312002667 - INTRODUCTION - MAINTENANCE

All the operations should be carried out taking great care to avoid personal injury.The engine compartment contains many moving parts, components at high temperatures and live wires.

Follow very carefully the precautions described below when carrying out operations in the engine compartment:

  • Switch off the engine and wait for it to cool down
  • No smoking
  • Make sure that there is a fire extinguisher nearby.
The use of special tools is required for certain procedures. The use of these tools is vital for working safely.Follow the current workshop safety regulations. Where necessary, the Manual contains specific procedures to be followed to prevent dangerous situations from arising.For the use of chemical products follow the safety instructions on the card from the supplier to the consumer (for Italy in accordance with D.M. No. 47/1992).
The engine oil, brake and clutch fluid, the power assisted steering fluid and the engine coolant are hazardous to the skin: keep contact with skin to a minimum and if there is contact wash with soap and water.
The fluid (electrolyte) in the battery is poisonous and corrosive. Avoid contact with skin and eyes. Keep naked flames and possible sources of sparks away from the battery: danger of explosion or fire risk.
The oils (engine, gearbox and differential), the fluids (brake and clutch, power steering, engine coolant), the battery and the oil and diesel filters that are changed contain substances that are dangerous to the environment: they should be deposited in the special containers.
The air conditioning system uses environmentally-friendly R134a coolant fluid.

The following safety instructions must be followed meticulously when working on the system:

  • Any R134a fluid that accidentally escapes from the climate control system or the drainage/collection/repressurizing equipment may become toxic if it is very close to a naked flame or in the presence of certain metals (e.g. magnesium or aluminium) in the form of fine particles or powder. It is therefore advisable to work in an area where there are no naked flames, and which is well-ventilated, with an extraction system working.
  • Avoid prolonged contact between R134a and the skin during evaporation because after expansion it can cause burns as a result of the low temperature (-26.5°C). It is therefore advisable to wear leather or thick fabric gloves.
  • It is vital to protect eyes from contact with the coolant fluid because the extremely low temperature can cause serious injuries.
  • Draining the fluid in the open air constitutes a danger to the environment. The R134a can only be drained using special equipment.
  • When the engine is hot the cooling system is pressurized. Wait for a few minutes before working on the cooling system components, making sure that the pressure has been discharged.
  • Before working on the electrical system (connectors, electrical components, wiring, etc.) turn the ignition key to STOP and DISCONNECT THE BATTERY.
  • Carry out the initialization of the central locking control unit using the key and closing and opening the door.
  • Start up the engine and switch on the air conditioning so that the engine management control unit detects the presence of the air conditioner.
  • Calibrate the ESP steering angle sensor by accelerating, in a straight line, for at least 10 metres and checking that the yellow "ESP fault" warning light goes out.
  • Using the diagnostic equipment, cancel the errors memory and check that the cancellation has taken place at the NCC (Cruise Control Node) control units, NFR (Brake Node) and NIT (Info Telematic Node) control units.
All the operations should be carried out taking great care to avoid damaging components.To release parts that are sticking, tap gently using an aluminium or lead hammer if iron materials are involved; use a wooden or resin hammer for light alloy parts.When dismantling, check that components that should be marked have the appropriate references.When refitting, lubricate the parts, where necessary, to prevent seizing or binding during the initial operating period.When refitting it is vital to follow the tightening torques and adjustment data.Each time they are refitted, replace gaskets, oil seals, flexible washers, safety washers, self-locking nuts and all parts that have deteriorated.If the system components have been disconnected, seal the connectors with suitable plugs to prevent moisture and impurities getting into the system.Replace the O-rings on the connectors before reconnecting the pipes. Use only green-coloured rings that are resistant to R134a coolant fluid.Lubricate the connector threads with anti-freeze and tighten the connectors to the recommended torque.R134a coolant fluid cannot be mixed with Freon R12, used in climate control systems on earlier vehicles; therefore Freon R12 should never be used in air conditioning systems operating on R134a.All the system components have been specifically designed for the use of R134a and are NOT INTERCHANGEABLE with those from earlier vehicles using Freon R12.There is a special draining/collection system for R134a fluid.The anti-freeze for lubricating the compressor is also special and differs from the one used for systems running on Freon R12.