engine FIAT FULLBACK 2017 Owner handbook (in English)

SERVICE
PRECAUTIONS
346) 347) 348) 349) 350) 351) 352) 353)
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.
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
346)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.
347)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.348)After performing the maintenance
work, make sure that no tools or cloths are
left behind in the engine compartment. If
they are left behind, a fire or damage to the
vehicle may occur.
349)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.
350)Do not smoke, cause sparks or allow
open flames around fuel or battery. The
fumes are flammable.
351)Be extremely cautious when working
around the battery. It contains poisonous
and corrosive sulphuric acid.
352)Do not get under your vehicle with
just the body jack supporting it. Always use
automotive jack stands.
353)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.
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SCHEDULED SERVICING PLAN
DIESEL ENGINE 4N15
Thousand of miles12,5 25 37,5 50 62,5 75 87,5 100 112 125
Thousands of kilometers or20 40 60 80 100 120 140 160 180 200
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●
Adjust the tappet clearance (where there is
no hydraulic clearance adjustment)●●●
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.
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Thousand of miles12,5 25 37,5 50 62,5 75 87,5 100 112 125
Thousands of kilometers or20 40 60 80 100 120 140 160 180 200
Years12345678910
Visually inspect conditions and check the
tension of the accessory 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●●
Visually check for any fluid leaks from the
transfer case (if leaks are found, check the
oil level)
●●●● ●●●●
Change transfer case oil●●
Change engine oil and replace oil filter●●●●●●●●●●
Replace accessory drive belts(3)
Replace fuel filter cartridge (4)
●●●●●
Replace air cleaner cartridge (5)●●●
Check the air filter cartridge for obstructions
or damage●● ●● ●● ●
Change the brake fluid (6)●●●●●
(3) The belt should only be replaced if damage/wear is found during the periodic inspection.
(4) In case of refueling with a type of diesel that does not comply with the Euro regulations, it is recommended to change this filter each 20,000 km.
(5) If the vehicle is used in dusty areas, this cleaner must be replaced every 20,000 km.
(6) The brake fluid replacement has to be done every two years, irrespective of the mileage.
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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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CHECKING LEVELS
1. Engine coolant reservoir 2. Brake fluid reservoir 3. Clutch fluid reservoir (where provided) 4. Engine oil cap 5. Engine oil
level gauge 6. Power steering fluid reservoir 7. Washer fluid reservoir 8. Battery
A— RHD versions
354) 355)
WARNING
354)Never smoke when performing operations in the engine compartment. Flammable gases and fumes may be present and risk igniting.
355)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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CATALYTIC
CONVERTER
356)
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
356)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
To check and refill engine oil
357)
A — Minimum level
B — Maximum level
C — Oil replacement indication mark
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 oil
to 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
step4to6.
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
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SERVICING AND MAINTENANCE
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 level will be increased
due to an amount of the fuel being
mixed in the engine oil when the DPF
regenerates to burn away the PM
(particulate matter). It does not indicate
a malfunction. In the following
conditions, the engine oil level may
increase easily. We recommend you to
have it checked frequently.:
frequent driving at uphill and
downhill;
frequent driving at high altitudes;
frequent and extended idling;
frequent driving through a traffic jam.
NOTE The engine oil will deteriorate
rapidly if the vehicle is subjected to
severe conditions, requiring earlier oil
replacement. Please refer to the
maintenance schedule.
Selection of engine oil
Refer to “Refill Capacities” under
Technical Specifications.
Safety and disposal information for
used engine oil
358) 359) 360)
Protect the environment
It is illegal to pollute drains, water
courses and soil. Use authorized waste
collection facilities, including civic
amenity sites and garages providing
facilities for disposal of used oil and
used oil filters. If in doubt, contact your
local authority for advice on disposal.
WARNING
357)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!
358)Prolonged and repeated contact may
cause serious skin diorders, including
dermatitis and cancer.
359)Avoid contact with the skin as far as
possible and wash thoroughly after any
contact.
360)Keep use engine olis out of reach of
children.
ENGINE COOLANT
To check the coolant level
A transparent coolant reserve tank (A) is
located in the engine compartment. The
coolant level in this tank should be kept
between the “L” (LOW) and “F” (FULL)
marks when measured while the engine
is cold.
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To add coolant
The cooling system is a closed system
and normally the loss of coolant should
be very slight. A noticeable drop in the
coolant level could indicate leakage. If
this occurs, we recommend you to
have the system checked as soon as
possible. If the level should drop below
the “L” (LOW) level on the reserve tank,
open the lid and add coolant.
Also, if the reserve tank is completely
empty, remove the radiator cap (B) and
add coolant until the level reaches the
filler neck.
361) 362)
Anti-freeze
The engine coolant contains an
ethylene glycol anti-corrosion agent.
Some parts of the engine are cast
aluminium alloy, and periodic changing
of the engine coolant is necessary to
prevent corrosion of these parts.
Use the recommended coolant by Fiat
or equivalent (similar high quality
ethylene glycol based non-silicate,
non-amine, nonnitrate and nonborate
coolant with long life hybrid organic
acid technology).
Fiat genuine coolant has excellent
protection against corrosion and rust
formation of all metals including
aluminium and can avoid blockages in
the radiator, heater, cylinder head,
engine block, etc.Because of the necessity of this
anti-corrosion agent, the coolant must
not be replaced with plain water even in
summer. The required concentration of
anti-freeze differs depending on the
expected ambient temperature.
Above -35 °C: 50 % concentration of
antifreeze
Below -35 °C: 60 % concentration of
antifreeze
180) 181) 182) 183) 184)
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
361)The used engine oil and the filter that
has been replaced contain substances that
are harmful to the environment. To change
the oil and filters, we advise you to contact
a Fiat Dealership.
362)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
180)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.
181)Concentrations exceeding 60 % will
result in a reduction of both the anti-freeze
and cooling performance thus adversely
affecting the engine.
182)Do not top up with water only.
183)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.
184)Do not use water to adjust the
concentration of coolant.
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SERVICING AND MAINTENANCE

WASHER FLUID
Open the washer fluid reservoir cap and
check the level of washer fluid with the
dipstick. If the level is low, replenish the
container with washer fluid.
NOTE The washer fluid container
server serves the windscreen and
headlamps (if so equipped).
During cold weather
To ensure proper operation of the
washers at low temperatures, use a
fluid containing an anti-freezing agent.
363) 364)
WARNING
363)Do not travel if the windscreen
washer reservoir is empty: using the
windscreen washer is essential for
improving visibility. Repeated operation of
the system without fluid could damage or
cause rapid deterioration of some system
components.
364)Some commercial additives for
windscreen washer fluid are flammable.
The engine compartment contains hot
components which may start a fire.
BRAKE FLUID
To check the fluid level
Check the brake fluid level in the
reservoir. The brake fluid level must be
between the “MAX” and “MIN” marks
on the reservoir.
The brake fluid level is monitored by a
float. When the brake fluid level falls
below the “MIN” mark, the brake fluid
warning lamp lights up.
The fluid level falls slightly with wear of
the brake pads, but this does not
indicate any abnormality.
If the brake fluid level falls markedly in a
short length of time, it indicates leaks
from the brake system. If this occurs,
we recommend you to have the vehicle
checked.
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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.
365) 366) 367) 368) 369) 370) 371) 372)
185) 186) 187)
WARNING
365)Prevent power steering fluid from
coming into contact with hot engine parts:
it is flammable.
366)Some commercial windscreen washer
additives are flammable. The engine
compartment contains hot parts which
could start a fire on contact.
367)Do not travel with the windscreen
washer reservoir empty: the windscreen
washer is essential for improving visibility.
368)The cooling system is pressurised. If
necessary, only replace the plug with
another original one or the operation of the
system may be adversely affected. Do not
remove the reservoir plug when the engine
is hot: risk of burns.
369)Take care in handling brake fluid as it
is harmful to the eyes, may irritate your skin
and also damage to painted surfaces.370)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.
371)Clean the filler cap before removing
and close the cap securely after
maintenance.
372)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
185)Keep the reservoir tank cap closed to
prevent the brake fluid from deteriorating
except maintenance.
186)Prevent brake fluid, which is highly
corrosive, from coming into contact with
painted parts. Should it happen,
immediately wash with water.
187)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
immediately inspected by a Fiat
Dealership.
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