Get SERVICING AND CARE Guide for Fiat Panda SUV Second Generation (2003-2012)

SERVICING AND CARE

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.

SCHEDULED SERVICING...............126

BATTERY RECHARGING ................135

ENGINE COMPARTMENT...............137

WINDSCREEN / REAR WINDOW

WIPERS ..........................................142

This chapter explains how.

LIFTING THE VEHICLE....................143

WHEELS AND TYRES.....................143

125

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.

DEMANDING USE OF THE

CAR

SCHEDULED

SERVICING

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:

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.

PERIODIC CHECKS

Every 1,000 km or before long

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.).

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.

check front disc brake pad condition

and wear;

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

the owner's explicit agreement only.

If your vehicle is used frequently for

towing, the interval between one

service operation and the next should

be reduced.

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.);

Every 3,000 km, check and top up if

required: engine oil level.

check battery charge and battery

fluid level (electrolyte);

visually inspect conditions of the

accessory drive belts;

check and, if necessary, change

engine oil and replace oil filter / pollen

filter / air cleaner.

126

SCHEDULED SERVICING PLAN (petrol versions)

The checks listed in the Scheduled Servicing Plan, after reaching 150,000 km/10 years, must be cyclically repeated starting

from the first interval, thus following the same intervals as before.

Thousands of kilometres

Years

15

1

30

2

45

3

60

4

75

5

90

6

105 120 135 150

10

7

8

9

Check tyre condition/wear and adjust pressure, if

necessary; check the expiry date of the “Fix&Go Airflat”

repair kit (for versions/markets, where provided)

Check operation of lighting system (headlights, direction

indicators, hazard warning lights, boot, passenger

compartment, glove compartment, instrument panel

warning lights, etc.)

Check and, if necessary, top up fluid levels (1)

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

(1) Always only use the liquids shown in the handbook for topping up after having checked that the system is not damaged.

127

Thousands of kilometres

Years

15

1

30

2

45

3

60

4

75

5

90

6

105 120 135 150

10

7

8

9

Check operation of the windscreen wiper/washer system

and adjust jets, if necessary

Check cleanliness of bonnet and luggage compartment

locks, cleanliness and lubrication of linkage

Check handbrake lever travel and adjust, if necessary

Check and adjust clutch pedal travel (0.9 TwinAir 60HPV/

65HP and 1.2 8V 69 HP versions only)

Visually inspect conditions and wear of front disc brake

pads and integrity of pad wear indicator

Visually inspect condition and wear of rear disc brake pads

and integrity of pad wear indicator (Panda Cross and

Panda 4x4 versions only)

Visually check condition and wear of rear drum brake

linings (Panda Cross and Panda 4x4 versions excluded)

Visually check conditions of accessory drive belt and

control and (for versions without automatic tensioner)

check tension

Visually inspect conditions of toothed timing drive belt (all

0.9 TwinAir versions excluded)

Check tappet clearance and adjust if necessary (1.2 8V 69

HP versions)

128

Thousands of kilometres

Years

15

1

30

2

45

3

60

4

75

5

90

6

105 120 135 150

10

7

8

9

Check and, if necessary, top-up the Dualogic gearbox oil

level (2)

Check manual gearbox with drive transmission idler unit

(PTU) oil level (Panda Cross and Panda 4x4 versions only)

Check rear differential oil level (Panda Cross and Panda

4x4 versions only)

Visually inspect condition of: LPG pipes and connectors,

LPG tank fixing (LPG versions only)

Check fuel system operation and parameters using the

diagnosis socket (LPG versions only)

Visually inspect condition of: methane pipes and

connectors and methane cylinder fastening, restore if

necessary (Natural Power versions only) (3)

Check pressure regulator and replace internal filter, if

necessary (Natural Power versions only) (3)

Check fuel system operation and parameters using self-

diagnosis socket (Natural Power versions only)

Check torque tightening of cylinder fastening bands

(Natural Power versions only)

Check pressure regulator heating pipes sealing (Natural

Power versions only)

(2) Check to be carried out every year for cars on the road in countries with particularly severe climates (cold countries).

(3) Or every year.

129

Thousands of kilometres

Years

15

1

30

2

45

3

60

4

75

5

90

6

105 120 135 150

10

7

8

9

Check correct fitting of injectors (positioning, clip retention)

(Natural Power versions only)

Change engine oil and replace oil filter (4) (O) (●)

Replace spark plugs (1.2 8V 69 HP and 0.9 TwinAir Turbo

80 HP/85 HP versions) (5)

Replace spark plugs (0.9 TwinAir 60 HP/65 HP) (5)

Replace accessory drive belt/s

(6)

(4) 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.

(O) Recommended operations

(●) Mandatory operations

(5) For 0.9 Twin Air versions, to guarantee correct operation and prevent serious damage to the engine, it is essential to proceed as follows: only use spark plugs

specifically certified for these engines; all spark plugs should be of the same type and brand (see the "Engine" paragraph in the "Technical specifications"

chapter); strictly comply with the spark plugs replacement intervals in the Scheduled Servicing Plan. It is advisable to contact a FIAT Dealership for plug

replacement.

(6) Areas that are not dusty: recommended maximum mileage 120,000 km. The belt must be replaced every 6 years, regardless of distance travelled. Dusty areas

and/or demanding use of the vehicle (cold climates, town use, long periods of idling): advised maximum mileage 60,000 km. The belt must be replaced every 4

years, regardless of distance travelled.

130

Thousands of kilometres

Years

15

1

30

2

45

3

60

4

75

5

90

6

105 120 135 150

10

7

8

9

Replace toothed timing drive belt (all 0.9 TwinAir versions

excluded)

(6)

(8)

Replace air cleaner cartridge (7)

Change the brake fluid

Replace filter inside the pressure regulator (LPG versions

only)

Replace paper filter (LPG in gaseous state) (LPG versions

only)

Replace the passenger compartment cleaner (7) (O) (●)

(6) Areas that are not dusty: recommended maximum mileage 120,000 km. The belt must be replaced every 6 years, regardless of distance travelled. Dusty areas

and/or demanding use of the vehicle (cold climates, town use, long periods of idling): advised maximum mileage 60,000 km. The belt must be replaced every 4

years, regardless of distance travelled.

(7) If the vehicle is used in dusty areas, this cleaner must be replaced every 15,000 km

(8) The brake fluid replacement has to be done every two years, irrespective of the mileage

(O) Recommended operations

(●) Mandatory operations

131

DIESEL VERSIONS

The checks listed in the Scheduled Servicing Plan, after reaching 200,000 km/10 years, must be cyclically repeated starting

from the first interval, thus following the same intervals as before.

Thousands of kilometres

Years

20

1

40

2

60

3

80

4

100 120 140 160 180 200

10

5

6

7

8

9

Check tyre condition/wear and adjust pressure, if

necessary; check the expiry date of the “Fix&Go Airflat”

repair kit (for versions/markets, where provided)

Check operation of lighting system (headlights, direction

indicators, hazard warning lights, boot, passenger

compartment, glove compartment, instrument panel

warning lights, etc.)

Check and, if necessary, top up fluid levels (1)

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

(1) Always only use the liquids shown in the handbook for topping up after having checked that the system is not damaged.

132

Thousands of kilometres

Years

20

1

40

2

60

3

80

4

100 120 140 160 180 200

10

5

6

7

8

9

Check operation of the windscreen wiper/washer system

and adjust jets, if necessary

Check cleanliness of bonnet and luggage compartment

locks, cleanliness and lubrication of linkage

Check handbrake lever travel and adjust, if necessary

Visually inspect conditions and wear of front disc brake

pads and integrity of pad wear indicator

Visually inspect condition and wear of rear disc brake pads

and integrity of pad wear indicator (Panda Cross and

Panda 4x4 versions only)

Visually check condition and wear of rear drum brake

linings (Panda Cross and Panda 4x4 versions excluded)

Visually inspect condition of the accessory drive belt(s)

Check drive transmission idler unit (PTU) oil level (Panda

Cross and Panda 4x4 versions only)

Check rear differential oil level (Panda Cross and Panda

4x4 versions only)

(2)

Change engine oil and replace oil filter

(2) The actual interval for changing engine oil and replacing the engine oil filter depends on the vehicle usage conditions and is signalled by the warning light or

message in the instrument panel. In any case, it must never exceed 2 years. If the vehicle is mainly used in towns and cities, change the engine oil and filter

every year.

133

Thousands of kilometres

Years

20

1

40

2

60

3

80

4

100 120 140 160 180 200

10

5

6

7

8

9

(3)

Replace accessory drive belt/s

Replace fuel filter cartridge (4)

Replace air cleaner cartridge (5)

Change the brake fluid

(6)

Replace the passenger compartment cleaner (5) (O) (●)

(3) Areas that are not dusty: recommended maximum mileage 120,000 km. The belt must be replaced every 6 years, regardless of distance travelled. Dusty areas

and/or demanding use of the car (cold climates, town use, long periods of idling): advised maximum mileage 60,000 km. The belt must be replaced every 4

years, regardless of distance travelled.

(4) If the vehicle runs on fuel with quality below the relevant European specification, this filter must be replaced every 20,000 km

(5) If the vehicle is used in dusty areas, this cleaner must be replaced every 20,000 km

(6) The brake fluid replacement has to be done every two years, irrespective of the mileage

(O) Recommended operations

(●) Mandatory operations

134

IMPORTANT The battery recharging

procedure is given as information only.

You are advised to contact a Fiat

Dealership to have this operation

performed.

turn on the battery charger. At the

end of the charging process, switch the

battery charger off;

BATTERY

RECHARGING

156) 157)

after having disconnected the

charging device, reconnect the

connector A to the sensor C.

IMPORTANT After turning the ignition

key to STOP and having closed the

driver's side door, wait at least one

minute before disconnecting and then

reconnecting the battery electrical

supply.

VERSIONS WITHOUT

Start&Stop SYSTEM

(for versions/markets, where provided)

Charge the battery as follows:

disconnect the negative battery

terminal;

IMPORTANT Charging should be slow

at a low ampere rating for

connect the charger cables to the

battery terminals, observing the polarity;

approximately 24 hours. Charging for a

longer time may damage the battery.

turn on the charger;

when it is recharged, turn the

charger off before disconnecting it from

the battery;

IMPORTANT The cables of the

electrical system must be correctly

reconnected to the battery, i.e. the

positive cable (+) to the positive

reconnect the negative battery

terminal.

terminal and the negative cable (–) to

the negative terminal. The battery

terminals are marked with the positive

(+) and negative (–) symbols, and are

shown on the battery cover. The battery

terminals must also be corrosion-free.

VERSIONS WITH

Stop/Start SYSTEM

(for versions/markets, where provided)

To recharge, proceed as follows:

disconnect the connector A fig. 122

(pressing the button B) from the sensor

C monitoring the battery conditions,

on the negative pole D of the battery;

F1D0136

122

IMPORTANT If a "quick-type" battery

charger is used with the battery fitted

on the vehicle, before connecting it

disconnect both cables of the battery

itself. Do not use a "quick-type" battery

charger to provide the starting voltage.

connect the positive cable of the

battery charger to the positive battery

pole E and the negative cable to the

terminal of sensor D;

135

WARNING

156) Battery fluid is poisonous and

corrosive: avoid contact with your skin and

eyes. The battery should be charged in a

well ventilated place, away from naked

flames or possible sources of sparks:

danger of explosion and fire.

157) Do not attempt to charge a frozen

battery: it must be thawed first, otherwise it

may explode. If freezing has occurred, the

battery should be checked by skilled

personnel to make sure that the internal

elements are not damaged and that the

body is not cracked, with the risk of leaking

poisonous and corrosive acid.

136

ENGINE COMPARTMENT

.

CHECKING LEVELS

158) 159)

59)

0.9 TwinAir/0.9 TwinAir Turbo versions

F1D0097

123

A. Engine oil plug / filler - – B. Engine oil dipstick - – C. Engine coolant - – D. Washer fluid for windscreen/rear window - – E. Brake fluid - – F.

Battery

137

1.2 8V 69 HP versions

F1D0098

124

A. Engine oil plug / filler - – B. Engine oil dipstick - – C. Engine coolant - – D. Washer fluid for windscreen/rear window - – E. Brake fluid - – F.

Battery

138

1.3 16V MultiJet versions

F1D0141

125

A. Engine oil plug / filler - – B. Engine oil dipstick - – C. Engine coolant - – D. Washer fluid for windscreen/rear window - – E. Brake fluid - – F.

Battery

139

ENGINE OIL

ENGINE COOLANT FLUID

BATTERY

60) 61)

3)

160)

62)

164) 165) 166) 167)

The coolant level must be checked

when the engine is cold and must

range between the MIN and MAX

marks on the reservoir.

Check the oil level a few minutes (about

five) after the engine has stopped,

with the vehicle parked on level ground.

Check that the oil level is between the

MIN and MAX references on the

dipstick B. If the oil level is near or even

under the MIN mark, add oil using the

filler A to reach the MAX mark.

64)

5)

Battery F does not require topping up

the electrolyte with distilled water. A

periodic check carried out at a Fiat

Dealership is, however, necessary to

check efficiency.

If the level is too low, unscrew reservoir

cap C and add the fluid described in

the "Technical Specifications" section.

WINDSCREEN/REAR

WINDOW WASHING FLUID

IMPORTANT After the battery is

disconnected, the steering must be

NOTE For the 0.9 TwinAir and 0.9

TwinAir Turbo versions, engine oil

dipstick B is integral with the cap A.

Take out the engine oil dipstick A, clean

it with a lint-free cloth and reinsert it.

Extract it again and check that the level

is between the MIN and MAX marks

on the dipstick.

161)

initialised. The

warning light on the

If the level is too low, raise reservoir cap

D (see previous pages) and add the

fluid described in the chapter "Technical

Specifications".

instrument panel switches on to

indicate this. To carry out this

procedure turn the steering wheel all

the way from one end to the other

or drive in a straight line for about a

hundred metres.

BRAKE FLUID

162) 163)

63)

Check that the fluid is at the maximum

level (the fluid level in the reservoir

must not exceed the MAX mark). If the

fluid level in the reservoir is too low,

undo reservoir cap E and add the fluid

described in the "Technical

Engine oil consumption

IMPORTANT If the charge level remains

under 50% for a long time, the battery

is damaged by sulphation, reducing

its capacity and efficiency at start-up.

The maximum engine oil consumption

is usually 400 grams every 1000 km.

During the initial period of use the

engine oil consumption conditions

should be considered as having

stabilised after the first 5000 - 6000

km.

CLIMATE CONTROL

SYSTEM MAINTENANCE

Specifications" chapter.

In winter, the climate control system

must be turned on at least once a

month for about 10 minutes. Before

summer, have the system checked at a

Fiat Dealership.

DUALOGIC GEARBOX

HYDRAULIC ACTIVATION

SYSTEM OIL

IMPORTANT After adding or changing

the oil, let the engine run for a few

seconds and wait a few minutes after

switching it off before checking the

level.

4)

The fluid level should only be checked

at a Fiat Dealership.

140

164) Battery fluid is poisonous and

corrosive. Avoid contact with the skin and

eyes. Keep naked flames and sources

of sparks away from the battery: risk of

explosion and fire.

63) Prevent brake fluid, which is highly

corrosive, from coming into contact with

painted parts. Should it happen,

immediately wash with water.

WARNING

64) Incorrect installation of electric and

electronic devices may cause severe

damage to your car. After purchasing your

vehicle, if you wish to install any

158) Never smoke while working in the

engine compartment: gas and inflammable

vapours may be present, with the risk of

fire.

165) Using the battery with insufficient

fluid irreparably damages the battery and

may cause an explosion.

accessories (anti-theft, phone, etc.),

contact a Fiat Dealership, which

will suggest the most appropriate devices

for your vehicle, and will, most importantly,

advise you if a higher capacity battery

needs to be installed.

166) If the car will be unused for an

extended period of time in extremely cold

weather conditions, remove the battery

and store it in a heated area to avoid

it freezing.

159) Be very careful when working in the

engine compartment when the engine

is hot: you may get burned.

160) The cooling system is pressurised. If

necessary, only replace the plug with

another original or the operation of the

system may be adversely affected. Do not

remove the reservoir plug when the engine

is hot: you risk scalding yourself.

167) Always wear appropriate goggles

when working on or near the battery.

WARNING

161) Do not travel with the windscreen

washer fluid reservoir empty: the

windscreen washer is essential for

improving visibility. Some commercial

windscreen washer additives are

flammable. The engine compartment

contains hot components which may set it

on fire.

WARNING

3) Used engine oil and oil filters contain

substances which are harmful to the

environment. To change the oil and filters,

we advise you to contact a Fiat Dealership.

59) Be careful not to confuse the various

types of fluids while topping up: they

are not compatible with each other!

Topping up with an unsuitable fluid could

severely damage your vehicle.

4) Used transmission fluid contains

substances that are harmful to the

environment. It is advisable to have the oil

changed by a Fiat Dealership where it

will be disposed of respecting the

environment and according to legal

requirements.

162) Brake fluid is poisonous and highly

corrosive. In the event of accidental

contact, immediately wash the affected

parts with water and mild soap. Then rinse

thoroughly. Call a doctor immediately if

swallowed.

60) The oil level must never exceed the

MAX reference.

61) Do not add oil with specifications other

than those of the oil already existing in

the engine.

5) Batteries contain substances which are

very dangerous for the environment. For

battery replacement, contact a Fiat

Dealership.

62) PARAFLU ^UPantifreeze is used in the

engine cooling system. Use the same fluid

as in the cooling system when topping

up. PARAFLU ^UPcannot be mixed with any

other type of fluid. If this occurs, do not

start the engine and contact your Fiat

Dealership immediately.

163) The symbol , on the brake fluid

container indicates if a brake fluid is

synthetic or mineral-based. Use of mineral

type fluids will damage the special rubber

seals of the braking system beyond repair.

141

REPLACING THE REAR

WINDOW WIPER BLADE

Rear window washer

WINDSCREEN /

REAR WINDOW

WIPERS

The rear window washer jets are fixed.

The nozzle holder is located above

the rear window.

Proceed as follows:

raise the cover A fig. 127, undo the

nut B and remove the arm C;

168)

65)

correctly position the new arm, fully

tighten the nut B then lower the cover

A.

WARNING

REPLACING THE

WINDSCREEN WIPER

BLADES

168) Driving with worn windscreen/rear

window wiper blades is a serious hazard,

because visibility is reduced in bad

weather.

raise the wiper arm, press tab A fig.

126 of the attachment spring and

remove the blade from the arm;

fit the new blade, inserting the tab

into the special slot in the arm, making

sure that it is locked;

WARNING

lower the wiper arm onto the

windscreen.

65) Do not operate the windscreen wiper

with the blades lifted from the windscreen.

F1D0101

127

NOZZLES

Windscreen washer

The windscreen washer jets can be

adjusted rotating the side notch with a

screwdriver. If there is no jet of fluid,

firstly check that there is fluid in the

reservoir (see "Checking fluid levels" in

this chapter). Then check that the

nozzle holes are not clogged; use a

needle to unblock them if necessary.

F1D0100

126

142

LIFTING THE

VEHICLE

WHEELS AND TYRES

WARNING

169)

170) 171)

If the vehicle needs to be raised, go to

a Fiat Dealership which is equipped

with arm lifts and workshop lifts fig.

128.

170) Do not cross switch the tyres if they

are "unidirectional" type. In this case,

always take care not to fit the tyres with a

direction of rotation that is opposite to that

indicated: you would risk losing grip and

control of the vehicle.

66) 67) 68) 69)

SUGGESTIONS ABOUT

THE ROTATION OF THE

TYRES

The front and rear tyres are subject to

different loads and stress due to

steering, manoeuvres and braking. For

this reason they are subject to uneven

wear.

171) Travelling with partially or completely

deflated tyres can cause safety problems

and damage the concerned tyre beyond

repair.

WARNING

To resolve this problem, tyres should be

rotated at the appropriate time. This

operation is recommended for tyres

with a deep tread pattern, suitable both

for on-road and off-road driving.

Tyre rotation contributes to the

66) The road holding qualities of the car

also depend on the correct inflation

pressure of the tyres.

F1D0135

128

67) If tyre pressure is too low, the tyre may

overheat and be severely damaged as a

result.

WARNING

169) Lift the vehicle exclusively by

preservation of the grip and traction

performance on wet, muddy or snowy

roads, guaranteeing optimal driveability

of the vehicle.

68) Do not switch tyres from the right-hand

side of the vehicle to the left-hand side,

and vice versa.

positioning the jack arms or the workshop

jack in the points illustrated.

In the case of irregular wear of the

tyres, the reason must be identified and

corrected before rotating them.

69) Never submit alloy rims to repainting

treatments requiring the use of

temperatures exceeding 150°C. The

mechanical properties of the wheels could

be impaired.

143

SERVICING AND CARE for Your Fiat Panda SUV Second Generation (2003-2012)

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