brake FIAT FULLBACK 2016 1.G Service Manual

WARNING
222)Do not crank the engine while jacking
up the vehicle. The tyre on the ground may
turn and the vehicle may roll off the jack.
BRAKING SYSTEM
All the parts of the brake system are
critical to safety. We recommend you to
have the vehicle checked at regular
intervals.
123)
Brake system
The service brake is divided into two
brake circuits. And your vehicle is
equipped with power brakes. If one
brake circuit fails, the other is available
to stop the vehicle. If your vehicle
should lose the power assist for some
reason, the brakes will still work.
In these situations even if the brake
pedal moves down to the very end of
its possible stroke or resists being
depressed, keep depressing the brake
pedal down harder and further than
usual; stop driving as soon as possible
and have the brake system repaired.
223) 224)
Warning lamp
The brake warning lamp illuminates to
indicate a fault in the braking system.
Refer to “Brake warning lamp”.When brakes are wet
Check the brake system while driving at
a low speed immediately after starting,
especially when the brakes are wet, to
confirm they work normally.
A film of water can be formed on the
brake discs or brake drums and
prevent normal braking after driving in
heavy rain or through large puddles, or
after the vehicle is washed. If this
occurs, dry the brakes out by driving
slowly while lightly depressing the brake
pedal.
When driving downhill
It is important to take advantage of the
engine braking by shifting to a lower
shift position while driving on steep
downhill roads in order to prevent the
brakes from overheating.
225)
Brake pads and linings
Avoid hard braking situations. New
brakes need to be broken-in by
moderate use for the first 200 km.
The disc brakes are provided with a
warning device which emits a shrieking
metallic sound while braking if the brake
pads have reached their wear limit. If
you hear this sound, have the brake
pads replaced.
226)
175

IMPORTANT
123)Avoid driving habits that cause heavy
braking and never “ride” the brakes by
resting your foot on the brake pedal while
driving. It causes brake overheating and
fade.
WARNING
223)Do not turn off the engine while your
vehicle is in motion. If you turn off the
engine while driving, the power assistance
for the braking system will stop working
and your brakes will not work effectively.
224)If the power assist is lost or if either
brake hydraulic system stops working
properly, have your vehicle checked
immediately.
225)Do not leave any objects near the
brake pedal or let a floor mat slide under it;
doing so could prevent the full pedal stroke
that would be necessary in an emergency.
Make sure that the pedal can be operated
freely at all times. Make sure the floor mat
is securely held in place.
226)Driving with worn brake pads will
make it harder to stop, and can cause an
accident.
CRUISE CONTROL
(where provided)
Cruise control is an automatic speed
control system that keeps a set speed.
It can be activated at about 40 km/h or
more.
124) 125) 126)
Cruise control may not be able to keep
your speed on uphills or downhills.
Your speed may decrease on a steep
uphill. You may use the accelerator
pedal if you want to stay at your set
speed.
Your speed may increase to more than
the set speed on a steep downhill. You
have to use the brake to control your
speed. As a result, the set speed
driving is deactivated.Cruise control switches
A — CRUISE CONTROL ON/OFF
switch
Used to turn on and off the cruise
control.
B — SET - switch
Used to reduce the set speed and to
set the desired speed.
C — RES + switch
Used to increase the set speed and to
return to the original set speed.
D — CANCEL switch
Used to deactivate the set speed
driving.
When operating the cruise control
switches, press the cruise control
switches correctly. The set speed
driving may be deactivated
automatically if two or more switches of
the cruise control are pressed at the
same time.
264AA0110608
176
STARTING AND DRIVING

To decrease the set speed
There are 2 ways to decrease the set
speed.
SET - switch
Push down and hold the SET - switch
(B) while driving at the set speed, and
your speed will slow down gradually.
When you reach your desired speed,
release the switch. Your new cruising
speed is now set.To slow down your speed in small
amounts, push down the SET - switch
(B) for less than about 1 second and
release it. Each time you push down the
SET - switch (B), your vehicle will slow
down by about 1.6 km/h.
Brake pedal
While driving at the set speed, use the
brake pedal, which disengages the
cruise control, then push down the SET
- switch (B) and release the switch
momentarily to set a new desired
cruising speed.
To temporarily increase the speed
Depress the accelerator pedal as you
would normally. When you release the
pedal, you will return to your set speed.
To temporarily decrease the speed
Depress the brake pedal to decrease
the speed. To return to the previously
set speed, push up the RES + switch(C). Refer to “To resume the set speed”.
To deactivate
The set speed driving can be
deactivated as follows:
Press the CRUISE CONTROL
ON/OFF switch (A) (Cruise control will
be turned off.)
Press the CANCEL switch (D).
Depress the brake pedal.
268AA0110640
269AA0110624
270AA0110653
271AA0110666
272AA0110679
178
STARTING AND DRIVING

and A in order of distance. The point A
and B actually are the same distances
from the vehicle, and the point C is
farther off than the point A and B.
WARNING
228)The responsibility for parking and
other manoeuvres is always and in any
case charged to the driver. While carrying
out these manoeuvres, always make sure
that no people (especially children) or
animals are in the area concerned. The
camera is an aid for the driver, but the
driver must never allow his/her attention to
lapse during potentially dangerous
manoeuvres, even those executed at low
speeds. Always keep a slow speed, so as
to promptly brake in the case of obstacles.229)The rear-view camera is an assistance
system that enables the driver to check for
obstacles behind the vehicle. Its range of
view is limited, so you should not overly
depend on it. Please drive just as carefully
as you would if the vehicle did not have the
rear-view camera.
230)Be sure to visually confirm safety
around the vehicle with your own eyes. Do
not depend entirely on the rear-view
camera.
IMPORTANT
128)It is vital, for correct operation, that
the camera is always kept clean and free
from mud, dirt, snow or ice. Be careful not
to scratch or damage the camera while
cleaning it. Avoid using dry, rough or hard
cloths. The camera must be washed using
clean water, with the addition of car
shampoo if necessary. In washing stations
which use steam or high-pressure jets,
clean the camera quickly, keeping the
nozzle more than 10 cm away from the
sensors. Do not apply stickers to the
camera.
129)The rear-view camera has a special
lens that can make objects shown on the
screen appear to be closer or further away
than they actually are.130)Due to the number of people in the
vehicle, the fuel quantity, the weight and
positioning of luggage, and/or the condition
of the road surface, the lines in the view
from the rearview camera may not be
accurately positioned relative to the actual
road. Use the reference lines only as a
guideline, and always do a safety check of
your behind and surroundings directly while
driving.
B
A
C
C
A
B
282AHA103765
183

IF THE VEHICLE
BREAKS DOWN
If the vehicle breaks down on the road,
move it to the shoulder and use the
hazard warning flashers and/or the
warning triangle etc. Refer to “Hazard
warning flasher switch”.
If the engine stops/fails
Vehicle operation and control are
affected if the engine stops. Before
moving the vehicle to a safe area, be
aware of the following:
The brake booster becomes
inoperative and the pedal effort will
increase. Press down the brake pedal
harder than usual.
Since the power steering system is
no longer operative, the steering wheel
feels heavy when turning it.
EMERGENCY
STARTING
231) 232) 233) 234) 235) 236) 237) 238) 239) 240) 241) 242)
243) 244) 245) 246) 247)
If the engine cannot be started because
the battery is weak or dead, the battery
from another vehicle can be used with
jumper cables to start the engine.
1. Get the vehicles close enough so the
jumper cables can reach, but be sure
the vehicles aren’t touching each other.
2. Turn off all lamps, heater and other
electrical loads.
3. Set the parking brake firmly on each
vehicle. Put an automatic transmission
in “P” (PARK) or a manual transmission
in “N” (Neutral). Stop the engine.
4. Make sure battery electrolyte is at the
proper level. Refer to “Battery”.
5. Connect one end of one jumper
cable (1) to the positive (+) terminal of
the discharged battery (A), and the
other end (2) to the positive (+) terminal
of the booster battery (B).
Connect one end of the other jumper
cable (3) to the negative (−) terminal of
the booster battery (B), and the other
end (4) to the engine block of the
vehicle with the discharged battery at
the point farthest from the battery.
NOTE Open the terminal cover before
connecting the jumper cable to the
positive (+) terminal of the battery. Refer
to “Battery”.Petrol-powered vehicles
Diesel-powered vehicles 4D56
A
B
1
4
23
283AHA102045
A
B
1
423
284AHA102058
185

Diesel-powered vehicles 4N15
6. Start the engine in the vehicle which
has the booster battery, let the engine
idle a few minutes, then start the engine
in the vehicle with the discharged
battery.
7. After the engine is started,
disconnect the cables in the reverse
order and keep the engine running for
several minutes.
NOTE On vehicles with anti-lock brake
system, if the vehicle is put in motion
without fully charging the battery, it
might cause the loss of the smooth
engine operation and the antilock brake
warning lamp to illuminate. Refer to
“Anti-lock brake system (ABS)”.
WARNING
231)To start the engine using jumper
cables from another vehicle, perform the
correct procedures according to the
instruction below. Incorrect procedures
could result in a fire or explosion or
damage to the vehicles.
232)Keep sparks, cigarettes and flames
away from the battery because the battery
may produce an explosion.
233)Do not attempt to start the engine by
pulling or pushing the vehicle. It could
damage your vehicle.
234)Check the other vehicle. It must have
a 12-volt battery. If the other system isn’t
12-volt, shorting can damage both
vehicles.
235)Use the proper cables suitable for the
battery size to prevent overheating of the
cables.
236)Check the jumper cables for damage
and corrosion before use.
237)Always wear protective eye goggles
when working near the battery.
238)Keep the battery out of the reach of
children.
239)Turn off the ignition on both vehicles
beforehand. Make sure that the cables or
your clothes cannot be caught by the fan
or drive belt. Personal injury could result.
240)If electrolyte fluid is not visible, or
appears to be frozen, Do Not Attempt
Jump Starting! A battery might rupture or
explode if the temperature is below the
freezing point or if it is not filled to the
proper level.241)Electrolyte is corrosive diluted
sulphuric acid. If electrolyte (battery acid)
comes into contact with your hands, eyes,
clothes or the painted surface of your
vehicle, it should be thoroughly flushed
with water. If electrolyte gets in your eyes,
flush them with water immediately and
thoroughly, and get prompt medical
attention.
242)Make sure that the connection is
made to the appointed position (shown in
the illustration). If the connection is made
directly to the negative (−) side of the
battery, the inflammable gases generated
from the battery might catch fire and
explode.
243)When connecting the jumper cables,
do not connect the positive (+) cable to the
negative (−) terminal. Otherwise sparks
might cause explosion of the battery.
244)Use care not to get the jumper cable
caught in the cooling fan or other rotating
part in the engine compartment.
245)Keep the engine of the vehicle giving
assistance running.
246)Battery fluid is poisonous and
corrosive: avoid contact with your skin and
eyes. The battery should be charged in a
well ventilated place, away from naked
flames or possible sources of sparks:
danger of explosion and fire.
247)Do not attempt to charge a frozen
battery: it must be thawed first, otherwise it
may explode. If freezing has occurred, the
battery should be checked by skilled
personnel to make sure that the internal
elements are not damaged and that the
body is not cracked, with the risk of leaking
poisonous and corrosive acid.A
B
1
4
23
285AHA102061
186
IN CASE OF EMERGENCY

HOW TO CHANGE A
TYRE
132) 133)
Before changing a tyre, first stop your
vehicle in a safe, flat location.
1. Park the vehicle on level and stable
ground, free of loose pebbles, etc.
2. Set the parking brake firmly.
3. On vehicles with manual
transmission, turn the ignition switch to
the “LOCK” position or put the
operation mode in OFF, and move the
gearshift lever to the “R” (Reverse)
position. On vehicles with automatic
transmission, move the selector lever to
the “P” (PARK) position, and turn the
ignition switch to the “LOCK” position
or put the operation mode in OFF.
4. Turn on the hazard flashers and set
up a warning triangle, flashing signal
lamp, etc., at an adequate distance
from the vehicle, and have all your
passengers leave the vehicle.
5. To prevent the vehicle from rolling
when jacking up the vehicle, place
chocks or blocks (A) at the tyre that is
diagonally opposite from the tyre (B)
you are changing.
257) 258)
NOTE The chocks shown in the
illustration do not come with your
vehicle. It is recommended that you
keep ones in the vehicle for use if
needed.
NOTE If chocks are not available, use
stones or any other objects that are
large enough to hold the wheel in
position.
6. Get the jack, jack handle and wheel
nut wrench ready. Refer to “Tools, jack
and jack handle”.Spare wheel information
The spare wheel is stored under the
floor of the cargo bed. Check the air
pressure of the spare tyre frequently
and make sure it is ready for
emergency use at any time.
Maintaining the spare wheel at the
highest specified air pressure will
ensure that it can always be used under
any conditions (city/high-speed driving,
varying load weight, etc.).
259)
To remove the spare wheel
1. Set the jack handle (Club cab) (refer
to “To use the jack handle, Club cab”).
2. Insert the jack handle (A) in the hole
(B) below the rear gate.
A
B
314AHA102162
A
B
315AHA102263
194
IN CASE OF EMERGENCY

NOTE Confirm that the hanger disc is
securely fitted in the wheel disc hole
when the wheel is just lifted off the
ground.
3. After winding up the spare wheel
sufficiently, make sure it is not loose (the
tightening torque should be
approximately 40 Nm (achieved by
applying a force of 200 N at the end of
the wheel nut wrench) then withdraw
the jack handle, taking care not to turn
it in the reverse direction.
278) 279) 280)
4. Have your damaged tyre repaired as
soon as possible.
To store the tools, jack and jack
handle
Reverse the removing procedure when
storing the jack, jack handle and wheel
nut wrench (refer to “Tools, jack and
jack handle”).
WARNING
257)Use your hazard lights, warning
triangle, etc. to show that your vehicle is
stationary according to the regulations in
force. Passengers should get out of the
vehicle, particularly if it is heavily loaded,
and wait for the wheel to be changed away
from the traffic. Apply the handbrake. in the
event of a wheel change on a slope or on
unsurfaced roads, put any object as stop
under the wheels.
258)Be sure to apply chocks or blocks to
the correct tyre when jacking up the
vehicle. If the vehicle moves while jacked
up, the jack could slip out of position,
leading to an accident.
259)The pressure should be periodically
checked and maintained at the specified
pressure while the tyre is stowed. Driving
with an insufficient tyre pressure can lead
to an accident. If you have no choice but to
drive with an insufficient tyre pressure,
keep your speed down and inflate the tyre
to the correct pressure as soon as
possible. (Refer to “Tyre inflation
pressures”).
260)Set the jack only at the positions
shown here. If the jack is set at a wrong
position, it could dent your vehicle or the
jack might fall over and cause personal
injury.
261)Do not use the jack on a tilted or soft
surface. Otherwise, the jack might slip and
cause personal injury. Always use the jack
on a flat, hard surface. Before setting the
jack, make sure there are no sand or
pebbles under the jack base.262)Stop jacking up the vehicle as soon
as the tyre is raised off the ground. It is
dangerous to raise the vehicle any higher.
Do not get under your vehicle while using
the jack. Do not bump the raised vehicle or
leave it sitting on the jack for a long time.
Both are very dangerous. Do not use a jack
except the one that came with your
vehicle. The jack should not be used for
any purpose other than to change a tyre.
No one should be in your vehicle when
using the jack. Do not start or run the
engine while your vehicle is on the jack. Do
not turn the raised wheel. The tyres still on
the ground could turn and make your
vehicle fall off the jack.
263)Do not get under your vehicle while
using the jack.
264)Do not bump the raised vehicle or
leave it sitting on the jack for a long time.
Both are very dangerous.
265)Do not use a jack except the one that
came with your vehicle.
266)The jack should not be used for any
purpose other than to change a tyre.
267)No one should be in your vehicle
when using the jack.
268)Do not start or run the engine while
your vehicle is on the jack.
269)Do not turn the raised wheel. The
tyres still on the ground could turn and
make your vehicle fall off the jack.
270)Handle the wheel carefully when
changing the tyre, to avoid scratching the
wheel surface.
B
336AHA102319
199

TOWING
If your vehicle needs to be towed
If towing is necessary, we recommend
you to have it done by your Fiat
Dealership or a commercial tow truck
service. In the following cases,
transport the vehicle using a tow truck.
The engine runs but the vehicle does
not move, or an abnormal noise is
produced.
Inspection of the vehicle’s underside
reveals that oil or some other fluid is
leaking.
If a wheel gets stuck in a ditch, do not
try to tow the vehicle. Please contact
your Fiat Dealership or a commercial
tow truck service for assistance.
Only when you cannot receive a towing
service from a Fiat Dealership or
commercial tow truck service, tow your
vehicle carefully in accordance with the
instructions given in “Emergency
towing” in this part. The regulations
concerning towing may differ from
country to country. It is recommended
that you obey the regulations of the
area where you are driving your vehicle.Towing the vehicle by a tow truck
138) 139) 140) 141)
281) 282)
Towing with front wheels off the
ground (Type B)
Place the gearshift lever in the “N”
(Neutral) position (manual transmission)
or the selector lever in the “N”
(NEUTRAL) position (automatic
transmission). Release the parking
brake.
142)
Towing with rear wheels off the
ground (Type C)
Place the gearshift lever in the “N”
(Neutral) position (manual transmission)
or the selector lever in the “N”
(NEUTRAL) position (automatic
transmission). Turn the ignition switch to
the “ACC” position or put the operation
mode in ACC and secure the steering
wheel in a straight-ahead position with
a rope or tiedown strap. Never place
the ignition switch in the “LOCK”
position or put the operation mode in
OFF when towing.
Emergency towing
If towing service is not available in an
emergency, your vehicle may be
temporarily towed by a rope secured to
the towing hook. If your vehicle is to be
towed by another vehicle or if your
vehicle tows another vehicle, pay
careful attention to the following points.
B
C
D
E
A
337AHE100108
201

WARNING
281)If the vehicle is towed with the ignition
switch in the “ON” position or the operation
mode in ON and only the front wheels or
only the rear wheels raised off the ground,
the active traction control system may
operate, resulting in an accident.
282)If your vehicle equipped with the
Active Stability & Traction Control system
(ASTC), if the vehicle is towed with the
ignition switch in the “ON” position or the
operation mode in ON and only the front
wheels or only the rear wheels raised off
the ground, the active traction control
system may operate, resulting in an
accident.
283)Avoid sudden braking, acceleration
and steering wheel movements; such
driving operation could cause damage to
the towing hook or towing rope. People in
the vicinity could be injured as a result.284)When going down a long slope, the
brakes may overheat, reducing
effectiveness. Have your vehicle transport
by a tow truck.
285)The person in the vehicle being towed
must pay attention to the brake lamps of
the towing vehicle and make sure the rope
never becomes slack.
286)Do not use flexible cables for towing
and avoid jerking. During towing
operations, make sure that the fastened
joint does not damage adjoining
components.
287)When towing the vehicle comply with
the specific rules of the Highway Code
regarding the towing device and the
behaviour on the road.
288)Do not start the engine while towing
the vehicle.
289)Towing must be made exclusively on
roads/streets; the device must not be used
to recover the vehicle if it got off the road.
290)Towing must not be made for getting
past significant obstacles on the road (e.g.
heaps of snow or material on the road
surface).
291)Towing must take place with the two
vehicles (one towing, the other towed)
aligned as much as possible; towing by
roadside assistance vehicles, too, must
take place with the two vehicles aligned as
much as possible.
IMPORTANT
138)This vehicle must not be towed by a
tow truck using sling lift type equipment
(Type A) as illustrated. Using a sling lift will
damage the bumper and front end.
139)On 4WD vehicles, be sure to set the
drive mode-selector to “2H” position and
transport the vehicle with the driving wheels
on a carriage (Type D or E) as illustrated.
Never try to tow with the drive
mode-selector in “4H” or “4L” positions
(easy select 4WD), “4H”, “4HLc” or “4LLc”
positions (super select 4WD II) and with the
front or rear wheels on the ground (Type B
or C) as illustrated. This could result in the
driving system damage or vehicle may
jump at the carriage. If you cannot set the
drive mode-selector to “2H” position or the
transmission is malfunctioning or damaged,
transport the vehicle with the all wheels on
a carriage (Type D or E) as illustrated.
140)On 2WD vehicles, if the transmission
is malfunctioning or damaged, transport the
vehicle with the driving wheels on a
carriage (Type C, D or E) as illustrated.
141)If you tow the vehicles with automatic
transmission with the driving wheels on the
ground (Type B) as illustrated, make sure
that the towing speed and distance given
below are never exceeded, causing
damage to the transmission. Towing speed:
30 km/h Towing distance: 80 km For the
towing speed and the towing distance,
follow the local driving laws and
regulations.
340AHZ101027
203