service FIAT PALIO 2003 178 / 1.G India Version Owners Manual

Dear New Car Owner,
Thank you for selecting Fiat and congratulations on your choice of a Fiat Palio.
We have produced this owner handbook to help you get to know all your Fiat Palio’s new features and use it
in the best possible way.
We suggest you to read it with the utmost attention prior to driving the car for the first time.
Information, suggestions and warnings, important for the use of the car, are contained in this owner handbook
and they will help you to derive the maximum from your Fiat Palio’s technological features. You will find indi-
cations for your own safety, the car’s well-being and about how to protect the environment.
You have also been given with Fiat Warranty (Owner’s Service Policy) Booklet, wherein you will find the
Warranty Certificate with the terms and the conditions for the maintenance of the car.
Best regards and happy motoring.
This Owner Handbook describes most of the features of the Fiat Palio. As a consequence, you should consider only that informa-
tion which is related to your version and optional which you have purchased.
Commitment to the Max
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74
If the engine begins to “lose its
smoothless” when travelling, continue
your journey but reduce the demands
you are making on the engine and go
to a
Fiat Dealership as soon as you
can.
When the instrument panel fuel re-
serve warning light comes on, fill up as
soon as possible. A low level of fuel
can cause an uneven supply of fuel to
the engine with the inevitable increase
in the temperature of the exhaust gas
and serious damage to the catalytic
converter.
Never run the engine with one or
more spark plugs disconnected, even
for testing purposes.
Do not warm up the engine by letting
it idle for a while before moving off un-
less the outside temperature is very low
and, even in this case, only do so for less
then 30 seconds.Do not install other heat shields and
do not remove those already fitted to
the catalytic converter and exhaust
pipe.
Do not allow anything to be sprayed
onto the catalytic converter, lambda
sensor and exhaust pipe.
Ignoring the above rules
may lead to fire.
The catalytic converter
develops high tempera-
ture during normal oper-
ation. Do not park the car on
grass, dry leaves, pine needles or
other flammable material: fire
hazard
LOOKING AFTER EMISSION
CONTROL DEVICES
The correct use of pollution control
devices not only ensures respect for
the environment but also has an effect
on the car’s performance.
Keeping these devices in good con-
dition is therefore a fundamental rule
for driving that is easy on your pock-
et and on the environment too.
The first step to take is to follow the
Service Schedule to the letter.
Use only unleaded petrol.
If you have trouble starting, do not
keep turning the ignition key for long
periods. Be especially careful to avoid
bump starting the car by pushing, tow-
ing or rolling downhill: these are all
manoeuvres that can damage the cat-
alytic exhaust. Use an auxiliary battery
for start-ups only (see “Starting with
auxiliary battery” in the chapter “In an
emergency”).
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75
CONTAINING RUNNING COSTS
AND POLLUTION
Tyres
Tyre pressure should be checked at
least once every four weeks: if the
pressure is too low fuel consumption
increases as the resistance to the
rolling movement of the tyre is
greater. In this state, tyre wear is in-
creased and handling suffers which will
effect safety.
Unnecessary loads
Do not travel with too much load in
the boot. The weight of the car (above
all in the urban traffic)and its trim
greatly effects consumption and sta-
bility.
Roof rack/ski rack
Remove roof racks and ski racks
from the roof of the car as soon as
they are no longer needed. These ac-
cessories reduce the aerodynamic
penetration of the car and will increase
consumption.
Electrical devices
Use electric devices for the neces-
sary time only. The heated rear win-
dow, additional lights, windscreen
wipers, heater, fan of the heating sys-
tem require large amounts of elec-
tricity and increasing the request for
power will also increase fuel con-
sumption (up to +25% when driving in
towns). Some suggestions which may help
you to keep the running costs of the
car down and lower the amount of
toxic emissions released into the at-
mosphere are given below.
GENERAL
CONSIDERATIONS
Car maintenance
The overall state of the car is an im-
portant factor which has a marked in-
fluence over fuel consumption and dri-
ving comfort and on the life span of
your car. For this reason care should
be taken to maintain your car by car-
rying out the necessary checks and
regulations in accordance with the
specifications given in the service
schedule (see sections: spark plugs,
idling, air cleaners, timing).
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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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105
SCHEDULED
SERVICING
Correct maintenance of the car is es-
sential for ensuring it stays in tip-top
condition for a long time to come.
For this reason, Fiat prepared a se-
ries of maintenance controls and in-
terventions, from 1000-1500, 7500 &
15000 km and so on.
However it is useful to remember
that the Scheduled Servicing does not
completely exhaust all the exigencies
of the car: also in the initial period of
time prior to the coupon of 1000-
1500 km and later on, between one
coupon and an other, the ordinary at-
tentions are always necessary such as
systematic control with possible fluid
level refuelling, tyre pressure restora-
tion etc…
IMPORTANTThe Scheduled Ser-
vicing Coupons are prescribed by the
Manufacturer. The failure in the exe-
cution of the coupons can cause the
cancellation of the warranty.
The service of Scheduled Servicing is
performed by all
Fiat Dealership,
with prefixed times.
If performing each intervention, in
addition to the prescribed operations,
the necessity of further replacements
or repairs occurs, these latter can be
performed only with the explicit
agreement of the Customer.
IMPORTANT We suggest you to
immediately signal to
Fiat Dealer-
ship
possible small operational non
conformities, without waiting for the
next coupon execution.
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106
Thousands of kilometers 15 3045 6075 90105 120135 150165 180
SERVICE SCHEDULE
Check of conditions and weariness of tyres
Check front disc brake pad
Check of conditions and weariness of rear drum brake gasket
Visually inspect: underbody protection, pipes
(exhaust - fuel supply - brakes), rubber elements
(guards - sleeves - bushes - etc.), supply and brake system tubing
Voltage check and possible adjustment of trapezoidal belts
and/or poly-V
Inspect conditions of V belts and/or ploy v-belts
Tappet clearance check/adjustment (petrol version)
(excluding the versions with hydraulic tappets)
Check and adjust tappet clearance (diesel version)
Check/adjustment of the stroke of the lever hand brake
Check evaporation system (diesel version)
Visually inspect fuel evaporation system (connections, lines,
containers, seals and filler cap)
Fuel filter replacement (see “important” in the “Additional
interventions” in this chapter) (for diesel version replace the filter
every 7,500 km)
Replace air cleaner cartridge (diesel version) (see “important” in the
“Additional interventions” in this chapter)
Replace air cleaner cartridge (see “Additional checks” in this chapter)
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107
Thousands of Kilometers 15 3045 6075 90105 120135 150165 180









(*) or every 3 years if the car is used in the following harsh conditions:
- Prolonged use in cold/hot climates, sity driving with prolonged lengths of time at idle speed, driving on dusty roads or roads covered with sand/salt.
- or every 5 years regardless of km covered and use conditions.
NOTE: For every 7,500 km service please refer Owner’s Warranty & Service Policy book.
For every 7,500 km or 6 months (whichever is erlier from previous service) replace engine oil and oil filter.
Top up fluids (engine coolant, brakes, power steering, windscreen washer etc.)
Timing command toothed belt check
Timing command toothed belt replacement
Spark plugs replacement, wire control (*)
Engine control system functionality check
(through autodiagnostic socket)
Change gear/differential gear oil level check
Changing engine oil (every 7,500 km or 6 months)
Replace engine oil filter (every 7,500 km or 6 months)
Brake fluid replacement (or every 24 months)
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109
IMPORTANT - Air cleaner
Using the car on dusty roads, replace
the air cleaner more frequently than
indicated in the Scheduled Servicing
Plan.
For any doubt on the air cleaner re-
placement, in relation to how the car
is used, contact the
Fiat Dealership.
The maintenance of the
car must be committed
to Fiat Dealership. For
those interventions of ordinary
and small maintenance, always
make sure to have the adequate
equipment, Fiat spare parts and
the consumption fluids; in any
event, do not perform such op-
erations, if you do not have any
experience. IMPORTANT - Fuel filter
Check the conditions of the fuel fil-
ter when changes (choking) are no-
ticed in the engine operation.
IMPORTANT - Battery
We suggest you to carry out the
check of the state of battery charge,
preferably at the beginning of the cold
season in order to avoid the possibil-
ity of freezing the electrolyte.
Such check must be carried out
more frequently if the car is mainly
used for short distances, or if it is
equipped with permanent absorption
users with disconnected key, above all
if applied in after market.
Please refer page no. 52 of 24
hours service assistance booklet
for BAT MOBILE service extend-
ed by M/s. Exide Batteries.You should check the battery fluid
(electrolyte) level more frequently
than shown in the service schedulein
this chapter if the car is used in hot cli-
mates or particularly demanding con-
ditions.
24 HOURS SERVICE
CALL - 9628 290 260
This single response num-
ber is available in 9 cities.*
AHMEDABAD - BANGALORE -
KOLKATA - CHENNAI - DELHI -
HYDERABAD - MUMBAI -
PUNE - LUCKNOW
* If you are not in, but near any of the above
cities; Dial city code followed by the single
response numberFor further information about Fiat Service Network please refer 24 Hours Service
AssistanceBooklet provided.
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116
AIR CLEANER
REPLACEMENT fig. 14
Release the clips A, remove the cov-
er
Band remove the filtering element
C.
fig. 14
P4E01442
The symbol π, present
on the container, indi-
cates synthetic brake flu-
ids distinguishing it from mineral
fluid. Using mineral type fluid
would damage the special rubber
braking system gasket beyond re-
pair.
Do not clean the filter-
ing element. You could
damage it and conse-
quently severely damage the en-
gine.
Replace the cleaner
more frequently than
shown in the Service
Schedule if the car is frequently
used on dusty roads. IMPORTANT
Brake fluid is hy-
groscopic (meaning it absorbs humid-
ity). This is why, the fluid should be
changed more frequently than shown
in the Scheduled Servicing Plan if the
car is mainly driven in areas with high
percentage of humidity in the air.
fig. 15 - 1.9 D versions
P4E02329
DIESEL FILTER
DRAINING THE
CONDENSATE
Drain the condense from the filter
every 5,000 km.
Loosen ring nut
A-fig. 15of some
turns and retighten it when fuel comes
out free from water.
You are however advised to have this
operation performed at a
Fiat deal-
ership.
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121
SPARK PLUGS
The cleanness and soundness of the
spark plugs
fig. 19 are very important
for keeping the engine efficient and
polluting emissions down.
The appearance of the spark plug, if
examined by an expert eye, is a good
way of pinpointing a problem even if it
has nothing to do with the ignition sys-
tem. Therefore, if the engine has prob-
lems, it is important to have the spark
plugs checked at a
Fiat Dealership.
The spark plugs must be
changed at the times
specified in the Service
Schedule. Only use the type of
plugs indicated. If the heat ratio is
less than required or the life spec-
ified is not guaranteed, problems
can arise.
Spark plug (type)
1.2
Champion RC7BMCChampion RC8BYC
1.6NGK BKR5EZ
Champion RC10YCC
Bosch FR8DE
fig. 19
P4E01444
WHEELS AND
TYRES
TYRE PRESSURE
Every two weeks and before long
journeys, check the pressure of each
tyre including the spare.
The pressure must be checked when
the tyre is rested and cold.
It is normal for the pressure to rise
when you are driving. If you have to
check or to restore the pressure
when the tyres are warm, remember
that the pressure value must be 0.3
bar above the specified value.
Tyre pressure must be
correct to ensure good
road holding.
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