engine FIAT SEDICI 2007 2.G Repair Manual

188
RReplace or Change
IInspect and correct or replace if necessary
LLubricate Severe condition code
ARepeated short trips
BDriving on rough and/or muddy roads
CDriving on dusty roads
DDriving in extremely cold weather and/ or salted roads
ERepeated short trips in extremely cold weather
FLeaded fuel use
HTrailer towing (if admitted)
MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that
applicable maintenance operation be performed at the particular interval as given in the chart below.
Severe Condition Code
B C D
AD
A C D E F H
A C D E H
A B C E F H
C
B C D H
B D E H
B E H
Maintenance Interval
Every 15,000 km (9,000 miles) or 12 months
Every 45,000 km (27,000 miles) or 36 months
Every 36 months
Every 7,500 km (4,500 miles) or 6 months
Every 7,500 km (4,500 miles) or 6 months
Every 30,000 km (18,000 miles) or 24 months
Every 10,000 km (6,000 miles) or 8 months
Every 30,000 km (18,000 miles) or 24 months
Every 15,000 km (9,000 miles) or 12 months
Every 15,000 km (9,000 miles) or 12 months
First time only: 15,000 km (9,000 miles) or
12 months
Second time and after: Every 30,000 km
(18,000 miles) or 24 months reckoning from
0 km (0 mile) or 0 month Maintenance
Accessory drive belt (V-belt)
Timing belt (Diesel versions)
Engine oil and oil filter (Petrol versions)
Engine oil and oil filter (Diesel versions)
Spark plugs
Air cleaner cartridge
(Check and replace more frequently, if required)
Wheel bearings
Driving axle /Propeller shaft casing (4WD)
Manual transaxle gear oil
Transmission unit oil (4WD)
Differential oil (4WD)Maintenance
Operation
I
R
R
R
R
R
R
R
I
I
R Iridium plugs (recommended)
Nickel plugs (traditional)
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189
ENGINE OIL
AND FILTER
OIL SPECIFICATIONS -
PETROL ENGINES
Check whether the adopted engine oil is
falling within the following quality classes:
API SL, SM or ACEA A3, recommended
product: SELENIA K SAE 5W-40, Fiat
9.55535-M2 qualification.
OIL SPECIFICATIONS -
DIESEL ENGINES
Check whether the adopted engine oil is
falling within the following quality classes:
API CF or ACEA B4, recommended
product: SELENIA WR SAE 5W-40,
Fiat 9.55535-N2 qualification.
DRIVE BELT
63J132
DEF: 4.5 – 5.5 mm
(0.18 – 0.22 in.)
DEF: 3 – 5 mm
(0.12 – 0.20 in.)
DEF: 7 – 8 mm
(0.28 – 0.31 in.)
AC GE
→: 100 N (10 kg, 22 lbs) press
GE: Generator
DEF: Deflection
AC: Air conditioner compressor
When the engine is running,
keep hands, hair, clothing,
tools, etc. away from the moving fan
and drive belts.
WARNING
For Petrol Engine Model
Make sure the drive belt tension is cor-
rect. If the belt is too loose, insufficient
battery charging, engine overheating, poor
power steering, poor air conditioning, or
excessive belt wear can result. When you
press the belt with your thumb midway
between the pulleys, there should be a de-
flection according to the following chart.
The belts should also be examined to en-
sure that they are not damaged.
If you need to replace or adjust the belt
have it done by your Fiat Dealership.
For Diesel Engine Model
The drive belts tension is adjusted auto-
matically.
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190
1.MIN
2.MAX
3.Oil dipstick
IMPORTANT Failure to check the oil lev-
el regularly could lead to serious engine
trouble due to insufficient oil.REFILLING
Remove the oil filler cap and pour oil
slowly through the filler hole to bring the
oil level to the upper limit on the dipstick.
Be careful not to overfill. Too much oil is
almost as bad as too little oil. After refill-
ing, start the engine and allow it to idle for
about a minute. Stop the engine, wait
about 5 minutes and check the oil level
again. OIL LEVEL CHECK
It is important to keep the engine oil at the
correct level for proper lubrication of
your vehicle’s engine. Check the oil level
with the vehicle on a level surface. The oil
level indication may be inaccurate if the
vehicle is on a slope. The oil level should
be checked either before starting the en-
gine or at least 5 minutes after stopping
the engine.
The handle of the engine oil dipstick is col-
ored yellow for easy identification. Pull out
the oil dipstick, wipe oil off with a clean
cloth, insert the dipstick all the way into
the engine, then remove it again. The oil
on the stick should be between the upper
and lower limits shown on the stick. If the
oil level indication is near the lower limit,
add enough oil to raise the level to the up-
per limit.
80G06481A147
Open
Close
For Petrol Engine Model
(3)
(2) (1)
79J170
For Diesel Engine Model
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191
Tightening torque for drain plug
For Petrol Engine Model:
50 Nm (5,0 kgm, 36.2 lb-ft)
For Diesel Engine Model:
20 Nm (2,0 kgm, 14.4 lb-ft)
❒Reinstall the drain plug and gasket.
Tighten the plug with a wrench to the
specified torque.
NOTE
(For Diesel Engine Model)
Whenever the engine oil is changed, the
monitoring system to find the next oil
change stage must be reset whether the
oil pressure light blinks or not. For details
on how to reset the system, ask your Fi-
at Dealership. CHANGING ENGINE OIL AND
FILTER
Drain the engine oil while the engine is still
warm.
❒Remove the oil filler cap.
❒Place a drain pan under the drain plug.
❒Using a wrench, remove the drain plug
and drain out the engine oil.
54G091
OpenClose
The engine oil temperature
may be high enough to burn
your fingers when the drain plug is
loosened. Wait until the drain plug is
cool enough to touch with your bare
hands.
WARNING
60G306A
New and used oil can be
hazardous.
Children and pets may be harmed by
swallowing new or used oil. Keep new
and used oil and used oil filters away
from children and pets.
Repeated, prolonged contact with
used engine oil may cause skin can-
cer.
Brief contact with used oil may irri-
tate skin.
WARNING
To minimize your exposure
to used oil, wear a long-
sleeve shirt and moisture- proof
gloves (such as dishwashing gloves)
when changing oil. If oil contacts your
skin, wash thoroughly with soap and
water.
Launder any clothing or rags if wet
with oil.
Recycle or properly dispose of used
oil and filters.
WARNING
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192
1.Oil filter
2.3/4 turn
Tightening torque for oil filter
For Petrol Engine Model:
3/4 turn or 14 Nm
(1,4 kgm, 10,1 lb-ft)
For Diesel Engine Model
28 Nm (2,8 kgm, 20.2 lb-ft)
IMPORTANT To prevent oil leakage,
make sure that the oil filter is tight, but do
not over- tighten it. For Petrol Engine Model:
1.Loosen
2.Tighten
REPLACE THE OIL FILTER
❒Using an oil filter wrench, turn the oil
filter counterclockwise and remove it.
❒Using a clean rag, wipe off the mount-
ing surface on the engine where the
new filter will be seated.
❒Smear a little engine oil around the rub-
ber gasket of the new oil filter.
❒Screw on the new filter by hand until
the filter gasket contacts the mounting
surface.
54G09254G093
Tightening (viewed from filter top)
For Diesel Engine Model
1.Loosen
2.Tighten
IMPORTANT To tighten the oil filter
properly, it is Important to accurately
identify the position at which the filter gas-
ket first contacts the mounting surface.
❒Tighten the filter specified turn from
the point of contact with the mount-
ing surface (or to the specified torque)
using an oil filter wrench.
(1)
(2)
79J142
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193
Refill with Oil and Check for Leaks
❒Pour oil through the filler hole and in-
stall the filler cap.
For the approximate capacity of the oil,
refer to the “Capacities” item in the
“SPECIFICATIONS” section.
❒Start the engine and look carefully for
leaks at the oil filter and drain plug. Run
the engine at various speeds for at least
5 minutes.
❒Stop the engine and wait about 5 min-
utes. Check the oil level again and add
oil if necessary. Check for leaks again.
IMPORTANT
❒When replacing the oil filter, it is rec-
ommended that you use a genuine
Fiat replacement filter. If you use an af-
termarket filter, make sure it is of
equivalent quality and follow the man-
ufacturer’s instructions.
❒Oil leaks from around the oil filter or
drain plug indicate incorrect installation
or gasket damage. If you find any leaks
or are not sure that the filter has been
properly tightened, have the vehicle in-
spected by your Fiat Dealership.Transfer oil (4WD)
Rear differential oil (4WD)
(API GL-5 Hypoid)
GEAR OIL
MANUAL TRANSAXLE OIL/
TRANSFER OIL (4WD)/
REAR DIFFERENTIAL OIL (4WD)
When adding gear oil, use gear oil with the
appropriate viscosity and grade as shown
in the chart below.
We highly recommend you use: TUTELA
CAR TECHNYX SAE 75W-85 API GL 4
Plus for manual transaxle gear oil.
Hypoid gear oil TUTELA W90/M -DA SAE
80W-90 API GL 5for transfer oil and rear
differential oil (4WD).
54G095
54G096
Manual transaxle oil (API GL-4)
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194
IMPORTANT When tightening the plug,
apply sealing compound Loctite 510 or
equivalent to the plug threads to prevent
oil leakage.
GEAR OIL CHANGE
Since special procedures, materials and
tools are required, it is recommended that
you trust this job to your authorized Fiat
Dealership.
54G097
(2)
79J005
Manual transaxleRear differential (4WD)
After driving the vehicle, the
gear oil temperature may be
high enough to burn you. Wait until
the oil filler plug is cool enough to
touch with your bare hands before in-
specting transaxle oil.
WARNING
GEAR OIL LEVEL CHECK
To check the gear oil level, use the fol-
lowing procedure:
❒Park the vehicle on a level surface with
the parking brake applied. Then, stop
the engine.
❒Remove the oil filler plug (1) or (2).
❒Feel the inside of the hole with your fin-
ger. If the oil level comes up to the bot-
tom of the plug hole, the oil level is cor-
rect. If so, reinstall the plug.
❒If the oil level is low, add gear oil
through the oil filler plug hole (1) or (2)
until the oil level reaches the bottom of
the filler hole, then reinstall the plug.
Tightening torque for oil filler and
level plug (1) and (2)
21 Nm (2,1 kgm, 15,2 lb-ft)
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195
IMPORTANT To avoid damaging your
cooling system:
❒Always use a high quality ethylene gly-
col base non- silicate type coolant di-
luted with distilled water at the correct
mixture concentration.
ENGINE COOLANT
SELECTION OF COOLANT
To maintain optimum performance and
durability of your engine, use PARAFLU
UP.
This type of coolant is best for your cool-
ing system as it:
❒Helps maintain proper engine temper-
ature.
❒Gives proper protection against freez-
ing and boiling.
❒Gives proper protection against cor-
rosion and rust.
Failure to use the proper coolant can dam-
age your cooling system. Your authorized
Fiat Dealership can help you select the
proper coolant.
79J006
Petrol engine
❒Make sure that the proper mix is 50/50
coolant to distilled water and in no case
higher than 70/30. Concentrations
greater than 70/30 coolant to distilled
water will cause overheating conditions.
❒Do not use straight coolant nor plain
water.
❒Do not add extra inhibitors or addi-
tives. They may not be compatible with
your cooling system.
❒Do not mix different types of base
coolants. Doing so may result in accel-
erated seal wear and/ or the possibili-
ty of severe overheating and extensive
engine/ automatic transaxle damage.
COOLANT LEVEL CHECK
Check the coolant level at the reservoir
tank, not at the radiator. With the engine
cool, the coolant level should be between
the “FULL” and “LOW” marks.
79J145
Diesel engine
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196
ADDING COOLANT
Engine coolant is harmful or
fatal if swallowed or inhaled.
Do not drink antifreeze or coolant so-
lution. If swallowed, do not induce
vomiting. Immediately contact a poi-
son control center or a physician.
Avoid inhaling mist or hot vapors; if
inhaled, remove to fresh air. If
coolant gets in eyes, flush eyes with
water and seek medical attention.
Wash thoroughly after handling. So-
lution can be poisonous to animals.
Keep out of the reach of children and
animals.
WARNINGIMPORTANT
❒The mixture you use should contain
50% concentration of antifreeze.
❒If the lowest ambient temperature in
your area is expected to be –35°C
(–31°F) or below, use higher concen-
trations up to 60% following the in-
structions on the antifreeze container.
❒When putting the cap on the reservoir
tank, line up the arrow on the cap and
the arrow on the tank. Failure to follow
this can result in coolant leakage.
If the coolant level is below the “LOW”
mark, more coolant should be added.
When the engine is cool, remove the de-
gassing tank cap by turning it anticlock-
wise slowly to release any pressure. And
add coolant until the degassing tank level
reaches the “FULL” mark. Never fill the
degassing tank above the “FULL” mark.
It is hazardous to remove the
degassing tank cap for Diesel
engine when the water temperature
is high, because scalding fluid and
steam may be blown out under pres-
sure. Wait until the coolant temper-
ature has lowered before removing
the cap.
WARNING
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197
COOLANT REPLACEMENT
79J007
It is hazardous to remove the
radiator cap when the water
temperature is high, because scalding
fluid and steam may be blown out un-
der pressure. Wait until the coolant
temperature has lowered before re-
moving the cap.
WARNING
For Petrol Engine Model
❒When the engine is cool, remove the
radiator cap by turning it slowly to the
left until a “stop” is felt. Do not press
down while turning the cap. Wait until
any pressure is released, then press
down on the cap and continue turning
it anticlockwise.
❒After filling, let the engine idle for about
2–3 minutes to get rid of air in the cool-
ing system.
❒Stop the engine.
❒Check the coolant level in the radiator
again. If the level has gone down, add
more coolant.
IMPORTANT The coolant must be re-
placed with the vehicle on level ground.
For Diesel Engine Model
Since special procedures are required, we
recommend you take your vehicle to your
Fiat Dealership for coolant replacement.
❒Remove the reservoir by lifting it up,
and drain the reservoir completely.
❒Loosen the drain plug attached to the
lower part of the radiator and drain the
coolant into a suitable container.
❒Reinstall the reservoir and fill it with
coolant to the “FULL” line.
❒Tighten the drain plug on the radiator.
❒Fill the radiator with coolant and install
the radiator cap.
60A212
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