Petrol FIAT PUNTO 1999 176 / 1.G Workshop Manual

FIAT
PUNTO
1994 to Oct 1999 (L to V registration) Petrol & Diesel
Haynes Service and Repair Manual
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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
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Contents
LIVING WITH YOUR FIAT PUNTO
Introduction to the Rat Punto Page 0-4 Safety lirstl Page 0*5
Roadside repairs If your car won't start Page 0*6 Jump starting Page 0*7 Wheel changing Page 0«8 Identifying teaks Page 0*9 Towing Page 0*9
Weekly checks Introduction Page 0*10 Underbonnet check points Page 0»10 Engine oil level Page 0*12 Coolant level Page 0*12 Brake fluid level Page 0*13 Power steering fluid level Page 0"13 Tyre condition and pressure Page 0*14 Automatic transmission fluid level Page 0«1S Screen washer fluid level Page 0«1S Wiper blades Page 0*15 Battery Page 0*16 Electrical systems Page 0-16
Lubricants and fluids Page 0*17
Tyre pressures Page 0*18
MAINTENANCE
Routine maintenance and servicing Rat Punto petrol models Page 1A«1 Servicing specifications Page 1A«2 Maintenance schedule Page 1A«3 Maintenance procedures Page 1A«6 Fiat Punto diesei models Page 1B-1 Servicing specifications Page 1B«2 Maintenance schedule Page 1B«3 Maintenance procedures Page 1B«5
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Contents
REPAIRS AND OVERHAUL
Engine and associated systems SOHC (8-valve) petrol engine in-car repair procedures Page 2A«1 DOHC (16-valve) petrol engine in-car repair procedures Page 2B«1 Diesel engine in-car repair procedures Page 2C«1 Engine removal and overhaul procedures Page 2D«1 Cooling, heating and ventilation systems Page 3»1 Fuel system - single-point petrol injection models Page 4A«1 Fuel system - multi-point petrol injection models Page 4B«1 Fuel system - diesel models Page 4C»1 Exhaust and emission control systems Page 4D*1 Starting and charging systems Page SA«1 Ignition system - petrol models Page SB«1 Preheating system - diesel models Page 5C>1
Transmission Clutch Page 6»1 Manual transmission Page 7A«1 Automatic transmission Page 7B*1 Driveshafts Page 8*1
Brakes and suspension Braking system Page 9*1 Suspension and steering Page 10-1
Body equipment Bodywork, trim and Fittings Page 11«1 Body electrical systems Page 12*1
Wiring diagrams Page 12»13
REFERENCE
Dimensions and weights Page REF«1 Conversion factors Page REF*2 Buying spare parts Page REF»3 Vehicle identification Page REF«3 General repair procedures Page REF«4 Jacking and vehicle support Page REF»5 Disconnecting the battery Page REF«5 Tools and working facilities Page REF-6 MOT test checks Page REF»8 Fault finding Page REF»12 Glossary of technical terms Page REF»20
index Page REF»24
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0.4 Introduction
The Fiat Punto range was Introduced in March 1994 with 1106 cc, 1242 cc and 1372 cc petrol engines and a 1698 cc diesel engine. At first, models wero only available in 5-door Hatchback form, however 3-door versions followed in May 19SM and Cabriolet and Automatic versions In June 1994. At the seme lime a lurbo diesel model was launched. Power-ass«sted steering and ABS were offered as options in October 1994, and the 6-speed 55SX and norrrally-asptraled dieset followed in June 1995. In June 1997 a minor facelift was undertaken which Included improvements to the suspension and steering and various cosmetic changes. This facelift also saw the introduction of fie ! 242 cc DOHC 1S-valve engine available In top of the range models.
Ait engines covered in this Manual are fitted with single- or double-overhead •camshaft engines, end all models have fully independent front and rear suspension. The distinguished lines of the bodywork together with tho high level rear lighting have made the Rat Punto a very popular small car.
Provided that regular servicing is earned out In accordance with tho manufacturer's recommendations, the Flat Punto should prove reliable and economical. The engine compartment is well-designed, and most of the items needing frequent attention are easily accessible.
The Fiat Punto Team
Haynes manuals are produced by dedicated and enthusiastic people working in close co-operation. The team responsible for the creation of this book included:
Authors
Sub-editor Page Make-up Workshop manager Photo Scans
Cover illustration & Une Art
Wiring diagrams

A.K. Legg laemimi
Spencer Drayton
Ian Barnes
Steve Churchill Paul Buckland
Steve Tanswell John Martin
Roger Healing
Matthew Marke
We hope the book will help you to get the maximum enjoyment from your car. By carrying out routine maintenance as described you will ensure your car's reliability and preserve its resale value.
Your Fiat Punto Manual
The aim ol this manual is to help you get the best value from your vehicle, It can do so-ln several ways. It can help you decide what worfc must be done (even should you choose to get It dons by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs, It may even be quicker than booking tho car into a garage and going there twice, io leave and collect it. Perhaps mosl important, a lot of money can be saved by avoiding the costs a garage must charge to cover Its labour and overheads, The manual has drawings and descriptions to show the function of the various components, so that their layoul can be understood, Then the tasks are described and photographed in a clear step-by-step sequence. References to the 'left' or 'right' are In the sense of a person in the driver's seat facing forward.
Acknowledgements Thanks are duo to the Champion Spark Plug Company, who supplied the Illustrations of various spark plug conditions. Thanks are also due to Oraper Tools Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped In the production of this manual. We take great pride In tho accuracy of information given In this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not Inform us. No liability oen be accepted by the authors or publishers for loss, damage or Injury caused by any errors in, or omissions from, the information given.

o.6 Roadside repairs
The following pages are Intended to help In dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair Information In the main chapters.
If your car won't start
and the starter motor
doesn't turn
If your car won't start
even though the starter
motor turns as normal
tf it's a model with automatic transmission, make sure the selector is in P or N. Open the bonnet and make sure that the battery terminals are clean and tight. Switch on the headlights and try to start the engine. If the headlights go very dim when you're trying to start, the battery is probably flat. Get out of trouble by Jump starting (see next page) using a friend's car.
• Is there fuel In the tank? • Is there moisture on electrical components under the bonnet? Switch off the ignition, then wipe off any obvious dampness with a dry cloth. Spray a water-repellent aerosol product (WD-40 or equivalent) on ignition and fuel system electrical connectors like those shown in the photos. Pay special attention to the ignition coil wiring connector and HT leads. (Note that Diesel engines don't normally suffer from damp.)

A

Check that the spark plug HT leads are securely connected by pushing them onto the plugs (petrol engine models).
B

Check that the wiring to the engine compartments is securely connected.
C

Check the security and condition of the battery terminals,
Check that electrical connections are secure (with the ignition switched off) and spray them with a water dispersant spray tike WD40II you suspect a problem due to damp

do Weekly checks
Introduction
There are some very simple checks which need only take a few minutes to carry out, but which could save you a lot of inconvenience and expense.
These Weekly checks require no great skill or special lools, and the small amount of lime they take to perform could prove to be very well spent, for example;
P Keeping an eye on tyre condition and pressures, will not only help to stop them wearing out prematurely, but could also save your life.
C Many breakdowns are caused by electacai problems. Battery-relalod faults are particularly common, and a quick check on a regular basis will ofton prevent the majority of these.
• If your car develops a brake fluid teak, the first time you might know about it is when your brakes don't work properly. Checking the level regularly will give advance warning of this kind of problem.
• If the oil or coolant levels run low. the cost of repairing any engine damage will be far greater than fixing the leak, for example.
Underbonnet check points
4 1.1 litre petrol
A Engine oil level dipstick Q Engine oil filler cap C Cooteof expansion tank P Brake fluid reservoir E Screen washer fluid reservoir p Battery
< 1.2 litre
m (8-valve) petrol
^ 1 A Engine oII level dipstick
B Engine otl tiller cap
fi i: c Coolant expansion tank
D Brake fluid reservoir
E Screen washer fluid reservoir
F Battery

Weekly checks o.n
Ulllllli
B
4 1.2 litre (16-valve) petrol
A Engine oil level dipstick
B Engine oil fitter cap 0 Coolant expansion tank D 8rake fluid reservoir £ Screen ivasfter fluid reservoir P Battery G Power steenng fluid reservoir
B

4
1.7 litre Turbo diesel
A Engine otl level dipstick B Engine oil filler cap Q Coolant expansion tank Q Brake fluid reservoir E Screen washer fluid reservoir F Battery
G Power steering fluid reservoir

o*i2 Weekly checks
Engine oil level
Before you start • Make euro that your cor is on level ground. • Check ihe oil level oefore ihe cor is driven, or at least 5 minutes alter the engine has been switched off.
HHifffl If tho oil Is checked rTf"™^ Immediately after driving the IHlAIT vehicle,
some
of the oil will " remain In the upper engine components, resulting in on inaccurate reading on the dipstick!
The correct oil Modern engines place great demands on their oil. It Is very important that the correct oil for your car is used
Lubricants and fluids).
Car Care • If you have to add oil frequently, you should check whother you have any oil leaks. Place some clean paper under the car overnight, and check for stains In the morning. If there are no leaks, the engine may be burning oil.
• Always maintain the level between the upper and lower dipstick marks (see pholo 2). If Ihe level Is too low
sqvoio
engine damage may oecur. Oil seal failure may result if tho engine is overfilled by adding too much oil.

I

Tho dipstick is brightly coloured for easy identification (seo Under bonnet check points). Withdraw the dipstick (petrol engine shown).

3

If more oil is needed, remove the oil filler cap Irom the top of the ongine (petrol engine shown).
SI i J

2

Using a clean rag or paper towel remove all oil from the dipstick. Insert the clean dipstick into the tube as far as it will go, then withdraw it again. The level should be between the upper and lower marks.

4

Oil Is added through the filler cap aperture (diesel engine shown). Add the oil a little at a time, checking the level on the dipstick often. Using a funnel will help to reduce spillage. Don't overfill (see Car Care).
Coolant level
A
Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a very great risk of scalding. Do not leave open containers of coo/ant about, as It is poisonous.
Car Care • With a sealed-type cooling system, adding coolant should not be necessary on a regular basis. If frequent topping-up is required, it is likely there Is a leak. Check the radiator, all hoses and Joint faces for signs of staining or wetness, and roctify as necessary.
• It is important that antifreeze is used in the cooling system all year round, not just during the winter months. Don't top-up with water alone, as the antifreeze will become too diluted.
H Check that the coolant level is between I the MIN and MAX marks, il topping up is necessary, wait until tho engine is cold. Slowly unscrew the expansion tank cap to release any pressure present in the cooling system, and remove it (petrol engine shown).

2

On diesel engine models, Ihe ooolant expansion tank is a different shape, but Ihe same procedure applies as for petrol engine models (see photo 1). Tho MlN and MAX marks appear on the side of tlie tank neorosl the engine.

3

Add a mixture of water and antifreeze to the expansion tank until the coolant level is up to the MAX mark (petrol engine shown), The MIN and MAX marks appear on the tank below the filler neck.

o«i6 Weekly checks
Battery
Caution: Before carrying out any work on the vehicle battery, read the precautions given In "Safety first" at the start of this manual. • Make sure thai the battery tray is in good condition, and that the clamp Is tight. Coirosion on the tray, retaining clomp and the battery itself can be removed with a solution of water and baking soda, Thoroughly rinse all cleaned areas with water. Any metal parts damaged by corrosion should be covered with a zinc-based primer, then painted. • Periodically (approximately every three months), check the charge condition of the battery as described In Chapter SA. • If the battery Is flat, and you need to jump start your vehicle, see Roadside Repalrz.
Battery corrosion can be kept to a minimum by applying o layer of petroleum Jelly to the clamps and terminals after they are reconnected
fin %

I

The battery is located on the left-hand side of the engine compartment, The exterior of the battery should be inspected penodlcaily for damage such as a cracked case or cover.

2

Check the tightness of battery clamps (A) to ensure good electrical connections. You should not be able to move them. Also check each cable (B) for cracks and frayed conductors.

3

If corrosion (while, fluffy deposits) is evident, remove the cables from the battery terminals, clean them with a small wire brush, then refit them. Automotive stores sell a tool for cleaning the battery post...
as well as the battery cable clamps
Electrical systems
• Check all external lights and the horn. Refer to the appropriate Sections of Chapter 12 for details if any of the circuits are found to be Inoperative,
• Visually chock all accessible wiring connectors, harnesses and retaining clips for security, and for signs of chafing or damage.
fffjffflg^ " y°u A**^ check your "T™*! broke lights and Indicators ,HllMT[ unaided, back up to a wall or garage door and operate the lights. The reflected light shouid show
If
they are working property.

I

I? a single indicator light, stop-light or headlight has failed, it Is likely that a bulb has blown and will need to be replaced. Refer to Chapter 12 for details. If both stop-lights have failed, it is passible that the switch has failed (see Chapter 9).

2

If more than one Indicator light or tail light has failed It is likely that either a fuse has blown or that there is a fault tn the circuit (see Chapter 12). The fuses are located behind the oddments tray on ihe facia. First unscrew the two screws and swivel Ihe tray down.

3

To replace a blown fuse, simply pull it out using the special plastic tool and fit a new fuse of tho correct rating (see Chapter 12). If the fuse blows again, it is importont that you find out why - a complete checking procedure Is given in Chapter 12.