automatic transmission fluid FIAT PUNTO 1995 176 / 1.G User Guide

2D*10 Engine removal and overhaul procedures
Engine and transmission -removal, separation, connection and refitting
Note: The engine Is lowered from the engine compartment as a complete unit with the transmission; tho two are then separated for overhaul.
Removal 1 Remove the bonnet and disconnect the washer tubing as described in Chapter 11 (see illustrations). 2 Apply the handbrake, then jack up the front of the vehicle and support on axle stands (see Jacking and vehicle support). Remove both front wheels. In order to remove tne engine/transmission assembly in an upright position from under the vehicle, there must be a minimum clearance of 660 mm between the floor and the front crossmember. Additional height Is necessary if the assembly is to be lowered onto a trolley. 3 Where fitted, unbolt and remove the engine compartment lower cover. 4 Remove the auxiliary drivebelt(s) with reference to Chapter 1A or 1B. 5 Dram the engine oil. transmission oil/fluid and coolant with reference to Chapter 1A or 1B. 6 Remove the battery (see Chapter 5A). 7 On manual transmission models with a cable dutch, disconnect the clutch cable from the transmission (refer to Chapter 6). On manual transmission models with a hydraulic clutch unbolt the clutch slave cylinder from the top of the transmission then fit a cable-tie around it to prevent the piston coming out (see Illustration). Position the cylinder to one side. 8 Unscrew the nut and disconnect the earth lead from the transmission (see illustration). Petrol engines 9 Unbolt and remove the battery tray. 10 Disconnect the wiring from the reversing light switch. 11 On manual transmission models disconnect the reverse Inhibition cable from the transmission then disconnect the gear selector rod from the lever on the transmission. 12 Remove the air cleaner and ducting as descnbed In Chapter 4A or 4B. 13 On automatic transmission models disconnect the kickdown cable and gear selector cable as described in Chapter 7B. Also disconnect the wiring for the electro-magnetic clutch. 14 Unbolt and remove the cover from the bulkhead then disconnect the oxygen sensor wiring. 15 Disconnect the remaining wiring at the bulkhead and release the fuse holders at the mounting. 16 Disconnect the vacuum pipe from the inlet manifold, and also disconnect the wiring connector located next to it.
4.1a Unscrewing the bonnet hinge bolts
17 Unscrewthenutsandseparatetheengine wiring harness lead from the battery positive cable terminal. 18 Disconnect the accelerator cable from the engine as described in Chapter 4A or 4B, 19 Loosen the clip and disconnect the radiator top hose from the elbow on the left-hand end of the cylinder head. Similarly disconnect the bottom hose. On 16-valve models, remove the radiator electric cooling fan as described in Chapter 3. 20 Identify the hoses connected to the throttle housing, then disconnect them. 21 Identify the coolant heater hoses on the bulkhead for position, then loosen the clips and disconnect the hoses. 22 Loosen the clip and disconnect the brake servo vacuum hose from the Inlet manifold. Where applicable, disconnect the remaining emission control system vacuum hoses from the Inlet manifold after Identifying their locations to aid refitting. 23 Disconnect tho fuel supply and return hoses from the throttle housing. 24 Release the connector from the ignition/fuel ECU located on the right-hand side of the engine compartment. 25 Unscrew the nut and detach the earth cable from its location near the ECU. 26 Disconnect the diagnostic connector located near the ECU. 27 On models fitted with power steering, refer to Chapter 10 and unbolt the power steering pump from the front of the engine without disconnecting the hydraulic fluid lines then tie It to one side so that it will not obstruct the removal of the engine. On
4.1b Disconnecting the washer tubing
models with air conditioning, similarly unbolt the air conditioning compressor and position it clear of the engine. Do not disconnect the air conditioning refngerant pipes/hoses. 26 On manual transmission models pull out the retaining plate and disconnect the gear selector cable from the lever on the transmission. 29 Unscrew the nuts retaining the track rod ends on the swivel hubs and use a balljoint separator tool to disconnect them. 30 Release the flexible brake fluid hoses and ABS system sensor wrring from the front suspension struts. 31 On manual transmission models, unscrew the nuts from the outer ends of each driveshaft. To prevent the hubs from turning either have an assistant depress the brake pedal, or temporarily Insert two wheel bolts and use a lever to hold the hub. 32 On automatic transmission models use a suitable drift to drive out Ihe roll pins securing 2D the inner ends of the drlveshafts to tho trans-mission output stubs. Turn the driveshalts as necossary to access the roll pins . 33 Unscrew the two bolts securing the right-hand swivel hub assembly to the front suspension strut, then move the hub assembly outwards. On manual transmission models release the outer end of the driveshaft from the hub assembly - on automatic transmission models slide the inner end of the driveshaft off the final drive output stub. Take care not to strain the flexible brake hose while doing this. Move the driveshaft to one side thon temporanly refit the hub assembly to the strut. On manual transmission models, make
^ - / //
4.7 Fit a cable tie around the dutch slave cylinder to prevent the piston coming out 4.8 Disconnecting the earth lead from the transmission

7B«1
Chapter 7 Part B:
Automatic transmission
Contents
Accelerator pedal micro-switch(es) - checking and adjustment II Automatic transmission filter and fluid change See Chapter 1A Automatic transmission fluid level check See Weekly checks Automatic transmission • overhaul 12 Automatic transmission • removal and refining 2 Bectro-magnetic clutch - removal, inspection and refitting 3 BectrO'fnagnetic clutch brushes- removal, inspection and refitting . 4
Electronic control unit - removal and refitting 5 Gear selector cable - adjustment 6 Gear selector cable - removal and refitting 9 General information 1 Kickdown cable - adjustment 7 Kickdown cable - removal and refitting 6 Transmission oil pump - removal and refitting 10
Degrees of difficulty

Easy,
suitable for novice
with
ittle experience ^
Party
easy,
suitable for beginner
with
^r someexperienoe ^
Faiily
difficult,
^ suitable
for
competent
DIY mechanic
^

Difficult, suitable
for fe, experienced DIY >8J mechanic
Verydfficult, ^
suitable
for
expert DIY
or professional ^
Specifications
General Type Ratios (at transmission): Lowest Highest Final drive
Torque wrench settings Esnh cable Control unit Sectro-magnetic clutch to flywheel Transmission-to-engine bolt/nut ..
ECVT (Electronic Continuously Variable Transmission)
2.503 0.497 4.647:1
Nm Ibftt 14 10 5 4 34 25 85 63
1 Genera) information
I The automatic transmission fitted is designated ECVT (Electronic Continuously Variable Transmission). The main components
01
the transmission are an electro-magnetic dutch, a variable-ratio coupling, a final drive/ differential unit, and the associated control mechanisms (see illustrations overleaf) 2 The variable-ratio coupling consists of two pulleys and a flexible metal drivebelt. The effective diameter of the two pulleys can be varied to provide different transmission ratios between them. 3 During normal driving, the transmission automatically selects the ratio giving the best
compromise between economy and speed. When the driver depresses the accelerator pedal to the floor, a kickdown effect is provided, and the transmission selects a lower ratio for improved acceleration. 4 The gear selector control resembles that fitted to conventional automatic transmissions. The control positions are as follows: P (Parking) The transmission is mech-anically locked by the engage-ment of a pawl with a toothed segment on the driven pulley. R (Reverse) Reverse gean's engaged, N (Neutral) The transmission is In neutral. D (Drive) Normal driving position. Trans-mission ratio is varied automat-ically to suit prevailing speed and load.
L (Low) Prevents the transmission
moving into high ratios. Provides maximum acceleration end maximum engine braking. 5 The engine can only be started In positions P and N. A warning buzzer sounds If the selector is in any position other than P when the ignition is switched off or when the driver's door is opened. 6 The electro-magnetic clutch consists of a driving element boiled to the engine flywheel, and a driven element spiined to the transmission Input shaft. The degree of coupling between the (wo elements Is determined by the intensity of a magnetic field generated by a current passing through windings in the driven element. The magnetic field acts on a layer of metallic powder between the driving and driven elements. When no magnetic field is present, the powder is loose and the two elements are effectively

7B*4 Automatic transmission
2 Automatic transmission - ^ removal and refitting St
Removal 1 Select a solid, level surface to park the vehicle upon. Give yourself enough space to move around it easily. Apply the handbrake then jack up the front of the vehicle and support on axle stands (see Jacking and vehicle support). Remove both front wheels, 2 Remove the battery and mounting tray as described In Chapter 5A. 3 Remove the air cleaner and air inlet duct as described In Chapter 4A. 4 Disconnect the kickdown cable at the sector on the throttle housing and detach It from the mounting on the camshaft cover. Also release the cable from the support on the left-hand end of the cylinder head. 5 Disconnect the wiring connectors on the transmission. 6 Disconnect the fluid inlet and outlet Unas from the heat exchanger on top of the transmission. 7 Pull the fluid level dipstick from Its tube on the front of the transmission and tape over the top of the tube to prevent dirt entry. 8 Unscrew and remove the retaining pin and disconnect the speed selector cable from the top of the transmission. 9 Unscrew the upper bolt securing the starter motor to the transmission. 10 Unscrew the upper bolts securing the transmission to the engine. 11 Support the weight of the engine using a hoist attached to the engine lifting eyes, or alternatively UBO a trolley jack and block of wood beneath the engine, 12 Remove the screws and remove the front wheel arch liner from under the left-hand wheel arch. 13 Unscrew the nut securing the earth cablo to the transmission. 14 Using a punch drive out the roll pins securing both driveshafts to the final drive output shafts. 15 Unscrew and remove the bolts securing the left-hand swivel hub assembly to the front suspension strut, then separate the components and support the swivel hub on an axle stand. 16 Move the swivel hub assembly outwards and slide the inner end of the driveshaft from the splines on the transmission output shaft. Support the shaft away from the transmission to prevent damage to the gaiters. 17 Unscrew the lambdafoxygen sensor from the exhaust downpipe and position it In a safe place to prevent damage. 18 Unscrew ihe nuts securing the downpipe to Ihe exhaust manifold, then lower It and suppon on an axle stand. Recover the gasket. 19 Unscrew the knurled nut and disconnect the speedometer cable from the top of the final drive housing.
3-2 Locking the flywheel when removing the electromagnetic clutch 20 Unscrew the remaining bolt securing the staner motor to the transmission 21 Unbolt and remove Ihe lower flywheel cover from the transmission. 22 Working beneath the vehicle, unscrew the bolts securing the rear engine mounting to the underbody then unscrew the bolts securing the mounting lo the transmission and withdraw the mounting assembly from under the vehicle. 23 Unscrew the bolts securing the left-hand engine/transmission mounting to the body thon unscrew the bolts from the transmission and remove the mounting. 24 Support the weight of the transmission on a trolley jack then unscrew the remaining nut and bolt from the bellhouslng and pull the transmission away from the engine. Lower it and remove from under the vehicle.

A


Warning: Support the transmission to ensure that It remains steady on the Jack head. Keep the transmission level until the Input shaft and pump shaft are fully withdrawn from the electromagnetic clutch housing.
Refitting 25 Refitting is a reversal of the removal procedure, but note the following points. a} Apply a smear of high-melting-point grease to the splines of the transmission input shaft and oil pump driveshaft.
3.6 Checking the resistance of the clutch windings 1 Slip rings
0) Tighten all nuts and bolts to the
specified
torque, where given, c) Renew both driveshaft roll pins.
3 Electro-magnetic clutch • & removal, inspection 5. and refitting ^
Removal 1 Remove Ihe transmission as described n Section 2. 2 Turn the flywheel so that two of the lour mounting bolts are accessible, Hold tha flywheel stationary then unscrew Ihe tvrt bolts. To hold the flywheel, Insert a wida bladed screwdriver In the ring gear teeth or alternatively use a piece of angle iron against one of the retaining bolts temporarily Inserted in the cylinder block (see illustration). 3 Turn the crankshaft half a turn and unscrew the remaining bolts, then withdraw the electromagnetic clutch.
Inspection 4 Turn the driven element by means of tha slip rings, and check that the bearing is not noisy or rough. 5 Inspect the slip rings for burning or other damage. Clean them if necessary using fid and a clean rag. 6 Check the resistance of the clutch windings, using an ohmmetor connected across the slip rings (see Illustration). The resistance at 20*0 should be 2 to 4 ohms. 7 Check the Insulation of the windings, using an ohmmeter connected between either sip ring and the body of the clutch (see illustration). Resistance should be Infinity. 8 If the clutch fails any of the foregoing checks, renew it. Apart from the brush gear, Individual spares are not available.
Refitting 9 Refitting is a reversal of removal but tighten all bolts to the specified torque.
windings

7B*6 Automatic transmission
Gear selector cable -adjustment
1 Remove the battery and tray as described In Chapter 5A for access to the transmission. 2 Disconnect the selector cable from the lever on Ihe transmission. 3 Move the selector fever inside the vehicle to the N (Neutral) position, then move the lever on the transmission to Its central (Neutral) position. Locate the cable end over the lever. If the cable end fitting does not line up exactly with the hole In Ihe lever, loosen the adjustment nut and reposition the end fitting. 4 With the adjustment correct reconnect tha cable to the lever, then move the selector lever to the P (Park) position. Check that the lever on the transmission has also moved to the P position. 6 Refit the battery and tray as described in Chapter 5A. 6 Road test the vehicle, and check for correct operation in all selector lever positions.
9 Gear selector cable -removal and refitting at
7 Inside the vehicle disconnect the selector cable from the bottom of the selector lever (hen remove it from the support bracket, a Withdraw the cable into the engine compartment, and remove it.
Refitting 9 Refitting is a reversal of removal, but adjust the cable as described in Section 8. 10 Check that It is only possible to start the engine in positions P and N. Reposition the selector lever switch If necessary. 11 Road test the vehicle, and check for correct operation In ell selector lever positions.
10 Transmission oil pump - & mnvtiifll rAtiMlitA removal a/id refitting
Removal 1 Using an Allen key. unscrew the screw and remove the selector lever knob from the lever. 2 Remove the oddment tray and the ashtray. 3 Remove the screws and withdraw the centre console and selector mechanism cover. 4 Unscrew the mounting screws, slightly lift the centre console, then disconnect the wiring and remove the console, 5 Remove the battery and tray as described in Chapter 5A for access to the transmission, 6 Disconnect the selector cable from the lever on the transmission.
Removal 1 Apply the handbrake, then lack up the front of the vehicle and support on axle stands (see Jacking and vehicle support). Remove the left-hand wheel. 2 Unscrew the screws and remove the wheel arch liner. 3 Working through the left-hand wheel arch, remove Ihe three bolts which secure the oil pump. 4 Attach a slide hammer to the oil pump, using the two tapped holes provided. Withdraw the pump using the slide hammer. Be prepared for some oil spillage. Recover the gasket end O-ring (see illustrations). 5 If the pump is defective, it must be renewed; no spares are available.
Refitting 6 Before refitting Ihe oil pump, clean Ihe mating surfaces of the transmission and pump. 7 Rt the oil pump, U9ing a new gasket and a new O-ring. Secure the pump with the three bolts.
8 Refit the wheel arch liner, then refit tto wheel and lower the vehicle to the ground. 9 Check the transmission fluid level » described earlier in this Section, and top-upif necessary.
11 Accelerator pedal & mfcro-Bwftcb(es) -checking
and
adjustment ^
1 Correct adjustment of the micro-awtlch which senses the accelerator pedal position s essential for correct operation of the clutch.
A
quick check can be made by listening for the switch clicking as the accelerator a depressed. For an accurate check, proceed as follows. 2 Disconnect Ihe mlcroswitch wiring connector (nside the vehicle. Connect a continuity tester across the terminals of the switch, located at the top of (he pedal box (see Illustration}. 3 Remove the air cleaner and air ducting as described in Chapter 4A. 4 With the accelerator pedal releassd, th« switch must be closed (zero resistance). Slowty depress the pedal, and check that the switch opens when the throttle valve on the throttle housing is 30° open. This will occur when the pedal has travelled between 3 and 7 mm. Adjust the switch position if necessary. 5 If the switch is permanently open or permanently closed, and adjustment makes no difference, renew ft. 6 Remake the original wiring connections on completion,
12 Automatic transmission -overhaul
Apart from the operations described earlier in this Section, transmission overhaul should be entrusted to a Rat dealer or transmission specialist.
10.4a Using a slide hammer to remove the oil pump from the transmission 10.4b Automatic transmission oil pump O-dng (1), housing (2) and gasket (3) 11.2 Continuity tester connected ecross the accelerator pedal micro-switch