light FIAT PALIO 2003 178 / 1.G India Version Service Manual

IN AN EMERGENCY
People who find themselves in an emergency situ-
ation need immediate and concrete help.
The following pages have been written to help you
if the need arises.
As you will see, a host of little snags have been taken
into account and, for each of them, the measures you
yourself can take are suggested. If the problems are
more serious however, you should have the car seen
at a Fiat Dealership.
With regard to this, we would like to remind you
that, in addition to the Owners Handbook you have
also been provided with the Warranty Booklet
where you will find details of all the services Fiat can
provide should you find yourself in difficulty.
We nevertheless recommend you read these
pages. If in need you will be able to find the informa-
tion you require much more quickly.
In addition to this you have also been provided
with 24 hours service assistance booklet, where in
you can find nearest contact number and address for
24 hour service assistance.JUMP STARTING ...................................................... PAGE 81
BUMP STARTING .................................................... PAGE 82
IF A TYRE IS PUNCTURED .................................. PAGE 82
IF A BULB BURNS OUT ........................................ PAGE 86
IF AN EXTERIOR LIGHT BURNS OUT ............ PAGE 88
IF AN INTERIOR LIGHT BURNS OUT ............. PAGE 92
IF A FUSE BLOWS ................................................... PAGE 93
IF THE BATTERY IS FLAT ..................................... PAGE 98
IF THE CAR NEEDS TO BE RAISED .................. PAGE 99
IF THE CAR NEEDS TO BE TOWED ................. PAGE 101
IF AN ACCIDENT OCCURS ................................. PAGE 102
80
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81
JUMP STARTING
If the battery is flat, you can use an-
other battery to start the engine. Its ca-
pacity must be the same or slightly
greater than the flat battery (see “Tech-
nical Specifications”).
Proceed as follows
fig. 1:
1)Connect positive terminals +of
the two batteries with a jump lead.
2)With a second lead, connect the
negative terminal (
–) of the auxiliary
battery and to an earth point E
on the
engine or the gearbox of the car to be
started.
IMPORTANTDo not directly
connect the negative terminals of the
two batteries: sparks could ignite the
flammable gas from the battery.
3)Start the engine.
4)When the engine has been start-
ed, remove the leads reversing the or-
der above.
If the engine fails to start after a few
attempts, do not keep turning the key
but have the car seen to at a
Fiat
Dealership
.
fig. 1
P4E01470
This starting procedure
must be carried out by
expert personnel; if it is
not done correctly it can cause
very intense electrical discharges.
In addition, the fluid contained in
the battery is poisonous and cor-
rosive. Avoid contact with skin
and eyes. You are also advised
not to put naked flames or light-
ed cigarettes near the battery
and not to cause sparks.
Under no circumstances
should a battery charger
be used for the emer-
gency procedure: it could dam-
age the electronic systems and in
particular the ignition and injec-
tion control units.
To avoid damages to the
car electric system, care-
fully follow the instruc-
tions of the cable manufacturer.
The cables must have a sufficient
diameter and must be enough
long to allow that the cars touch
each other.
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83
1. STOP THE CAR
– Stop the car in a position that is not
dangerous for oncoming traffic where
you can change the wheel safely. The
ground should be flat and adequately
firm. If you have to change the wheel
at night, choose a lit area if possible.
– Turn the engine off and pull up the
handbrake.
– Engage first or reverse gear.
– Alert other drivers that the car is
stationary in compliance with local
regulations: hazard warning lights,
warning triangle etc.
Any passenger should get out and
wait as far away as possible from the
dangers of traffic.
If the road is sloping or bumpy, place
wedges or other suitable material un-
der the wheels to prevent the car from
moving.
2. TAKE OUT THE TOOLS,
JACK AND SPARE WHEEL
They are in the boot.
The tool bag is secured to the inter-
nal boot wall by proper belts,
fig. 2;
to take it out, lift the adhesive strip of
the belts. The bag contains: the jack
A-
fig. 3
, the jack operating handle B, the
wheel bolt wrench
C, the tow hitch D
and the screwdriver E.
fig. 2
P4E02373
fig. 4
P4E02375
fig. 3
P4E02374
– Lift the carpet covered flap.
– Loosen the fastener
A-fig. 4and
take the spare wheel.
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5) Warn anyone nearby that the car
is about to be lifted. They must stay
clear and not touch the car until it is
back on the ground.
6)Fit the operating handle on the
jack and turn it until the wheel to be
changed lifts a few centimetres off the
ground. When turning the jack handle
make sure that it can be used easily
and take care not to scrape your hand
against the ground› . The moving parts
of the jack (screw and joints) may al-
so cause injury if touched. Clean off
any grease.
7)Unscrew the 4 wheel bolts and
remove the wheel.
8) Ensure that the housing for the
wheel bolts on the spare wheel are
clean and free from dirt, which could
cause the wheel bolts to come loose.
Fit the spare wheel, in order that the
holes
A-fig. 6coincide with the rele-
vant pins
B.
9) Fasten one bolt A-fig. 7near the
inflation valve
B.
fig. 6
P4E01642
fig. 5
P4E02376
84
Please note:
– the jack weighs 2.900 kg;
– the jack requires no adjustments;
– the jack cannot be repaired. If it
breaks it must be replaced with a new
jack;
– No tool with the exception of the
handle can be fitted on the jack.
3. CHANGE THE WHEEL
1)
Loosen the bolts on the wheel to
be changed by approximately one turn.
2) If the wheel to be changed has a
light-alloy rim, rock the car a few times
from the roof so as to loosen the rim
from the hub if necessary.
3) Turn the jack handle so that the
jack opens partially.
4)Arrange the jack at the Osymbol
B-fig. 5 near the wheel to be changed
and make sure that the groove
Aon
the jack fits well into the sidemember
C.
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86
IF A BULB BURNS OUT
Modifications or repairs
to the electrical system
carried out incorrectly
and without bearing the features
of the system in mind can cause
malfunctions with the risk of fire.
You should have the
bulbs replaced at a Fiat
Dealership. The correct
operation and direction of the
headlights is essential for safety
and is governed by the highway
code.Only touch the metal
part when handling halo-
gen bulbs. If the transpar-
ent bulb is touched it reduces the
intensity of the light emitted and
can also reduce the life of the
bulb. If you touch the bulb acci-
dentally, rub it with a cloth moist-
ened with alcohol and leave it to
dry.
GENERAL INSTRUCTIONS
When a light is not working, check
that it has not fused before changing the
bulb.
For the location of the fuses, refer to
“If a fuse blows” in this chapter.
Before replacing a bulb that does not
work, check that the contacts are not
oxidised.
Halogen bulbs contain
pressurised gas which, if
broken, may cause small
fragments of glass to be project-
ed outwards.
Burnt-out bulbs must be replaced
with ones of the same type. Bulbs with
low power offer low illumination,
bulbs with too much power absorb
too much energy.
Always check the height of the head-
light beam after changing a bulb.
TYPES OF BULBS
Several types of bulbs are installed in
the car
fig. 12:
A. Glass bulbs
Clipped into position. Pull to remove.
B. Bayonet connection bulbs
Remove from the bulb holder by
pressing the bulb and rotating it anti-
clockwise.
C. Cylindrical bulbs
Remove by pulling away from termi-
nals.
D-E. Halogen bulbs
To remove bulb, loosen the fixing
spring from the relevant seat.
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87
fig. 12
P4E01417
Bulbs Reference Type Powera fig. 12
Dipped beam
Main beam
Front parking/tail lights
Front direction indicators
Rear direction indicators
Front foglights
Rear parking/tail lights
Stop
Reversing light
Number plate light
Front ceiling lightE H7 55W
D H1 55W
A W5W 5W
B PY21W21W
B P21W21W
D H3 55W
B P21/5W21/5W
B P21/5W21/5W
B P21W21W
C W5W 5W
C C10W10W
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88
3) Pull side tabs of the fixing clips C-
fig. 14
; remove the bulb holder and
the relevant bulb.
4) Insert the new bulb, making sure
that the tabs on the metal part coin-
cide with the special grooves in the
headlight dish.
5) Refasten the clip, insert the con-
nector and refit the cover.
MAIN BEAM HEADLIGHTS
To replace a halogen bulb (type H1,
12V-55W):
1) Remove the plastic cover, by
pulling the stop spring.
2) Remove the electrical connector
E-fig. 15.
3) Pull side tabs D-fig. 15of the fix-
ing clip; remove the bulb holder and
replace the bulb.
4)Insert the bulb holder and fix it
through the relevant clip; connect the
electrical connector and refit the cov-
er.
IF AN EXTERIOR
LIGHT BURNS
OUT
DEEP BEAM HEADLIGHTS
To replace a halogen bulb (type H7,
12V-55W):
1)Remove the spring A-fig. 13and
remove the plastic protective cover.
2)Remove the electrical connector
B-fig. 13.
fig. 13
P4E02179
fig. 14
P4E02180
fig. 15
P4E02181
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89
FRONT SIDE LIGHTS
To replace the 12V-5W bulb:
1)Release the spring A-fig . 16and
remove the plastic protective cover.
2)Remove the bulb holder C-fig.
16-17
, by turning it anticlockwise.
3) Remove the bulb by turning it an-
ticlockwise.
4) After having replaced the bulb, re-
fit the bulb holder and the protective
cover.
FRONT DIRECTION
INDICATORS
To replace the 12V-21W bulb:
1) Release the spring A-fig . 16and
remove the plastic protective cover.
2)Remove the bulb holder B-fig.
16-17
, by turning it anticlockwise.
3) Remove the bulb by turning it an-
ticlockwise.
4) After having replaced the bulb, re-
fit the bulb holder and the protective
cover.
FRONT FOGLIGHTS
To replace the halogen bulb (type
H3, 12V-55W).
1) Loosen the fog light fastening
screws
A-fig. 18to the front bumper.
fig. 16
P4E02182
fig. 17
P4E02183P4E02437
fig. 18
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90
FRONT FOGLIGHTS
To replace the halogen bulb (type
H3, 12V-55W).
1) Turn the wheels to the left to re-
place the right-hand light and vice-ver-
sa.
2) Loosen the screws A-fig. 19of
the cover on the wheelhouse and pull
the cover downwards.
3) Disconnect the connectorA-fig.
20
and turn the cover B anticlockwise.
4)release the clip C-fig. 20and re-
move the bulb holder.
5)Remove the bulb and replace it
with an other one of same type and
power
fig. 21.
6)Then insert the bulb holder in its
seat and fix it through clip
C-fig. 20.
7)Refit the cover Bby turning it
clockwise and connect the electrical
connector.
8)Refit the wheelhouse cover and
fix it by using screws
A-fig. 19.
REAR LIGHT CLUSTER
To replace a bulb:
1) From inside the boot, lift the
opening on the covering panel and un-
screw nut
A-fig. 23.
2) Remove the electrical connector
A-fig. 22.
3)
Remove the bulb group fig. 24.
4)Remove the bulbs by pushing
them lightly and turning them anti-
clockwise.
fig. 20
P4E02185
fig. 21
P4E02186
fig. 19
P4E02184
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91
The bulbs fig. 24are:
A- 12V-21/5W for brake lights;
B- 12V-21W for direction indicators;
C- 12V-21W for the reversing lights;
3)Unscrew the screws B-fig. 26
and replace the bulb group C or only
the burnt-out bulb.
D- 12V-21/5W for parking/tail
lights.
THIRD BRAKE LIGHT
To replace the light cluster:
1) With the boot open, loosen the
screws
A-fig. 25 and remove the unit.
2) Disconnect the electrical connec-
tion.
fig. 25
P4E01758
fig. 22
P4E02378
fig. 23
P4E02188
fig. 24
P4E02189
fig. 26
P4E01759
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