fuel filter location FIAT PUNTO 1996 176 / 1.G Workshop Manual

ia«6 Component location - petrol models
Rear underbody view (diesel model shown, petrol model similar)
1 Fuel
tank
2
Exhaust
tailpipe
and
silencer 3
Rear axle
4 Coll
springs
5
Rear
anti-mil
bar
6
Handbrake cables
T
Rear brake pressure
regulating
valve
S
Rear
shock absorber lower mountings
Maintenance procedures
1 Introduction
This Chapter is designed to help the home mechanic maintain his/her vehicle (or safety, eoonomy, long life and peak performance. The Chapter contains a master maintenance schedule, and Sections dealing specifically with each task in the schedule. Visual checks. ad}ustments, component renewal and other helpful Items are included. Refer to the accompanying Illustrations of the engine compartment and tho underside of the vehicle for the locations of the various components. Servicing your vehicle in accordance with ihe mlleaget/time maintenance schedule and the following Sections will provide a planned maintenance programme, which should result m a long and reliable service life. This Is a comprehensive plan, so maintaining some Items but not others at the specified service Intervals, will not produce the same results. As you service your vehicle, you will discover that many of the procedures can, and should, be grouped together, because of the particular procedure being performed, or because of the proximity of two otherwise-unrelated components to one another. For example, if the vehicle Is raised for any reason, the exhaust can be inspected at the same time as the suspension and steering components. The first step in this maintenance programme is to prepare yoursell before tne
actual work begins. Read through all the Sections relevant to the work to be carried out, then make a list and gather all the parts and tools required. If a problem is encountered, seek advice from a parts specialist, or a dealer service department.
2 Regular maintenance
1 If. from the time the vehicle is new, the routine maintenance schedule is followed closely, and frequent checks are made of fluid levels and high-wear items, as suggested throughout this manual, the engine will be kept in relatively good running condition, and the need for additional work will be minimised. 2 II is possible that there will be times when the engine rs running poorly due to the lack of regular maintenance. This is even more likely If a used vehicle, which has not received regular and frequent maintenance checks, is purchased. In such cases, additional work may need to be carried out. outside of the regular maintenance intervals. 3 If engine wear is suspected, a compression test (refer to the relevant Part of Chapter 2) will provide valuable information regarding the overall performance of the main internal components. Such a test can be used as a basis to decide on the extent of the work to bo carried out. II, for example, a compression test indicates serious internal engine wear, conventional maintenance as described in this
Chapter will not greatly improve the performance of the engine, and may prove a waste of time and money, unless extensive overhaul work is carried out first. 4 The following series of operations are those usually required to improve the performance of a generally poor-running engine:
Primary operations a) Cloan, inspect and test the battery
(See
Weekly checks), b) Check alt the engine-related fluids (See Weekly checks). c) Check the condition and tension of the auxiliary drivebeft($) (Section 13). d) Renew the spark plugs (Section 19). e) Inspect the ignition HT leads (Section 20). 0 Check the condition of the air filter, and renew if necessary (Section 18). g) Check the fuel filter (Section 17). h) Check tho condition of ell hoses, and check for fluid leaks (Sect/on 7). i) Check theexhaust
gas emissions (Section 11).
5 If the above operations do not prove fully effective, carry out the following secondary operations;
Secondary operations All items listed under Primary operations, plus the following; e) Check the charging system (Chapter 5K Section 4). b) Check the ignition system (Chapter 58). c) Check tho fuel system (see relevant Part of Chapter
4).
d) Renew the ignition HT leads (Section 20)

Every 20 000 miles - petrol models ia-h
clearance within specification. For example, if the measured valve clearance was 1.27 mm too great, a shim thicker by this amount will be required. Conversely, if the clearance was 1.27 mm too small, a shim thinner by this amount will be required. 13 Shims have their thickness (mm) engraved on them; although the engraved side should be fitted so as not to be visible, wear still occurs and often obliterates the number. In this case, measuring their thickness with a metric micrometer is the only method to establish their thickness (see illustration). t4 In practice, if several shims have to be changed, they can often be interchanged, so avoiding the necessity of having to buy more new shims than is necessary. 15 If more than two or three valve clearances are found to be incorrect, it will be more convenient to remove the camshaft for easier removal of the shims. 16 Where no clearance can be measured, even with the thinnest available shim in position, the valve will have to be removed and the end of its stem ground off squarely. This will reduce its overall length by the minimum amount to provide a clearance. This job should be entrusted to your dealer as it is important to keep the end of the valve stem square. 17 On completion, refit the camshaft cover and gasket, air cleaner and duct, and spark plugs. 18 lower the vehicle to the ground.
16 Manifold mounting check
Refer
1O
Chapters 4A. 48 and 4D and check tne tightness of the nuts and bolts securing the inlet and exhaust manifolds.
17
Fuel
filter renewal I I
Warning: Before carrying out the !\ f°llow'n9 operation, refer to the precautions given In Safety firstI A
15.13 Shim thickness is marked on the tower face (here 4.20 mm) at the beginning of this manual, and follow them Implicitly. Petrol Is a highly-dangerous and volatile liquid, and the precautions necessary when handling it cannot be overstressed. Note: 1242 cc (8-vatve) engine mode's from 1998 onwards are equipped with a modified fuel system incorporating a fuel fitter integral with the fuel pump. On these engines fuel filter renewal is not required. 1 The fuel filter is situated underneath the rear of the vehicle, on the right-hand side of the fuel tank (see illustration). To gain access to the filter, chock the front wheels, then jack up the rear of the vehicle and support it on axle stands (see Jacking and vehicle support). 2 Unscrew the bolt securing the filter to its support bracket. 3 Noting the fitted position of the filter body, release the retaining clips and disconnect the fuel hoses from the filter. The correct position is indicated by an arrow marked on ihe filter body 4 Remove the filter from the vehicle. Dispose safely of the old filter; it will be highly flammable, and may explode if thrown on a fire. 5 Locate the new filter into position, ensuring that the arrow on the filter body is pointing in the direction of the fuel flow, as noted when removing the old filter. The flow direction can otherwise be determined by tracing the fuel hoses back along their length. 6 Connect the fuel hoses to the filter and lighten the clips, then locate it in the support bracket and tighten the mounting bolt.
17.1 Fuel filter location on tho right-hand side of the fuel tank 7 Start the engine, check the filter hose connections for leaks, then lower the vehicle to the ground.
18 Air fitter renewal
I
f f 08 cc and 1242 cc (8-valve) engines 1 Prise open the spring clips and withdraw the air cleaner cover a little way from the main body (see illustration). Leave the cover attached to the hot air tube and inlet duct. 2 Lift out the filter element (see illustration). 3 Remove any debris that may have collected inside the air cleaner and wipe the inner surfaces clean. 4 Fit a new air filter element In position, ensuring that the edges are securely seated. 5 Refit the air cleaner top cover and snap the retaining clips into position.
1242 cc (16-valve) engines 6 Undo the three bolts securing the front of Ihe air cleaner cover to the main body. Lift the cover up at the front, disconnect the rear retainers and move it clear of the main body {see illustration). Leave the cover attached to the hot air tube and inlet duct. 7 Lift out the filter element (see illustration). 8 Remove any debris that may have collected inside the air cleaner and wipe the inner surfaces clean.
18.1 Prise open the spring clips... . and remove the filter element (8-valve engines)
18.6 Undo the three bolts (arrowed) and disconnect the air cleaner cover rear retainers (16-vatve engines)

ia.14 Every 20 000 miles - petrol models
16 Test the operation of the brake servo unit as follows. With the engine off, depress the footbrake four or five times to exhaust the vacuum. Hold the brake pedal depressed, then start the engine. As the engine starts.
there should be a noticeable give In the brake pedal as vacuum builds up. Allow the engine to run for at least tsvo minutes, and then switch it off. If the brake pedal is depressed now. it should be possible to detect a hiss
from the servo as the pedal is depressed. After about four or five applications, no further hissing should be heard, and the pedal shouto feel considerably harder.
Every 30 000 miles (45 000 km) or 3 years
. transmission (see illustration). Using an Allen 25 Lambda/oxygen sensor ^ key, unscrew the plug and clean it. check \ 3 The oil level should reach the lower edge of ^ the filler/level hole. A certain amount of oil will have gathered behind the filler/level plug, and If the CO level at the exhaust tailpipe is too w,u tr,cWe out when is 'e™oved; this does high or low, Ihe vehicle should be taken to a «©l necessarily Indicate that the level is Fiat dealer so lhat the complete fuel-injection correct. To ensure that a true level is and ignition systems, including the Lamoda/ established, wait until the Initial trickle has oxygen sensor, can be thoroughly checked stopped, then ado oil as necessary until a using the special diagnostic equipment. Once ,r,ckle o1 new oil can be seen emerging. The these have been checked and are known to 'W wl" be correct when ,he flow ceases-us® be free from faults, the fault must be in the good-quality oil of the specified type, catalytic converter, which must be renewed Make sur®that vehicle Is completely level as described In Chapter 4D, Section 6. checking the level and do not overfill, 4 When the level Is correct refit and tighten the plug and wipe away any spilt oil.
26 Manual transmission oil level check ^ 27 Evaporative loss system ^ check
1 Park Ihe vehicle on a level surface, If possible over an inspection pit or on a ramp as the filler/level plug is best reached from under Ihe engine compartment. The oil level must be checked before the car is driven, or at least 5 minutes after the engine has been switched off. If the oil ts checked Immediately alter driving the car, some of the oil will remain distributed around the transmission components, resulting in an inaccurate level reading. 2 Wipe clean the area around the filler/level plug, which is situated on the front of the
Refer to Chapter 40 Section 2 and check that all wiring and hoses are correctly connected to the evaporative toss system components.
28 Automatic transmission fitter and fluid change
1 Take the vehicle on a short run. to warm the transmission up to operating temperature.
Park the car on level ground, then switch off the Ignition. 2 Firmly apply the handbrake, then jack up the front of the car and support It securely on axle stands (see Jacking and vehicle support]. Note thai, when refilling and checking Uie fluid level, the car must be lowered to the ground, and level, to ensure accuracy. 3 Remove the dipstick, then position a suitable container under the transmission, Unscrew the sump drain plug and allow the fluid to drain for at ieast 10 minutes. Refit and tighten the drain plug when the fluid has completely drained.

A


Warning: The transmission fluid may be very hot and precautions must be taken to avoid scalding.
4 Clean around the transmission sump mating flange. Unboll and remove the sump and remove the gasket. 5 Remove the two bolts and withdraw the transmission fluid filter {see illustration). 6 Fit the new filter, and secure It with the two bolts. 7 Refit the sump using a new gasket, then
_
lower the vehicle to the ground, 8 Fill the transmission with the specified quantity of fluid via Ihe dipstick tube, using a funnel with a fine mesh filter. 9 Run the engine to normal operating temperature, then check the fluid level as described In Weekly checks. 10 Dispose of the old fluid safely.
26.2 Transmission filler/level plug location 28.5 Automatic transmission fluid filter retaining bolts

ib-4 Component location - diesel models
Underbonnet view - turbo diesel model
1 Engine oil filter
cap
2 Engine oil dipstick 3 Oil
tilter
4 Brake/clutch fluid
reservoir
5 Air cleaner
cover
6 Power steering pump 7 Coolant expansion
tank
8 Windscreen washer
fluid
reservoir 9 Front suspension strut upper mounting 10 Fuel filter/heater
housing
11
Fuel
injection pump 12 Battery 13 Power steering fluid reservoir
Front underbody view - turbo diesel model
1 Oil
fitter
2 Sump drain plug 3 Transmission drain plug 4 Electric cooling fan unit 5 Left-hand
driveshaft
6 Intermediate
shaft
7 Bight-hand
driveshaft
8 Front suspension lower arms 9 Front anti-roll
bar
10 Exhaust downpipe 11 Front brake calipers 12
Rear
engine mounting 13 Radiator bottom hose
expert22 fl/ia http://rutracker.org

Component location - diesel models ib-s
Rear underbody view - turbo diesel model
1
Fuel tank
2
Exhaust
tailpipe
and
silencer 3 Fear axle 4 Coil springs 5
Rear anti-roll bar
€
Handbrake cables
7
Rear brake pressure regulating valve
8
Rear shock
absorber
lower
mountings
Maintenance procedures
1 Introduction
This Chapter Is designed to help the home mechanic maintain his/her vehicle for safety, economy, long life and peak performance. The Chapter contains a master maintenance schedule, and Sections dealing specifically with each task in the schedule. Visual checks, adjustments, component renewal and other helpful items are included. Refer to the accompanying illustrations of the engine compartment and the underside of the vohicle for the locations of the various components. Servicing your vehicle in accordance with ihe mileage/time maintenance schedule and the following Sections will provide a planned maintenance programme, which should result in a long and reliable service life. This is a comprehensive plan, so maintaining some items but not others at the specified service internals, will not produce the same results. As you service your vehicle, you will ctecover that many of the procedures can. and should, be grouped together, because of the particular procedure being performed, or because of the proximity of two otherwise-unrelated components to one another. For example, if the vehicle is raised for any reason, the exhaust can be inspected at the same time as the suspension and steering components. The first step in this maintenance programme is to prepare yoursetf before the
actual work begins. Read through all the Sections relevant to the work to be carried out. then make a list and gather all the parts and tools required. If a problem is encountered, seek advice from a parts specialist, or a dealer service department.
2 Regular maintenance
1 If, from the time Ihe vehicle is new, the routine maintenance schedule is followed closely, and frequent checks are made of fluid levels and high-wear Items, as suggested throughout this manual, the engine wifl be kept in relatively good running condition, and the need for additional work will be minimised. 2 It is possible that there will be times when the engine is running poorly due to the lack of regular maintenance. This is even more likely if a used vehicle, which has not received regular and frequent maintenance checks, is purchased, in such cases, additions! work may need to be carried out, outside of the regular maintenance intervals. 3 If engine wear is suspected, a compression test {refer to Chapter 2C} will provide valuable information regarding the overall performance of the main internal components. Such a test can be used as a basis to decide on the extent of the work to be carried out. If, for example, a compression test indicates serious Internal engine wear, conventional maintenance as
described in this Chapter will not greatly improve the performance of the engine, and may prove a wa3te of time and money, unless extensive overhaul work Is carried out first. 4 The following series of operations are those usually required to Improve the performance of a generally poor-running engine:
Primary operations a,I Clean, Inspect and test the battery (See Weekly checks). b) Check all the engine-related fluids (See Weekly checks). c) Drain the water from the fuel filter (Section 4) d) Check the condition and tension of the auxiliary dnvebeft(s) (Section 16). e) Check the condition of the air fitter, and renew if necessary (Section 13). f) Check the condition of all hoses, and check for fluid leaks (Section 8). g) Check the engine idle speed setting {Section 11). h) Check the exhaust gas emissions (Section 25). 5 If the above operations do not prove fully effective, carry out the following secondary operations:
Secondary operations All items listed under Pnmary operations, plus the following: a) Check the charging system (Chapter 5A, Section 4). b) Renew the fuel filter (Section 12) and check the fuel system (see Chapter 4Q.

Every 10 000 miles - diesel models ib«9
4 Completely unscrew the filter and pour the remaining contents into the container. Ensure (hat the rubber sealing ring comes away with
me
fitter and unscrew the drain screw from the
bottom
of tho filter (see illustrations). 5 Wipe clean the contact surfaces then smear
a
ittfe fuel on the sealing rubber of the new Nter. 6 Screw on the new filter fully using the hands orty. 7 Prime the fuel system and start the engine wth reference to Chapter 4C. Check for any signs of fuel leakage around the new filter.
13 Air fitter renewal
t Release the retaining clips and withdraw
Ihe
air cleaner cover a little way from the main body. Leave the cover attached to the inlet duct. 2 Lift out the filter element (see illustration). 3 Remove any debris that may have collected Inside the air cleaner and wipe the Inner surfaces clean. 4 Fit a new air filter element in position, ensuring that the edges are securely seated. 6 Refit the air cleaner top cover and snap the retaining clips into position.
14 Pollen filter renewal
t
1 The pollen filter (where fitted) Is located under the engine bulkhead cover pane). 2 Refer to Chapter 12 and remove both windscreen wiper arms. 3 Undp tho rubber seal from the relevant end of
the top
of the engine compartment bulkhead. 4 Unscrew the retaining fastener screws and Duiout the fasteners securing the bulkhead eovar panel in position. Release the cover panel from the base of the windscreen and remove it from the vehicle. 5 Pivot the pollen filter cover upwards and away then release the retaining clips and withdraw the filter from Its housing (see lustration).
12.3 Using an olt filter strap to loosen the fuel filter 6 Wipe clean the filter housing then fit the new filter, Clip the filter securely In position and refit the cover. 7 Refit the trim cover, secunng it >n position with the fasteners, and seat Ihe rubber seal on the bulkhead.
12.4a Removing the fuel filter
15 Steering and §S> suspension check ^
Front suspension and steering check 1 Raise the front of the vehicle, and securely support it on axle stands (see Jacking and vehicle support). 2 Visually Inspect the balljoint dust covers and the steering rack-and-pinion gaiters for splits, chafing or deterioration. Any wear of Ihese components will cause loss of lubricant, together with dirt and water entry, resulting in rapid deterioration of the balljoints or steering gear. 3 On vehicles with power steering, check the fluid hoses for chafing or deterioration, and the pipe and hose unions for fluid leaks. Also check for signs of fluid leakage under pressure from the steering gear rubber gaiters, which would indicate failed fluid seals within the steenng gear. 4 Grasp the roadwheel at the 12 o'clock and 6 o'clock positions, and try to rock it (see illustration). Very slight free play may be felt, but if the movement is appreciable, further investigation is necessary to determine the
fplllll iHpjiiisisps fa^aJw a LJgr >
H58B92
12.4b Showing the drain screw components on the bottom of the fuel filter source. Continue rocking the wheel while an assistant depresses the footbrake. If the movement Is now eliminated or significantly reduced, it is likely that the hub bearings are at fault. If the free ptay is still evident with the footbrake depressed, then there Is wear In the suspension joints or mountings. 5 Now grasp the wheel at the 9 o'clock and 3 o'clock positions, and try to rock it as before. Any movement felt now may again be caused by wear in the hub bearings or the steering track-rod balljoints. If the inner or outer balljoint Is worn, the visual movemont will be obvious. 6 Using a large screwdriver or flat bar. check for wear in the suspension mounting bushes by levering between the relevant suspension component and its attachment point. Some movement is to be expected as the mountings are made of rubber, but excessive wear should be obvious. Also check the condition of any visible rubber bushes, looking for splits, cracks or contamination of the rubber.
13.2 Removing the air filter element 14.5 Location of pollen filter 15.4 Rocking a roadwheel to check for wear in the steering/suspension components

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