engine FIAT SEDICI 2009 2.G Repair Manual

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Thousands of km
Check cleanliness of locks, bonnet and boot, and cleanliness
and lubrication of linkages
Replace spark plugs (replace iridium spark plugs
every 105,000 km) or every 7 years
Change engine oil and oil filter
Check air cleaner conditions
Replace air filter cartridge
Change engine coolant
Replace auxiliary drive belt
Sight inspect fuel tank conditions
Check manual transaxle gear oil level
Check automatic transaxle gear oil level
Change manual transaxle gear oil
Change automatic transaxle gear oil
Check transmission unit oil level (4x4 version)
Check rear differential oil level (4x4 version)
Change rear differential oil (4x4 version)
(just the first time at 15,000 km)
Check suspension operation
Check steering system
Check engine management system operation
(via diagnostic socket)
Change brake and clutch fluid (or every 2 years)
Replace pollen filter (or every 2 years)
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SERVICE SCHEDULE - DIESEL VERSIONS
Service coupons shall be carried out every 15,000 km
Thousands of km
Check tyre condition/wear and adjust pressure, if required
Check lighting system operation (headlights, direction indicators,
hazard lights, passenger compartment lights, boot lights,
instrument panel warning lights, etc.)
Check windscreen wiper/washer operation and adjust nozzles,
if required
Check the position/wear of the windscreen/rearscreen
wiper blades
Check condition and wear of front disc brake pads and brake
pad wear indication
Check rear disc brake pad or shoes condition and wear
Visually inspect the condition of: bodywork,
underbody protection, pipes and hoses (exhaust - fuel - brakes),
rubber parts (gaiters, sleeves, bushes, etc.)
Check and top up, if required, fluid levels (brake/hydraulic clutch
fluid, windscreen washer fluid, battery fluid, engine coolant, etc.)
Visually inspect condition of auxiliary drive belt
Check the handbrake lever travel and adjust it, if required
Check exhaust emissions
Check cleanliness of locks, bonnet and boot, and cleanliness and
lubrication of linkages
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Thousands of km
Change engine oil and oil filter (DPF versions) (**)
Check air cleaner conditions
Replace air filter cartridge
Change engine coolant
Replace auxiliary drive belt
Replace timing belt (*)
Replace fuel filter (or every 4 years)
Sight inspect fuel tank conditions
Check manual transaxle gear oil level
Change manual transaxle gear oil
Check transmission unit oil level (4x4 version)
Check rear differential oil level (4x4 version)
Change rear differential oil (4x4 version)
(just the first time at 15,000 km)
Check suspension operation
Check steering system
Check engine management system operation
(via diagnostic socket)
Change brake and clutch fluid (or every 2 years)
Replace pollen filter (or every 2 years)
(*) Regardless of the number of kilometres covered, the timing belt should be replaced every 4 years for particularly demanding use
(cold climates, driving in the city, idling for a long time) or in any case every 5 years.
(**) The engine oil and oil filter should be changed when the warning light on the dashboard comes on, or every 2 years.
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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.
190
G----
HTrailer towing (if admitted)
Maintenance Operation
IInspect and correct or replace if necessary
RReplace or Change
NOTE 4WD: 4-wheel drive 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
Severe Condition Code
B C D
A D
A C D E F H
A C D E H
A B C E F H
C
B E H
B C D H
B D E H
B E H
C D
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 2,500 km (1,500 miles)
Every 30,000 km (18,000 miles) or 24 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
Every 15,000 km (9,000 miles) or 12 months
Every 45,000 km (27,000 miles) or 36 months Maintenance
Engine accessory drive belt (V-rib belt)
Camshaft timing belt (Diesel engine)
Engine oil and oil filter (Gasoline engine)
Engine oil and oil filter (Diesel engine)
Spark plugs
Air cleaner filter element
(Inspect or replace more frequently if necessary)
Automatic transaxle fluid change
Wheel bearings
Drive axle boots/Propeller shaft (4WD)
Manual transaxle oil/Transfer oil (4WD)
Differential oil (4WD)
Air conditioner filter element (for versions/markets, where provided)
(Clean more frequently if the air flow from the air conditioner
decreases)Maintenance
Operation
I
R
R
R
R
R
R
I
R
R
I
I
R
I
R Iridium plug
(Highly recommended)
Nickel plug
(Standard type)
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191
ENGINE OIL
AND FILTER
OIL SPECIFICATIONS -
GASOLINE 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 Gasoline 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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192
1.MIN
2.MAX
3.Engine 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 Gasoline Engine Model
(3)
(2) (1)
79J170
For Diesel Engine Model
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193
Tightening torque for drain plug
For Gasoline Engine Model:
35 Nm (3.5 kgm, 25.3 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.
54G091S
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
60G306
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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194
1.Oil filter
2.3/4 turn
Tightening torque for oil filter
For Gasoline 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. 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)
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
For Gasoline Engine Model For Diesel Engine Model
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195
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.
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.
TUTELA XVI SAE 75W-90, API GL-4,
FIAT 9.55550-MZ4 Contractual Technical
Reference N° F808.G08, for gasoline en-
gine, manual transaxle gear oil.
TUTELA XVI SAE 75W-90, API GL-3, FIAT
9.55550-MZ4 Contractual Technical Refer-
ence N° F808.G08 for diesel engine, manual
transaxle gear oil.
Hypoid gear oil TUTELA W90/M -
DA SAE
80W-90 API GL-5for transfer oil and rear
differential oil (4WD).
Gasoline engine, manual transaxle
oil (API GL-4)
54G095
54G096
79JM023
Transfer oil (4WD)
Rear differential oil (4WD)
(API GL-5 Hypoid)
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. Diesel engine, manual transaxle oil
(API GL-3)
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196
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.
(1)
(2)
79J143
(2)
79J005
Manual transaxle
Rear 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
AUTOMATIC
TRANSAXLE (AT) FLUID
SPECIFIC FLUID
Contact Fiat Dealership to receive indi-
cations about the proper fluid to use.
FLUID LEVEL CHECK
IMPORTANT Driving with too much or
too little fluid can damage the transaxle.
You must check the fluid level with the au-
tomatic transaxle fluid at normal operat-
ing temperature.
To check the fluid level:
❒To warm up the transaxle fluid, drive
the vehicle or idle the engine until the
temperature gauge indicates normal op-
erating temperature.
❒Then drive for ten more minutes.
IMPORTANT To prevent damages to the
automatic transaxle of your vehicle, nev-
er use a fluid different than that recom-
mended by Fiat Dealership.
❒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)
Manual transaxle/Transfer:
21 Nm (2.1 kgm, 15.2 lb·ft)
Rear differential:
23 Nm (2.3 kgm, 17.0 lb·ft)
NOTE To check the transfer oil (4WD),
bring your vehicle to your FIAT Dealer-
ship since special procedures, materials
and tools are required.
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