service FIAT PUNTO 1996 176 / 1.G Workshop Manual

FIAT
PUNTO
1994 to Oct 1999 (L to V registration) Petrol & Diesel
Haynes Service and Repair Manual
expert22 fl/ia http://rutracker.org
Includes Roadside Repairs and MOT Test Checks

Fiat Punto
Service and Repair Manual
A K Legg LAEMIMI and Spencer Drayton
Models covered P251 •272 • WAC2>
Fiat Punto Hatchback, including Selecta and special/limited editions Petrol engines: 1.1 litre (1108 cc) and 1,2 litre (1242 cc, 8-valve and 16-valve) Diesel & turbo-dlesel engines: 1.7 litre (1698 cc)
Does NOT cover 1.4 litre (1372 cc) or 1.6 litre (1581 cc) petrol engines, or Cabriolet
©Haynos Publishing 1999 KLWH A book in the Haynes Service end Ropalr Manual Series
All rights reserved. No part of this book may bo reproduced or transmitted in any form or by any means, electronic or mechanical, Including photocopying, recording or by any information storage or retrieval system, without permission In writing from the copyright hokJer.
ISBN 1 85960 561 3
British Library Cataloguing tn Publication Data A catalogue record for this book Is available from the British Ubrary.
Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil, Somerset BA22 7JJ
Haynes Publishing
Sparkford. Nr Yeovil. Somerset BA22 7JJ, England
Haynes North America, Inc
681 Lawrence Drive, Newbury Park. Califomio 91320. USA
Editions Haynes S.A. Tour Aurora - La
D6 2,18 Place des Reflets, 92975 PARIS LA 0EFENSE Cedex Francs Haynes Publishing Nordfska AB Box 1504, 761 45 UPPSALA, Sverga
expert22 fl/i* http://rutracker.org

Roadside repairs 0.9
Puddles on the garage floor or drive, or obvious wetness under the bonnet or underneath the car, suggest a leak that needs Investigating. It can sometimes be difficult to decide where the leak is coming from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the problem lies.
A
Warning: Most automotive oils and fluids aro poisonous. Wash them off skin, and change out of contaminated clothing, without delay.
Identifying leaks
The smell of 0 fluid leaking from the car may provide a clue to what's leaking. Some fluids are distinctively coloured. It may help to clean the car carefully and to park It over some clean paper overnight as an aid to locating the source of the leak. Remember that some leaks may only occur while the engine is running.
Sump oil
Engine oil may leak from the drain plug...
Antifreeze
Leaking antifreeze often leaves a crystalline oeposit like this.
Oil from filter
A leak occurring at a wheel Is almost certainly brake fluid.
Gearbox oil
Gearbox oil can leak from the seals at the inboard ends of the drivoshafts.
Power steering fluid
Power steering fluid may leak from the pipe connectors on the steering rack.
When ail else falls, you may llnd yourself having to get a tow home - or of course you may be helping somebody else. Long-distance recovery should only be done by a garage or breakdown service. For shorter distances. OIY towing using another car is easy enough, but observe the following points: • Use a proper tow-rope - they are not expensive. The vehicle being towed must display an ON TOW sign in its rear window. • Always turn the Ignition key to the ON position when the vehicle is being towed, so that the steering lock is released, and that the direction indicator and brake lights will work. • Only attach the tow-rope to the towing eyes provided.
• Before being towed, release the handbrake and select neutral on the transmission. • Note that greater-then-usual pedal pressure will be required to operate the brakes, since the vacuum servo unit is only operational with the engine running. • On models with power steering, greater-than-usual steering effort will also be required. • The driver of the car being towed must keep the tow-rope taut at all times to avoid snatching. • Make sure that both drivers know the route before setting off. • Only dnve at moderate speeds and keep the distance towed to a minimum. Drive smoothly and allow plenty of time for slowing down at junctions.
Towing
• On models with automatic transmission, special precautions apply(see Chapter 7B. Section 1). If In doubt, do not tow, or transmission damage may result. • The front towing eye is supplied as part of the tool kit stored in the luggage compart-ment. To fit the eye pnse out the plastic cover from the front or rear bumper using a screwdriver, then screw the eye onto the threaded pin as tightly as possible.

A


Warning: To prevent damage to the catalytic converter, e vehicle must not be push'started, or started by towing, when the engine is at operating temperature. Use jump leads (see Jump starting).

Maintenance schedule - petrol models 1A.3
The maintenance Intervals in this manual are provided with the assumption that you, not the dealer, will be carrying out the work. These axe the minimum maintenance intervals recommended by us for vehicles driven daily.
if you wish to keep your vehicle in peak condition at all times, you may wish to perform some of these procedures more often. We encourage frequent maintenance, because it enhances the efficiency.
performance and resale value of your vehicle. When the vehicle Is new, it should be serviced by a factory-authorised dealer service department, In order to preserve the factory warranty.
Every 250 miles (400 km) or weekly Q Refer to Weekly checks
Every 5000 miles (7500 km) or
6 months - whichever comes first • Renew the engine oil and filter (Section 3)
Note: Frequent oil and fitter changes am good tor the engine. We recommend changing the oil at the mileage specified here, or at least
twice
a year if the mileage covered Is a less.
Every 10 000 miles (15 000 km) or
12 months - whichever comes first
In
addition to the items listed above, cany out the following: Q Check the operation of the brake warning lamp (Section 4) • Check the front brake pads for wear (Section 5) • Check the underbody and sealant for damage (Section 6) • Hose and fluid leak check (Section 7) • Check the condition of the exhaust system and its mountings (Section 8) • Check the condition of the driveshaft gaiters (Section 9) • Renew pollen filter (Section 10) • Check exhaust gas content and idle speed (Section 11) • Check the steering and suspension components for condition and security (Section 12)
Every 20 000 miles (30 000 km) or
2 years - whichever comes first
In
addition to the Items listed above, carry out the following: • Check and if necessary adjust the tension of the auxiliary drlvebelt(s) (Section 13) • Check the freeplay and height of the clutch pedal (Section 14) • Check and if necessary adjust the valve clearances (Section 15) HI Check and if necessary tighten inlet and exhaust manifold mountings (Section 16) • Renew the fuel filter (Section 17) D Renew the air filter element (Section 18) O Renew the spark plugs (Section 19) • Check the condition of the HT cables (Section 20) • Check the engine management system (Section 21) Q Lubricate all hinges and locks (Section 22) O Check the headlight beam adjustment (Section 23) • Carry out a road test (Section 24)
Every 30 000 miles (45 000 km) or
3 years - whichever comes first In addition to the items listed above, cany out the following: • Check the operation of the Lambda sensor (Section 25) • Check and if necessary top-up the manual transmission oil level (Section 26) • Check the operation of the evaporative loss system (Section 27) • Automatic transmission inner filter and fluid renewal (Section 28)
Every 40 000 miles (60 000 km) or
4 years - whichever comes first In addition to the items fisted above, carry out the following: • Check the rear brake shoes for wear (Section 29) • Renew the timing belt (Section 30)"
*Noto: Although the normal interval for timing belt renewal is 70 000 miles (105 000 km), It is strongly recommended that the belt Is renewed at 40 000 miles (60 000 km) on vehicles which are subjected to Intensive use, ie. malniy short Journeys or a let of stop-start driving. The actual belt renewal Interval Is therefore very much up to the individual owner, but bear in mind that severe engine damage will result if the belt breaks.
Every 60 000 miles (90 000 km) or
6 years - whichever comes first in addition to the items listed above, cany out the following: • Check the condition and operation of the crankcase emission control system (Section 31)
Every 80 000 miles (120 000 km) • Renew the manual transmission oil (Section 32)
Every 2 years
(regardless of mileage) • Renew the engine coolant (Section 33) • Renew the brake fluid (Section 34)

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 1A.13
20 Ignition system check
81
21 Engine management system check

A


Warning: Voltages produced by an electronic ignition system are considerably higher than those produced by conventional ignition systems. Extreme care must be taken when working on the system with the Ignition switched on. Persons with surgically-Implanted cardiac pacemaker devices should keep well clear of the ignition circuits, components and test oquipment. 1 The ignition system components should be checked for damage or deterioration as follows.
General component check 2 The spark plug (HT) leads should be checked whenever new spark plugs are fitted. 3 Pull the leads from the plugs by gripping
the end
fitting, not the lead, otherwise the lead connection may be fractured.
Ensure that the leads are i numbered before removing i them, to avoid confusion when refitting
4 Check Inside the end fitting for signs of corrosion, which will look like a white crusty powder. Push the end fitting back onto the spark plug, ensuring that it is a tight fit on the plug. if not, remove the lead again and use pliers to carefully crimp the metal connector inside the end fitting until it fits securely on the
end
of the spark plug. 5 Using a clean rag, wipe Ihe emlre length of the lead to remove any built-up dirt and grease. Once the lead is clean, check for bums, cracks and other damage. Do not bend the lead excessively, nor pull the lead lengthways - the conductor inside might break. 6 Disconnect the other end of the lead from the ignition coll. Again, pull only on the end fitting. Check for corrosion and a tight fit in the
same
manner as the spark plug end. Refit the bad securely on completion. 7 Check the remaining leads one at a time, in
ihe same
way. 8 if new spark plug (HT) leads are required, purchase a set for your specific car and engine. 9 Even with the ignition system In first-class condition, some engines may still occasionally experience poor starting attributable to damp ignition components. To disperse moisture, a water-dispersant aerosol should be liberally
Ignition timing -
check
and adjustment 10 Check the ignition timing as described In Chapter 58.
1 This check is part of the manufacturer's maintenance schedule, and Involves testing Ihe engine management system using special dedicated test equipment. Such testing will allow the test equipment to read any fault codes stored in the electronic control unit memory. 2 Unless a fault is suspected, this test te not essential, although it should be noted that it is recommended by the manufacturers. 3 If access to suitable test equipment is not possible, make a thorough check of all ignition, fuel and emission control system components, hoses, and wiring, for security and obvious signs of damage. Further details of the fuet system, emission control system and ignition system can be .found In the relevant parts of Chapters 4 and 5.
22 Hinge and lock lubrication %
1
1 Lubricate the hinges of the bonnet, doors and tailgate with a light general-purpose oil. Similarly, lubricate ail latches, locks and lock strikers. At the same time, check the security and operation of all the locks, adjusting them If necessary (see Chapter 11). 2 Lightly lubricate the bonnet release mechanism and cable with a suitable grease.
23 Headlight beam adjustment % & ^
1 Accurate adjustment of the headlight beam is only possible using optical beem-setting equipment, and this work should therefore be carried out by a Fiat dealer or service station with the necessary facilities. In an emergency, however, the following procedure will provide an acceptable light pattern. 2 Position the car on a level surface with tyres correctly inflated, approximately 10 metres in front of. and at right-angles to, a wall or garage door, 3 Draw a horizontal line on the wall or door at headlamp centre height. Draw a vertical line corresponding to the centre line of the car, then measure off a point either side of this, on the horizontal line, corresponding with the headlamp centres. 4 Switch on the main beam and check that the areas of maximum illumination coincide with the headlamp centre marfcs on Ihe wall, if not. turn the adjustment screw located on the upper inside edge of the headlight unit to adjust the beam laterally, and the adjustment screw located on the upper outside edge of the headlight unit to adjust the beam
vertically. On models with electric headlight adjustment, make sure that it is set at its basic setting before making the adjustment.
24 Road test
Instruments and electrical equipment 1 Check the operation of all Instruments and electrical equipment. 2 Make sure that all instruments read correctly, and switch on all electrical equipment in turn, to check that it functions properly.
Steering and suspension 3 Check for any abnormalities in the steering, suspension, handling or road feel. 4 Drive the vehicle, and check that there are no unusual vibrations or noises. 5 Check that the steering feels positive, with no excessive sloppiness, or roughness, and check for any suspension noises when cornering and driving over bumps.
Drivetrain 6 Check the performance of the engine, clutch (where applicable), transmission and driveshafts. 7 Listen for any unusual noises from the engine, clutch and gearbox/transmission. 8 Make sure that the engine runs smoothly when Idling, and that there Is no hesitation when accelerating. 9 Check that, where applicable, the clutch action Is smooth and progressive, that the drive is taken up smoothly, and that the pedal travel is not excessive. Also listen for any noises when the clutch pedal is depressed. 10 On manual gearbox models, check that all gears can be engaged smoothly without noise, and that the gear lever action is not abnormally vsgue or notchy. 11 On automatic transmission models, check that all Ihe gear positions can be selected with the vehicle at rest, if any problems are found, they should be referred to a Flat dealer. 12 Listen for a metallic clicking sound from the front of the vehicle, as the vehicle is driven slowly in a circle with the steering on full-lock. Carry out this check in both directions. If a clicking noise is heard, this Indicates wear in a drtveshaft joint, In which case renew the joint if necessary.
Check the braking system 13 Make sure that the vehicle does not pull to one side when braking, and that the wheels do not lock prematurely when braking hard. 14 Check that there is no vibration through the steering when braking. 15 Check that the handbrake operates correctly without excessive movement of the lever, and that It holds the vehicle stationary on a slope.

Maintenance schedule - diesel models 1B.3
The mamtenance intervals in this manual are provided with the assumption that you. reI ihe dealer, will be carrying out the work.
These
are the minimum maintenance intervals recommended by us for vehicles driven daily.
ff you wish to keep your vehicle In peak condition at all times, you may wish to perform some of these procedures more often. We encourage frequent maintenance, because it enhances the efficiency.
performance and resale value of your vehicle. When the vehicle Is new, it should be serviced by a factory-authorised dealer service department, in order to preserve the factory warranty.
Every 250 miles (400 km) or weekly O Refer to Weekly checks
Every 5000 miles (7500 km) or

6
months - whichever comes first • Renew the engine oil and filter (Section 3) P Drain any water from the fuel filter (Section 4)
Every 10 000 miles (15 000 km) or

12
months - whichever comes first ill addition lo tho Items listed above, cany out the following; D Check the operation of the brake warning lamp J (Section 5) Check the front brake pads for wear (Section 6) :-G Check the underbody and sealant for damage j" (Section 7) n Hose and fluid leak check (Section 8) 0 Check the condition of the exhaust system and its 1 mountings (Section 9) -D Check the condition of the driveshaft gaiters ", (Section 10) O Check and adjust the idle speed (Section 11) ;0 Renew (he fuel filter (Section 12) J] Renew the air filter element (Section 13) L) Renew the pollen filter (Section 14) •• Check the steering and suspension components • for condition and security (Section 15)
Every 20 000 miles (30 000 km) or

2
years - whichever comes first In addition to the Items listed above, cany out the following: (P Check and if necessary adjust the tension of the auxiliary drlvebeltfs) (Section 16) '• Check the freeplay and height of the clutch pedal " (Section 17) D Check and if necessary adjust the valve clearances (Section 18) Lubricate all hinges and locks (Section 19) • Check the headlight beam adjustment (Section 20) O Cany out a road test (Section 21)
Every 30 000 miles (45 000 km) or
3 years - whichever comes first In addition to the Items listed above, cany out the following: • Check and if necessary top-up the manual transmission oil level (Section 22)
Every 40 000 miles (60 000 km) or
4 years - whichever comes first In addition to the items listed above, cany out the following: • Check the rear brake shoes for wear (Section 23) • Renew the timing belt (Section 24)'
•Note: Although the normal interval for timing belt renewal is 70 000 miles (ids 000 km), it is strongly recommended that the belt Is renewed at 40 000 miles (60 000 km) on vehicles which are subjected to intensive use, le. mainly short Journeys or a lot of stop-start driving. The actual bait renewal interval Is therefore very much up to the Individual owner, but bear in mind that sevefe engine damage will result if the belt breaks.
Every 60 000 miles (90 000 km) or
6 years - whichever comes first In addition to the Items listed above, cany out the following: • Check the condition and operation of the emission control system components (Section 25)
Every 80 000 miles (120 000 km) • Renew the manual transmission oil (Section 26)
Every 2 years
(regardless of mileage) • Renew the engine coolant (Section 27) • Renew the brake fluid (Section 28)

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 20 000 miles - diesel models ib.h
18
Valve clearance check and
adjustment
1 The Importance of having the valve clearances correctly adjusted cannot be Distressed, as they vitally affect the performance of the engine. Adjustment should only be necessary when the valve gear nas become noisy, after engine overhaul, or when trying to trace the cause of power loss. The clearances are checked as follows. The engine must be cold for the check to be ttcurate. 2 Apply the handbrake then jack up the right-hand front of the vehicle and support on an axle stand (see Jacking and vehicle support). Engage 4th gear. The engine can now be rotated by turning the right-hand front roadwfteei. 3 Remove ail four glove plugs as described In Chapter 5C. 4 Remove the air cleaner cover and air duct
then
remove the camshaft cover as described
in
Chapter 2C. 6 Each valve clearance must be checked wnen the high point of the cam is pointing directly upward away from the cam follower. 6 Check the clearances in the firing order 1-3-4-2, No 1 cylinder being at the timing belt end of the engine. This will minimise the amount of crankshaft rotation required. 7 Insert the appropriate feeler blade between
the heel
of the cam and the cam follower shim of the First valve (see Illustration). If necessary alter the thickness of the feeler blade until it is a stiff, sliding fit. Record the thickness, which will, of course, represent the
vafve
clearance tor Ihis particular valve. 8 Turn the engine, check the second valve devance and record it. t Repeat the operations on all the remaining valves. recording their respective clearances. 10 Remember that the clearance for inlet and exhaust valves differs - see Specifications. Counting from the timing cover end of the
engine,
the valve sequence is: Wef 2-4-5-7 Etfiat/sf 7-3-6-8
11 Where clearances are incorrect the particular shim will have to be changed. To remove the shim, turn the crankshaft until the high point of the cam is pointing directly upward. The cam follower will now have to bo depressed so that the shim can be extracted. Special tools are available from your Fiat dealer to do the job. otherwise you will have to make up a forked lever to locate on the rim of ihe cam follower. This must allow room for the shim to be prised out by means of the cut-outs provided in the cam follower rim (see illustration). 12 Once Ihe shim is extracted, establish Its thickness and change it for a thicker or thinner one to bring the previously recorded clear-ance 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 ihem; 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). 14 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 lor easier removal of the shims. 16 Where no clearance can be measured, even with the Ihinnest 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 glosvplugs. 18 Lower the vehicle to the ground.
19 Hinge and lock lubrication
I
1 Lubricate the hinges of the bonnet, doors and tailgate with a light general-purpose oil. Similarly, lubricate all latches, locks and lock stnkers. At the same time, check the security and operation of all the locks, adjusting them if necessary (see Chapter 11). 2 Lightly lubricate the bonnet release mechanism and cable with a suitable grease.
20 Headlight beam adjustment
I
1 Accurate adjustment of the headlight beam Is only possible using optical beam-setting equipment, and this work should therefore be carried out by a Fiat dealer or service station with the necessary facilities. In an emergency, however, the following procedure will provide an acceptable light pattern. 2 Position the car on a level surface with tyres correctly inflated, approximately 10 metres in front of, and at right-angles to, a wall or garage door. 3 Draw a horizontal tine on the wall or door at headlamp centre height. Draw a vertical line corresponding to the centre line of the car. then measure off a point either side of this, on the horizontal line, corresponding with the headlamp centres. 4 Switch on the main beam and check that the areas of maximum Illumination coincide with the headlamp centre marks on the wall. If not, turn the adjustment screw located on the upper Inside edge of the headlight unit to adjust the beam laterally, and the adjustment screw located on the upper outside edge of the headlight unit to adjust the beam vertically. On models with electric headlight adjustment, make sure that it Is set at its basic setting before making the adjustment,

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