oil FIAT PUNTO 1998 176 / 1.G User Guide

Maintenance schedule - petrol models 1A.3
The maintenance Intervals in this manual are provided with the assumption that you, not the dealer, will be carrying out the work. These axe the minimum maintenance intervals recommended by us for vehicles driven daily.
if you wish to keep your vehicle in peak condition at all times, you may wish to perform some of these procedures more often. We encourage frequent maintenance, because it enhances the efficiency.
performance and resale value of your vehicle. When the vehicle Is new, it should be serviced by a factory-authorised dealer service department, In order to preserve the factory warranty.
Every 250 miles (400 km) or weekly Q Refer to Weekly checks
Every 5000 miles (7500 km) or
6 months - whichever comes first • Renew the engine oil and filter (Section 3)
Note: Frequent oil and fitter changes am good tor the engine. We recommend changing the oil at the mileage specified here, or at least
twice
a year if the mileage covered Is a less.
Every 10 000 miles (15 000 km) or
12 months - whichever comes first
In
addition to the items listed above, cany out the following: Q Check the operation of the brake warning lamp (Section 4) • Check the front brake pads for wear (Section 5) • Check the underbody and sealant for damage (Section 6) • Hose and fluid leak check (Section 7) • Check the condition of the exhaust system and its mountings (Section 8) • Check the condition of the driveshaft gaiters (Section 9) • Renew pollen filter (Section 10) • Check exhaust gas content and idle speed (Section 11) • Check the steering and suspension components for condition and security (Section 12)
Every 20 000 miles (30 000 km) or
2 years - whichever comes first
In
addition to the Items listed above, carry out the following: • Check and if necessary adjust the tension of the auxiliary drlvebelt(s) (Section 13) • Check the freeplay and height of the clutch pedal (Section 14) • Check and if necessary adjust the valve clearances (Section 15) HI Check and if necessary tighten inlet and exhaust manifold mountings (Section 16) • Renew the fuel filter (Section 17) D Renew the air filter element (Section 18) O Renew the spark plugs (Section 19) • Check the condition of the HT cables (Section 20) • Check the engine management system (Section 21) Q Lubricate all hinges and locks (Section 22) O Check the headlight beam adjustment (Section 23) • Carry out a road test (Section 24)
Every 30 000 miles (45 000 km) or
3 years - whichever comes first In addition to the items listed above, cany out the following: • Check the operation of the Lambda sensor (Section 25) • Check and if necessary top-up the manual transmission oil level (Section 26) • Check the operation of the evaporative loss system (Section 27) • Automatic transmission inner filter and fluid renewal (Section 28)
Every 40 000 miles (60 000 km) or
4 years - whichever comes first In addition to the items fisted above, carry out the following: • Check the rear brake shoes for wear (Section 29) • Renew the timing belt (Section 30)"
*Noto: Although the normal interval for timing belt renewal is 70 000 miles (105 000 km), It is strongly recommended that the belt Is renewed at 40 000 miles (60 000 km) on vehicles which are subjected to Intensive use, ie. malniy short Journeys or a let of stop-start driving. The actual belt renewal Interval Is therefore very much up to the individual owner, but bear in mind that severe engine damage will result if the belt breaks.
Every 60 000 miles (90 000 km) or
6 years - whichever comes first in addition to the items listed above, cany out the following: • Check the condition and operation of the crankcase emission control system (Section 31)
Every 80 000 miles (120 000 km) • Renew the manual transmission oil (Section 32)
Every 2 years
(regardless of mileage) • Renew the engine coolant (Section 33) • Renew the brake fluid (Section 34)

ia«4 Component location - petrol models
Underbonnet view -1108 cc engine model
1 Engine oil filler
cap
2 Engine oil dipstick 3 Brake vacuum servo unit 4 Brake fluid
reservoir
5 Air cleaner
cover
6 Coolant expansion lank 7 Windscreen washer fluid reservoir 8 Front suspension strut upper mounting 9 Ignition coil cover 10 Engine wiring connector cover 11 Battery 12 ECU
Underbonnet view - 1242 cc (8-valve) engine model
1 Engine oil tiller
cap
2 Engine oil dipstick 3 Brake vacuum servo unit 4 Brake fluid
reservoir
5 Air cleaner cover 6 Coo/ant expansion tank 7 Windscreen washer
fluid
reservoir 8 Front suspension strut upper mounting 9 Ignition coil cover 10 Engine wiring connector cover 11 Battery 12 ECU

Component location - petrol models 1A.5
Underbonnet view - 1242 cc (16-valve) engine model
1
Engine
olt filler
cap
2
Engine
oil dipstick 3
Brake
fluid
reservoir
4
Power
steering fluid reservoir 5
Engine
wiring connector cover 6
Windscreen
washer
fluid
reservoir 7 Battery 8
Coolant
expansion
tank
9 Air cleaner
cover
10 Resonator 11 ECU
1
Oil filter
2
Sump
drain plug 3
Transmission
drain plug A
Electric
cooling Ian unit 5
Left-hand driveshaft
6
Intermediate shaft
7
Right-hand driveshaft
B
Front
suspension lower arms 9
Front
anti-roll
bar
10
Exhaust
downpipe 11
Front
brake calipers (2
Rear engine
mounting IS Radiator bottom hose
Front underbody view (diesel model shown, petrol model similar)

Maintenance procedures - petrol models ia./
Every 5000 miles (7500 km) or 6 months
3 Engine oil and filter renewal Ja*
1 Frequent oil and filter changes are the most important preventative maintenance which can be undertaken by the DIY owner. As engine oil ages, it becomes diluted and contaminated, which leads to premature engine wear. 2 Before starting this procedure, gather all Ihe necessary tools and materials. Also make sure that you have plenty of clean rags and newspapers handy, to mop up any spills. Ideally, the engine oil should be warm, as It
will
drain better, and more built-up sludge will
be
removed with it. Tske care, however, not to touch the exhaust or any other hot parts of the engine when working under the vehicle. To avoid any possibility of scalding, and to protect yourself from possible skin irritants end other harmful contaminants in used engine oils, it Is advisable to wear gloves when carrying out this work. Access to the underside of the vehicle will be greatly Improved if it can be raised on a lift, driven onto ramps, or jacked up and supported on axle stands (see Jacking and vehicle support). Whichever method is chosen, make sure that
the
vehicle remains level, or if it is at an angle, that the drain plug Is at the lowest point. 3 Slacken the drain plug about half a turn using an Allen key. Position the draining container under the drain plug, then remove
the plug
completely (see Haynes Hint). 4 Allow some time for the old oil to dram, noting that it may be necessary to reposition
the
container as the oil flow slows to a trickle. 5 After all the oil has drained, wipe off the drain plug with a clean rag, then clean the area around the drain plug opening and refit
(MB
HiNT '
Keep the drain plug pressed Into the sump white unscrewing it by hand the last couple of turns. As the plug releases, move it away sharply so that the stream
of
oil Issuing from the sump runs into the container, net up your sleeve.
the plug. Tighten the plug securely. 6 It the filter is also to be renewed, move the container into position under tho oil filter, which is located on the front right-hand side of the engine (see illustration). 7 Using an oil filter removal tool if necessary, slacken the filter initially, then unscrew It by hand the rest of the way. Empty the oil in the old filter into the container. 8 Use a clean rag to remove all oil, dirt and sludge from the filter sealing area on the engine. Check the old filter to make sure that the rubber sealing ring has not stuck to the engine. If it has. carefully remove It. 9 Apply a light coating of clean engine oil to the sealing ring on the new filter, then screw it into position on the engine. Tighten the filter firmly by hand only • do not use any tools. 10 Remove the old oil and all tools from under the vehicle then lower the vehicle to the ground (if applicable).
3.6 Oil filter location (viewed from above)
11 Remove the dipstick, then pull out the oil filler cap from the cylinder head cover. Fill the engine, using the correct grade and type of oil (see Weekly checks). An oil can spout or funnel may help to reduce spillage. Pour In half the specified quantity of oil first, then wail a few minutes for the oil to fall to the sump. Continue adding oil a small quantity at a time until the level is up to the MAX mark on the dipstick. Refit the filler cap. 12 Start the engine and run it for a few minutes: check for leaks around the oil filter seal and the sump drain plug. Note that there may be a delay of a few seconds before the oil pressure warning light goes out when the engine is first started, as the oil circulates through the engine oil galleries and the new oil filter before (he pressure builds up. 13 Switch off the engine, and wait a few minutes for the oil to settle In the sump once more. With the new oil circulated and the filter completely full, recheck the level on the dipstick, and add more oil as necessary. 14 Dispose of the used engine oil safely, with reference to General repair procedures in the reference Sections of this manual.
Every 10 000 miles (15 000 km) or 12 months
4 Brake warning lamp ag operation check J§
1 With the ignition key inserted and turned to the MAR position, open the bonnet and depress the button on the top of the brake ftuid reservoir cap (see illustration). 2 As the button is depressed, the brake warning lamp on the instrument panel should Illuminate. 3 If the lamp fails to illuminate, check the operation of the level switch using a continuity tester, then refer to Chapter 12, Section 5, wd check the instrument panel bulb.
5 Front brake pad check
1 Firmly apply the handbrake, then jack up the front of the car and support it securely on axle stands (see Jacking and vehicle support). Remove the front roadwheels, 2 Using a steel rule, measure the thickness of the friction material of the brake pads on both front brakes- This must not be less than 1.5 mm. Check the thickness of the pad friction material through the hole on the front of the caliper (see illustration). 3 For a comprehensive check, the brake pads 4.1 Depress the button on the top of the brake fluid reservoir cap

ia«8 Every 10 000 miles - petrol models
5.2 Check the thickness of the pad friction material through the hole on the front of the caliper should be removed and cleaned. The operation of the caliper can then
bIbo
be checked, and the condition of the brake disc itself can be fully examined on both sides. Refer to Chapter 9 for further Information. 4 If any pad's friction material is worn to the specified thickness or less, all four psds must tie renewed as a set. Refer to Chapter 9. 5 On completion refit the roadwheels and lower the car to the ground
6 Underbody sealant check
I
1 Jack up the front and rear of the car and support It securely on axle stands (see Jacking and vehicle support). Alternatively position the car over an inspection pit. 2 Check the underbody. wheel housings and side sills for rust and/or damage to the under-body sealant. If evident, repair as necessary.
7 Hose and fluid leak check ^
I
1 Visually Inspect the engine joint laces, gaskets and seals for any signs of water or oil leaks. Pay particular attention to the areas around the camshaft cover, cylinder head, oil (liter and sump joint faces. Bear in mind that.
A leak In the cooling system will usually show up as white or rust~coloured deposits on the area adjoining the leak
over a period of time, some very slight seepage from these areas is to be expected -what you are really looking for is any indication of a serious leak (see Haynes Hint). Should a leak be found, renew the offending gasket or oil seal by refemng to the appropriate Chapters in this manual. 2 Also check the security and condition of all the engine-related pipes and hoses. Ensure that all cable-ties or securing clips ore In place and In good condition, Clips which are broken or missing can lead to chafing of the hoses, pipes or wiring, which could cause more serious probioms In the luture. 3 Carefully check the radiator hoses and heater hoses along their entire length. Renew any hose which is cracked, swollen or deteriorated, Cracks will show up better if the hose is squeezed. Pay close attention to the hose clips that secure the hoses to the cooling system components. Hose clips can pinch and puncture hoses, resulting in cooling system leaks. 4 Inspect all 'he cooling system components {hoses. |olnt faces etc.) for leaks. A leak in the coolmg system will usually show up as white-or rust-coloured deposits on the area adjoining the leak. Where any problems of this nature are found on system components, renew the component or gaskel with reference to Chapter 3. 5 Where applicable, inspect the automatic transmission fluid cooler hoses for leaks or deterioration. 6 With the vehicle raised, inspect the fuel tank and filler neck for punctures, cracks and other damage. The connection between the filler neck and tank Is especially critical. Sometimes a rubber filler neck or connecting hose will leak due to loose retaining clamps or deten orated rubber. 7 Carefully check all rubber hoses and metal fuel lines leading away Irom the fuel tank. Check for loose connections, deteriorated hoses, crimped lines, and other damage. Pay particular attention to the vent pipes and hoses, which often loop up around the fitter neck and can become blocked or crimped. Follow the lines to the front of the vehicle, carefully inspecting them all the way. Renew damaged sections as necessary. 8 From within tne engine compartment,
check the security of all fuel hose attachments and pipe unions, and inspect the fuel hoses and vacuum hoses for kinks, chafing and deterioration. 9 Where applicable, check the condition of the power steering fluid hoses and pipes.
8 Exhaust system check fe
1 With the engine cold (at least an hour after the vehicle has been driven), check the complete exhaust system from the engine to the end of the tailpipe. The exhaust system is most easily checked with the vehicle raised on a hoist, or suitably supported on axle stands (see Jacking and vehicle support), so that the exhaust components are readily visible and accessible. 2 Check the exhaust pipes and connections for evidence of leaks, severe corrosion and damage. Make sure thai all brackets and mountings are in good condition, and that all relevant nuts and bolts are tight, Leakage at any of the Joints or in other parts of the system will usually show up as a black sooty stain in the vicinity of the leak. 3 Rattles and other noises can often bo traced to the exhaust system, especially the brackets and mountings. Try to move the pipes and silencers. If the components are able to come Into contact with the body or suspension parts, secure the system with new mountings Otherwise separate the joints {if possible) and twist the pipes as necessary to provide additional clearance.
9 Driveshaft gaiter check
9.1 Checking the condition of a driveshaft gaiter
1
1 With the vehicle raised and securely supported on stands (see Jacking and vehicle support), turn the steering onto full lock, then s'owly rotate the roadwheel. Inspect the condition of Ihe outer constant velocity (CV) joint rubber garters, squeezing the gaiters to open out the folds. Check for signs of cracking, splits or deterioration of the rubber, which may allow the grease to escape, and lead to water and grit entry into the joint. Also check the security and condition of the retaining clips. Repeat these checks on the Inner CV joints (see Illustration), If any damage or deterioration Is found, the gaiters should be renewed (see Chapter 8, Section 3). 2 At the same time, check the general condition of (he CV joints themselves by first holding (he driveshaft and attempting to rotate the wheel. Repeat this check by holding the inner joint and attempting to rotate the driveshaft. Any appreciable movement indicates wear in the joints. wear In the driveshaft splines, or a loose driveshaft retaining nut

1A.12
Every 20 000 miles - petrol models
18.7 Lift up the cover and remove the filter element (18-va!ve engines) 9 Fit a new air (liter element In position, ensuring that the edges are securely seated 10 Refit the air cloaner cover, engage the rear retainers and secure with the three bolts.
19 Spark plug renewal
1 The correct functioning of the spark plugs is vital for the correct running and efficiency of the engine. It is essential that the plugs fitted are appropnate for the engine (a suitable type is specified at the beginning of this Chapter. If this type is used and the engine Is In good condition, the spark plugs should not need attention between scheduled replacement intervals Spark plug cleaning Is rarely necessary, and should not be attempted
19.2a Disconnecting tho HT leads from Iho spark plugs on 8-valve engines ...
19.4 Removing the spark plugs
unless specialised equipment Is available, as damage can easily be caused to the firing ends. 2 To remove the plugs first remove the air cleaner assembly (8-vaive engines) or the a»r cleaner, resonator and inlet air duct (16-valve engines) with reference to Chapter 4A or 4B. if the marks on the original-equipment spark plug (HT) leads cannot be seen, mark the leads 1 to 4, to correspond to the cylinder the lead serves (No 1 cylinder is at the timing belt end of the engine). Pull the leads from the plugs by gripping the end fitting, not the lead, otherwise the lead conneciion may be Iractured (see illustrations) 3 It is advisable to remove the dirt from the spark plug recesses using a clean brush, vacuum cleaner or compressed air before removing the plugs, to prevent dirt dropping into the cylinders. 4 Unscrew the plugs using a spark plug spanner, suitable box spanner or a deep socket and extension bar (see illustration). Keep the socket aligned with the spark plug • If it is forcibly moved to one side, the ceramic insulator may be broken off. As each plug is removed examine 4 as fallows. 5 Examination of the spark plugs will give a good Indication of the condition of the engine. If the Insulator nose of the spark plug Is clean and white, with no deposits, this is Indicative of a weak mixture or too hot a plug (a hot plug transfers heal away from the electrode slowly, a cold plug transfers heat away quickly). 6 If the tip and insulator nose are covered with hard black-looking deposits, this
19.2b ... and on 16-valve engines
19.9 Ad|ustlng a spark plug electrode gap
indicates that the mixture Is too rich. If the plug is black and oily, then It is likely that the engine is fairly worn, as well as the mixture being too rich. 7 If the Insulator nose is covered with light tan to greyish-brown deposits, then the mixture Is correct and it is likely that (he engine Is in good condition. 6 The spark plug electrode gap is of considerable importance as, if it Is too large or too small, the size of the spark and its efficiency will be seriously impaired. The gap should be set to the value given in the Specifications at the beginning of this Chapter. 9 To set the gap. measure it with a feeler blade and then bend open, or closed, the outer plug elect/ode until the correct gap l9 achieved. The centre electrode should never be bent, as this may crack the insulator and cause plug I allure, if nothing worse. If using feeler blades, the gap is correct when the appropriate-size blade is a firm sliding fit (see illustration). 10 Special spark plug electrode gap adjusting tools are available from most motor accessory shops, or from some spark plug manufacturers, 11 Before fitting the spark plugs, check that the threaded connector sleeves are tight, and that the plug exterior surfaces and threads are clean (see Haynes Hint). 12 Remove the rubber hose (If used), and tighten the plug to the specified torque using the spark plug socket and a torque wrench, Refit the remaining spark plugs In the same manner. 13 Connect the HT leads In their correct order, and refit any components removed for access.
It is very often difficult to insert spark plugs into their holes without cross-threading them. To, avoid this possibility, fit a short length of Si 16 Inch Internal diameter rubber hose over the end of the spark plug. The flexible hose acts as a universal Joint to help align the plug with the plug hole. Should the plug beginto cross-thread, the hose will slip on the spark plug, preventing thread damage to the cylinder head

Every 20 000 miles - petrol models 1A.13
20 Ignition system check
81
21 Engine management system check

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Warning: Voltages produced by an electronic ignition system are considerably higher than those produced by conventional ignition systems. Extreme care must be taken when working on the system with the Ignition switched on. Persons with surgically-Implanted cardiac pacemaker devices should keep well clear of the ignition circuits, components and test oquipment. 1 The ignition system components should be checked for damage or deterioration as follows.
General component check 2 The spark plug (HT) leads should be checked whenever new spark plugs are fitted. 3 Pull the leads from the plugs by gripping
the end
fitting, not the lead, otherwise the lead connection may be fractured.
Ensure that the leads are i numbered before removing i them, to avoid confusion when refitting
4 Check Inside the end fitting for signs of corrosion, which will look like a white crusty powder. Push the end fitting back onto the spark plug, ensuring that it is a tight fit on the plug. if not, remove the lead again and use pliers to carefully crimp the metal connector inside the end fitting until it fits securely on the
end
of the spark plug. 5 Using a clean rag, wipe Ihe emlre length of the lead to remove any built-up dirt and grease. Once the lead is clean, check for bums, cracks and other damage. Do not bend the lead excessively, nor pull the lead lengthways - the conductor inside might break. 6 Disconnect the other end of the lead from the ignition coll. Again, pull only on the end fitting. Check for corrosion and a tight fit in the
same
manner as the spark plug end. Refit the bad securely on completion. 7 Check the remaining leads one at a time, in
ihe same
way. 8 if new spark plug (HT) leads are required, purchase a set for your specific car and engine. 9 Even with the ignition system In first-class condition, some engines may still occasionally experience poor starting attributable to damp ignition components. To disperse moisture, a water-dispersant aerosol should be liberally
Ignition timing -
check
and adjustment 10 Check the ignition timing as described In Chapter 58.
1 This check is part of the manufacturer's maintenance schedule, and Involves testing Ihe engine management system using special dedicated test equipment. Such testing will allow the test equipment to read any fault codes stored in the electronic control unit memory. 2 Unless a fault is suspected, this test te not essential, although it should be noted that it is recommended by the manufacturers. 3 If access to suitable test equipment is not possible, make a thorough check of all ignition, fuel and emission control system components, hoses, and wiring, for security and obvious signs of damage. Further details of the fuet system, emission control system and ignition system can be .found In the relevant parts of Chapters 4 and 5.
22 Hinge and lock lubrication %
1
1 Lubricate the hinges of the bonnet, doors and tailgate with a light general-purpose oil. Similarly, lubricate ail latches, locks and lock strikers. At the same time, check the security and operation of all the locks, adjusting them If necessary (see Chapter 11). 2 Lightly lubricate the bonnet release mechanism and cable with a suitable grease.
23 Headlight beam adjustment % & ^
1 Accurate adjustment of the headlight beam is only possible using optical beem-setting equipment, and this work should therefore be carried out by a Fiat dealer or service station with the necessary facilities. In an emergency, however, the following procedure will provide an acceptable light pattern. 2 Position the car on a level surface with tyres correctly inflated, approximately 10 metres in front of. and at right-angles to, a wall or garage door, 3 Draw a horizontal line on the wall or door at headlamp centre height. Draw a vertical line corresponding to the centre line of the car, then measure off a point either side of this, on the horizontal line, corresponding with the headlamp centres. 4 Switch on the main beam and check that the areas of maximum illumination coincide with the headlamp centre marfcs on Ihe wall, if not. turn the adjustment screw located on the upper inside edge of the headlight unit to adjust the beam laterally, and the adjustment screw located on the upper outside edge of the headlight unit to adjust the beam
vertically. On models with electric headlight adjustment, make sure that it is set at its basic setting before making the adjustment.
24 Road test
Instruments and electrical equipment 1 Check the operation of all Instruments and electrical equipment. 2 Make sure that all instruments read correctly, and switch on all electrical equipment in turn, to check that it functions properly.
Steering and suspension 3 Check for any abnormalities in the steering, suspension, handling or road feel. 4 Drive the vehicle, and check that there are no unusual vibrations or noises. 5 Check that the steering feels positive, with no excessive sloppiness, or roughness, and check for any suspension noises when cornering and driving over bumps.
Drivetrain 6 Check the performance of the engine, clutch (where applicable), transmission and driveshafts. 7 Listen for any unusual noises from the engine, clutch and gearbox/transmission. 8 Make sure that the engine runs smoothly when Idling, and that there Is no hesitation when accelerating. 9 Check that, where applicable, the clutch action Is smooth and progressive, that the drive is taken up smoothly, and that the pedal travel is not excessive. Also listen for any noises when the clutch pedal is depressed. 10 On manual gearbox models, check that all gears can be engaged smoothly without noise, and that the gear lever action is not abnormally vsgue or notchy. 11 On automatic transmission models, check that all Ihe gear positions can be selected with the vehicle at rest, if any problems are found, they should be referred to a Flat dealer. 12 Listen for a metallic clicking sound from the front of the vehicle, as the vehicle is driven slowly in a circle with the steering on full-lock. Carry out this check in both directions. If a clicking noise is heard, this Indicates wear in a drtveshaft joint, In which case renew the joint if necessary.
Check the braking system 13 Make sure that the vehicle does not pull to one side when braking, and that the wheels do not lock prematurely when braking hard. 14 Check that there is no vibration through the steering when braking. 15 Check that the handbrake operates correctly without excessive movement of the lever, and that It holds the vehicle stationary on a slope.

ia.14 Every 20 000 miles - petrol models
16 Test the operation of the brake servo unit as follows. With the engine off, depress the footbrake four or five times to exhaust the vacuum. Hold the brake pedal depressed, then start the engine. As the engine starts.
there should be a noticeable give In the brake pedal as vacuum builds up. Allow the engine to run for at least tsvo minutes, and then switch it off. If the brake pedal is depressed now. it should be possible to detect a hiss
from the servo as the pedal is depressed. After about four or five applications, no further hissing should be heard, and the pedal shouto feel considerably harder.
Every 30 000 miles (45 000 km) or 3 years
. transmission (see illustration). Using an Allen 25 Lambda/oxygen sensor ^ key, unscrew the plug and clean it. check \ 3 The oil level should reach the lower edge of ^ the filler/level hole. A certain amount of oil will have gathered behind the filler/level plug, and If the CO level at the exhaust tailpipe is too w,u tr,cWe out when is 'e™oved; this does high or low, Ihe vehicle should be taken to a «©l necessarily Indicate that the level is Fiat dealer so lhat the complete fuel-injection correct. To ensure that a true level is and ignition systems, including the Lamoda/ established, wait until the Initial trickle has oxygen sensor, can be thoroughly checked stopped, then ado oil as necessary until a using the special diagnostic equipment. Once ,r,ckle o1 new oil can be seen emerging. The these have been checked and are known to 'W wl" be correct when ,he flow ceases-us® be free from faults, the fault must be in the good-quality oil of the specified type, catalytic converter, which must be renewed Make sur®that vehicle Is completely level as described In Chapter 4D, Section 6. checking the level and do not overfill, 4 When the level Is correct refit and tighten the plug and wipe away any spilt oil.
26 Manual transmission oil level check ^ 27 Evaporative loss system ^ check
1 Park Ihe vehicle on a level surface, If possible over an inspection pit or on a ramp as the filler/level plug is best reached from under Ihe engine compartment. The oil level must be checked before the car is driven, or at least 5 minutes after the engine has been switched off. If the oil ts checked Immediately alter driving the car, some of the oil will remain distributed around the transmission components, resulting in an inaccurate level reading. 2 Wipe clean the area around the filler/level plug, which is situated on the front of the
Refer to Chapter 40 Section 2 and check that all wiring and hoses are correctly connected to the evaporative toss system components.
28 Automatic transmission fitter and fluid change
1 Take the vehicle on a short run. to warm the transmission up to operating temperature.
Park the car on level ground, then switch off the Ignition. 2 Firmly apply the handbrake, then jack up the front of the car and support It securely on axle stands (see Jacking and vehicle support]. Note thai, when refilling and checking Uie fluid level, the car must be lowered to the ground, and level, to ensure accuracy. 3 Remove the dipstick, then position a suitable container under the transmission, Unscrew the sump drain plug and allow the fluid to drain for at ieast 10 minutes. Refit and tighten the drain plug when the fluid has completely drained.

A


Warning: The transmission fluid may be very hot and precautions must be taken to avoid scalding.
4 Clean around the transmission sump mating flange. Unboll and remove the sump and remove the gasket. 5 Remove the two bolts and withdraw the transmission fluid filter {see illustration). 6 Fit the new filter, and secure It with the two bolts. 7 Refit the sump using a new gasket, then
_
lower the vehicle to the ground, 8 Fill the transmission with the specified quantity of fluid via Ihe dipstick tube, using a funnel with a fine mesh filter. 9 Run the engine to normal operating temperature, then check the fluid level as described In Weekly checks. 10 Dispose of the old fluid safely.
26.2 Transmission filler/level plug location 28.5 Automatic transmission fluid filter retaining bolts

Maintenance procedures - petrol models 1A.15
Every 40 000 miles (60 000 km) or 4 years
29 Rear brake shoe check
1 Chock the front wheels then Jack up the rear of Ihe car and support it on axle stands (see Jacking and Vehicle Support). Remove the rear roadwheels. 2 Using the inspection hole at the edge of the brake drum, check that the linings are not worn below Ihe minimum thickness given in the Specifications (see illustration). If necessary use a torch. 3 If the friction material on any shoe is worn down to the specified minimum thickness or
less,
all four shoes must be renewed as a set. 4 At the same time check for signs of brake
Kutti
leakage. 5 For a comprehensive check, the brake drum should be removed and cleaned. This
will allow the wheel cylinders to be checked, and the condition of the brake drum itself to be fully examined (see Chapter 9). 6 Refit the lubber plugs then lower the car to the ground.
30 Timing belt renewal
Refer to Chapter 2A or 2B. Note: Although the norma/ interval for timing belt renewal is 70 000 miles (105 000 km), it is strongly recommended that the interval Is reduced on vehicles which are subjected to intensive use. ie, mainly short journeys or a lot of stop-start driving. The actual belt renewal interval is therefore very much up to the individuaf owner. That being said, it is highly recommended to err on the side of safety, and
29.2 Check the thickness of the shoe friction material through the hole on the edge of the drum (arrowed)
renew the belt at 40 000 miles (60 000 km), bearing in mind the drastic consequences resulting from belt failure.
Every 60 000 miles (90 000 km) or 6 years
31 Emission control system check
Refer to Chapter 4D. A full check of the emissions control systems must be made by a Fiat dealer.
Every 80 000 miles (120 000 km)
32 Manual transmission all renewal S
1 Park the vehicle on a level surface, if possible over an inspection pit or on a ramp as the filler/level and drain plugs are accessed from order
the
engine compartment. If necessary
Jack
ip the vehicle and support on axle stands (see
Jacking and vehicle
support). 2 Wipe clean the area around the filler/leval And drain plugs, which are on the front and bottom of the transmission (see illustration).
3 Using an Allen key. unscrew the filler/level plug and clean it. 4 Position a suitable container beneath the transmission, then use the Allen key to unscrew the drain plug. Allow the oil to completely drain. 5 Wipe clean the drain plug then refit and tighten It. 6 Fill the transmission with ihe correct grade and quantity of oil, referring to Section 26 when checking the level. Refit and lighten the filler/level plug. 7 Where applicable lower the vehicle to the ground. 32.2 Transmission drain plug location (viewed from under the vehicle)
Every 2 years (regardless of mileage)
33 Coolant renewal
I
Cooling system draining

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Warning: Walt until the engine Is cold before starting this pro-cedure. Do not allow antifreeze to come In contact with your skin, or with the painted surfaces of the vehicle. Rinse off spills immediately with plenty of water.
Ndver
leave antifreeze lying around In an open container, or fn a puddle In the
driveway or on the garage floor. Children and pets are attracted by its sweet smell, but ant/freeze can be fatal if ingested. 1 With the engine completely cold, cover the expansion tank cap with a wad of rag. and slowly turn the cap anticlockwise to relieve the pressure in the cooling system (a hissing sound will normally be heard). Wait until any pressure remaining in the system is released, then continue to tum the cap until it can be removed. 2 Position a suitable container beneath the radiator bottom hose connection, then release the retaining clip and ease the hose from the radiator stub (see illustration). If the hose 33.2 Disconnecting the radiator bottom hose to drain tho coolant

1B»1
Chapter
1
Part B:
Routine maintenance & servicing - diesel models
Contents
Air filter renewal 13 Auxiliary drivebelt(s) check and renewal 16 Brake fluid renewal 2d Brake warning lamp operation check 5 Clutch adjustment check 17 Coolant renewal 27 Drtv«shaft gaiter check 10 Emissions control systems check 25
Engage
oil and filter renewal 3 Exhaust system check 9 Front brake pad check 6
Fuel
fitter renewal 12 Fuel Filter water draining 4 Headlight beam adjustment 20
Hinge and lock lubrication 19 Hose and fluid leak check 6 Idle speed check and adjustmenl 11 Introduction ... 1 Manual transmission oil level check 22 Manual transmission oil renewal - 26 Pollen filter renewal 14 Rear brake shoe check 23 Regular maintenance 2 Road test 21 Steering and suspension check 15 Timing belt renewal 24 Underbody sealant check 7 Valve clearance check and adjustment 16
^m
Degrees of difficulty
Easy, sutable for % Fairly easy, suitable FaHycifficult, i'. Difficult, suitable fa Very difficult, novice with irttte % for beginner with suitable for competent experienced DIY
1
suitable for expert DIY * or professional jQ experience some experience DIY mechanic mechanic 1
suitable for expert DIY * or professional jQ