ECO mode FIAT PUNTO 1999 176 / 1.G Owner's Manual

ib-io Every 10 000 miles - diesel models
7 With the car standing on Its wheels, have an assistant turn the steering wheel back and forth about an eighth of a turn each way. There should be very hide. If any, lost movement between the steering wheel and roadwheels. If this is not the case, closely observe the joints and mountings previously described, but in addition, check the steering column universal joints for wear, and the rack-and-plnion steering gear itself.
Suspension strut/ shock absorber check 8 Check for any signs of fluid leakage around the suspension strut/shock absorber body, or from the rubber gaiter around the piston rod, Should any fluid be noticed, the suspension strut/shock absorber is defective Internally, and should be renewed. Note: Suspension struts/shock absorbers should always be renewed in pairs on the same axle.
9 The efficiency of the suspension strut/shock] absorber may be checked by bouncing 0*1 vehicle at each comer. Generally speaking. th»| body will return to its normal position and 8top| after being depressed. If It rises and returns cn| a rebound, the suspension strut/shocH absorber is probably suspect. Examine also* the suspension strut/shock absorber uppeij and lower mountings for any signs of wear.
Every 20 000 miles (30 000 km) or 2 years
18 Auxiliary drivebeltfs) % check and renewal
Note: Fiat specify the use of a spec/a/ toot to correctly set the drivebelt fens/on. if access to this equipment cannot be obtained, an approximate setting can be achieved using the method described beiow. If the method described Is used, the tension should be checked using the spec/a/ too! at the earliest possible opportunity. 1 Depending on equipment fitted, one, two or three auxiliary drivebeits may be fitted. The alternator, power steering pump and air conditioning compressor, as applicable, are each driven by an individual drivebelt. Checking 2 Disconnect the battery negative terminal (refer to Disconnecting the battery In the Reference Section of this manual). 3 Firmly apply the handbrake, then Jack up the Iront of the car and support it securely on exie stands (see Jacking and vehicle support). 4 Remove the right-hand wheel. 5 Remove the Inner cover(s) from under the right-hand wheelarch for access to the right-hand side of the engine. 6 Using a socket on the crankshaft sprocket bolt, rotate the crankshaft so that the full length of the auxiliary drivebelt(s) can be examined. Look for cracks, splitting and fraying on the surface of the belt: check also for signs of glazing (shiny patches) and
16.10a Loosening the alternator drivebelt adjustment bolt
separation of the belt plies. If damage or wear Is visible, the bell should be renewed, 7 If the condition of the belt Is satisfactory, check tho drivebelt tension as described below.
Renewal
Alternator drivebelt 8 On models with air conditioning, remove the compressor drivebelt as described below, 9 Unclip and remove the upper timing belt cover, then unbolt end remove the lower timing belt cover. 10 Loosen the pivot bolt and adjustment lockbolt then unscrew the adjustment bolt to move the alternator towards the engine so that the drivebelt may be slipped off the alternator, crankshaft, and, on models with air con-ditioning, the Idler pulley (see Illustrations), 11 When renewing a drivebelt. ensure that the correct type is used. Fit the belt around the pulleys then tighten the adjustment bolt to take up any slsck In the belt. Adjust the tension correctly as described below. Power steering pump drivebelt
12 Remove the alternator drivebelt as described previously. 13 Slacken the bolts securing the power steering pump to the mounting bracket. 14 Slacken the adjusting bolt locknut and turn the adjusting bolt until ail the tension Is removed from the dnvebelt. 15 Undo the bolts and remove the pulley guard from the power steering pump then slip the drivebelt off the pulleys,
16.10b Removing the drivebelt from the alternator pulley
18 Ensuring that the correct type of dnveberti^ used, fit the belt around the pulleys and turn
the
adjusting bolt to just take up the slack in thi j belt. Adjust the tension correctly as described! below. Air conditioning compressor drivebelt 17 Slacken the bolts securing the adjustment j pulley bracket to the engine. 18 Slacken the adjusting bolt locknut and] turn the adjusting bolt until ell the tension is | removed from the drivebelt. then slip the be& | off the pulleys. 19 Ensuring that the correct type of drivebeX; is used, fit ihe belt around the pulleys and turn | the adjusting bolt to just take up the slack
m
] the belt. Adjust the tension correctly as described below.
Tensioning 20 Correct tensioning of the belt will ensure that it has a long life. A belt which is too slack will slip and perhaps squeal. Beware, however, of overiightenlng. as this can cause wear in the alternator, power steering pump or air conditioning compressor bearings. Note: Flat recommend use of their spec's/ tensioning tool however the following procedure will set the tension correctly. 21 The belt(s) should be tensioned so that, under firm thumb pressure, there is approximately 5.0 mm of free movement at the mid-point between the pulleys. To adjust, tighten or loosen the relevant adjustment bolt until the tension is correct. Fully tighten the pivot and adjustment lockbotts. Repeat this procedure for any remaining drivebeits removed for access. 22 Refit the lower timing belt cover end tighten the mounting bolts. 23 Refit the upper timing belt cover and secure with the clips. 24 Refit the inner cover and wheel, lower the vehicle to the ground, then reconnect the battery negative terminal.
17 Clutch adjustment check
Refer lo Chapter 6, Section 2.

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,

1B«12 Every 20 000 miles - diesel models
21 Road test
Instruments and electrical equipment 1 Check the operation of atl instruments and electrical equipment. 2 Make sure that all instruments read correctly, and switch on all electrical equipment rn 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 feete positive, with no excessive sloppiness, or roughness, and check for any suspension noises when cornering and driving over bumps. Drivetrain 6 Check (he performance of the engine, clutch, transmission and driveshafts.
7 Listen for any unusual noises from the engine, clutch and transmission. 8 Make sure that the engine runs smoothly when Idling, and that there is no hesitation when accelerating. 9 Check that the clutch action is smooth and progressive, that tho 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 Check that all gears can be engaged smoothly without noise, and that the gear lever action Is not abnormally vague or notchy. 11 Listen for a metallic clicking sound from ihe front of the vehicle, as the vehicle « 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 driveshaft |oinl, in which case renew the joint if necessary.
Check the braking system 12 Make sure that the vehicle does not pull to one side when braking, and that the wheels do not lock prematurely when braking hard.
13 Check that there Is no vibration through the steering when braking. 14 Check that the handbrake operates correctiy without excessive movement of th« lever, end that it holds the vehicle stationery on a slope. 15 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 two minutes, and then switch it off. If the brake pedal is depressed now, it should be possible to detect a hiss from the servo es the pedal is depressed. After about four or five applications, no fimher hissing should be heard, and the pedal should feel considerably harder. Note: The vacuum for the servo unit is provided by the vacuum pump mounted on the left-hand end of t/ie cylinder head.
Every 30 000 miles (45 000 km) or 3 years
22 Manual transmission oil level check ;5§
1 Park the 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 is checked Immediately after driving the car. some of the oil will remain distnbuted around the transmission compo-nents, resulting In an inaccurate level reading. 2 Wipe clean the area around the filler/level plug, which is situated on tho front of the
transmission (see illustration). Using an Allen key. unscrew the plug and clean it. 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 will trickle out when it is removed; this does not necessarily Indicate that the level Is correct. To ensure that a true level Is established, wait until the Initial trickle has stopped, then add oil as necessary until a trickle of new oil can be seen emerging. The level will be correct when the flow ceases; use only good-quality oil of the specified type-Make sure that the vehicle Is completely level when checking the level and do not overfill. 4 When the level is correct refit and tighten the plug and wipe away any spilt oil.
22.2 Transmission filler/level plug location
Every 40 000 miles (60 000 km) or 4 years
23 Rear brake shoe check
1 Chock the front wheels then jack up the rear of the car and support It on axle stands (see Jacking and Vehicle Support), Remove the rear roadwhecla. 2 Using the inspection hole at the edge ot the brake drum, check that the linings are not worn below the minimum thickness given In the Spec ifi cat Ions (see Illustration). If necessary use a torch. 3 If the friction material on any shoe is worn down to the specified minimum thickness or iess. all four shoes must be renewed as a set, 4 At the same time check for signs of brake fluid leakage. 5 For a comprehensive check, the brake
drum should be removed and cleaned. This will allow the wheel cylinders to be checked, and the condition of the brake drum itself to be fully examined (see Chapter 9). 8 Refit the rubber plugs then lower the car to the ground.
24 Timing belt renewal
Refer to Chapter 2C. Note: Although the normal interval for timing belt
ranees/a!
is 70 000
mHes
(105 000
km),
it is strong recommended that the interval is reduced on vehicles which are subjected to intensive use, ie, mainly short journeys or a lot of stop-start driving. The actual belt renewal interval is therefore very much up to tho individual owner.
That being said, it is highly recommended to err on the side of safety, and renew (he belt at
this
earlier interval, bearing in mind the drastic consequences resulting from belt fetfure.
23.2 Check the thickness of the shoe friction material through the hole on the edge of the drum (arrowed)

Maintenance procedures - diesel models 1B.13
Every 60 000 miles (90 000 km) or 6 years
Refer to Chapter 40. A full chock of the 26 Emissions control systems emissions control systems must be made by a check Fiat dealer.
Every 80 000 miles (120 000 km)
26 Manual transmission ,v->> oil renewal K
1 Pak the vehicle on a level surface, if possible over an inspection pit or on a ramp as the filer/level and drain plugs are accessed from
under the
engine compartment, ff necessary tack up Ihe vehicle and support on axle stands (see Jacking and
vehicle
support). 2
Wipe
clean the area around the filler/! a vol and vain plugs, which are situated on the front and bottom of the transmission (see Illustration}.
3 Using an Allen key, unscrew the fillor/level plug and clean it. 4 Position a suitable container beneath the transmission, then use the Allen key to unscrew the drain plug. Allow the oil to completely dram. 5 Wipe clean the drain plug then refit and tighten It. 6 Fill the transmission with the correct grade and quantity of oil, referring to Section 22 when checking the level. Refit and tighten the filler/level plug. 7 Where applicable lower the vehicle to the ground. 26.2 Transmission drain plug location (viewed from undor tho vohlcle)
Every 2 years (regardless of mileage)

27
Coolant renewal St I
Coo//ng system draining

A


Warning: Wait until the engine is coid before starting this procedure. Do not allow anti-fnue to come in contact with your skin, or with the painted surfaces of the vehicle.
Rinse
off spills immediately with plenty of water. Never leave antifreeze lying around fh an open container, or in a puddle in the driveway or on the garage floor. Children
and
pets are attracted by Its sweet smell,
bat
antifreeze can be fatal if ingested. 1 With the engine completely cold, cover the expansion tank cap with a wad of rag, and slowly turn the cap anti-clockwise to relieve the
pressure in the cooling system (a hissing sound will normally be heard). Wail until any pressure remaining in the system is released, then continue to turn the cap until it can be removed. 2 Position a suitable container beneath the radiator bottom hose connection, then release the retaining clip and ease the hose from the radiator stub (see Illustration), If the hose joint has not been disturbed for some time, it will be necessary to gently manipulate the hose to break the joint. Do not use excessive force, or the radiator stub could be damaged. Allow the coolant to drain into the container. 3 Certain models are fitted with cooling system bleed plugs, which should be opened to aid the draining process and help prevent airlocks. These are located on the heator Inlet hose and on the top right hand edge of the radiator (see Illustrations), ff the coolant has
been drained for a reason other than renewal, then provided It is clean and less than two years old, it can be re-used, though this is not recommended. 4 Once all the coolant has drained, reconnect the hose to the radiator and secure it in position with the retaining clip.
Cooling system flushing 5 If coolant renewal has been neglected, or if the antifreeze mixture has become diluted, then In time, the cooling system may gradually lose efficiency, as the coolant passages become restricted due to rust, scale deposits, and other sediment. The cooling system efficiency can be restored by flushing tho system clean. 6 The radiator should be (lushed independently of the engine, to avoid unnecessary contam-ination.
27.2 Disconnecting the radiator bottom hose to drain the coolant 27.3a Location of cooling system bleed plugs (arrowed) 27.3b Bleed screw located on the top right hand edge of the radiator

ib.14 Every 2 years - diesel models
Radiator flushing 7 To flush the radiator disconnect the top and bottom hoses and any other relevant hoses from the radiator, with reference to Chapter 3. 8 Insert a garden hose into the radiator top inlet. Direct a flow of dean water through the radiator, and continue Hushing until clean water emerges from the radiator bottom outlet. 9 II after a reasonable period, the water still does not run clear, the radiator can be flushed with a good proprietary cooling system cleaning agent. It is important that their manufacturer's instructions are followed carefully. If Ihe contamination is particularly bad, insert the hose in the radiator bottom outlet, and reverse-flush the radiator.
Engine flushing 10 To flush tho engine, remove the thermostat as described in Chapter 3. 11 With the bottom hose disconnected, direct a clean flow of water through the engine, and continue Hushing until clean water emerges from the radiator bottom hose. 12 On completion of flushing, refit the thermostat and reconnect the hose with reference to Chapter 3.
Cooling system filling 13 Before attempting to fill the cooling system, make sure that all hoses and clips are in good condition, and that the clips are tight. Note that an antifreeze mixture must be used all year round, to prevent corrosion of the engine components (see following sub* Section). 14 Remove the expansion tank filler cap. and fill the system by slowly pouring the coolant Into Ihe expansion tank to prevent airlocks from forming. Ensure that all bleed plugs/screws are open. 15 If the coolant is being renewed, begin by pouring in a couple of litres of water, followed by the correct quantity of antifreeze, then top* up with more water. 18 Once ihe level in the expansion tank starts to rise, squeeze the radiator top and bottom hoses to help expel any trapped air in
the system. Once all the air is expelled, top-up the coolant level to the MAX mark and refit the expansion tank cap. Close all bleed plugs. 17 Start Ihe engine and run il until it reaches normal operating temperature, then stop the engine and allow It to cool. 18 Check for leaks, particularly around disturbed components. Check the coolant level In the expansion tank, and top-up if necessary. Note that the system must be cold before an accurate level Is indicated In the expansion tank. If the expansion tank cap Is removed while the engine is still warm, cover the cap with a thick cloth, and unscrew the cap slowly to gradually relieve the system pressure (a hissing sound will normally be heard). Wait until any pressure remaining in the system Is released, then continue to turn the cap untH it can be removed.
Antifreeze mixture 19 The antifreeze should always be renewed at the specified intervals. This is necessary not only to maintain the antifreeze properties, but also to prevent corrosion which would otherwise occur as the corrosion Inhibitors become progressively less effective. 20 Always use an ethylene-glycol based antifreeze which is suitable for use in mixed-metal cooling systems. The quantity of antifreeze and levels of protection are indicated in the Specifications. 21 Before adding antifreeze, the cooling system should be complelely drained, preferably flushed, and all hoses checked for condition and security. 22 After filling with antifreeze, a label should be attached to the expansion tank, stating the type and concentration of antifreeze used, and the dale installed. Any subsequent topping-up should bs made with the same type and concentration of antifreeze. 23 Do not use engine antifreeze In the windscreen/tailgate washer system, as it will cause damage to the vehicle paintwork. A screenwash additive should be added to the washer system in the quantities stated on the bottle.
28 Brake fluid renewal

A


Warning: Brake hydraulic fluid can harm your eyas and damage painted surfaces, so use extreme caution when handling and pouring It. Do not use fluid that has been standing open for some time, as It absorbs moisture from the air. Excess moisture can causa a dangerous loss of braking effectiveness. 1 The procedure is similar to that for the bleeding of the hydraulic system as described In Chapter 9. except that the brake fluid reservoir should be emptied by siphoning, using a clean poultry baster or similar before starting, and allowance should be made for the old fluid to be expelled when bleeding a section of the circuit. 2 Working as described in Chapter 9, open Ihe first bleed screw in the sequence, and pump the brake pedal gently until nearly all the old fluid has been emptied from the master cylinder reservoir.
ffffTOgf Old hydraulic fluid Is
lifcjllitt*
Invariably much darker In [HINT] colour than the new, making /{easy to distinguish the two.
3 Top-up to the MAX level with new fluid, and continue pumping until only the new fluid remains in the reservoir, and new fluid can be seen emerging from (he bleed screw. Tighten the screw, and top the reservoir level up to Ihe MAX level line. 4 Work through all the remaining bleed screws In the sequence until new fluid can be seen al all of them. Be careful to keep the master cylinder reservoir topped-up 10 above the MIN level al all limes, or air may enter the system and greatly increase the length of the task. 5 When the operation is complete, check thai all bleed screws are securely tightened, and that their dust caps are refitted. Wash off ail traces of split fluid, and recheck the master cylinder reservoir fluid level. 6 Check the operation of the brakes before taking the car on the road,

2A*10 SOHC (8-valve) petrol engine in-car repair procedures
6.3 Camshaft cover gasket
not attempt to lover it ofl • instead free >t by working around the cover and lapping it lightly with a soft-faced mallet, 3 Recover the camshaft covor gasket {see Illustration). Inspect the gasket carefully. And renew It If damage or deterioration is evident. 4 Clean the mating surfaces of the cylinder head and camshaft cover thoroughly, removing all traces of oil and old gasket - take care to avoid damaging the surfaces as you do this.
Refitting 5 Locate a new gasket on the cylinder head and make sure it Is correctly seated. 6 Lower the cover onto the gasket making sure the gasket is not displaced. 7 Insert Ihe mounting bolts and tighten them progressively to the specified torque. 8 Refit the air cleaner assembly and inlet duct with reference to Chapter 4A or 48.
7 Camshaft oil seal • renewal I
1 Remove the timing beft and camshaft sprocket as described in Sections 4 and 5, 2 Using a suitable hooked Instrument, remove the oil seal from the cylinder head taking care not to damage the surface of (he camshaft. 3 Clean the seating in the cylinder head and the end of the camshaft. To prevent damage to the new olf seal as it is being fitted, wrap some adhesive tape around the end of the camshaft and lightly oil it.
4 Dip the new oil seal In oil then locate it over the camshaft making sure that the sealing lips are facing inwards, 5 Using a suitable tubular drift, drive the oil seal squarely Into the cylinder head. Remove the adhesive tape. 8 Refit the camshaft sprocket and liming belt wtth reference to Sections 5 and 4.
8 Crankshaft oil seals - ^ renewal S
Front (right-hand side) oil seal 1 The fronl oil seal is located in tho oil pump on the front of the crankshaft. Remove the timing belt as described in Section 4 and the crankshaft sprocket as described in Section 5. 2 Using a hooked instrument, remove the oil seal from the oil pump casing taking care not to damage the surface of the crankshaft. 3 Clean Ihe seating in the housing and the surface of the crankshaft. To prevent damage to the new oil seal as it is being fitted, wrap some adhesive tape around the end of the crankshaft and lightly oil it. 4 Dtp the new oil seal In oil then offer It up 1o the oil pump casing making sure that tho sealing lips are facing Inwards. G Using a suitable tubular drift, drive the oil seal squarely into the casing. Remove the adhesive tape. 6 Refit the crankshaft sprocket and timing belt with reference to Sections S and 4.
Rear {left-hand side) oil seal Note: The following paragraphs describe renewal of the rear oil seal leaving the housing in position. Refer to Chapter 2D for details of removing the housing. 7 Remove the fiywheel/drlveplate as described in Section 10. 8 Using a suitable hooked instrument, remove the oil seal from the rear oil seat housing taking care not to damage the surface of Ihe crankshaft. 9 Clean the seating In the nousing and the surface of the crankshaft. Check the crankshaft for burrs which may damage the sealing lip of the new seal, and If necessary use a fine file to remove them,
10 Dip the new seal In clean engine oil and carefully locate it over the crankshaft rear flange making sure that It is the correct way round. 11 Progressively tap the oil seal Into the housing keeping It square to prevent distortion. A block of wood is useful for this purpose. 12 Refit the fiywheet/drlvepiate with refer-ence to Section 10.
9 Cylinder head -removal and refitting I
i Removing the timing belt inner covers 9.12 Removing the cylinder head
Removal 1 Disconnect the battery negative termine! (refer to Disconnecting the battery In the Reference Section of this manual). 2 Drain the cooling system as described In Chapter 1A. then remove the air cleaner and ducting as described in Chapter 4A or 48. 3 Disconnect the accelerator cable and controls from the throttle housing. 4 Disconnect the fuel hoses. 5 Disconnect the coolant and vacuum hoses from the cylinder head and inlet manifold. 6 Disconnect all electrical leads noting their location. 7 Remove the Ignition colls with reference to Chapter 58. 8 Remove the timing belt as described in Section 4, then unbolt end remove the timing belt inner covers (see Illustration). 9 Unbolt and remove the Inlet manifold, complete with throttle housing. On MPI models unbolt the fuel rail. 10 Unbolt the exhaust manifold from th» cylinder head, and tie it to the front of tto engine compartment. If preferred remove the manifold completely by unbolting Ihe downpipe. Also disconnect iha downpipe bracket. 11 Unscrew the cylinder head bolts hall a turn at a time in the reverse order to thai shown In illustration 9.24b. When the bolts in free, remove them wtth their washers. 12 Lift the cylinder head from Ihe block (see Illustration), if It is stuck tight Insert pieces
of
wood Into the exhaust or Inlet ports, and use them as levers to rock the head off the block. On no account drive levers into the gasket joint, nor attempt to tap the head sideways,
as
It Is located on positioning dowels. 13 Remove and discard the cylinder heed gasket and the manifold gaskets. 14 The cylinder head can be dismantled after removing the camshaft and cam followers as described in Chapter 2D. 15 If the valves have been ground-in, the valve clearances will require adjusting, as described In Chapter 1A. This should be dons before the cylinder head is refitted to the engine.

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

2A*10 SOHC (8-valve) petrol engine in-car repair procedures
10.10 Tighten the flywheel bolt to the specified torque However, it may be possible lo have it surface*ground; seek (he advice of a Rat dealer or engine reconditioning specialist, 5 If Ihe ring gear is badly worn or has missing teeth, the flywheel must be renewed. Automatic transmission models 6 Check the driveplate for signs of damage and renew it if necessary. If the ring gear is badly worn or has missing teeth, the driveplate must be renewed.
Refitting 7 Clean the mating surfaces of the flywheel/ drivoplate and crankshoft. Remove any remaining locking compound from the threads of the crankshaft holes, using the correct-size tap. if available.
ft a suitable tap fs not . # | available, cut two slots down jHlNTI
toe
threads of ono of the old bolts with a hacksaw, and use the bolt to remove the locking compound from the throads.
8 If the new retaining bolts are not supplied with their threads already pre-coated, apply a suitable thread-locking compound to the threads of each bolt. 9 Offer up the fiywhee'/drlveplate lo the crankshaft, using the alignment marks made during removal, and fit the new retaining bolts (together with the spacer plate on manual transmission models), 10 Lock the flywheel/dnveplate using Ihe method employed on dismantling, and tighten
the retaining bolts to the specified torque (see illustration), 11 Refit the clutch on manual transmission models as described in Chapter 6. 12 Relit the transmission as described In Chapter 7A or 78.
11 Engine mountings • inspection and renewal
inspection 1 Firmly apply the handbrake, then jack up the front of the car and support it securely on axle stands (see Jacking and vehicle support). 2 Check Ihe mounting rubbers to see if they are cracked, hardened or separated from the metal at any point; renew the mounting if any such damage or deterioration is evident. 3 Check that all the mounting's fasteners are securely tightened; use a torque wrench to check II possible. 4 Using a large screwdriver or a crowbar, check for wear In the mounting by carefuliy levering against It to check for free play. Where this is not possible enlist the
aid
of
an
assistant to move the engina/transmission back
and
forth, or from s»de to side, while you watch the mounting. While some free play rs to bo expected even from new components, excessive wear
should
be obvious. If excessive free play is found, check first that the fasteners are correctly secured, then renew any worn components as described below.
Renewal Right-hand mounting 5 Firmly apply the handbrake, then jack up the front of the car and support it securely on axle stands (see Jacking and vehicle support). 8 Place a trolley jack beneath the right-hand side of Ihe engine, with a block of wood on the jack head. Raise the jack until it is supporting the weight of the engine. 7 Unscrew the nut securing the engine bracket to the mounting. 8 Lower the engine slightly then unboll the mounting from the body. 9 Locate the new mounting on the body, insert the bolts and tighten to the specified torque.
10 Raise tne engine and locate the bracket on the mounting. Refit tho nut and tighten lo the specified torque. 11 Remove the trolley jack and lower the vehicle to the ground. Left-hand mounting 12 Firmly apply the handbrake, then jack up the front of the car and support it securely on axle stands (see Jacking and vehicle support) 13 Place a trolley |sck beneath the transmission, with a block of wood on the jack head. Raise the jack until it is supporting tne weight of the engine/transmission. 14 Unscrew Ihe bolts securing the left-hand mounting to tho body. 15 Unscrew the nut securing ihe mounting to the transmission bracket and recover the washers. 16 Lower the transmission sufficiently to remove the mounting from the transmission bracket. 17 Locate the new mounting In the trans-mission bracket and refit the nut and washers. Tighten the nut to the specified torque. 18 Raise the engine and refit the mounting-to-body bolts. Tighten the bolts to the specified torque. 19 Remove the Irolloy jack and lower the vehicle lo the ground. Rear mounting 20 Firmly apply the handbrake, then Jack up the front of the car and support It securely on axle stands (see Jacking and vehicle support). 21 Working beneath Ihe vehicle, unscrew Ihe bolts secunng the rear engine mounting to the underbody. 22 Temporarily support the weight of the engine/transmission using a trolley jack. 23 Unbolt the rear mounting assembly from Ihe transmission and withdraw from under the vehicle. 24 Unscrew the bolt and separate Ihe bracket from tlve mounting. 28 Fitting the new mounting Is a reversal of the removal procedure.
12 Sump -removal and refitting
12.2 Removing the flywheel housing cover plate 12.4 Removing the sump
Removal 1 Firmly apply the handbrake, then jack up the front of the car and support it securely on axle stands (see Jacking and vehicle support). Drain the engine oil as described in Chapter 1 A. 2 Unbolt and remove the cover plate from the lower pari of the llywheel housing (see illustration). 3 Refer to Chapter 4D and unbolt the exhaust Iront pipe from Ihe manifold. Undo Ihe support bracket fastenings and lower the front pipe clear of the sump. 4 Unscrew the sump securing screws and nuts and pull the sump downwards to remove it (see Illustration). The joint sealant will

11.15 Left-hand engine mounting viewed from below 9 lower the engine sufficiently to remove the mounting from the engine bracket. 10 Locate the new mounting in the engine bracket, refit the nut and washers and tighten securely. 11 Raise the engine and refit and tighten the mounting-to-body bolts. 12 Remove the trolley jack and lower the vehicle to the ground. Left-hand mounting 13 If not already done, firmly apply the handbrake, then jack up the front of the car and support It securely on axle stands (see
Jacking
and vehicle support). 14 Place a trolley jack beneath the trans-mission. with a block of wood on the jack head. Raise the jack until it is supporting the weight of the engine/transmission. 15 Unscrew the bolts securing the left-hand mounting to the body (see Illustration). 16 Unscrew the nut securing the mounting to the transmission bracket and recover the washers. 17 Lower the transmission sufficiently to remove the mounting from the transmission bracket. 18 Locate the new mounting in the transmission bracket, refit the nut and washers and tighten securely. 19 Raise the engine and refil and tighten the mounting-to-body bolts. 20 Remove the trolley jack and lower the vehicle to the ground. Rear mounting 21 If not already done, firmly apply the handbrake, then jack up the front of the car and support it securely on axle stands (see
Jacking
and vehicle support). 22 Working beneath the vehicle, unscrew the bolts securing the rear engine mounting to the underbody (see illustration). 23 Temporarily support the weight of the engine/transmission using a trolley jack. 24 Unbolt the rear mounting assembly from the transmission and withdraw from under the vehicle. 25 Unscrew the bolt and separate the bracket from the mounting. 28 Fitting the new mounting is a reversal of tha removal procedure.
Diesel engine in-car repair procedures 2C*11
11.22 Rear engine mounting viewed from below
12 Sump -removal and refitting
Removal 1 Disconnect the battery negativo terminal (refer to Disconnecting the battery in the Reference Section of this manual). 2 Firmly apply the handbrake, then jack up the front of the car and support it securely on axie stands (see Jacking and vehicle support). 3 Drain the engine oil as described in Chap-ter 1B. Where applicable, remove the screws and lower the engine undertray away from the vehicle. 4 On turbo models disconnect the turbo-charger oil drain hose from the sump (see illustration). 5 Working around the outside of the sump, progressively loosen and withdraw the sump retaining bolts. 6 Break the joint by striking the sump with the palm of your hand, then lower the sump and withdraw it from underneath the vehicle. Recover and discard the sump gasket. 7 While the sump Is removed, take the opportunity to check the oil pump pick-up/strainer for signs of clogging. If necessary, clean or renew the strainer.
Refitting 8 Thoroughly clean the sump inside and out ensuring that all traces of gasket are removed from the mating surfaces of both the sump and the cylinder block/crankcase.
12.4 Turbocharger-to-sump oil drain hose
9 Ensure that the mating surfaces are clean and dry, then apply a little grease to the surface of the sump. This will retain the gasket in position while refitting the sump. 10 Lay the new sump gasket In position on the sump mating surface, then offer up the sump and refit the retaining bolts. Tighten the bolts evenly and progressively lo the specified torque. 11 On turbo models reconnect the turbo-charger oil drain hose. 12 Lower the vehicle to the ground then refer to Chapter 1B and refill the engine with the specified grade and quantity of oil. 13 Reconnect the battery negative terminal.
13 Oil pump and pick-up tube -removal, inspection and refitting
Removal 1 The oil pump Is mounted on the timing belt end of the cylinder block and is driven by flats on the crankshaft nose. Incorporated In the oil pump body is the crankshaft oil seal. 2 Remove the timing belt as described in Section 4, and the crankshaft sprocket as described in Section 5. 3 Remove the sump as described in Section 12. 4 Unscrew the bolts securing Ihe pick-up tube to the bottom of the oil pump. Also unscrew the bolt securing the tube to the No 2 main bearing cap. Withdraw the tube from the oil pump and crankcase. Recover the gasket (see illustrations).
13.4a Removing the oil pump pick-up tube... 13.4b ... and gasket

2D*10 Engine removal and overhaul procedures
Engine and transmission -removal, separation, connection and refitting
Note: The engine Is lowered from the engine compartment as a complete unit with the transmission; tho two are then separated for overhaul.
Removal 1 Remove the bonnet and disconnect the washer tubing as described in Chapter 11 (see illustrations). 2 Apply the handbrake, then jack up the front of the vehicle and support on axle stands (see Jacking and vehicle support). Remove both front wheels. In order to remove tne engine/transmission assembly in an upright position from under the vehicle, there must be a minimum clearance of 660 mm between the floor and the front crossmember. Additional height Is necessary if the assembly is to be lowered onto a trolley. 3 Where fitted, unbolt and remove the engine compartment lower cover. 4 Remove the auxiliary drivebelt(s) with reference to Chapter 1A or 1B. 5 Dram the engine oil. transmission oil/fluid and coolant with reference to Chapter 1A or 1B. 6 Remove the battery (see Chapter 5A). 7 On manual transmission models with a cable dutch, disconnect the clutch cable from the transmission (refer to Chapter 6). On manual transmission models with a hydraulic clutch unbolt the clutch slave cylinder from the top of the transmission then fit a cable-tie around it to prevent the piston coming out (see Illustration). Position the cylinder to one side. 8 Unscrew the nut and disconnect the earth lead from the transmission (see illustration). Petrol engines 9 Unbolt and remove the battery tray. 10 Disconnect the wiring from the reversing light switch. 11 On manual transmission models disconnect the reverse Inhibition cable from the transmission then disconnect the gear selector rod from the lever on the transmission. 12 Remove the air cleaner and ducting as descnbed In Chapter 4A or 4B. 13 On automatic transmission models disconnect the kickdown cable and gear selector cable as described in Chapter 7B. Also disconnect the wiring for the electro-magnetic clutch. 14 Unbolt and remove the cover from the bulkhead then disconnect the oxygen sensor wiring. 15 Disconnect the remaining wiring at the bulkhead and release the fuse holders at the mounting. 16 Disconnect the vacuum pipe from the inlet manifold, and also disconnect the wiring connector located next to it.
4.1a Unscrewing the bonnet hinge bolts
17 Unscrewthenutsandseparatetheengine wiring harness lead from the battery positive cable terminal. 18 Disconnect the accelerator cable from the engine as described in Chapter 4A or 4B, 19 Loosen the clip and disconnect the radiator top hose from the elbow on the left-hand end of the cylinder head. Similarly disconnect the bottom hose. On 16-valve models, remove the radiator electric cooling fan as described in Chapter 3. 20 Identify the hoses connected to the throttle housing, then disconnect them. 21 Identify the coolant heater hoses on the bulkhead for position, then loosen the clips and disconnect the hoses. 22 Loosen the clip and disconnect the brake servo vacuum hose from the Inlet manifold. Where applicable, disconnect the remaining emission control system vacuum hoses from the Inlet manifold after Identifying their locations to aid refitting. 23 Disconnect tho fuel supply and return hoses from the throttle housing. 24 Release the connector from the ignition/fuel ECU located on the right-hand side of the engine compartment. 25 Unscrew the nut and detach the earth cable from its location near the ECU. 26 Disconnect the diagnostic connector located near the ECU. 27 On models fitted with power steering, refer to Chapter 10 and unbolt the power steering pump from the front of the engine without disconnecting the hydraulic fluid lines then tie It to one side so that it will not obstruct the removal of the engine. On
4.1b Disconnecting the washer tubing
models with air conditioning, similarly unbolt the air conditioning compressor and position it clear of the engine. Do not disconnect the air conditioning refngerant pipes/hoses. 26 On manual transmission models pull out the retaining plate and disconnect the gear selector cable from the lever on the transmission. 29 Unscrew the nuts retaining the track rod ends on the swivel hubs and use a balljoint separator tool to disconnect them. 30 Release the flexible brake fluid hoses and ABS system sensor wrring from the front suspension struts. 31 On manual transmission models, unscrew the nuts from the outer ends of each driveshaft. To prevent the hubs from turning either have an assistant depress the brake pedal, or temporarily Insert two wheel bolts and use a lever to hold the hub. 32 On automatic transmission models use a suitable drift to drive out Ihe roll pins securing 2D the inner ends of the drlveshafts to tho trans-mission output stubs. Turn the driveshalts as necossary to access the roll pins . 33 Unscrew the two bolts securing the right-hand swivel hub assembly to the front suspension strut, then move the hub assembly outwards. On manual transmission models release the outer end of the driveshaft from the hub assembly - on automatic transmission models slide the inner end of the driveshaft off the final drive output stub. Take care not to strain the flexible brake hose while doing this. Move the driveshaft to one side thon temporanly refit the hub assembly to the strut. On manual transmission models, make
^ - / //
4.7 Fit a cable tie around the dutch slave cylinder to prevent the piston coming out 4.8 Disconnecting the earth lead from the transmission