from the
positive (+) terminal.
NOTE Keep the terminals clean. After
the battery is connected, apply terminal
protection grease. To clean the
terminals, use lukewarm water.
NOTE Check to see if the battery is
securely installed and cannot be moved
during travel. Also check each terminal
for tightness.
NOTE When the vehicle is to be left
unused for a long period of time,
remove the battery and store it in a
place where the battery fluid will not
freeze. The battery should be stored
only in a fully charged condition.
400AHA102595
A
B
401AHZ101072
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SERVICING AND MAINTENANCE