engine FIAT PANDA 2016 319 / 3.G Workshop Manual

WARNING
136)If the replaced fuse blows again,
contact a Fiat Dealership.
137)Never replace a blown fuse with metal
wires or other material.
138)Never replace a fuse with another with
a higher amp rating; DANGER OF FIRE.
139)If a general fuse (MEGA-FUSE,
MIDI-FUSE, MAXI-FUSE) cuts in, do not
attempt any repair and contact a Fiat
Dealership.
140)Before replacing a fuse, make sure
that the ignition key has been removed and
that all the other devices are switched off
and/or deactivated.
141)If a general protection fuse for safety
systems (airbag system, braking system),
power unit systems (engine system,
transmission system) or steering system
blows, contact a Fiat Dealership.
WARNING
50)If you need to wash the engine
compartment, take care not to directly hit
the fuse box and the window wiper motors
with the water jet.
CHANGING A WHEEL
142) 143) 144) 145) 146)
JACK
Important notes:
❒the jack weight is 1.76 kg;
❒the jack requires no adjustment;
❒the jack cannot be repaired and in
the event of a fault it must be replaced
by another original one;
❒no tool other than its cranking device
may be fitted on the jack.
CHANGING PROCEDURE
Proceed as follows:
❒stop the vehicle in a position that is
not dangerous for oncoming traffic
where you can change the wheel safely.
The ground should be flat if possible,
and sufficiently firm;
❒switch off the engine, pull up the
handbrake and engage the 1
stgear or
reverse. Wear the reflective safety
jacket (compulsory by law) before
getting out of the vehicle;
❒open the luggage compartment, pull
tab A fig. 109 and lift up the mat;❒using the wrench A fig. 110 located
in the tool box, loosen the locking
device, take the tool box B and place it
close to the wheel to be replaced.
Then take the space-saver wheel C.
For the Panda VAN and Panda 4x4
versions, the jack and the tools can be
located under the passenger side
front seat;
109F1D0072
110F1D0073
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❒make sure that the compressor
switch is in position 0 (off), start the
engine, plug into the power socket in
the central tunnel and operate the
compressor, turning switch A to
position I (on);
❒inflate the tyre to the pressure
specified in the "Inflation pressure"
paragraph in the "Technical
specifications" section. Check tyre
pressure on gauge B with compressor
off to obtain a more precise reading;
❒if after five minutes it is still impossible
to reach at least 1.8 bar, disengage
the compressor from the valve and
power socket, then move the vehicle
forwards by approx. ten metres in order
to distribute the sealing fluid inside the
tyre evenly, then repeat the inflation
operation;
❒if after this operation you still cannot
reach at least 1.8 bar after 5 minutes
from switching on the compressor,
do not resume driving but contact a
Fiat Dealership;
❒after driving for about 10 minutes
stop and check the tyre pressure again;
engage the handbrakeand park
safely;❒if a pressure value of at least 1.8 bar
is detected, restore the correct
pressure (with the engine running and
the handbrake engaged), resume
driving and drive with great care to the
nearest Fiat Dealership.
WARNING
147)Give the instruction brochure to the
personnel charged with handling the
tyre treated with the quick tyre repair kit.
148)Punctures on the sides of the tyre
cannot be repaired. Do not use the quick
tyre repair kit if the tyre is damaged as
a result of driving with it deflated.
149)If the wheel rim has been damaged
(bent so as to cause air to leak), the wheel
cannot be repaired. Do not remove foreign
bodies (screws or nails) from the tyre.
150)Do not use the compressor for more
than 20 consecutive minutes. Risk of
overheating. Tyres repaired with the quick
tyre repair kit must only be used
temporarily, as the kit is not suitable for a
definitive repair.
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6
151)The information required by current
regulations, regarding the chemical
substances for the protection of human
health and the environment and on the safe
use of the sealing fluid, are on the
packaging label. Compliance with the
indications on the label is an essential
condition to ensure the safety and
the effectiveness of the product.
Remember to carefully read the label
before use; the user of the product
is responsible for any damages caused by
improper use. The sealing fluid has an
expiry date. Replace the bottle if the
sealant has expired.
152)Put on the protective gloves provided
together with the quick tyre repair kit.
153)Apply the adhesive label where it can
be easily seen by the driver as a reminder
that the tyre has been treated with the
quick repair kit. Drive carefully, particularly
on bends. Do not exceed 80 km/h. Avoid
sudden acceleration or braking.
154)If the pressure has fallen below 1.8
bar, do not drive any further: the quick tyre
repair kit cannot guarantee the correct
hold because the tyre is too damaged.
Contact a Fiat Dealership.
155)Always indicate that the tyre was
repaired using the quick tyre repair kit. Give
the leaflet to the personnel charged with
handling the tyre treated with the tyre
repair kit.

❒connect the other end of the cable
used for positive (+) to the positive
terminal (+) of the auxiliary battery;
❒connect one end of the cable used
for negative (–) to the negative terminal
(–) of the auxiliary battery;
❒Connect the other end of the cable
used for negative (–) to an engine earth
(the visible metal part of the vehicle
engine with flat battery) away from the
battery and the fuel injection system;
❒start the vehicle engine with the
auxiliary battery, let it run for a
few minutes at idling. Start the engine
of the vehicle with flat battery.
Cable disconnection.
Once the engine has been started,
remove the cables proceeding as
follows:
❒disconnect the end of the cable used
for negative (–) from the engine earth
of the vehicle with flat battery;
❒disconnect the other end of the cable
used for negative (–) from the negative
terminal (–) of the auxiliary battery;
❒disconnect the end of the cable used
for positive (+) from the positive terminal
(+) of the auxiliary battery;
❒disconnect one end of the cable
used for positive (+) from the positive
terminal (+) of the vehicle with flat
battery;If it is often necessary to perform a
jump starting, have the vehicle battery
and the recharging system checked
by a Fiat Dealership.
IMPORTANT Any accessories (e.g.
mobile phones, etc.) connected to the
vehicle power sockets draw current
even if they are not used. These
devices, if left connected too much time
with engine off, may cause the battery
to drain with following reduction of
its life and/or failure to start the engine.
WARNING
156)This procedure must be performed by
qualified personnel as incorrect actions
may cause high-intensity electrical
discharge. Furthermore, battery fluid is
poisonous and corrosive: avoid contact
with skin and eyes. Keep naked flames and
lighted cigarettes away from the battery
and do not cause sparks.
157)Remove any metal objects (e.g. rings,
watches, bracelets), that might cause an
accidental electrical contact and cause
serious injury.
WARNING
53)Do not connect the cable to the
negative terminal (–) of the flat battery. The
following spark could lead to battery
explosion and cause serious harm. Only
use the specific earth point; do not use any
other exposed metallic part.
54)Never use a fast battery-charger to
start the engine as this could damage the
electronic systems of your vehicle,
particularly the ignition and engine fuel
supply control units.
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18

FUEL CUT-OFF
SYSTEM
158)
This intervenes in the case of an impact
causing:
❒the interruption of the fuel supply with
the engine consequently cutting out;
❒the automatic unlocking of the doors;
❒the automatic switching on of the
interior lights
❒the switching on of the hazard
warning lights.
IMPORTANT Carefully check the car for
fuel leaks, for instance in the engine
compartment, under the car or near the
tank area. After an impact, turn the
ignition key to STOP to prevent the
battery from running down.
To restore the correct operation of the
car, proceed as follows:
❒turn the ignition key to the MAR
position;
❒activate the right direction indicator;
❒deactivate the right direction
indicator;
❒activate the left direction indicator;
❒deactivate the left direction indicator;
❒activate the right direction indicator;
❒deactivate the right direction
indicator;❒activate the left direction indicator;
❒deactivate the left direction indicator;
❒turn the ignition key to STOP and
then to MAR.
LPG versions: in the event of an
impact, petrol supply is immediately
cut-off, the LPG safety valves are
closed and the injection is interrupted,
switching off the engine.
Natural Power versions: in the event
of an impact, the power supply is
immediately cut off, causing engine
switching off.
WARNING
158)If, after an impact, you smell fuel or
notice leaks from the fuel system, do
not reactivate the system to avoid the risk
of fire.
TOWING THE
VEHICLE
159) 160) 161) 162) 163)
The tow hook, which is supplied with
the vehicle, is housed in the tool box,
under the carpet in the luggage
compartment.
ATTACHING THE TOW
HOOK
Manually remove cap A fig. 116 (front
bumper) or A fig. 117 (rear bumper),
pressing the lower part, take the tow
hook B from its housing in the tool box
and tighten it completely on the front
or rear threaded pin.
116F1D0094
119

Versions with Dualogic gearbox
Make sure that the gearbox is in neutral
(N) (checking that the vehicle moves
when pushed) and proceed in the same
way as for towing a normal vehicle
with a manual gearbox. If the gearbox
cannot be put in neutral, do not tow the
vehicle and contact a Fiat Dealership.
Panda Cross and Panda 4x4
versions
The vehicle can only be towed in one of
the following ways (and always with
the engine off, gear set to neutral and
handbrake released):
❒with all the wheels on the road
surface;
❒with the front (or rear) wheels raised
or resting on an emergency vehicle and
the rear (or front) wheels resting on a
specific trolley;❒loaded on the flatbed of the rescue
vehicle with all the wheels on the
flatbed.
IMPORTANT For Panda Cross versions,
the tow hooks A fig. 118 the vehicle is
equipped with can only be used for
towing it in an emergency.
WARNING
159)Before starting towing operations,
turn the ignition key to MAR and then
to STOP, without extracting it. The steering
column will automatically lock when the
key is removed and the wheels cannot be
steered.
160)Before tightening the ring clean the
threaded housing thoroughly. Make sure
that the ring is fully fastened in the housing
before towing the vehicle.161)Whilst towing, remember that as the
assistance of the brake servo and the
electric power steering is not available,
greater force needs to be exerted on the
brake pedal and more effort is required on
the steering wheel. Do not use flexible
cables when towing and avoid jerky
movements. While towing, make sure that
the trailer hitch does not damage any
components it is touching. When towing
the vehicle, you must comply with all
specific traffic regulations, both in terms of
the towing device and behaviour on the
road. Do not start the engine while towing
the vehicle.
162)The front and rear tow hooks should
be used only for emergencies on the road.
You are allowed to tow the vehicle for
short distances using an appropriate
device in accordance with the highway
code (a rigid bar), to move the vehicle on
the road in readiness for towing or
transporting via a breakdown vehicle. Tow
rings MUST NOT be used to tow vehicles
off the road or where there are obstacles
and/or for towing operations using cables
or other non-rigid devices. In compliance
with the above conditions, towing must
take place with the two vehicles (one
towing, the other towed) aligned as much
as possible along the same centre line.
163)Do not use tow hooks for securing the
vehicle on ships.
117F1D0095
118F1D0120
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SERVICING AND MAINTENANCE
Correct maintenance permits the
performance of the vehicle to be
maintained over time, as well as limited
running costs and safeguarding the
efficiency of the safety systems.
This chapter explains how.SCHEDULED SERVICING ...............12
ENGINE COMPARTMENT ...............13
BATTERY RECHARGING ................137
WINDSCREEN/REAR WINDOW
WIPER ............................................139
LIFTING THE VEHICLE....................139
WHEELS AND TYRES.....................139
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1

SCHEDULED
SERVICING
Correct servicing is crucial for
guaranteeing a long life for the vehicle
under the best conditions. For this
reason, Fiat has planned a series of
checks and services at fixed distance
intervals and, where provided, at fixed
time intervals, as described in the
Scheduled Servicing Plan.
Before each service, it is always
necessary to carefully follow the
instructions in the Scheduled Servicing
Plan (e.g. periodically check level of
fluids, tyre pressure, etc.).
Scheduled Servicing is offered by all
Fiat Dealerships according to a set time
schedule. If, during each operation, in
addition to the ones scheduled, the
need arises for further replacements or
repairs, these may be carried out with
your explicit agreement only. If your
vehicle is used frequently for towing,
the interval between one service
operation and the next should be
reduced.IMPORTANT Scheduled Servicing
interventions are set out by the
Manufacturer. Failure to have them
carried out may invalidate the warranty.
It is advisable to inform a Fiat
Dealership of any small operating
irregularities without waiting for the next
service.
PERIODIC CHECKS
Every1,000km or before long
journeys, check and if necessary, top
up: engine coolant level; brake fluid
level; screen washer fluid level; tyre
inflation pressure and condition; lighting
system operation (headlights, direction
indicators, hazard warning lights, etc.);
screen washer/wiper system operation
and positioning/wear of windscreen/
rear window wiper blades.
Every3,000km, check and top up if
required: engine oil level.HEAVY-DUTY USE OF THE
VEHICLE
If the vehicle is used under one of the
following conditions: towing a trailer
or motorhome; dusty roads; short (less
than 7-8 km) and repeated journeys
with sub-zero outside temperatures;
engine often idling or driving long
distances at low speed 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 condition
and wear;
❒check cleanliness of bonnet and
luggage compartment locks,
cleanliness and lubrication of linkage;
❒visually inspect conditions of: engine,
gearbox, transmission, pipes and
hoses (exhaust/fuel system/brakes) and
rubber elements (gaiters/sleeves/
bushes, etc.);
❒check battery charge and battery
fluid level (electrolyte);
❒visually inspect conditions of the
auxiliary drive belts;
❒check and, if necessary, change
engine oil and replace oil filter / pollen
filter / air cleaner.
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SERVICING AND MAINTENANCE
2

SCHEDULED SERVICING PLAN (petrol versions)
The checks listed in the Scheduled Servicing Plan, after reaching 120,000 km/8 years, must be cyclically repeated starting from
the first interval, thus following the same intervals as before.
Thousands of miles 9 18 27 36 45 54 63 72 81 90
Thousands of kilometres 15 30 45 60 75 90 105 120 135 150
Years12345678910
Check tyre condition/wear and adjust pressure, if
necessary; check “Fix&Go Automatic” kit recharge expiry
date (for versions/markets, where provided)●●●●●●●●●●
Check operation of lighting system (headlights, direction
indicators, hazard warning lights, luggage compartment,
passenger compartment, glove compartment, instrument
panel warning lights, etc.)●●●●●●●●●●
Check and, if necessary, top up fluid levels (engine
coolant, hydraulic clutch/brakes, windscreen washer,
battery, etc.)●●●●●●●●●●
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●●●●●●●●●●
Visually inspect conditions of: exterior bodywork,
underbody protection, pipes and hoses (exhaust, fuel
system, brakes), rubber elements (gaiters, sleeves,
bushes, etc.)●●●●●
Check windscreen/rear window wiper blade position/wear●●●●●
123

Thousands of miles 9 18 27 36 45 54 63 72 81 90
Thousands of kilometres 15 30 45 60 75 90 105 120 135 150
Years12345678910
Check pressure regulator heating pipes sealing (Natural
Power versions only)●●●●●
Check correct fitting of injectors (positioning, clip retention)
(Natural Power versions only)●●●●●
Change engine oil and replace oil filter (3)●●●●●
Replace spark plugs (1.2 8V 69 HP and 0.9 TwinAir Turbo
80 HP/85 HP versions)(2)●●●●●
Replace spark plugs (0.9 TwinAir 60 HP/65 HP)●●
Replace accessory drive belt(s) (4)●
(3) If the vehicle is used mainly on urban routes or the annual distance travelled is less than 10,000 km, the engine oil and engine oil filter must be changed every
year.
(2) Or every year
(4) Areas that are not dusty: recommended maximum mileage 120,000 km. Regardless of the mileage, the belt must be replaced every 6 years.
Dusty areas and/or demanding use of the vehicle (cold climates, town use, long periods of idling): advised maximum mileage 60,000 km. Regardless of the
mileage, the belt must be replaced every 4 years.
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SERVICING AND MAINTENANCE

DIESEL VERSIONS
The checks listed in the Scheduled Servicing Plan, after reaching 120,000 km/6 years, must be cyclically repeated starting from
the first interval, thus following the same intervals as before.
Thousands of miles 12 24 36 48 60 72 84 96 108 120
Thousands of kilometres 20 40 60 80 100 120 140 160 180 200
Years12345678910
Check tyre condition/wear and adjust pressure, if
necessary; check “Fix&Go Automatic” kit recharge expiry
date (for versions/markets, where provided)●●●●●●●●●●
Check operation of lighting system (headlights, direction
indicators, hazard warning lights, luggage compartment,
passenger compartment, glove compartment, instrument
panel warning lights, etc.)●●●●●●●●●●
Check and, if necessary, top up fluid levels (engine
coolant, hydraulic clutch/brakes, windscreen washer,
battery, etc.)●●●●●●●●●●
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●●●●●●●●●●
Visually inspect conditions of: exterior bodywork,
underbody protection, pipes and hoses (exhaust, fuel
system, brakes), rubber elements (gaiters, sleeves,
bushes, etc.)●●●●●
Check windscreen/rear window wiper blade position/wear●●●●●
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SERVICING AND MAINTENANCE