fuel FIAT FULLBACK 2016 1.G Service Manual

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.
236
SERVICING AND MAINTENANCE

Thousands of miles6 121825313743505662
Thousands of kilometers or10 20 30 40 50 60 70 80 90 100
Years12345678910
Change transfer case oil (8)●
Change engine oil and replace oil filter●●●●●●●●●●
Replace accessory drive belts(3)
Replace the toothed timing drive belts (8)
●
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●●●●●●●●●●
(8) to be done only on a mileage basis, independently of the time.
(3) The belt should only be replaced if damage/wear is found during the periodic inspection.
(8) to be done only on a mileage basis, independently of the time.
(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.
239

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.
240
SERVICING AND MAINTENANCE

CATALYTIC
CONVERTER
314)
The exhaust gas scavenging devices
used with catalytic converter are
extremely efficient for the reduction of
noxious gases. The catalytic converter
is installed in the exhaust system.
It is important to keep the engine
properly tuned to ensure proper catalyst
operation and prevent possible catalyst
damage.
NOTE Use fuel of the type
recommended in “Fuel selection”.
WARNING
314)As with any vehicle, do not park or
operate this vehicle in areas where
combustible materials such as dry grass or
leaves can come in contact with a hot
exhaust since a fire could occur.
ENGINE OIL
315)
To check and refill engine oil
A — Minimum level
B — Maximum level
C — Oil replacement indication mark
Petrol-powered vehiclesDiesel-powered vehicles
391AHA102481
392AHA106261
393AHA102508
245

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
246
SERVICING AND MAINTENANCE

GENERAL
MAINTENANCE
Fuel, engine coolant, oil and
exhaust gas leakage
Look under the body of your vehicle to
check for fuel, engine coolant, oil and
exhaust gas leaks.
Exterior and interior lamp operation
Operate the combination lamp switch
to check that all lamps are functioning
properly. If the lamps do not illuminate,
the probable cause is a blown fuse or
defective lamp bulb. Check the fuses
first. If there is no blown fuses, check
the lamp bulbs. For information
regarding the inspection and
replacement of the fuses and the bulbs,
refer to “Fuses” and “Replacement of
lamp bulbs”. If the fuses and bulbs are
all OK, we recommend you to have
your vehicle checked and repaired.
Meter, gauge and indicator/
warning lamps operation
Start the engine to check the operation
of all instruments, gauges, and indicator
and warning lamps. If there is anything
wrong, we recommend you to have
your vehicle inspected.
Hinges and latches lubrication
Check all latches and hinges, and, if
necessary, have them lubricated.
VEHICLE CARE
PRECAUTIONS
337)
161)
5)
In order to maintain the value of your
vehicle, it is necessary to perform
regular maintenance using the proper
procedures.
Always maintain your vehicle in
compliance with any environmental
pollution control regulations.
Carefully select the materials used for
washing, etc., to be sure that they do
not contain corrosives. If in doubt, we
recommend you to consult a specialist
for the selection of these materials.
WARNING
337)Cleaning products can be dangerous.
Always follow the instructions of the
cleaning product supplier.
IMPORTANT
161)To avoid damage, never use the
following to clean your vehicle: Petrol; Paint
Thinner; Benzine; Kerosene; Turpentine;
Naphtha; Lacquer Thinner; Carbon
Tetrachloride; Nail Polish Remover;
Acetone.
IMPORTANT
5)Detergents pollute the environment. Only
wash your vehicle in areas equipped to
collect and treat wastewater from this type
of activity.
255

ItemDiesel-powered vehicles
4D56
Without intercoolerWith intercooler
Not for vehicles with 15 inch tyreWith intercooler
Vehicles with 15 inch tyre
Engine models 4D56
No. of cylinders 4 in line
Total displacement 2,477 cc
Bore91.1 mm
Stroke95.0 mm
Camshaft Double overhead
Mixture preparation Electronic direct injection
Maximum output (EEC net) 81 kW/4,000 r/min100 kW/4,000 r/min
131 kW/4,000 r/min
(1)94 kW/4,000 r/min
Maximum torque (EEC net)200 Nm/1,500
–3,500 r/min324 Nm/2,000 r/min
400 Nm/2,000 r/min
(1)240 Nm/1,500 – 3,500 r/min
(1) Vehicles with high power engine
344)
WARNING
344)Modifications or repairs to the fuel supply system that are not carried out properly or do not take the system’s technical specifications
into account may cause malfunctions leading to a risk of fire.
270
TECHNICAL SPECIFICATIONS

FLUIDS AND LUBRICANTS
Product specifications
Your vehicle is equipped with an engine oil that has been thoroughly developed and tested in order to meet the requirements of
the Scheduled Servicing Plan.
Constant use of the prescribed lubricants guarantees the fuel consumption and emission specifications. Lubricant quality is
crucial for engine operation and duration.
Lubricant Characteristics SpecificationOriginal Fluids and
LubricantsReplacement interval
Engine oil
With DPF
Without DPFSAE 5W-30
ACEA C39.55535-S3
or MS-11106SELENIA MULTIPOWER C3
Contractual Technical
Reference N° F129.F11According to Scheduled
Servicing Plan
If lubricants compliant with the required specifications are not available, products that comply with the minimum required
characteristics can be used for topping up; in this case optimal performance of the engine is not guaranteed.
192)
300
TECHNICAL SPECIFICATIONS
IMPORTANT
192)The use of products with specifications different than those indicated above could cause damage to the engine that is not covered by
the warranty.

INDEX
4Wheel drive operation........170
Accessory socket............76
Active safety systems..........126
Air conditioning system.........52
Air purifier..................67
Ashtray....................75
Assist grip..................80
Automatic climate control air
conditioner................59
Automatic transmission.........149
Auxiliary driving system.........130
Battery..................252
Bleeding the fuel system........188
Bonnet....................72
Bottle holder................80
Brake fluid.................249
Cargo area.................74
Cargo loads.................74
Catalytic converter.........71,245
Central door locks.............28
Checking levels..............241
Child restraint...............107
Child restraint system..........110
Child-protection rear doors (Double
cab)....................29
Cigarette lighter..............76
.257.256
Clutch fluid................250
Coat hook..................80
Combination headlamps and
dipper switch..............40
Convenient hook.............80
Cooler Manual air conditioning.....55
Cruise control...............176
Cup holder.................79
Demanding vehicle use........240
Diesel particulate filter..........71
Digital clock.................77
Doors.....................26
Driving, alcohol and drugs.......134
Easy select 4WD............154
Economical driving...........133
Electric window control.........68
Electrical system.............289
Electronic immobilizer..........13
Emergency starting...........185
Engine compartment...........72
Engine coolant..............247
Engine oil.................245
Engine overheating...........187
Engine switch...............24
External Lights...............40
Fluids and Lubricants.........300Fog lamp switch..............44
Force limiter................106
Front seats.................31
Fuel selection................81
Fuses....................205
Fusible links................205
General maintenance.........255
Graphical index...............9
Handling of 4 wheel drive vehicles.173
Hazard warning flasher switch.....44
Head restraints...............34
Headlamp levelling switch........42
Heater Manual air conditioning.....55
How to change a tyre..........194
If the vehicle breaks down.......185
Ignition switch...............23
Important operation tips for the air
conditioning...............66
Inside rearview mirror...........37
Installing a child restraint system to
lower anchorage...........116
Instruments.................86
Interior features..............74
Interior lamps................47
ISOFIX positions.............110
Key number tag..............13
Keyless Entry System...........14
Keys.....................13
Cleaning the exterior of your vehicleCleaning the interior of your vehicle

Masking the headlamps.........45
Multi information display.........86
Operation under adverse driving
conditions...............204
Outside rearview mirror.........38
Parking..................140
Parking brake...............139
Periodic checks.............240
Power steering fluid...........251
Pretensioners...............106
Read this carefully.............2
Rear Differential lock..........166
Rear gate..................29
Rear seat..................32
Rear view camera............180
Rear window demister switch.....67
Rearview mirrors..............37
Refill capacities..............292
Removal of water from the fuel filter......................188
Replacement of lamp bulbs......213
Safe driving techniques........134
safety systems..............126
SBR system................105
Scheduled Servicing Plan.......225
Seat adjustment..............31
Seat belt reminder............105
Seat belts
Use ...................103
Seats.....................31
Service precautions...........224
Side airbags................122
Sport mode................149
Starting and stopping the engine. . .141
Steering wheel...............35
Steering wheel height and reach
adjustment................35
Steering wheel lock............36
Sun visors..................74
Super Select 4WD II...........162
Supplemental restraint system
airbag..................118Tools, jack and jack handle......189
Towing...................201
Turbocharger operation........145
Turn-signal lever..............43
Tyres ....................260
Tyres and wheels.............291
Use of the Owner Handbook......3
Vanity mirror................75
Vehicle care precautions........255
Vehicle changes/alterations........5
Vehicle dimensions...........271
Vehicle labeling..............266
Vehicle performance..........279
Ventilators..................52
Washer fluid...............249
Weights..................281
Window...................68
Windscreen wiper.............48
Wiper and washer switch........48
Wiper blade rubber replacement . . .254
FCA Italy S.p.A. - MOPAR - Technical Services - Service Engineering
Largo Senatore G. Agnelli, 3 - 10040 Volvera - Turin (Italy)
Print no.
INDEX
Manual transmission..........146
603.99.982 - 04/2016- Edition1