Bore FIAT PUNTO 1996 176 / 1.G Workshop Manual

2A*10 SOHC (8-valve) petrol engine in-car repair procedures
Torque wrench settings Nm
IM
ft Camshaft cover 8 6 Camshaft sprocket 70 52 Cylinder head; Stage 1 30 22 Stage 2 Angle-lighten a further 90° Siege 3 Angle-tighten a further 90B Crankshaft sprocket centre bott 100 74 Engine mounting bolt: M10X1.25 69 44 MB 25 18 Engine mounting nut (M10x 1.25) 60 44 Flywheet/driveplate 44 32 Sump 10 7 Timing belt tensJoner 28 21
1 General information
Using this Chapter Chapter 2 is divided Into four Parts: A. 8. C and D. Repair operations that can be carried out with the engine in the vehicle are described in Part A. SOHC (8-valve) petrol engines, Part B. DOHC (18-valve) petrol engines and Part C, diesel engines. Part 0 covers the removal of the engine/transmission as a unit, and describes the engine dismantling and overhaul procedures. In Parts A, 9 and C, the assumption Is made lhat the engine is Installed in the vehicle, with sll ancillaries connected. If the engine has been removed for overhaul, the preliminary dismantling Information which precedes each operation may be ignored.
Engine description Throughout this Chapter, engines are identified by their capacities. A listing of all engines covered, together with their code letters, is given in the Specifications. The engines covered In this Part of Chapter 2 are water-cooled, single overhead camshaft, in-line four-cylinder units, with cast Iron cylinder Mocks and aluminium-alloy cylinder heads. All are mounted transversely at the front ot the vehicle, with the transmission bolted to the left-hand side of the engine, The cylinder head carries the camshaft which is driven by a toothed timing belt and runs In three bearings. It also houses the inlet and exhaust valves, which are closed by single coil springs, and which run in guides pressed Into the cylinder head. The camshaft actuates the vatves directly via cam followers mounted in the cylinder head. Adjustment of the valve clearances is by means of shims located on top of the followers. The cylinder head contains Integral oitways which supply and lubricate the tappets. The crankshafl Is supported by five main bearings, and endftoat is controlled by a thrust bearing fitted to the upper section of the centre main bearing.
Engine coolant is circulated by 8 pump, driven by the timing belt. For details of the cooling system, refer to Chapter 3. Lubricant is circulated under pressure by a pump, driven from ihe front of the crankshaft. Oil Is drawn from the sump through a strainer, and then forced through an externally-mounted, replaceable screw-on filter. From there, It is distributed to the cylinder head, where It lubricates the camshaft journals and tappets, and also to the crankcase, where il lubricates the main bearings, connecting rod big and smell-ends, gudgeon pins and cylinder bores. On 1242 cc engines, oil jets are fitted lo the base of each cylinder bore -these spray oil onto the underside of the pistons, to Improve cooling.
Repair operations possible with the engine in the car The following work can be carried out with the engine in the car a) Compression pressure - testing b) Auxiliary drivebelt - removal and refitting (refer to Chapter 1A) c) Vatve clearances - checking and adjustment (refer to Chapter I A) d) Camshaft cover - removal and refitting e) Timing belt and covens - removal and refitting f) Timing belt tensioner and sprockets -removal and refitting g) Cylinder head - removal and refitting' h) Camshaft and cam followers • removal and refitting' t) Camshaft oil seal - renews/ j) Crankshaft oil seals - renewal k) Flywheel/dnvepfate • removal, inspection and refitting l) Engine mountings - inspection and renewal m)Sump - removal and refitting n) Oil pump and pick-up tube assembly
•
removai. inspection and refitting *Cylinder head dismantling procedures are detailed In Chapter SO, with details of camshaft and cam follower removal. Note: It is possible to remove the pistons and connecting rods (after removing the cylinder head and sump) without removing the engine. However, this is not recommended. Work of
this nature is more easily and thoroughly completed with the engine on the bench, as described In Chapter 2D.
2 Location of
TDC
on % No
1
cylinder
General Information 1 The camshaft Is driven by the crankshaft, by means of sprockets and a timing belt. Both sprockets rotate In phase with each other and this provides the correct valve timing as the engine rotates. When (he liming belt is removed during servioing or repair, it Is possible for the camshaft and crankshaft to rotate Independently of each other and the correct valve timing Is then lost. 2 The design of the engines covered In this Chapter are such lhat potentially damaging piston-to-valve contact may occur if the camshaft is rotated when any of the pistons are stationary at, or near, the top of their stroke. 3 For this reason it is important lhat Ihe correct phasing between the camshaft and crankshaft is preserved whilst the timing belt Is off the engine. This is achieved by setting the engine In a reference position (known as Top Dead Centre or TDC) before the timing belt Is removed and then preventing the camshaft and crankshaft from rotating until the belt is refitted. Similarly, if ths engine has been dismantled for overhaul, the engine can be set to TOC during reassembly to ensure that Ihe correct shaft phasing is restored. 4 TDC is the highest point In the cylinder that each piston reaches as the crankshaft turns. Each piston reaches TDC at Ihe end of the compression stroke and again at the end of the exhaust stroke. However, for the purpose of timing the ongine. TDC refers to the position of No 1 piston at the end of Its compression stroke. On ail engines In this manual, No 1 piston (and cylinder) Is at the timing belt end of the engine. 5 The camshaft sprocket Is equipped with a marking which, when aligned with a reference marking on the cylinder head, indicates that the camshaft is correctly positioned for cyl-inder No 1 al TDC on its compression stroke.

2A*10 SOHC (8-valve) petrol engine in-car repair procedures
2.11 Unscrewing the crankshaft pulley bolts
6 Itae crankshaft sprocket Is also equipped •nth a timing mark - when this is aligned with 3relarence marking on the oil pump cover.
Hie
engine is set with cylinders No 1 and 4 at
TDC.
Note that it is the camshaft positioning that determines whether a cylinder is on its comcression or exhaust stroke.

Location
of TDC on cylinder No 1 7 Remove the air cleaner and ducting as descnbed in Chapter 4A or 4B. Remove the
spark
plug from No 1 cylinder as described in Chapter 1A. 8 Firmly apply the handbrake, then |ack up
the
front of the car and support it securely on iiia stands (see Jacking end vehicle support). 9 Remove the auxiliary drivebelt(s) as described in Chapter 1A. 10 Unbolt and remove the timing belt cover. Mole the bolt located at the bottom of the
coven
this can be easily overlooked. 11 Undo the three bolts and remove the crankshaft pulley from the sprocket (see {lustration). 12 Turn Ihe engine in its normal direction of rotation (using a socket or spanner on Ihe crankshaft sprocket centre bolt) until pressure an be felt at No
1
cylinder spark plug hole.
1 flfliyflg^ Remove all four spark plugs; "••"•1 this will make the engine HlNTl easier to turn; refer to Chapter 1A for details.
13 Continue turning the engine until the crahaft sprocket TDC timing mark is aligned with the mark on the cylinder head and the crankshaft sprocket timing mark is aligned with the mark on the oil pump cover (see ilustrations). 14 The engine is now set at TDC for No 1 cylinder on compression.
3 Cylinder compression test t ^
1 When engine performance Is down, or if misfiring occurs which cannot be attributed to tne ignition or fuei systems, a compression isst can provide diagnostic clues as to the
2.13a Camshaft sprocket and cylinder head TDC timing marks (arrowed) aligned -shown with timing belt removed engine's condition. II the test is performed regularly, it can give warning of trouble any other symptoms become apparent. 2 The engine must be fully warmed-up to normal operating temperature, the battery must be fufly charged, and all the spark plugs must be removed (Chapter 1A). The aid of an assistant will also be required. 3 Disable the ignition system by dis-connecting the LT wiring plug to the ignition coils. 4 Fit a compression tester to the No 1 cyl-inder spark plug hole - the type of tester which screws into the plug thread is to be preferred, 5 Have the assistant hold the throttle wide open, and crank the engine on the starter motor; after one or two revolutions, the compression pressure should build up to a maximum figure, and then stabilise. Record the highest reading obtained. 6 Repeat the lest on the remaining cylinders, recording the pressure in each. 7 All cylinders should produce very similar pressures; any excessive difference indicates the existence of a fault. Note that the compression should build up quickly in a healthy engine; low compression on the first stroke, followed by gradually increasing pressure on successive strokes, indicates worn piston rings. A low compression reading on the first stroke, which does not build up during successive strokes, indicates leaking valves or a blown head gasket (a cracked head could also be the cause). 8 If the pressure in any cylinder is very low. carry out the following test to isolate the cause. Introduce a teaspoonful of clean oil into that cylinder through its spark plug hole and repeat the test. 9 If the addition of oil temporarily improves the compression pressure, this indicates that bore or piston wear Is responsible for the pressure loss. No improvement suggests that leaking or burnt valves, or a biown head gasket, may be to blame. 10 A low reading from two adjacent cylinders is almost certainly due to the head gasket having blown between them; the presence of coolant in the engine oil will confirm this. 11 If one cylinder is about 20 percent lower
2.13b Crankshaft sprocket and oil pump cover TDC timing marks (arrowed) aligned
than the others and Ihe engine has a slightly rough idle, a worn camshaft lobe could be the cause. 12 On completion of the test, refit the spark plugs and reconnect the ignition LT wiring plug.
4 Timing belt and covers -removal and refitting ^
Note: Fiat specify the use of a special timing belt fens/on measuring toot to correctly set tho timing belt tension. If access to this equipment cannot be obtained, an approximate setting can be achieved using the method described below. It the method described is used, the tension must be checked using the special tool at the earliest possible opportunity. Do not drive the vehicle over large distances, or use high engine speeds, until the belt tension is known fo be correct. Refer to a Fiat dealer foradvSce.
General information 1 The function of the timing belt is to drive Ihe camshaft and coolant pump. Should the belt slip or break In service, the valve timing will be disturbed and piston-to-valvo contact will occur, resulting in serious engine damage, 2 The timing belt should be renewed ai the specified intervals (see Chapter 1A), or earlier if it is contaminated with oil. or if it is at all noisy in operation (a scraping noise due to uneven wear). 3 If the timing belt is being removed, it Is a wise precaution to check the condition of the coolant pump at the same time (check for signs of coolant leakage). This may avoid the need to remove the timing belt again at a later stage, should the coolant pump fall.
Removal 4 Firmly apply the handbrake, then jack up the front of the car and support it securely on axle stands (see Jacking and vehicle support). Remove the right-hand front road wheel. 5 Remove the air cleaner and air ducting as described in Chapter 4A or 46. 6 Remove the auxiliary drivebelt(s) and the spark plugs as described in Chapter 1A.
2A

2A*10 SOHC (8-valve) petrol engine in-car repair procedures
Preparation for refitting 16 The mating faces of the cylinder head and cylinder block must be perfectly clean before
refitting
the head. Use a hard plastic or wooden scraper to remove all traces of gasket and carbon; also clean the piston crowns. Take padicular care when cleaning the piston crowns as the soft aluminium alloy is easily damaged. Make sure that the carbon is not afowed to enter the oil and water passages -Ihs is particularly important for the lubrication
system, as
carbon could block the oil supply to
Ihe
engine's components. Using adhesive tape
and
paper, seal the water, oil and bolt holes in tf« cylinder block. To prevent carbon entering twgap between the pistons and bores, smear
a
iittte grease in the gap. After cleaning each piston, use a small brush to remove all traces of grease and carbon from the gap, then wipe away the remainder with a clean rag. Clean all
ttie pistons
in the same way. 17 Check the mating surfaces of the cylinder block and the cylinder head for nicks, deep scratches and other damage. If slight, they may be removed carefully with a file, but if (xcassive, machining may be the only alternative to renewal. If warpage of the Cytodar head gasket surface is suspected, use a straight-edge to check it for distortion.
Refer
to Part 0 of this Chapter if necessary. 18 Check the condition of the cylinder head
MRS.
and particularly their threads, whenever
they are
removed. Wash the bolts In a suitable solvent, and wipe them dry. Check each bolt for any sign of visible wear or damage, renewing them if necessary.
Refitting 18 Before refitting Ihe assembled cylinder head, make sure that the head and block mating surfaces are perfectly clean, and that
the
bolt holes in the cylinder block have been
mopped
out to clear any oil. 20 Check that the camshaft and crankshaft sprocket timing marks are still aligned with tteir respective cylinder head and oil pump covtr marks as described in Section 2. 21 The new gasket should not be removed from its nylon cover until required for use. Fit
the
gasket dry, and make sure that the mating surfaces on the head and block are perfectly dean.
9.22a Place the cylinder head gasket on the cylinder block ... 22 Place the gasket on the cylinder block so that the word ALTO can be read from above (see illustrations). 23 Lower the cylinder head onto the block so that It locates on the positioning dowel. 24 The cylinder head bolt threads must be clean. Dip the bolts In engine oil. and allow them to drain for thirty minutes. Screw the bolls in finger-tight then working progressively and in the sequence shown, tighten all the cylinder head bolts to the Stage 1 torque setting given In the Specifications, using a torque wrench and a suitable socket. With all the bolts tightened to their Stage 1 setting, working again in the specified sequence, first angle-tighten the bolts through ihe specified Stage 2 angle, then again through the Stage 3 angle, using a socket and extension bar. It is recommended that an angle-measuring gauge is used dunng this stage of tightening, to ensure accuracy (see Illustrations). 25 Refit the inlet manifold and throttle body using a new gasket (refer to Chapter 4A or 4B). 28 Refit the exhaust manifold using a new gasket. Tighten all nuts. Reconnect the exhaust downplpe bracket. 27 Refit the timing belt inner covers and tighten the bolls. 28 Refit the timing belt, and tension It as described in Section 4. Refit the timing belt outer cover. 29 Refit the ignition colls and camshaft cover. 30 Reconnect all hoses, electrical leads and controls referring the relevant Chapters of this manual. 31 Fit the air cleaner and ducting.
9.22b ... so that the ALTO marking can be read from above 32 Reconnect the battery then fill and bleed the cooling system as described in Chapter 1A.
10 Flywheel/driveplate • ^ removal, inspection
and
refitting ^
Removal 1 Remove the transmission as described in Chapter 7A or 7B. On manual transmission models also remove the clutch (Chapter 6). 2 Mark the position of the flywheel/driveplate with respect to the crankshaft using a dab of paint. Note thai on some models although there is only one location dowel on the flywheel/driveplate there are two holes in the eno of the crankshaft and it is therefore possible to locate Ihe flywheel 180n out. The flywheel/driveplate must now be held stationary while the bolts are loosened. A home-made locking tool may be fabricated from a piece of scrap metal and used to lock the ring gear. Bolt the tool to one of the transmission bellhousing mounting holes. 3 Unscrew then remove the mounting bolts then lift off the flywheel/driveplate. Recover the spacer plate on manual transmission models. Discard the fiywheet/drivepiate boils; new ones must be used on refitting.
Inspection
Manual transmission models 4 If the flywheel's clutch mating surface is deeply scored, cracked or otherwise damaged, the flywheel must be renewed.
JEaMKA. mar 9.24c Using an angle gauge to tighten the cylinder head bolts to their second and third stage torque settings
L

2B»1
Chapter 2 Part B:
DOHC (16-valve) petrol
engine in-car repair procedures
Contents
Auxiliary drlvebelts - removal and refitting See Chapter 1A Camshaft oil seal - renewal 6 Camshafts and cam followers - removal, inspection and refitting .. 9 Crankshaft oil seals • renewal 7 Cylinder compression test 3 Cylinder head - dismantling and overhaul See Chapter 2D Cylinder head • removal and refitting 10 Cylinder head extension • removal and refitting 8 Engine assembly/Valve timing holes - general information and usage 2
Engine mountings - inspection and renewal 12 Engine oil and filter - renewal See Chapter 1A Engine oil level - check See Weekly checks Flywheel - removal, Inspection and refitting 11 General Information 1 Oil pump and pick-up tube - removal, inspection and refitting 14 Sump - removal and refitting 13 Timing belt and covers - removal and refitting 4 Timing belt tensioner and sprockets • removal and refitting 5
Degrees of difficulty

Easy,
sitable
for
J; Fairly
easy,
suitable Fairtydifflcutt, ^
Difficult,
aitabtefcr Very
difficult,
^ nwice
wim
(ttls for beginner with £
suitable
for competent KYmechanic ^ experienced DIY > suitable
for
expert DIY« experience
some
experience £
suitable
for competent KYmechanic ^ mechanic > or professional ^
Specifications
General Engine code* 176.09.000 •Note: See Vehicle Identification for the location of code marking on the engine. Bore 70.8 mm Stroke 78.86 mm Capacity 1242 cc Compression ratio 10.2:1 Firing order 1-3-4-2 No
1
cylinder location Timing belt end of engine Timing belt tension See text
Camshaft Orlve Toothed belt
No
of bearings 3 Camshaft bearing journal diameters: Ho
1
bearing 35.000 to 35.015 mm
Mo
2 bearing 48.000 to 48.015 mm No 3 bearing 49.000 to 49.015 mm Camshaft bearing Journal running clearance 0.030 to 0.070 mm Camshaft endfloat 0.15 to 0.34 mm
Cylinder head extension Camshaft bearing diamelers: No
1
bearing 35.045 to 35.070 mm No 2 bearing 48,045 to 48.070 mm No 3 bearing 49.045 to 49.070 mm
Cam
follower (tappet) type Hydraulic
Cam
follower (tappet) diameter 28.353 to 28.370 mm
Cam
follower (tappet) bore diameter in cylinder head extension 28.400 to 28.421 mm
Cam
follower (tappet) running clearance 0.046 to
0.051
mm

2A*10 SOHC (8-valve) petrol engine in-car repair procedures
Lubrication system Oil pump type By-rotor driven from front of crankshaft Outer rotor-io-houslng clearance 0.100 to 0.210 mm Axial clearance 0.025 to 0.070 mm
Torque wrench settings Nm itrf ft Camshaft driven gears 120 89 Camshaft sprocket 120 89 Crankshaft sprocket centre bolt: Stage
1
20 15 Stage 2 Angle-tighten a further 90® Cylinder head: Stage
1
30 22 Stage 2 Angle-tighten a further 90" Stage 3 Angle-tighten a further 90° Cylinder head extension to cylinder head 15 11 Engine mounting bolt: M10
x
1.25 59 44 M8 25 18 Engine mounting nut (MlOx 1.25) 60 44 Flywheel 44 32 Timing belt tensioner 25 18 Sump 10 7
1 General information
Using this Chapter Chapter 2 is divided into four Parts; A, B. C and O. Repair operations that can be carried out with the engine hi the vehicle are described in Part A. SOHC (8-valve) petrol engines. Part B, DOHC (16-valve) petrol engines and Pari C, dlesei engines. Part D covers the removal of the engine/transmission as a unit, and describes the engine dismantling and overhaul procedures. In Parts A, B and C, the assumption Is made that the engine is Installed In the vehicle, with all ancillaries connected. If the engine has been removed for overhaul, the preliminary dismantling information which precedes each operation may be ignored.
Engine description Throughout this Chapter, engines are identified by their capacities. A listing of all engines covered, together with their code letters, Is given in the Specifications. The engine covered in this Part of Chapter 2 is a water-cooled, double overhead camshaft, in-line four-cylinder unit, with cast iron cylinder block and aluminium-alloy cylinder head. The unit is mounted transversely at the front of the vehicle, with the transmission bolted to the left-hand side of the engine. The cylinder head houses the eight inlet and eight exhaust valves, which are closed by single coil springs, and which run in guides pressed Into the cylinder head. The two camshafts are housed in 8 cylinder head extension which is bolted to the top of the cylinder head. The exhaust camshaft is driven by a toothed timing belt and In turn drives the inlet camshaft via a pair of gears located at the left-hand end of the cylinder head extension.
The camshafts actuate the valves directly via self-adjusting hydraulic cam followers mounted in the cylinder head extension. The crankshaft is supported by five main bearings, and endfioat is controlled by a thrust bearing fitted to (he upper section of the centre main bearing. Engine coolanl is circulated by a pump, driven by the timing belt. For details of the cooling system, refer to Chapter 3. Lubricant is circulated under pressure by a pump, driven from the front of the crankshaft. Oil is drawn from Ihe sump through a strainer, and then forced through an externally-mounted, replaceable screw-on filter. From there, It is distributed to the cylinder head and cylinder head extension, where it lubricates the camshaft journals and cam followers, and also to the crankcase, where it lubricates the main bearings, connecting rod big and small-ends. gudgeon pins and cylinder bores. Oil Jets are fitted to the base of each cylinder bore - these spray oil onto the underside of the pistons, to improve cooling.
Repair operations possible with the engine in the car The following work can be carried out with the engine in the car: a) Auxiliary drivebett - removal and refitting (refer to Chapter 1A) b) Oil pump and pick-up tube assembly -removal, Inspection and refitting c) Timing belt and covers • removal and refitting d) Timing belt tensioner and sprockets -removal and refitting e) Cylinder head - removal and refitting' f) Cylinder hoad extension - removal and refitting g) Camshaft and cam followers - removal and refitting h) Camshaft oil seal - renewal i) Crankshaft oil seals • renewal
f) Flywheel - removal, inspection and
refitting
k) Engine mountings - Inspection and
renews'
f) Sump • removal and refitting 'Cylinder head dismantling procedures are detailed In Chapter 2D. Note 1: It is possible to remove the
pistons
and connecting rods (after removing (to cylinder head and sump) without removing
tt*»
engine. However, this Is not recommended. Work of this nature is more easily and thoroughly completed with the engine on fix bench, as described in Chapter 20. Note
2x
Many of the procedures in this Ctopfer entail the use of numerous special tools. Whet possible, suitable alternatives are descnbei with details of their fabrication. Before starring any operations on the engine, read through
tto
entire procedure first to familiarise yourself
wft
the work involved, tools to be obtained mi new parts that may be necessary.
2 Engine assembly/ valve timing holes -genera! information
and
usage
Note: Do not attempt to rotate the angint whilst the camshafts are locked In position,
il
the engine is to be left in this state foratofi$ period of time. It Is a good idea to plect suitable warning notices inside the vehicle, and in the engine compartment. This wfl reduce the possibility of the engine being accidentally cranked on the starter motor, which is likely to cause damage with the locking tools In place. 1 To accurately set the valve timing for ell operations requiring removal and refitting of
the
timing belt, liming holes are drilled in ihe camshafts and cylinder head extension. Ihe holes are used In conjunction with camshaft locking tools and crankshaft positioning
rods w
lock the camshafts when all the pistons me positioned at the mid-point of their stroke. Ths

2B*4 DOHC (16-valve) petrol engine in-car repair procedures
4.8 Undo three bolts and romove tho crankshaft pulley from the sprocket
Crankshaft setting toot fabrication 7 To make Ihe crankshafl setting tools, four old spark plugs will be required, together with four lengths of dowel rod. The length of each dowel rod is not critical, bul It must be long enough to protrude about 100 mm above the top of the cylinder head extension when resting on top of a piston located half way down its bore. What is critical, however, is that all four do wo I rods must be exactly the same length. 8 Break off the ceramic upper section of each plug and remove the centre electrode and earth tip. The easiest way to do this is to mount each spark plug in a vice (attar removing the ceramic uppor plug section) and drill a hole down through ihe centre of the plug. The diameter of Ihe drill bit should be the same as Ihe diameter of Ihe dowol rod to be used. When finished you should have four spark plug bodies and four equal length dowel rods which will slide through the centre of the spark plugs.
3 Cylinder compression test
1 When engine performance is down, or it misfiring occurs which cannot be attnbuted to the Ignition or fuel systems, a compression test can provide diagnostic clues as to the engine's condition. If the lest is performed regularly, it can give warning of trouble bofore any other symptoms become apparent.
4.10 Undo the upper timing cover upper retaining bolt, and the rear retaining boll
4.9 Undo the retaining bolt in the centre of the lower timing cover
2 The engine must be fully warmed-up to normal operxrtrfjg temperature, the battery must be fully charged, and all the spark plugs muse be removed (Chapter 1A>. The aid of an assistant wilt also be required. 3 Disable the ignition system by discon-necting the LT wiring plugs to the Ignition coils. 4 Fit a compression tester to the No t cylinder spark plug hole • the type of tester which screws into the plug thread is to be preferred. 5 Have the assistant hold the throttle wide open, and crank the engine on the starter motor; after one or two revolutions, the compression pressure should build up to a maximum figure, and then stabilise. Record the h.ghest reading obtained 6 Repeat the test on the remaining cylinders, recording Ihe pressure in each. 7 All cylinders should produce very similar pressures; any excessive difference indicates Ihe existence of a fault. Note that the compression should build up quickly in a healthy engine; low compression on (he first stroke, followed by gradually increasing pressure on successive strokes, indicates worn piston rings. A low compression reading on the first stroke, which does not build up during successive strokes, indicates leaking valves or a blown head gasket (a cracked head could also be tho cause). 6 If the pressure in any cylinder is very low, carry out the following test to isolate the cause. Introduce a teaspoonful of dean oil into that cylinder through its spark plug hole and repeal the lest. 9 If the addition of oil temporarily improves the compression pressure, this indicates that bore or piston wear is responsible for the pressure loss. No improvement suggests that leaking or burnt valves, or a blown head gasket, may be to blame. 10 A low reading from two adjacent cylinders is almost certainly due to the head gasket having blown between Ihem; the presence of coolant in the engine oil will confirm this. 11 If one cylinder is about 20 percent lower than the others and the engine has a slightly rough idle, a worn camshaft lobe could be the cause. 12 On completion of the test, refit the spark plugs and reconnect the ignition LT wiring plug.
4 Timing belt and covers -removal and refitting §
General information 1 The luncUon of the timing belt Is to drive the camshafts and coolant pump. Should the bell slip or creak in service, the valve timing will be disturbed and piston-to-valve contact wiu occur, resulting in serious engine damage. 2 The timing belt should be renewed at the specified Intervals (see Chapter 1A), or earlier If It is contaminated with oil, or if it is at all noisy In operation (a scraping noise due to uneven wear}. 3 If the timing belt is being removed, it is
a
wise precaution to check the condition of the coolam pump at the same time (oheck for signs of coolant leakage). This may avoid the need to remove the timing belt again at a later stage, should the coolant pump fail. 4 Before carrying out this procedure, it will be necessary to obtain or fabricate suitable camshaft locking tools and piston positioning tools as described in Section 2. The procedures contained In this Section depict the use of the home-made alternative tools described in Section 2. which were fabricated In the Haynes workshop. If the manufacturers tools are being used instead, the procedures are virtually identical. Oo not attempt to remove the timing bell unless the special totfs or their alternatives are available.
Removal 5 Disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Section of Ihis manual). 6 Remove the auxiliary drivebelt(s) as described In Chapter 1A. 7 Remove the air cleaner, Inlet air duct and resonator as desenbed In Chapter 4B. 8 Undo the three bolts and remove the crankshaft pulley from the sprocket (see illustration). 9 Undo the retaining bolt In the centre of the lower liming cover (see illustration). 10 Undo tho uppor timing cover upper retaining bolt, and the rear retaining bolt located above the alternator (see illustration). 11 Release the crankshaft TDC sensor wiring from the clip on the upper timing cover, then withdraw the cover slightly and slide Ihe wiring plug and socket from the liming cover slot (see illustrations). 12 Release the TDC sensor wiring from the periphery ol the upper and fower timing covers and remove both covers (see Illustrations). 13 Free the accelerator inner cable from the throttle cam, remove the outer cable spring dip, then pull the outer cable out from its mounting bracket rubber grommet. 14 From the side of the throttle body, disconnect the wiring connectors from the

2B*10 DOHC (16-valve) petrol engine in-car repair procedures
9.10 Extract the exhaust camshaft oil seal...
Inspection 12 Examine the camshaft bearing surfaces and cam lobes for signs of wear ridges and scoring. Renew ihe camshaft If any of these conditions are apparent. Examine the condition of the bearing surfaces, both on the camshaft journals and in the cylinder head extension. If the head extension beanng surfaces are worn excessively, the extension will need to be renewed. If suitable measuring equipment Is available, camshaft bearing journal wear can be checked by direct measurement. 13 Examine the cam follower bearing surfaces which contact the camshaft lobes for wear ridges and scoring. Renew any follower on which these conditions are apparent. If a follower bearing surface is badty scored, also examine the corresponding lobe on the camshaft for wear, as it is likely that both will be worn. Renew worn components as necessary.
9.11 ... then remove the exhaust camshaft from the cylinder head extension
Refitting 14 Liberally lubricate the camshaft journals and cylinder head extension bearings, then locate both camshafts in position Note that the exhaust camshaft is nearest to the front facing side of the engine. 15 With the camshafts In position, rotate them as necessary until the camshaft locking tools can be re-inserted (see illustration). 16 Lubricate the Hps of a new exhaust camshaft oil seal with clean engine oil, and drive It into position until it seats on its locating shoulder (see Illustration). Use a suitable tubular drifl, such as a socket, which bears only on the hard outer edge of the seaJ. Take care not to damage the seal lips during fitting. Noto that the seal lips should face inwards. 17 Refit the Inlet camshaft drive gear and retaining boll then tighten the bolt to the specified torque (see illustration).
9.16 Fit a new exhaust camshaft oil seal M7 Tighten the Inlet camshaft drive gear retaining bolt to the specified torque
9.15 Refit the camshaft locking tools
18 Refit the exhaust camshaft drive gear to the exhaust camshaft. As the gear is being fitted, It will be necessary to align the anti» backlash inner gear teeth using a screwdriver to enable the teeih of both Ihe gears to mes-i (see Illustration). 19 At this stage it is advisable lo check tie camshaft endfloat using a dial gauge mounted on the cylinder head extension, with its probe in contact with Ihe camshaft being checked Move the camshaft one way. zero the gauge, then move the camshaft as far as it will go ihe other way. Record the reading on the dial gauge and compare the figure with that given in the Specifications. Repeat on the other camshaft. If either of the readings exceeds the tolerance given, a new cylinder head extension will be required. 20 Locate a new gasket on the cylinder head extension end cover, then wrap round the protruding tangs on Ihe gasket to retain it in position (see Illustrations). 21 Locate the end cover on the cylinder heed extension and secure with the retaining nuts securely tightened. 22 Locate a new O-ring on the inlet camshaft cover plate, then apply RTV gasket sealant lo the cover plate contact face (see Illustrations), Fit tho cover plate and secure with the nut and bolt. 23 Refit the camshaft sprocket and secure with the retaining bolt tightened finger tight only at this stage. 24 Liberally lubricate the cam followers and piece them in position in their respective cylinder head extension bores (see illustration),
9.18 Refit the exhaust camshaft drive gear white aligning the anti-backlash Inner gear teeth 9.20a Locate a new gasket on the cylinder head extension end cover... 9.20b ... then wrap round the protruding tangs to retain the gaskel

DOHC (16-valve) petrol engine in-car repair procedures 2B*11
camshaft cover plate... 25 Locate the cam follower retaining tools in position and refit the cylinder head extension
as
described In Section 8.

10
Cylinder head - &
removal and
refitting S
Removal Note; The cylinder head bolts are of special
sekned
design and a Fiat tool should be
obtained
to unscrew them. A Ton key will not
JSt however
in practise It was found that a dose-httlng Alien key could be used as an itemative. 1 Drain the cooling system as described in Chapter 1A. 2 Remove the cylinder head extension as oescAbed
m
Section 8. 3 Disconnect the radiator hose from the thermostat housing on the left-hand end of
Ihe
cylinder head. 4 Disconnect the heater hose from the outlet
at the
rear of the cylinder head. 5 Disconnect the coolant temperature sensor md temperature gauge sensor wiring plugs
torn
the left-hand end of the cylinder head. 9 Undo the engine oil dipstick tube bracket retaining bolt and the two bolts securing the wing harness support clips to the inlet marriold lower section. 7 Undo Ihe retaining nuts and separate the ixhaust system front pipe from the exhaust manifold flange.
8
Check that nothing remains attached to the cinder head likely to impede removal. It Is assumed that the head will be removed complete with exhaust manifold and inlet manifold lower section. 9 Unscrew the cylinder head bolts half a turn K
e
time in the reverse order to that shown in (lustration 10.20a. When the bolts are free. «mwe them from their locations.. Id Lift the cylinder head from the block. If it is stuck tight rock the head to break the joint by mans of the manifolds. On no account drive
levers
into the gasket Joint, nor attempt to tap tf« head sideways, as it is located on positioning dowels. 11 Remove and discard the cylinder head gasket.
JK'
l^. 9.22b ... then apply RTV gasket sealant to the cover plate contact face 12 Refer to Chapter 20 for cylinder head dismantling and inspection procedures. Preparation for refitting 13 The mating faces of the cylinder head and cylinder block must be perfectly dean before refitting the head. Use a hard plastic or wooden scraper to remove all traces of gasket and carbon; also clean the piston crowns, Take particular care when cleaning the piston crowns as the soft aluminium alloy is easily damaged. Make sure that the carbon is not allowed to enter the oil and water passages -this Is particularly important for the lubncahon system, as carbon could block the oil supply to the engine's components. Using adhesive tape and paper, seal the water, oil and bolt holes in the cylinder block. To prevent carbon entering the gap between the pistons and bores, smear a little grease In the gap. After cleaning each piston, use a small brush to remove all traces of grease and carbon from the gap. then wipe away the remainder with a clean rag. Clean all the pistons in the same way. 14 Check the mating surfaces of the cylinder block and the cylinder head for nicks, deep scratches and other damage. If slight, they may be removed carefully with a file, but If excessive, machining may be the only alternative to renewal. If warpage of the cylinder head gasket surface Is suspected, use a straight-edge to check it for distortion. Refer to Part 0 of this Chapter if necessary. 15 Check the condition of the cylinder head bolts, and particularly their threads, whenever they are removed. Wash the bolts In a suitable
sequence
9.24 Lubricate the cam followers and place them in position in their respective bores solvent, and wipe them dry. Check each bolt for any sign of visible wear or damage, renewing them if necessary.
Refitting 18 Before refitting the assembled cylinder head, make sure that the head and block mating surfaces are perfectly clean, and that the bolt holes in the cylinder block have been mopped out to clear any oil, 17 The now gasket should not be removed from its nylon cover until required for use. Fit Ihe gasket dry, and make sure that the mating surfaces on the head and block are perfectly clean. 18 Place the gasket on the cylinder block so that the word ALTO can be read from above. 19 Lower the cylinder head onto the block so that it locates on the positioning dowel. 20 The cylinder head bolt threads must be clean and lightly lubricated. Screw the bolts in finger-tight then working progressively and in the sequence shown, lighten all the cylinder head bolts to the Stage 1 torquo setting given In the Specifications, using a torque wrench and a suitable socket. With all the bolts tightened to their Stage 1 setting, working again in the specified sequence, first angle-tighten the bolts through the specified Stage 2 angle, then again through the Stage 3 angle, using a socket and extension bar. It Is recommended that an angle-measuring gauge Is used during this stage ot tightening, to ensure accuracy (see Illustrations). 21 Reconnect the exhaust system front pipe to the manifold using a new flange gasket.
10.20b Tighten the cylinder head bolts to the Stago 1 torque setting ...

2C«1
Chapter 2 PartC:
Diesel engine in-car repair procedures
Contents
Auxiliary drivebelts - removal and refitting See Chapter 1B Camshaft cover - removal and refitting 6 Camshaft oil seal - renewal 7 Camshaft - removal and refitting See Chapter 20 Crankshaft oil seats - renewal 8 Cylinder compression test « 3 Cylinder head - dismantling and overhaul See Chapter 20 Cylinder head - removal and refitting 9 Engine mountings - inspection and renewal 11 Engine oil and fitter - renewal See Chapter 18 Engine oil level check See Weekly checks
Degrees of difficulty
Flywheel * removal, inspection and refitting 10 General information 1 Location of TDC on No 1 cylinder 2 Oil cooler - removal and refitting 14 Oil pump and pick-up tube • removal, Inspection and refitting 13 Sump • removal and refitting 12 Timing belt and covers • removal and refitting 4 Timing belt tensioner and sprockets - removal, Inspection and refitting 5 Valve clearance check and adjustment See Chapter 1B

Easy,
suitable for novice
with Irttle
|| experience g^
FaMy
eesy,
suitable ^
forbeglnnerwilti
some experience ^
Falrtydfficult, ^ suitable
for
competent DIYmechanic ^

Difficult, suitable
for & experienced DIY mechanic ^
Very
difficult,
^ suitable
for
expert
DfY
jR or professional ^
Specifications
General Engine code:' 1698 cc non-turbo engine 176.B3.000 1698 cc turbo engine: Up to 1997 t76.A3.00aor176.A5.000 1997 onward 176.A3.000or176.B7.000 •Note: See Vehicle Identification for the location of the code marking on the engine. Bore 82.6 mm Stroke 79.2 mm Compression ratio: Non-turbo engine 20.5:1 Turbo engine 19:1 Firing order 1-3-4-2
No 1
cylinder location Timing belt end of engine Titling belt tension See text
Lubrication system Oi pump type By-rotor driven from front of crankshaft Outer rotor-to-houslng clearance 0.080 to 0.186 mm Axial clearance 0.025 to 0.056 mm
Torque wrench settings Nm ibf ft Camshaft cover 10 7 Camshaft sprocket 11B 87 Crankshaft sprocket centre bolt 190 140 Cylinder head: Stage 1 50 37 Stage 2 100 74 StageS Angle-tighten a furtfier 90" Stage 4 Angle-tighten a further 90° CySnder head front bolts 30 22 Flywheel 142 105
Fuel
injection pump sprocket 49 36 Inlet and exhaust manifolds 25 18 Sump 10 7 Timing belt tensioner and idler 44 32

2C*2 Diesel engine in-car repair procedures
1 General information
Using this Chapter Chapter 2 is divided Into four Parts; A. 8, C and 0. Repair operations that cart be carried out with the engine in the vehicle are described In Part A, SOHC (B-valve) petrol engines. Part B, DOHC (16-valve) petrol engines and Part C. diesel engines, Part D covers the removal of the engine/transmission as a unit, and describes the engine dismantling and overhaul procedures. In Parts A. 8 and C. the assumption Is made that the engine is installed in Ihe vehicle, with all anciliaries connected If the engine has been removed for overhaul, the preliminary dismantling information which precedes each operation may be ignored.
Engine description Both normally aspirated (non-turbo) and turbocharged diesel engines are fitted to the Punto range. The engines together with their codes are given in the Specifications at the start of lhis Chapter. The engines are water-cooled, single-overhead camshaft. In-line lour cylinder units with cast-iron cylinder blocks and aluminium-alloy cylinder heads. The engine is mounted transversely at the front of the vehicle, with the transmission bolted to the left-hand side of the engine. The cylinder head carries the camshaft which is driven by a toothed timing belt. It also houses the inlet and exhaust valves which are closed by single coll valve springs and run in valve guides pressed into the cylinder head. The valves are operated by cam followers fitted over each valve, and the clearances are adjusted by shims positioned between the followers and the camshaft lobes. The camshaft is supported by four bearings • the end bearings are machined in the cylinder head and the remaining bearings have caps bolted to the cylinder head. The cylinder head contains integral oiiways which supply and lubricate the camshaft and followers and it also Incorporates renewable swirl chambers. The crankshaft Is supported by five main bearings, and endfloat Is controlled by a thrust bearing fitted on the rear main bearing. All diesel engines are fitted with a brake servo vacuum pump dnven from the left-hBnd end of the camshaft. Engine coolant is circulated by a pump, driven by the auxiliary drivebeit. For details of the cooling system refer to Chapter 3. Lubricant is circulated under pressure by a pump, driven from the front of the crankshaft. Oil is drawn from the sump through a strainer, and then forced through an externally-mounted, replaceable screw-on filter. From there, it is distributed to the cylinder head.
where il lubncates the camshaft journals and followers, and also to the crankcase, where it lubricates the main bearings, connecting rod big- and small-ends, gudgeon pins and cylinder bores. Oil jets are fitted to the base of each cylinder bore - these spray oil onto the underside of the pistons, lo Improve cooling. An oil cooler is also fitted to reduce the temp-erature of oil before it re-enters the engine.
Repair operations possible with the engine in the car The following work can be carried out with the engine in the can a) Compression pressure - testing b) Auxiliary drivebeit - removal and refitting (refer to Chapter rej c) Valve clearances • checking and adjustment (refer to Chapter 1B) d) Camshaft cover - removal and refitting e) Tim/ng belt and covers • removal and refitting 0 Timing belt tensioner and sprockets -removal and refitting g) Cylinder head - removal and refitting' h) Camshaft and cam followers - removal end refitting' I) Camshaft oil seal - renewal j) Crankshaft oil seals - renewal k) Flywheel • removal, inspection and refitting I) Engine mountings - inspection and renewal m)Sump • removal and refitting n) Oil pump and pick-up tube assembly -removal, inspection and refitting 'Cylinder head dismantling procedures are detalfed In Chapter 2D, with details of camshaft and cam follower removal. Note: It ts possible to remove the pistons and connecting rods (after removing the cylinder nead and sump) without removing the engine. However, this is not recommended. Work of this nature is more easily and thoroughly completed with the engine on tho bench as described in Chapter 2D.
2 Location of
TDC
on ^ No
1
cylinder ||
General information 1 The camshaft and fuel Injection pump are driven by the crankshaft, by means of sprockets and a timing belt. All three sprockets rotate in phase with each other and this provides the correct valve and injection pump timing as the engine rotates. When the timing bell is removed during servicing or repair, it is possible for the camshaft, injection pump and crankshaft to rotate independently of each other and the correct timing Is then lost.
2 It Location of TDC on cylinder No
1
6 Remove the air inlet ducting as described ft Chapter 4C, Section 2. 7 Remove the heater glow plugs with reference to Chapter 5C. Due to the high compression ratio of diesel engines this Is necessary to allow the engine to be turned by hand. 8 Unscrew the mounting bolts and move the coolant expansion tank to one side for access to the timing covers. Release the hose from the clips on Ihe camshaft cover. 9 Release the toggle clips and remove the upper timing cover (see illustration),
2.9 Removing the upper timing cover