glove box FIAT PUNTO 1997 176 / 1.G Workshop Manual

3*2 Cooling, heating and ventilation systems
Heater matrix Removal 10 Remove the complete heater assembly as described previously in this Section. 11 Slacken and remove the securing screws, then withdraw the heater matrix from the tester assembly casing. Refitting 12 Refitting is a reversal of removal; refit Ihe neater assembly as described previously in
this
Section.
Heater blower motor
Removal 13 Disconnect the battery negative terminal {refer to Disconnecting the battery in the Reference Section of this manual). 14 Unplug the wiring from the blower motor
al the
connector. 15 Working in the passenger front footwell, under the glovebox. remove the securing grows and lower the blower motor and rotor assembly from Its casing (see illustration). Refitting
16 Refitting is a reversal of removal.
Heater blower motor resistor
Removal 17 The resistor is located at the bottom of the heater casing, behind the blower motor. 18 Disconnect the battery negative terminal (refer to O/sconnecf/ng the battery in the Reference Section of this manual). 19 For improved access, remove the blower motor as described in the previous sub-Section. 20 Disconnect the wiring plug from the resistor. 21 Working under the glovebox. remove the two securing screws, and withdraw the resistor from the blower unit case (see lustrations).
8.15 Removo the securing screws and lower the blower motor and rotor assembly from its casing Refitting 22 Refining Is a reversal of removal.
Heater control panel
Removal 23 Pull the ventilation fan speed control knob from the panel. 24 Unscrew and remove the three screws securing the panel cover. Two screws are under the lower edge of the panel, whilst Ihe remaining screw is located in the ventilation fan speed control knob recess. Remove the panel. 25 Unscrew and remove the four screws securing the control panel to the facia. The screws are located in each comer of the panel. 26 Remove the facia as described in Chap-ter 11. 27 Make a careful note of the cable and electrical connections. Unscrew the cable clamps and unclip the inner cables from the controls. Unplug the ventilation fan speed control. 28 Unclip and remove the control panel from the heater distributor box assembly. Refitting 29 Refitting is a reversal of removal.
9 Air conditioning system -general Information and precautions
General information An air conditioning system is available on certain models. It enables the temperature of Incoming air to be lowered, and also dehumidifies the air, which allows rapid demisting and increased comfort. The cooling side of the system works In the same way as a domestic refrigerator. Refrigerant gas is drawn into a belt-driven compressor where the increase In pressure causes the refrigerant gas to turn to liquid. It then passes through a condenser mounted on the front of the radiator, where it is cooled. Tho liquid then passes through an expansion vaive to an evaporator, where it changes from liquid under high pressure to gas under low pressure. This change is accompanied by a drop in temperature, which cools the evaporator and hence the air passing over it. The refrigerant returns to the compressor, and the cycle begins again. The air bfown through the evaporator passes to the air distribution unit where it is mixed, if required, with hot air blown through the heater matrix to achieve the desired temperature in the passenger compartment. The heating side of ihe system works in the same way as on models without air conditioning (see Section 8). The system Is electronically-controlled. Any problems with the system should be referred to a Fiat dealer.
Precautions With an air conditioning system. It is necessary to observe special precautions whenever dealing with any part of the system, or its associated components. If for any reason the system must be disconnected, it Is
8.21a Remove the two securing screws (arrowed)... ,21b ... and withdraw the resistor from the blower unit case

Fuel system - diesel models 4C*3
8.5 Dial gauge (1), mounting bracket (2) and setting rod (3) In position on the injection pump (Lucas)
so that Its tip Is In contact with the bracket linkage (see Illustration). Position the dial gauge so that its plunger is at the mid-point of its travel and zero the gauge. 6 Rotate the crankshaft slowly in the correct direction of rotation (clockwise) until the crankshaft is positioned at TDC on No 1 piston with ell the sprocket timing marks aligned. 7 Check the reading on the dial gauge which should correspond to the value marked on the pump (there is a tolerance of * 0.04 mm). The timing value may be marked on a plastic disc attached to the front of the pump, or alternatively on a tag attached to Ihe pump control lever (see illustrations). 8 If adjustment is necessary, slacken the front pump mounting nuts/bolt and the raar mounting bolt, then slowly rotate tne pump body until the point is found where the specified reading is obtained on the dial gauge (access to the lower front bolt is gained through the hole in the injection pump sprocket). When the pump Is correctly positioned, tighten both its front mounting nuta/bolt and the rear bolt to their specified torque settings. 9 Withdraw the timing probe slightly, so that it
positioned clear of the pump rotor dowel. Rotato the crankshaft ihrough one and three quarter rotations in the normal direction of rotation. 10 Slide the timing probe back Into position ensuring that it Is correctly seated against the guide sealing washer surface, not (he upper Hp, then zero the dial gauge. 11 Rotate the crankshaft slowly in the correct direction ol rotation to the TDC position and recheck the timing measurement 12 If adjustment Is necessary, slacken the pump mounting nuts and bolt and repeat the operations in paragraphs 6 to 11. 13 When the pump timing is correctly set. remove the dial gauge and mounting bracket and withdraw the timing probe. 14 Refit the screw and sealing washer to the guide and tighten it securely.
8.7a Pump timing value (x) marked on plastic diso (Lucas)
15 If the procedure is being carried out as part of the pump refilling sequence, proceed as described in Section 5. 16 If the procedure is being carried out with the pump fitted to the engine, refit the injector pipes tightening their union nuts to the specified torque setting. Reconnect the battery and refit the air inlet ducting. 17 Start the engine, and check for any leakage at the fuel unions. To enable the engine to start it may be necessary to loosen tho injector union nuts while turning the engine on the starter motor in order to purge trapped air. 18 Check and If necessary adjust the Idle speed as described In Chapter 1B.
9 Fuel Injectors -testing, removal and refitting Sk ^

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Warning: Exercise extreme caution when working on the fuel injectors. Never expose the hands or any part of the body to Injector spray, as the high working pressure can cause the fuel to pen ot rate the skin, with possibly fatal results. You are strongly advised to have any work which involves testing the injectors under pressure carried out by a dealer or fuel Injection specie list.
Testing 1 Injectors do deteriorate with prolonged uso, and it is reasonable to expect them to need reconditioning or renewal after 60 000 miles
8.7b Pump timing values marked on label (1) and tag (2) (Lucas)
(100 000 km) or so. Accurate testing, overhaul and calibration of the Injectors must be left to a specialist. A defective injector which Is causing knocking or smoking can be located without dismantling as follows. 2 Run the engine at a fast idle. Slacken each Injector union In turn, placing rag around the union to catch spilt fuel, and being careful not to exposa the skin to any spray. When tho union on the defective Injector is slackened, the knocking or smoking will stop.
Removal 3 Remove ihe air Inlet ducting from tho front part of the onglne. 4 Carefully clean around the Injectors and injector pipe union nuts. 5 Pull the leak-off pipes from the injectors (see illustration). 6 Unscrow the union nuts securing Ihe injector pipes to the fuel Injection pump. Counterhold the unions on the pump when unscrewing the nuts. Cover open unions lo keep dirt out, using small plastic bags, or fingers cut from discarded (but clean!) rubber gloves. 7 Unscrew the union nuts and disconnect the pipes from the ln|ectors, If necessary, the Injector pipes may be completely removed-Note carefully the locations of the pipe clamps, for use when refitting. Cover tho onds ot (he injectors, to prevent dirt ingress. 8 Unscrew the injectors using a deep socket or box spanner, and remove Ihem from the cylinder head (see Illustration). 9 Recover the tire seal washers from the cy-linder head and discard them (see illustration).
9.5 Disconnecting the Injector leak-off pipes 9.8 Removing an injector

11 *12 Bodywork and fittings
switch panel, then remove the panel from the facia (see illustration). Label tho wiring connector to aid refitting, then unplug It. 0 Work along the lower edge of Ihe facia and remove all the securing screws; there are three on the drivers side and three on the passenger side - one is concealed inside the glove compartment, behind a plastic cap. 10 Wilh reference to Chapter 12, remove the cover and open the main fuse box. Where applicable, unscrew the fixings that secure the electronic control unit to Its mounting bracket. Remove the facia mounting bolts located adjacent to the mounting bracket (see illustration). 11 Refer to Chapter 10 and unbolt the steering column from Its support bracket, allowing the column to rest in the footwell. There is no need to slacken the clamp bolt at Ihe base of the steering column to separate it from the steering gear. 12 With reference to Chapter 12, remove front right and left speaker grilles. Remove the two facis upper mounting screws ihat are now exposed. Similarly, prise open the plastic cover from centre of upper edge of the fada and remove the mounting screw behind. 13 Carefully pull whole facia moulding forward away from tho bulkhead slightly. Label all wiring connectors to aid correct refitting later, then unplug Ihem. Check that nothing remains connected between the facia and bulkhead then draw the facia moulding away and remove It from the vehicle.
20.8 Remove the bolt (arrowed) and detach the backrest from the mounting bracket
Refitting 14 Refit the facia by following the removal procedure in reverse, noting the following points: a) Reinstate all electrical connections according to (he labels made during removal and ensure that cables are secured in their clips, using the origins/ routing. b) Ensure thai all ventilation ducting locates correctly over the rear of the grilles before tightening the facia retaining screws. c) On completion, reconnect the battery negative cable and chock the operation of all controls, gauges and Instruments disturbed during the removal process, Including the ventilation/heating system.
20 Seats -removal and refitting JS:
Front seats
Removal

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Warning: On models with seat belt pre-tonsionors, entrust the work of seat removal to a Flat dealer. DQNOTattempt to remove the seat on vehicles so equipped. 1 The front seats frames are secured to the fioorpan by four bolts. Whero applicable, prise out the caps from the plastic trim panel lo expose the bolt heads. 2 Slide the seat towards the rear of the car to gain access to the two bolts at the front, Ihen slacken and withdraw them. 3 Slide Ihe seat fully forwards and remove the two rearmost bolls. 4 Ufl the seat out of the cabin area.
(arrowed) located adjacent to the control unit mounting bracket Refitting 5 Refil the seat by reversing the remove! procedure. Rear seat back rests
Removal 6 Using the hand straps, raise the seal cushion and lilt it fully forward. 7 The rear seat back rests are mounted or hinged brackets which aro boiled to Ihe fioorpan. To remove both back rests together, first remove the screws and detach the load space carpet panel. 8 Unbolt the back rest panel from the mounting brackets (see illustration). Refitting 9 Refit tho back rests by reversing Ihe removal procedure. Rear seat cushion
Removal 10 Using the hand straps, raise the seat cushion and tilt it fully forward. 11 Remove ihe screws Ihat secure Ihe hinged brackets to tho fioorpan. then lift out the cushion (see illustration}. Refitting 12 Refit the seat cushion by reversing Ihe removal procedure.
20.11 Remove the screws (arrowed) that secure the hinged brackets to the fioorpan

Body electrical systems 12*3
3.4 The auxiliary fusebox, located inside the glovebox behind a drop-down panel auxiliary fusebox, which is located inside the glovebox behind a drop-down panel (see Illustration). 5 A blown fuse can be recognised from its melted or broken wire (see illustration). 6 To remove a fuse, first ensure that the relevant circuit is switched off. 7 Using the plastic tool clipped to the main fusebox lid, pull the fuse from its location. 8 Spare fuses are provided in the main fusebox. 9 Before renewing a blown fuse, trace and rectify the cause, and always use a fuse of the correct rating (fuse ratings are specified on the inside of the fusebox cover flap). Never substitute a fuse of a higher rating, or make temporary repairs using wire or metal foil; more serious damage, or even fire, could result. 10 Note that the fuses are colour-coded as follows. Refer to the wiring diagrams for details of the fuse ratings used and the circuits protected. Colour Rating Orange 5A Red 10A Blue 15A Yellow 20A Clear or White 25A Green 30A 11 The radio/cassette player fuse is located In the rear of the unit, and can be accessed after removing the radio/cassette player -refer to Section 12for greater detail.
Relays 12 A relay is an electncally-operated switch, which Is used for the following reasons: 4 A relay can switch a heavy current remotely from the circuit in which the current is flowing, therefore allowing the use of lighter-gauge wiring and switch contacts.
b)
A relay can receive more than one control input, unlike a mechanical switch. c) A relay can have a timer function - for example, the intermittent wiper relay. 13 The main and optional equipment relays are located in the main and auxiliary toseboxes (see Fuses). A number of additional relays may be fitted, depending on model and specification. These are generally mounted
3.5 A blown fuse can be recognised from its melted or broken wire adjacent lo the component being controlled; e.g. the radiator cooling fan relay(s) are mounted on a bracket next the cooling fan itself. 14 The direction Indicator/hazard warning flasher unit is mounted on the underside of the steering column slalk switch unit. It can be accessed by removing the steering column lower shroud panel (see illustration). 15 If a circuit or system controlled by a relay develops a fault, and the relay is suspect, operate the system. If the relay is functioning, it should be possible to hear it click as it is energised, if this is Ihe case, the fault lies with the components or wiring of the system. If the relay is not being energised, then either the relay is not receiving a main supply or a switching voltage, or the relay itself is faulty. Testing is by the substitution of a known good unit, but be careful - while some relays are identical in appearance and in operation, others look similar but perform different functions. 16 To remove a relay, first ensure that the relevant circuit is switched off. The relay can then simply be pulled out from the socket, and pushed back into position.
4 Buibs (exterior lights) -renewal
General 1 Whenever a bulb is renewed, note the following points:
3.14 Removing the direction indlcator/ha2ard warning flasher unit
a) Ensure that the relevant electrical circuit is isolated before removing a bulb. If in doubt, disconnect the battery negative lead before starting work. b) Remember that, if the circuit has just been in use, the bulb may be extremely hot. c) A/ways check the bulb contacts and holder, ensuring that there is clean metal-to-metal contact between the bulb and its live contacts) and earth. Clean off
any
corrosion or dirt before fitting a nevt bulb. d) Wherever bayonet-type bulbs are fitted, ensure that the live contacts) bear firmly against the bulb contact. e) Always ensure that the new bulb is of the correct rating (see Specifications), and that it is completely clean before fitting it; this applies particularly to headlight/foglight bulbs (see following
0 Pay attention to the orientation when fitting multi-filament bulbs (e.g. combined tail/brake light bulbs) • incorrect fitting will cause the filaments to illuminate In the wrong sequence.
Headlight 2 Open the bonnet. Ensure that the headlights are turned off at the stalk switch. Models with single reflector 3 Pull the wiring plug from the rear of the bulb (see illustration). 4 Pull the rubber boot from the rear of the headlight unit (see Illustration).
4.3 Pull the wiring plug from the rear of the bulb 4.4 Pull the rubber boot from the rear of the headlight unit