CD player FIAT PUNTO 1998 176 / 1.G Workshop Manual

10*1
Chapter 12
Body electrical systems
Contents
Bulbs (exterior lights) - renewal 4 Bulbs (interior lights) - renewal 5 Electrical fault finding - general information 2 Exterior light units - removal and refitting 6 Fuses and relays - general Information 3 General information and precautions 1 Headlight beam alignment • general Information 6 Horn • removal and refitting 9 Instrument panel - removal and refitting 7 Loudspeakers - removal and refitting 10
Degrees of difficulty
Radio aerial - removal and refitting 11 Radio/cassette player • removal and refitting 12 Speedometer drive cable - removal and refitting 13 Switches - removal end refitting 14 Tailgate wiper motor - removal and refitting 15 Windscreen wiper motor - removal and refitting 17 Windscreen/tailgate washer system components • removal and refitting 16 Wiper arm • removal and refitting 18

Easy,
statable for ^
novice with liffle
|| experience ^
Fairly
easy,
suitable for beginner with ^ some experience ^
Fabtycffficiit,
suitable
for competent ^
DIY
mechanic ^

Difficult, suitable for
^ experienced DIY JR mechanic

Very difficult,
A,
suitable
for
expert DIY
Sj or professional ^
Specifications
Bulb ratings Watts Headlights 60/55 Front long range driving light 55 Front fogllght 55 Front direction Indicator light 21 Front sidelight 5 Front direction indicator repeater light 5 Stop light 21 Tall light 5 Rear direction indicator light 21 Reversing light 21 near fogllght 21 Hear number plate light 5 Courtesy light 10 Map reading light 5
1 Genera! information and precautions

A


Warning: fie/Ore carrying out any work on the electrical system, read through the precautions given in Safety first! at the beginning of this manual, and in Chapter 8. The electrical system is of 12-volt negative earth type. Power for the lights and all electrical accessories is supplied by a lead/acid type battery, which is charged by the alternator. This Chapter covers repair and service procedures for the various electrical components not associated with the engine. Information on the battery, alternator and starter motor can be found in Chapter 5. It should be noted that, prior to working on any component In the electrical system, the
battery negative terminal should first be disconnected, to prevent the possibility of electrical short-circuits and/or fires. Caution: Before proceeding, refer to Disconnecting the battery In the Reference Section of this manual for further information.
2 Electrical fault finding-general information
Note: Refer to the precautions given In Safety first! and in Section 1 of this Chapter before starting work. The following tests relate to testing ot the main electrical circuits, and should not be used to test delicate electronic circuits (such as antHock braking systems), particularly where an electronic con fro/ module is used.
General 1 A typical electrical circuit consists of an electrical component, any switches, relays, motors, fuses, fusible links or circuit breakers related to that component, and the wiring and connectors which link the component to both the battery and the chassis. To help to pinpoint a problem in an electrical circuit, wiring diagrams are Included at the end of this manual. 2 Before attempting to diagnose an electrical fault, first study the appropriate wiring diagram, to obtain a more complete understanding of the components included In the particular circuit concerned. The possible sources of a fault can be narrowed down by noting whether other components related to the circuit are operating properly. If several components or circuits fait at one time, the problem Is likely to be related to a shared fuse or earth connection.

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

Body electrical systems 12*9
3 Undo the mounting screws and lift out the speaker (see Illustration). Unplug the wiring at the connector. 4 Refitting is a reversal of removal,
Rear parcel shelf speakers 5 Working underneath the relevant parcel shetf support bracket, remove the securing screws and lower the loudspeaker from the support bracket. Unplug the wiring at the connector (see illustration). 6 Refitting is a reversal of removal.
11 Radio aerial - J^s removal and refitting ^
Removal 1 Carefully prise off the plastic cap. then remove the securing screws and withdraw the aerial from the roof. 2 Oraw the aerial co-axial cable through the roof aperture and disconnect it. If there is insufficient slack In the aerial cable, remove the courtesy light unit/overhead panel from the inside of the vehicle (as described earlier in this Chapter) to gain access to the cable connector,
Refitting 3 Refitting Is a reversal of removal, but ensure that seal between the aerial housing and the roof panel is in good condition.
12.2 Removing the radio/cassette unit using the special extraction tools
12.3 Disoonnect the wiring plugs from the rear of the unit. Note the bayonet fuse (arrowed) which is a push fit In the rear of the unit
10.3 Lift out the speaker and unplug the wiring at the connector
12 Radio/cassette player -removal and refitting ^
Removal Note: Once the battery has been disconnected, the radio/cassette unit cannot be re-activated until the appropriate security code has been entered. Do not remove the unit unless the appropriate code Is known. 1 Disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual). 2 Insert the special extraction tools supplied with the vehicle into the holes on either side of the radio/cassette unit. Press them home until the Internal clips can be felt to release (see illustration). 3 Pull the unit forwards from the facia, then disconnect the wiring plugs and the aerial lead from the rear of the unit. Note the bayonet fuse, which is a push fit in the rear of the unit, (see illustration).
Refitting A Refitting is a reversal of removal, ensuring that the wiring Is routed freely behind the unit.
13 Speedometer drive cable - % removal and refitting Ss ^
Note: Later vehicles are fitted with an electronic transducer in place of the mechanical speedometer drive. This is mounted on the fransm/ss/on casing; refer to Chapter 7A, Section 3, for details.
Removal 1 Remove the instrument panel as described in Section 7. 2 Working in the engine compartment, unscrew the sleeve securing the cable end to gearbox, then pull the cable from gearbox. 3 Where applicable, release the cable from the brackets in the engine compartment bulkhead, then pull the cable through into the engine compartment. If necessary, pull the cable grommet from the bulkhead.
10.S Lower the loudspeaker from the support brackot and unplug tho wiring at the connector
Refitting 4 Refitting is a reversal of removal, bearing in mind the following points: a} Ensure that the bulkhead grommet is securely seated. b) Refit the instrument panel with reference to Section 7. c) Note that certain models have alignment marks on the cable outer for use when refitting. The marks should be aligned with the bulkhead bracket when the cable is correctly refitted and routed.
14 Switches -removal and refitting ^
Steering column stalk switches Note: On vehicles equipped with sfeezing wheel-mounted radio controls, the column stalk switch unit also incorporates the rotary contacts for the steering wheel switches. Removal 1 Disconnect the battery negative cable and position it away from the terminal. Turn the steering wheel so that the roadwheeis are pointing in the straight-ahead position. 2 Refer to Chapter 10 and remove the steering wheel from the column. 3 Remove the screws and lift off the upper and lower steering column shrouds. 4 Using an Allen key. slacken Ihe clamp ring at the rear of the switch unit (see illustration),
14.4 Using an Allen key, slacken the clamp ring at the rear of the switch unit