2753565 - Introduction - MAINTENANCE

All operations should be carried out taking great care to avoid injury to persons.The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage.

Follow these precautions scrupulously when carrying out operations in the engine compartment:

• Switch off the engine and wait for it to cool down.
• Do not smoke.
• Make sure that there is a fire extinguisher in the vicinity.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with D.M. no. 47/1992).

Engine oil, brake and clutch fluid, power steering fluid and engine coolant are harmful to the skin: reduce contact with the skin to a minimum, and in the event of contact, wash with soap and water.

The fluid (electrolyte) contained in the battery is poisonous and corrosive. Avoid contact with the skin or eyes. Do not allow naked flames or possible sources of sparks to come near the battery: risk of explosion or fire.

Oils (engine, gearbox and differential), fluids (brake and clutch, pwer steering, coolant), the battery and replaced oil and diesel filters contain substances which are harmful to the environment: they must be deposited in special containers.

The air conditioning circuit uses R134a refrigerant fluid which is environmentally friendly.

Closely observe the following safety regulations when working on the circuit:

• Any R134a fluid which accidentally escapes from the climate control system or the draining/recovery/re-pressurizing equipment can become toxic if very close to naked flames or in the presence of certain metals (for example magnesium or aluminium) in the form of fine particles or powder. It is therefore advisable to work away from naked flames, in well ventilated areas with an exhaust system switched on.
• Avoid prolonged contact between R134a fluid and skin during the evaporation stage because the low temperature (-26.5° C) reached at the end of the expansion can cause cold 'burns'. It is advisable to wear leather or thick fabric gloves.
• It is vital to protect eyes from contact with the refrigerant fluid because the extreme low temperature could cause serious injury.
• Draining the fluid in the open air constitutes a danger to the environment. Only use the special equipment to drain the R134a from the system.
• With the engine warm, the engine cooling system is pressurized. Wait for several minutes before working on the cooling circuit components, making sure that the pressure has decreased.
• Before working on the electrical system (connectors, electrical components, wiring etc.), turn the ignition off (STOP position) and DISCONNECT THE BATTERY.
• Carry out the initialization of the central locking control unit using the key that comes with the vehicle closing and opening the door.
• Start up the engine and switch on the air conditioning to learn of the presence of the air conditioning in the engine management control unit.
• Carry out the calibration of the steering angle sensor for the ESP by accelerating for at least 10 metres in a straight line and checking that the yellow 'ESP failure' warning light goes out.
• Using the diagnostic equipment, delete the errors memory and check that it has been deleted from the NCC (Cruise Control Node). NFR (Brake Node) and NIT (Info Telematic Node) control units.

All the operations should be carried out taking great care not to damage the components.In order to release parts which are sticking, tap gently with an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.When dismantling, check that the components have reference marks.During refitting, lubricate the parts as necessary to prevent seizure during the initial period of operation.When refitting, it is vital to follow the recommended tightening torques and adjustment data.During refitting operations, replace gaskets, oil seals, spring washers, safety plates, self-locking nuts and any worn parts.During the operations, when the system components are disconnected, seal the connectors with suitable plugs to prevent humidity and impurities from entering the system.Before reconnecting the pipes, replace the O-rings on the connectors. Only use green coloured seals, resistant to R134A refrigerant.Lubricate the threads of the connectors with anti-freeze and tighten the connectors to the recommended torque.R134a refrigerant fluid cannot be mixed with Freon R12 used in climate control systems on previous vehicles; therefore never, under any circumstances, use Freon R12 for air conditioning systems operating on R134a.All the system components are specifically for use with R134a and are NOT INTERCHANGEABLE with those from previous vehicles using Freon R12.There is a special draining/recovery station for the R134a fluid.The anti-freeze for lubricating the compressor is also specific and differs from the one used in systems running on Freon R12.