Content .. 11 12 13 14 ..

Lancia FLAVIA. Service Manual - part 13

When cleaning the inside rearview

Replace the belts if they appear frayed

CONVERTIBLE TOP CARE

mirror, spray cleaner on the towel or

or worn or if the buckles do not work

rag that you are using. Do not spray

properly.

CAUTION!

cleaner directly on the mirror.

Failure to follow these cautions may

CLEANING CENTER

cause interior water damage, stains

Cleaning Plastic Instrument

CONSOLE CUPHOLDERS

or mildew on the top material:

Cluster Lenses

Removal

• Avoid high-pressure car washes,

The lenses in front of the instruments

as they can damage the top mate-

in this vehicle are molded in clear

Grab the rubber portion of the cup-

rial. Also, increased water pres-

plastic. When cleaning the lenses,

holder and lift upward.

sure may force past the weather

care must be taken to avoid scratch-

Cleaning

strips.

ing the plastic.

Soak the rubber cupholder liner in a

• Remove any standing water from

1. Clean with a wet soft rag or micro-

mixture of medium hot tap water and

the top and dry the surface before

fiber towel. A mild soap solution may be

one teaspoon of mild liquid dish soap.

opening it. Operating the top,

used, but do not use high alcohol con-

Let soak for approximately one hour.

opening a door or lowering a win-

tent or abrasive cleaners. If soap is used,

After one hour pull the liner from the

dow while the top is wet may al-

wipe clean with a clean damp rag.

water and dip it back into the water

low water to drip into the vehicles

2. Dry with a soft cloth.

about six times. This will loosen any

interior.

remaining debris. Rinse the liner thor-

• Use care when washing the vehicle,

Seat Belt Maintenance

oughly under warm running water.

water pressure directed at the

Do not bleach, dye, or clean the belts

Shake the excess water from the liner

weather strip seals may cause wa-

with chemical solvents or abrasive

and dry the outer surfaces with a

ter to leak into the vehicles interior.

cleaners. This will weaken the fabric.

clean soft cloth.

Sun damage can also weaken the fabric.

Installation

If the belts need cleaning, use MOPAR®

Align the liner in the cupholder and

Total Clean or equivalent, a mild soap

press down firmly.

solution, or lukewarm water. Do not

remove the belts from the vehicle to

wash them. Dry with a soft cloth.

206

Immediate removal of any contami-

brush, and a mild soap solution such

Additional Cleaning Procedure

nant is recommended. Regular wash-

as liquid dishwashing soap. Do not

For additional cleaning assistance in

ing of the top will enhance its life and

use detergent.

removing stubborn stains, apply ap-

appearance, and make successive

propriate cleaners to the complete

cleanings easier. Do not subject the top

CAUTION!

stain, extending 50 mm beyond the

to excessive heat. Frequently vacuum

Never use an abrasive type cleaner

stain. With a soft bristle brush, scrub

the top and storage compartment.

or bleaches. Cleaners should not

in all directions over the stain. Avoid

contain silicones, organic solvents,

Washing

heavy scrubbing. Rinse the area with

petroleum distillates, or plasticiz-

warm water. If the stain is still appar-

Hand washing is highly recommended.

ers. Always wait until the top is

ent, repeat the cleaning procedure.

Automatic car washing equipment can

thoroughly dry before lowering it

When the stain is no longer showing,

damage the top material. If you must

into the storage area.

rinse the complete top with warm wa-

use an automatic car wash, soft cloth

ter. Let the top dry before lowering it.

systems are preferred.

Scrub in all directions, covering an

area of about two square feet at a

Protection

CAUTION!

time. Avoid heavy scrubbing. Rinse

For appearance purposes, you may

Avoid high-pressure car washes, as

the entire vehicle with water to re-

wish to protect your cloth top periodi-

they can damage the top material.

move all soap and dirt from the top

cally. A fabric protectant is suggested.

Also, increased water pressure may

fabric and to prevent streaking on

The top should be clean and dry be-

force water past the weather strips.

painted and chrome surfaces. Allow

fore application of the protectant.

the top to dry before lowering. Vacu-

General Cleaning

uming the top with a wet/dry shop

CAUTION!

vacuum will decrease the top's drying

Careful vacuuming of the top before

Avoid getting the fabric protectant

time, ensure removal of all dirt, and

washing is helpful in removing dust

on the surrounding weather strips,

delete streaks in the material. Mul-

and other foreign particles. Wash in

moldings, paint, or glass. Damage

tiple cleanings may be necessary to

partial shade instead of direct sun.

to these items might occur.

remove stubborn stains. If stains per-

Wet the entire vehicle before washing

sist, contact your local dealership for

the top. The top should be washed

further suggestions.

with a soft, natural bristle scrub

207

WEATHER STRIP CARE -

FUSES

SOFT AND HARD TOP

INTEGRATED POWER

Lubricate all top and door glass

MODULE

weather strips periodically with a

The Integrated Power Module is lo-

weather strip lubricant to keep them

cated in the engine compartment near

soft and pliable.

the air cleaner assembly. This center

contains cartridge fuses and mini

Integrated Power Module

fuses. A label that identifies each

component may be printed on the in-

side of the cover. Refer to the graphic

below for FUSES/TIPM location.

Cavity

Cartridge Fuse

Mini Fuse

Description

40 Amp Green

—

Power Top Module

—

20 Amp Yellow

Brake Vacuum Pump

—

10 Amp Red

Center High Mounted Stop Light

(CHMSL)/Brake Switch

—

10 Amp Red

Ignition Switch

—

20 Amp Yellow

Trailer Tow (when present)

—

10 Amp Red

Power Mirror Switch/Climate Controls

—

30 Amp Green

Ignition Off Draw (IOD) Sense 1

—

30 Amp Green

Ignition Off Draw (IOD) Sense 2

40 Amp Green

Battery Feed - Power Seats (for

versions/markets, where provided)

208

Cavity

Cartridge Fuse

Mini Fuse

Description

—

20 Amp Yellow

Instrument Panel/Power Locks/

Interior Lights

—

15 Amp Lt Blue

Selectable Power Outlet (Inside Center

Arm Rest)

—

20 Amp Yellow

—

20 Amp Yellow

Ignition/Cigar Lighter

—

10 Amp Red

Instrument Panel

40 Amp Green

—

Radiator Fan Relay

—

15 Amp Lt. Blue

Sunroof (for versions/markets, where

provided)

—

10 Amp Red

Wireless Control Module (WCM)/

Clock/Steering Control Module (SCM)

40 Amp Green

—

Auto Shutdown (ASD) Relay

—

20 Amp Yellow

Audio Amplifier (for versions/markets,

where provided)

—

15 Amp Lt. Blue

Radio

—

10 Amp Red

Siren (for versions/markets, where

provided)

209

Cavity

Cartridge Fuse

Mini Fuse

Description

—

10 Amp Red

Ignition Run - Climate Controls/Hot

Cupholder (for versions/markets,

where provided)

—

15 Amp Lt. Blue

Auto Shutdown (ASD) Relay 3

—

25 Amp Natural

Sunroof (for versions/markets, where

provided)

—

10 Amp Red

Ignition Run — Heated Mirrors (for

versions/markets, where provided)

—

15 Amp Lt. Blue

Auto Shutdown (ASD) Relay 2

—

10 Amp Red

Ignition Run - Occupant Classification

Module (OCM)/Occupant Restraint

Controller (ORC)

—

10 Amp Red

Ignition Run — Occupant Classifica-

tion Module (OCM)/Occupant

Restraint Controller (ORC)

—

Hot Car (No Fuse Required)

—

20 Amp Yellow

Ignition Run - Heated Seats (for

versions/markets, where provided)

210

Cavity

Cartridge Fuse

Mini Fuse

Description

—

10 Amp Red

Headlamp Washer (for versions/

markets, where provided)

30 Amp Pink

—

Auto Shutdown (ASD) Relay 1

—

10 Amp Red

Switch Bank/Diagnostic Link

Connector/

Powertrain Control Module (PCM)

30 Amp Pink

—

Anti-Lock Brakes (ABS) Module (for

versions/markets, where provided)/

Electronic Stability Control (ESC)

Module (for versions/markets, where

provided)

40 Amp Green

—

Anti-Lock Brakes (ABS) Module (for

versions/markets, where provided)/

Electronic Stability Control (ESC)

Module (for versions/markets, where

provided)

30 Amp Pink

—

Passenger Door Module (PDM)/Driver

Door Module (DDM)

—

Amp Natural

Power Top Module (for versions/

markets, where provided)

211

VEHICLE STORAGE

REPLACEMENT BULBS

CAUTION!

• When installing the Integrated

If you will not be using your vehicle

All the inside bulbs are brass or glass

Power Module cover, it is impor-

for more than 21 days, you may want

wedge base. Aluminum base bulbs are

tant to ensure the cover is prop-

to take steps to preserve your battery.

not approved and should not be used

erly positioned and fully latched.

for replacement.

•

Disengage the mini-fuse in the

Failure to do so may allow water

to get into the Integrated Power

Power Distribution Center labeled

Module, and possibly result in an

IOD (Ignition Off-Draw).

LIGHT BULBS -

electrical system failure.

Interior

Bulb No.

•

Or disconnect the negative cable

• When replacing a blown fuse, it is

from the battery. Refer to “Prepa-

Front Courtesy/Reading

important to use only a fuse hav-

ration for Jump Start” in “Jump-

Lamp

578/W5W

ing the correct amperage rating.

Starting” to identify the location of

Center Courtesy/Reading

The use of a fuse with a rating

the negative post.

Lamp

578/W5W

other than indicated may result in

•

Anytime you store your vehicle, or

Glove Box Lamp

194

a dangerous electrical system

keep it out of service (i.e., vacation)

Shift Indicator

overload. If a properly rated fuse

for two weeks or more, run the air

Lamp

IKLE14140

continues to blow, it indicates a

conditioning system at idle for

Rear Compartment (Trunk)

problem in the circuit that must

about five minutes in the fresh air

Lamp

579

be corrected.

and high blower setting. This will

NOTE: For lighted switches, see

ensure adequate system lubrication

your authorized dealer for re-

to minimize the possibility of com-

placement.

pressor damage when the system is

started again.

212

LIGHT BULBS -

BULB REPLACEMENT

Exterior

Bulb No.

HEADLAMP

Bi-Halogen Headlamp

. . . HIR2

Front Turn Signal

CAUTION!

Lamp

3157NAK

Where possible, it is advisable to

Front Park Lamp

LED

have bulbs changed at a LANCIA

(Serviced at Authorized Dealer)

Dealership. Proper operation and

Side Repeater Lamp . . . WY5W

orientation of the external lights are

3. Rotate bulb and connector

one-

Front Fog Lamp

H11

essential for driving safety and

quarter turn and pull outward from

Center High Mounted

complying with the law.

assembly.

Stop (CHMSL) Lamp

LED

1. Raise and prop open the hood.

(Serviced at Authorized Dealer)

Locate the connector behind the

Rear Tail/Stop Lamp

LED

headlamp.

(Serviced at Authorized Dealer)

Rear Turn Signal

NOTE: It may be necessary to re-

Lamp

W16W

move the air cleaner filter housing

and position the totally integrated

Rear Fog Lamp

LED

power module aside prior to re-

(Serviced at Authorized Dealer)

placing the low beam headlamp on

Backup Lamp

W16W

the driver's side of the vehicle.

License Lamp

W5W

CAUTION!

2. Reach into engine compartment

Do not touch the new bulb with

and from behind the lamp assembly

your fingers. Oil contamination will

and grasp the connector.

severely shorten bulb life.

213

4. Pull the bulb out of the socket and

3. Remove the bulb from the connec-

CAUTION!

replace the bulb.

tor socket and install the replacement

Do not touch the new bulb with

bulb.

your fingers. Oil contamination will

4. Install the bulb and connector as-

severely shorten bulb life. If the

sembly into the headlamp housing

bulb comes in contact with an oily

and rotate the connector one-quarter

surface, clean the bulb with rub-

turn clockwise to lock it in place.

bing alcohol.

FRONT FOG LAMP

3. Install the bulb and connector as-

sembly into the fog lamp housing and

NOTE: Access to the lamps through

5. If the bulb comes in contact with

rotate the connector one-quarter turn

the lower fascia cutout is limited. We

any oily surface, clean the bulb with

clockwise to lock it in place.

recommend you access the lamps by

rubbing alcohol.

turning the steering wheel to allow

REAR TURN SIGNAL

6. Reinsert the bulb and socket as-

access and remove the inner fender

LAMPS

sembly and rotate clockwise one-

shield.

1. Open the trunk and gently pull

quarter turn to secure.

1. Rotate the bulb's electrical con-

back the trunk liner behind the tail

nector one-quarter turn counter-

FRONT TURN SIGNAL

lamp (requires removal of a push pin

clockwise and remove it from the fog

holding the trunk trim in place near

1. Raise and prop open the hood.

lamp housing.

the tail lamp).

2. Rotate the bulb's electrical connec-

2. Remove the bulb from the connec-

2. Remove the two plastic wing nuts

tor one-quarter turn counterclockwise

tor socket and install the replacement

from the tail lamp housing.

and remove it from the headlamp hous-

bulb.

ing.

214

4. Remove bulb from socket by pull-

ing directly out (do not turn/twist)

and install replacement bulb.

5. Insert socket back into the housing

with a clockwise ¼ turn.

6. Return bracket into position.

7. Snap the six (6) push pins back

NOTE: Placing a small flat head

4. Twist and remove socket from

into place.

screwdriver or similar tool be-

lamp.

tween the lamp outboard ball stud

LICENSE PLATE LAMP

5. Remove bulb from socket and re-

and plastic grommet from inside

place.

1. Using a small screwdriver, press

the trunk can help to disengage the

inward the locking tab on the side of

outboard edge of the tail lamp.

6. Reinstall the tail lamp, fasteners,

the lamp assembly and pull down on

and trunk liner.

3. Grasp the tail lamp by both the

the lamp assembly for removal.

outboard and inboard sides, and pull

BACKUP LAMP

2. Remove bulb socket by twisting

firmly to disengage the tail lamp from

out of lamp assembly.

1. Remove four push pins from the

the vehicle.

bottom of the lower valance (from left

3. Pull bulb from socket, replace, and

NOTE: It is normal to hear a

to right: 1st, 3rd, 6th & 8th) and two

reinstall the bulb socket into lamp

loud sound when the lower tail

push pins from the rear of the bracket.

assembly.

lamp area unsnaps from the ve-

2. Remove bracket by pulling for-

4. Install lamp assembly to lightbar

hicle mounting bracket during tail

ward of vehicle.

ensuring the locking tab is secure.

lamp removal.

3. Remove socket from housing with

a counter-clockwise ¼ turn.

215

FLUID CAPACITIES

Metric

Fuel (Approximate)

All

64 Liters

Engine Oil with Filter

2.4L Engine

4.4 Liters

Cooling System*

2.4L Engine

7.3 Liters

* Includes heater and coolant recovery bottle filled to MAX level.

FLUIDS, LUBRICANTS AND GENUINE PARTS

ENGINE

Component

Fluids and Lubricants Specs (Genuine Parts)

Engine Coolant*

Red protective agent with antifreeze action, based on inhibited monoethyl glycol with

organic formula. Exceeds CUNA NC 956-16, ASTM D 3306 specifications, FIAT

Classification 9.55523 (PARAFLU UP Contractual Technical Reference N° F101.M01.

Cooling circuit usage percentage: 50% water 50% PARAFLU UP **)

Engine Oil**

SAE 5W-20 grade totally synthetic lubricant that meets FIAT Classification 9.55535-CR1,

API SN, ILSAC GF-5 (SELENIA K POWER, Contractual Technical Reference N° F102.F11)

Spark Plugs

ZFR5F-11 (Gap 1.1 mm)

Fuel Selection

91 Octane or higher

* Do not top up or mix with fluids

** For particularly harsh climate con-

*** In the event of an emergency in

with different specifications.

ditions, a mixture of

60% PARA-

which the original products are not

FLUUP and 40% demineralised water

available, lubricants with at least IL-

is recommended.

SAC GF-5 performance are acceptable.

216

In this case optimum engine perfor-

The use of products with features

mance is not guaranteed and the lubri-

lower than ILSAC GF-5 could cause

cants should be replaced with recom-

engine damage not covered by the

mended products as soon as possible.

warranty.

CHASSIS

Component

Fluids and Lubricants Specs (Genuine Parts)

Automatic Transmission

Totally synthetic lubricant that meets FIAT Classification 9.55550-AV4

(TUTELA TRANSMISSION FORCE4, Contractual Technical

Reference N° F108.F11)

Brake Master Cylinder

Synthetic fluid that meets FIAT Classification 9.55597, FMVSS n° 116,

DOT 4, ISO 4925, SAE J-1704 (TUTELA TOP 4, Contractual Technical

Reference N° F001.A93)

Power Steering Reservoir

Totally synthetic lubricant that meets FIAT Classification 9.55550-AV4

(TUTELA TRANSMISSION FORCE4, Contractual Technical Reference

N° F108.F11)

Windshield/Rear Window

Mixture of alcohol, water and surfactants that meets FIAT Classification

Washer Fluid

9.55522, CUNA NC 956-11 (TUTELA PROFESSIONAL SC35,

Contractual Technical Reference N° F201.D02)

217

ARRANGEMENTS FOR DEALING

The European Directive sets out that

These centres have been carefully

WITH THE VEHICLE AT THE

when the vehicle is handed over the

chosen to offer high quality service for

END OF ITS LIFE

last keeper or owner should not incur

the collection, treatment and recy-

any expenses as a result of it having a

cling of unused vehicles with respect

LANCIA has been committed for

zero or negative market value.

to the environment.

many years to safeguarding the envi-

ronment through the constant im-

In all European Union countries, until

You can find further information on

provement of its production processes

1st January 2007, only vehicles regis-

these collection and scrapping centres

and manufacturing products that are

tered after 1st July 2002 were col-

either from a LANCIA or LANCIA

increasingly “eco-compatible”.

lected free of charge, while since 2007

Commercial Vehicle Dealership or by

collection has been free of charge irre-

calling the freephone number 00800

To give customers the best possible

spective of the year of registration as

526242

or by going on the

service in terms of respecting environ-

long as the vehicle contains its basic

LANCIA website.

mental laws and in response to Euro-

components (in particular, the engine

pean Directive 2000/53/EC govern-

(*) Vehicle for transporting passen-

and bodywork) and has no additional

ing vehicles at the end of their life,

gers with a maximum of nine seats

waste.

LANCIA is offering its customers the

and a total permitted weight of 3.5 t

opportunity of handing over their ve-

To hand your vehicle over at the end

hicle* at the end of its life without

of its life without extra cost, go to one

incurring any additional costs.

of our Dealerships or LANCIA-

authorized collection and scrapping

centres.

218

MAINTENANCE

On Electronic Vehicle Information

• Under no circumstances should

Center (EVIC) equipped vehicles “Oil

oil change intervals exceed

SCHEDULE

Change Required” will be displayed

12,000 km or 12 months, which-

The Scheduled Maintenance services

in the EVIC and a single chime will

ever comes first.

listed in this manual must be done at the

sound, indicating that an oil change is

Your authorized dealer will reset the

times or mileages specified to protect

necessary.

oil change indicator message after

your vehicle warranty and ensure the

NOTE:

completing the scheduled oil change.

best vehicle performance and reliability.

More frequent maintenance may be

• The oil change indicator message

CAUTION!

needed for vehicles in severe operating

will not monitor the time since the

Failure to perform the required

conditions, such as dusty areas and very

last oil change. Change your ve-

maintenance items may result in

short trip driving. Inspection and ser-

hicles oil if it has been 12 months

damage to the vehicle.

vice should also be done anytime a mal-

since your last oil change even if

function is suspected.

the oil change indicator message

is NOT illuminated.

The oil change indicator system will

remind you that it is time to take your

vehicle in for scheduled maintenance.

Thousands Of Kilometers

120

144

168

192

Months

Inspect and replace PCV valve if necessary.

•

Check battery charge status and possibly recharge.

•

Check tire condition/wear and adjust pressure, if necessary.

•

Check operation of lighting system (headlamps, direction

•

indicators, hazard warning lights, luggage compartment,

passenger compartment, glove compartment, instrument

panel warning lights, etc.).

Check operation of windshield washer system and adjust jets if

•

necessary.

222

Thousands Of Kilometers

120

144

168

192

Months

Check windshield/rear window wiper blade position/wear.

•

Check cleanliness of hood and tailgate locks and cleanliness

•

and lubrication of linkages.

Visually inspect condition of: exterior bodywork, underbody

•

protection, pipes and hoses (exhaust - fuel system - brakes),

rubber elements (boots, sleeves, bushes, etc.).

Check conditions and wear of front disc brake pads.

•

Check conditions and wear of rear disc brake pads.

•

Check and, if necessary, top up fluid levels (brakes, windshield

•

washer, battery, engine coolant, etc.).

Visually inspect the condition of accessory drive belt/s.

•

Check the handbrake lever stroke and adjust it, if necessary.

•

Check exhaust gas emissions.

•

Check engine management system operation (via diagnostic

•

socket).

Change the automatic transmission fluid and filter. (*)

•

Replace spark plugs.

•

Replace air filter cartridge.

•

Change engine oil and replace oil filter.**

Change brake fluid (or every 24 months).

•

Replace pollen filter.

•

(*) Change the automatic transmis-

short (less than 7-8 km) and repeated

** The engine oil

and the oil filter

sion fluid and filter(s) at 96 kkm or

journeys, or frequent trailer or cara-

must be changed when the instrument

48 months if using your vehicle for

van towing.

panel warning light comes on or in

any of the following: city driving,

any case every 12 months.

223

Periodic Checks

Heavy-Duty Use Of The Car

•

visually inspect conditions of: en-

gine, transmission, pipes and hoses

Every 1,000 km or before long jour-

If the car is used mainly under one of

(exhaust - fuel system - brakes) and

neys, check and, if necessary, restore:

the following conditions:

rubber elements (boots - sleeves -

•

engine coolant;

• towing a trailer or caravan;

bushes - etc.);

•

brake fluid;

• dusty roads;

•

check battery charge and battery

fluid level (electrolyte);

•

Power Steering Fluid;

• short, repeated journeys (less than

7-8 km) at sub-zero outside

•

windshield washer fluid level;

•

visually inspect condition of the

temperatures;

accessory drive belts;

•

power steering fluid;

• engine often idling or driving long

•

check and, if necessary, change

• tire inflation pressure and condition;

distances at low speeds or long pe-

engine oil and replace oil filter;

riods of idleness.

•

operation of lighting system (head-

•

check and, if necessary, replace pol-

lights, direction indicators, hazard

You should perform the following in-

len filter;

warning lights, etc.);

spections more frequently than shown

on the Scheduled Servicing Plan:

•

check and, if necessary, replace air

•

operation of windshield washer/

cleaner.

wiper system and positioning/wear

• check front disc brake pad condi-

of windshield/rear window wiper

tions and wear;

blades.

• check cleanliness of hood and trunk

Every 3,000 km, check and top up, if

locks, cleanliness and lubrication of

required, the engine oil level.

linkage;

224

Content .. 11 12 13 14 ..