1994 FIAT PUNTO key

2A*10 SOHC (8-valve) petrol engine in-car repair procedures
I To make o camshaft sprocket holding ; tool, obtain two lengths of steel strip I about 6 mm thick by 30 mm wide or ; similar, one €00 mm long, the other 200 mm long (all dimensions approximate). Bolt the two strips together to form a forked end, leaving the bolt slack so that the shorter strip can pivot freely. At the end of each 'prong' of the fork, secure a bolt with a nut and a locknut, to act as the fulcrums; these will engage with the cut-outs In the sprocket, and should protrude by about 30 mm
11 Check and adjust the tension of the timing tel with reference to Section 4. 12 Relit Ihe timing belt cover and tighten the bolts. 13 Relit the crankshaft pulley. 14 Refit and tension the auxiliary drivebelt(s)
as
described in Chapter 1. 15 Refil the air cleaner and air ducting as described in Chapter 4A or 48. 16 Refil the roadwheel and lower the vehicle
to the
ground.

Camshaft
sprocket
Removal 17 Remove the timing bell as described in Section 4. 16 The camshaft sprocket must now be held stationary while the retaining bolt is loosened. To
cto this,
make up a tool as follows and engage it
with the
holes
in
the sprocket (see Tool Tip). 19 Alternatively pass a rod through one of the holes in the camshaft sprocket to prevent it rotating. Position a pad of rag or a piece of
integral key
securing bolt and washer...
wood under the rod to avoid damaging the cylinder head. 20 Unscrew the bolt and slide the sprocket from the end of tho camshaft. Note the integral location key on the inner face of the sprocket (see illustrations). Inspection 21 With the sprocket removed, examine the camshaft oil seal for signs of leaking. If necessary, refer to Section 7 and renew it. 22 Check the sprocket teeth for damage. 23 Wipe clean the sprocket and camshaft mating surfaces. Refitting 24 Locate the sprocket on the end of the camshaft, then refit the bolt and washer and tighten to the specified torque while holding the camshaft stationary using the method described previously. 25 Refit the timing belt as described in Section 4.
Crankshaft sprocket
Removal 26 Remove the timing belt as described in Section 4. 27 Working beneath the engine, unbolt and remove the flywheel lower cover, then hold the flywheel stationary preferably using a toot which engages the flywheel starter ring gear (see Section 10). Alternatively have an assistant engage a wide-bladed screwdriver with the stader ring gear. 26 Unscrew the crankshaft sprocket retaining bolt and slide the sprocket off the end of the
^P
5.32 Tighten the crankshaft sprocket bolt to the specified torque
end of the camshaft Integral location key (arrowed)
crankshaft. The sprocket may have an integral location key on its inner face (see illustration), or a separate key which locates in a groove in the crankshaft nose may be fitted. Inspection 29 With the sprocket removed, examine the crankshaft oil seal for signs of leaking. If necessary, refer to Section 8 and renew it. 30 Check the sprocket teeth for damage. 31 Wipe clean the sprocket and crankshaft mating surfaces. Refitting 32 Slide the sprocket onto the crankshaft making sure it engages the integral key or separate key, then refit the bolt and washer and tighten the bolt to the specified torque while holding the crankshaft stationary using the method described in paragraph 27 (see illustration). 33 Refit the timing belt as described in Section 4.
6 Camshaft cover -removal and refitting
Removal 1 Remove the air cleaner assembly and inlet duct as described in Chapter 4A or 4B. 2 Progressively unscrew the mounting bolts from the top of the camshaft cover and lift off the cover • note the location of any supports on the bolts (see illustration). If it sticks, do
6.2 Removing the camshaft cover

2B*7 DOHC (16-valve) petrol engine in-car repair procedures
35 Slacken the tensioner pulley retaining nut and reposition the tensioner to align the
mobile
indicator with the fixed reference mark
on the
pulley face (see illustration). Hold the
pdley in
this position and tighten the retaining
nut to the
specified torque. 36 Turn the crankshaft through a further two complete turns In the normal direction of rotation. Check that the timing is correct by alining Ihe piston positioning tools and
camshaft
locking tools as described previously. 37 When all is correct, remove the setting rri
locking
tools and refit the sealing plugs to 1ft© cylinder head extension, using new 0-
nr^s if
necessary. Tighten the plugs securely. 38 Refit the spark plugs as described in Chapter 1A. 39 Refit Ihe ECU and secure with Ihe mooning bolts. 40
Renew the
injector O-ring seals, smear them Kith
8 little
Vaseline then locate the injectors and tef rail onto the inlet manifold lower section.
Saute Ihe fuel rail
with the two retaining bolts. 41 Relit the inlet manifold upper section using new sealing O-rlngs If necessary and
sectre
with the two bolts. 42 Reconnect the wiring connectors for the tot injector harness and the intake air temp-erature/pressure sensor, then connect the fuel pressure regulator vacuum hose and tha
EVAP
purge valve hose. 43 Reconnect the wiring connectors for the ihrottls potentiometer, idle control stepper motor and coolant temperature sensor. Reconnect the brake servo vacuum hose. 44 Refit and adjust the accelerator cable as described in Chapter 4B. 46 Refit the upper and lower timing belt
covers
together with the TDC sensor wiring. 46 Refit the crankshaft pulley and tighten the
three
retaining bolts securely. 47 Refit the air cleaner. Inlet air duct and resonator as described in Chapter 4B. 48
Refit
tha auxiliary drivebelt(s) as described i/t Chapter 1A, then reconnect the battery
S Timing belt tensioner
and
sprockets -
removal
and refitting

Timing
belt tensioner
Removal I
Remove
the timing belt as described in
Section
4. 1 Completely unscrew the tensioner nut and Wiethe tensioner off the mounting stud-Inspection
3 Wipe
the tensioner clean but do not use Kfrents that may contaminate the bearings.
Spin
the tensioner pulley on its hub by hand.
Sfcfl
movement or excessive freeplay is an rcfceticn of severe wear: the tensioner is not 3 serviceable component, and should be nnewsd.
4.33 Holding the camshaft sprocket with the tool described previously while tightening the sprocket bolt Refitting 4 Slide the tensioner pulley over the mounting stud and fit the securing nut. 5 Refit the timing belt as described in Section 4. Camshaft sprocket Removal 6 Remove the timing belt as described in Section 4. 7 Unscrew the bolt and slide the sprocket from the end of the camshaft. Inspection 8 With the sprocket removed, examine the camshaft oil seal for signs of leaking. If necessary, refer to Section 6 and renew it. 9 Check the sprocket teeth for damage. 10 Wipe clean the sprocket and camshaft mating surfaces. Refitting 11 Locate the sprocket on the end of the camshaft, then refit the retaining boll finger tight only at this stage. 12 Refit the timing belt as described in Section 4.
Crankshaft sprocket Removal 13 Remove the timing bell as described In Section 4. 14 Working beneath the engine, unbolt and remove the flywheel lower cover, then hold the flywheel stationary preferably using a tool which engages the flywheel starter ring
<

Alternatively have an assistant engage a wide-bladed screwdriver with the starter ring gear. 15 Unscrew the crankshaft sprocket retaining bolt and slide the sprocket off the end of the crankshaft. The sprocket may have an integral location key on its inner face, or a separate key which locates In a groove in the crankshaft nose may be fitted. Inspection 16 With the sprocket removed, examine the crankshaft oil seal for signs of leaking. If necessary, refer to Section 7 and renew it. 17 Check the sprocket teeth for damage. 18 Wipe clean the sprocket and crankshaft mating surfaces. Refitting 19 Slide the sprocket onto the crankshaft making sure
11
engages the integral key or separate key, then refit the bolt and washer and tighten the bolt to the specified torque while holding the crankshaft stationary using the method described in paragraph 14. 20 Refit the timing belt as described in Section 4.
6 Camshaft
oil
seal -renewal
1 Remove the timing belt and camshaft sprocket as described in Sections 4 and 5. 2 Punch or drill a small hole in the oil seal. Screw a self-tapping screw into the hole, and pull on the screws with pliers to extract the seal. 3 Clean the seal housing, and polish off any burrs or raised edges, which may have caused the seal to fall in the first place. 4 Lubricate the lips of the new seal with clean engine oil, and drive it into position until It seats on its locating shoulder. Use a suitable tubular drift, such as a socket, which bears only on the hard outer edge of the seal. Take care nof to damage the seal lips during fitting. Note that the Seal lips should face inwards. 5 Refit the camshaft sprocket and timing belt as described in Sections 5 and 4.
7 Crankshaft oil seats -renewal I
4.35 Position the tensioner so that the mobile Indicator (1) is aligned with the fixed reference mark (2)
Front (right-hand side) oil seal 1 The front oil seal is located in the 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 the 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.

DOHC (16-valve) petrol engine in-car repair procedures 2B*11
camshaft cover plate... 25 Locate the cam follower retaining tools in position and refit the cylinder head extension
as
described In Section 8.

10
Cylinder head - &
removal and
refitting S
Removal Note; The cylinder head bolts are of special
sekned
design and a Fiat tool should be
obtained
to unscrew them. A Ton key will not
JSt however
in practise It was found that a dose-httlng Alien key could be used as an itemative. 1 Drain the cooling system as described in Chapter 1A. 2 Remove the cylinder head extension as oescAbed
m
Section 8. 3 Disconnect the radiator hose from the thermostat housing on the left-hand end of
Ihe
cylinder head. 4 Disconnect the heater hose from the outlet
at the
rear of the cylinder head. 5 Disconnect the coolant temperature sensor md temperature gauge sensor wiring plugs
torn
the left-hand end of the cylinder head. 9 Undo the engine oil dipstick tube bracket retaining bolt and the two bolts securing the wing harness support clips to the inlet marriold lower section. 7 Undo Ihe retaining nuts and separate the ixhaust system front pipe from the exhaust manifold flange.
8
Check that nothing remains attached to the cinder head likely to impede removal. It Is assumed that the head will be removed complete with exhaust manifold and inlet manifold lower section. 9 Unscrew the cylinder head bolts half a turn K
e
time in the reverse order to that shown in (lustration 10.20a. When the bolts are free. «mwe them from their locations.. Id Lift the cylinder head from the block. If it is stuck tight rock the head to break the joint by mans of the manifolds. On no account drive
levers
into the gasket Joint, nor attempt to tap tf« head sideways, as it is located on positioning dowels. 11 Remove and discard the cylinder head gasket.
JK'
l^. 9.22b ... then apply RTV gasket sealant to the cover plate contact face 12 Refer to Chapter 20 for cylinder head dismantling and inspection procedures. Preparation for refitting 13 The mating faces of the cylinder head and cylinder block must be perfectly dean 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 particular care when cleaning the piston crowns as the soft aluminium alloy is easily damaged. Make sure that the carbon is not allowed to enter the oil and water passages -this Is particularly important for the lubncahon system, as carbon could block the oil supply to the engine's components. Using adhesive tape and paper, seal the water, oil and bolt holes in the cylinder block. To prevent carbon entering the gap between the pistons and bores, smear a little 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 the pistons in the same way. 14 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 excessive, machining may be the only alternative to renewal. If warpage of the cylinder head gasket surface Is suspected, use a straight-edge to check it for distortion. Refer to Part 0 of this Chapter if necessary. 15 Check the condition of the cylinder head bolts, and particularly their threads, whenever they are removed. Wash the bolts In a suitable
sequence
9.24 Lubricate the cam followers and place them in position in their respective bores solvent, and wipe them dry. Check each bolt for any sign of visible wear or damage, renewing them if necessary.
Refitting 18 Before refitting the 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, 17 The now gasket should not be removed from its nylon cover until required for use. Fit Ihe gasket dry, and make sure that the mating surfaces on the head and block are perfectly clean. 18 Place the gasket on the cylinder block so that the word ALTO can be read from above. 19 Lower the cylinder head onto the block so that it locates on the positioning dowel. 20 The cylinder head bolt threads must be clean and lightly lubricated. Screw the bolts in finger-tight then working progressively and in the sequence shown, lighten all the cylinder head bolts to the Stage 1 torquo 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 the 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 during this stage ot tightening, to ensure accuracy (see Illustrations). 21 Reconnect the exhaust system front pipe to the manifold using a new flange gasket.
10.20b Tighten the cylinder head bolts to the Stago 1 torque setting ...

Diesel engine in-car repair procedures
2C*11

5.31c ... followed by the Woodruff key
rocking motion to remove It, Note that the sprocket Is located by an integral key. Inspection 23 With the sprocket removed, examine the crankshaft oil seal for signs of leaking. If necessary, refer to Section 8 and renew it. 24 Check the sprocket teeth for damage. Also check the key and if necessary renew it. 25 Wipe clean the sprocket and crankshaft mating surfaces. Refitting 26 Slide the sprocket onto the crankshaft and engage the key with the slot In the crankshaft. 27 Refit the bolt, washer and spacer and tighten the bolt to the specified torque white holding the crankshaft stationary using the method described in paragraph 21. 28 Refit the timing belt as described in Sectton 4.
6.3a Support bracket positions on the camshaft cover
5.31a Use a puller to release the sprocket from the injection pump shaft
5.35 Tightening the injection pump sprocket bolt
Injection pump sprocket
Removal 29 Remove the timing belt as described In Section 4. 30 Using a suitable tool hold Ihe injection pump sprocket stationary, then unscrew the nut securing the sprocket to the injection pump shaft (see illustration). 31 Using a suitable puller remove the sprocket from the end of the injection pump shaft and recover the Woodruff key from the groove (see illustrations),
Inspection 32 With the sprocket removed, check the sprocket teeth for damage. Also check the key and if necessary renew It. 33 Wipe clean the sprocket and injection pump shaft,
5.31b Removo tho injection pump sprocket...
Refitting 34 Locate the key in the groove making sure that it is fully Inserted and parallel with the shaft surface. 35 Refit the sprocket onto the Injection pump shaft then refit the bolt and washer and tighten the bolt to the specified torque while holding the sprocket stationary (soe illustration). 36 Refit the timing belt as described In Section 4,
6 Camshaft cover -removal and refitting ^
Removal 1 Remove the air ducting from the camshaft cover as described in Chapter 40, Section 2. 2 Unclip the coolant hoses from the camshaft cover and tie them out of tho way. 3 Note the position of the support brackets then progressively unscrew the mounting bolts from the top of the camshaft cover and lilt off the cover (see illustrations). If it sticks, do not attempt to lever it off • instead free it by working around the cover and tapping it lightly with a soft-faced mallet. 4 Recover the camshaft cover gasket. Inspect the gasket carefully, and renew It if damage or deterioration is evident (see illustration). 5 Clean the mating surfaces of the cylinder head and camshaft cover thoroughly, removing all traces of oil and old gasket • take oaro to avoid damaging the surfaces as you do this.
6.4 ... and gasket

2C*2 Diesel engine in-car repair procedures
Refitting 6 Locate a new gasket on the cylinder head and make sure tt Is correctly seated. 7 Lower the cover onto the gasket making sure the gasket Is not displaced, 8 Insert the mounting bolts and tighten them securely In a progressive sequence. Position Ihe support brackets as noted during removal. 9 Clip ihe coolant hoses in position then refil the air ducting.
7 Camshaft oil seal -renewal
8 Crankshaft oil seals -renswal I
9 Cylinder head -
removal
and refitting
1 Remove the timing belt and camshaft sprocket as descnbed in Sections 4 and 5. 2 Using a suitable hooked instrument, remove tho oil seal from the cylinder head taking care nol to damage the surface of the camshafl. Alternatively drill a small hole In tho oil seal and Insert a self-topping screw - the seal can then be removed by pulling on the screw with a pair of pliers. 3 Clean the seating In the cylinder head and tho end of the camshaft To prevent damage to the new oil seal as It is being fitted, wrap some adhesive tape around the end ol the camshaft and lightJy oil it. 4 Dip tho new ail s«al In oil then locate it over Ihe camshaft making sure that the sealing lips are facing inwards. 5 Using a suitable tubular drift, drive the oil seal squarely into the cylinder h*ad. Remove the adhesive tap© 6 Refit the camshaft sprocket and timing belt with reference to Sections 6 and 4.
Front (right-hand side) oil seal t The front oil seal is located in the oil pump casing 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 suitable hooked instrument, remove the oil seal from the oil pump casing taking care not to damage the surface of the crankshaft. Alternatively drill a small hole In the oil soal and insert a self-tapping screw - the seal can then be removed by pulling on the screw with a pair of pliers. 3 Clean the seating in the oH pump and the surface of the crankshaft. To prevent damage to the new off seal as It Is being fitted, wrap some adhesive tape around the end of tha crankshaft and lightly oil it. 4 Oip the new oii seal In oil then otter it up to the oil pump casing making sure that the sealing Hps are facing inwards,
8.Ba Rear oil soal and housing
5 Using a suitable tubular drift, driva the oil sea! squarely into the casing. Remove the adhesive tape. 6 Refit the crankshaft sprocket and timing belt with reference to Sections 5 and 4.
Rear (left-hand side) oil seal Note: The following paragraphs describe renewal of the rear oil seal leaving the housing In position. The alternative mathod is to remove the housing and renew the oil seel on the bench, however there is then the possibility of damaging the sump gasket. Refer to Chapter 2D for details of removing the mar oil sea! housing. 7 Ramove the flywheel as described in Section 10. 8 Using a suitable hooked Instrument. remove 1he oil seat from the roar oil seal housing taking care not to damage Ihe surface of Ihe crankshaft. Alternatively dnll a small hole In the o» seal and insert a self-tapping screw - the seal can ihan be removed by pulling on the screw with a pair of pliers (see Illustrations), 9 Clean the seating in the housing and the surface of the crankshaft. Check the crankshaft for burrs which may damage the oil seal tip of tno new saal, and It necessary use a Una file to removothem. 10 Dip the new soal in clean engine oil and carefully tocato it over tho crankshafl rear Range making sure that
H
the correct way round. 11 Progressively tap the oH seal into the housing keepfng it square to prevent distortion. A block of wood is useful for this purpose. 12 Refit the flywheel with reference to Section 10.
I
5.8b Using a self-tapping screw and pliers to remove the rear oil seal
Removal Note: The cylinder head bolts are of special splined design and a Fiat tool should be obtained to unscrew them. A Torn key will
not
fit however In practise It was found that a close-fitting Allen key could bo used as an alternative. 1 Disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual), 2 Remove tha battery as described In Chapter 5A. 3 Refer to Chapter IB and carry out the following: o) Drain the engine oil, b) Drain the cooling system. 4 Remove the timing belt as described in Section 4. 5 Unbolt and remova the relay guard and bracket from the left-hand side of the engine. 6 Unbolt and remove the battery mounting tray and disconnect the wiring and lines from the modulator valva and relays. 7 Remove the air eleanar assembly and air duct with reference lo Chapter 4C. 8 Loosen the clip and disconnect the vacuum hosa from the vacuum pump on the left-hand end of the cylinder head. 9 Loosen Ihe clips and disconnect the radiator top hose from the cylinder head outlet. Also disconnect the heater inlet hose from the thermostat housing, 10 Loosen the clips and disconnect the expansion tank and heater outlet hoses. 11 Identify all wiring connectors then disconnect them from the cylinder head, 12 Unscrew the expansion tank mounting screws, then disconnect tha expansion tank hoses at their connections to the engine. Remove the expansion tank from tha engine compartment. 13 Release tha clip and disconnect ihe crankcase breather from the left-hand rear of the cylinder head. 14 Unbolt the power steering pump uppar cover bracket then unscrew the pivot ana adjustment bolts while leaving ihe tMd lioses still attached. Release the drivebelt (if still In place) then tie the pump to the bulkhead. 15 Loosen tha clips and disconnect Ihe short coolant hose from the cylinder head outlet to the coolant pump (soe illustration). 18 At the rear of the engine, unbolt and disconnect the oil delivery pipe from the turbocharger (where applicable) and crankcase (see Illustrations). 17 Disconnect the return hose from tha thermostat housing to the coolant pump (see Illustration), 18 Unbolt the metal coolant return pipe and pull it out from the coolant pump inlet elbow (see Illustrations).
expert22 flna http://rutracker.org

2D*10 Engine removal and overhaul procedures
60 At the otl filter, unscrew the union nuts and disconnect the oil cooler lines/hoses then remove the oil cooler from the vehicle (see Illustration). Be prepared for some oil leakage. Note the fitted position of the hoses before disconnecting them so that they can be refitted correctly. 61 Disconnect the reversing light wiring from Ihe switch on the front of the transmission (see illustration) 82 Using an Allen key, unscrew the bolts securing the inner ends of the driveshafts to the flanges on the transmission. The right-hand driveshaft is disconnected from the Intermediate shaft flange on the rear of the engine. Recover the plates beneath the heads ol the driveshaft bolls (see illustrations). 63 Unscrew the bolts securing the front sv/lvel hub assemblies to the struts. Also
4.59c Removing the radiator from the vehicle
4.62a Use an Allen key to unscrew the inner driveshaft bolts
release the flexible brake hoses from the struts. 64 Move the swivel hub assemblies outwards and support the inner ends of the dnveshafts on axle stands (see Jacking and vehicle support). Take care not to strain the flexible brake hoses. 65 Remove the exhaust front pipe with reference to Chaptor 4D. If difficulty is expenenced in separating Ihe front pipe from the intermediate pipe, it may prove easier to remove the complete exhaust system. Ail models 66 Attach a suitable hoist to the engine and transmission lifting eyes (see illustration). The left-hand eye is located on the transmission and the right-hand one on the right-hand side of the engine, Take the weight of the engine/transmission.
4.60 Loosening the union nuts securing the oil cooler lines to the oil filter housing
4.62b Removing the driveshaft bolts and plates
67 Working boneath the vehicle, unscrew the bolts securing tne rear engine mounting to the underbody and transmission, and withdraw the mounting. 68 In the engine compartment, unscrew the bolts securing the right-hand engine mounting to the body and engine. For additional working room completely remove the mounting. 69 Unscrew the boils securing the left-hand engine/transmission mounting to the body. For additional working room completely remove Ihe mounting. 70 With the help of an assistant lower the engine/transmission from the engino compartment taking care not to damage the surrounding components (see illustration). Ideally lower the unit onto a low trolley so that it may be withdrawn from under the vehicle. Disconnect the hoist from ihe assembly.
4.61 Disconnecting the reversing light wiring
4.66 Attaching a hoist to tho ongine and transmission assembly

2D*10 Engine removal and overhaul procedures
12.18 Angle-tightening the main bearing cap bolts (petrol engine)
12.Ida Application area for silicone Instant gasket on crankshaft rear oil seal housing (petrol engine) 12.19b Refitting the crankshaft rear oil seal housing (petrol engine)
19 Fit a new oil seal to the crankshaft rear oil seal housing. Apply grease to the seal lips. On 1108 cc petrol engines a conventional gasket Is not used at the oil seal retainer joint face, but a 3 mm diameter bead of RTV (Instant) silicone gasket must be applied as shown -allow at least one hour 1or the gasket to cure before oil contacts it. On all other engines a gasket Is fitted Securely tighten the housing bolts (see Illustrations). 20 Check that Ihe crankshaft rotates freely by turning It by hand. If resistance Is fell, re-check the running clearances, as described above. 21 Carry out a check of the crankshaft endfloat as described at the beginning of Section 8. If the thrust surfaces of the crankshaft have been checked and new thrust washers hove been fitted, then the endfioat should be within specification.
22 Refit the pistons and connecting rods as described in Section 7. 23 Refit the flywheeVdriveplate, and-vibration plate (16-valvo engines), oil pump and pick-up tube, and sump with reference to the relevant Sections of Parts A, B or C of this Chapter.
13 Engine -initial start-up after overhaul and reassembly
1 With the engine refitted In the vehicle, double-check the engine oil and coolant levels. Make a final check that everything has been reconnected, and that there are no tools or rags left In the engine compartment.
Petrol engine models 2 Remove the spark plugs, then disable the
ignition system by disconnecting the LT wiring plug to the ignition colls. 3 Turn the engine on the starter until Ihe oi pressure warning light goes out. Refit ihe spark plugs, and reconnect the LT wiring.
Diesel engine models 4 Disconnect tho wiring from the stop solenoid on the Injection pump, then turn the engine on the starter motor until the oil pressure warning light goes out. Reconnect ihe wire to the stop solenoid. 6 Fully depress the accelerator pedal, turn tho ignition key to its first position and wait tor HHJ preheating warning light to go out.
All models 6 Start the engine, noting that this may take i little longer than usual, due to the fuel system components having been disturbed.
12.19c On diesel engines use a screwdriver to prise out the rear oil seal 12.19d Locate the new oil soalln the housing (diosel engine)... 12.19e ... and use a block of wood to drive it in
12.19f On Diesel engines fit the gasket to the cylinder block ... 12.19g ... then locate the rear oli seal housing... 12.19h ... and Insert the bolts

4A*2 Fuel system - single-point petrol Injection models
motor c) Ensure that all hoses are correctly reconnected and, where necessary, that their retaining clips are securely tightened. d) Adjust the accelerator cable as described In Section 4.
Fuel injector Note: If a faulty Injector Is suspected, before condemning the Injector, it is worth vying the effect of one of the proprietary Injector cleaning treatments. Removal 8 Remove the air cleaner and air duct as described In Section 2. 9 Disconnect the wiring then unscrew the mounting screws and remove Ihe Injector from the throttle body. Refitting 10 Refitting is a reversal of removal.
Fuel pressure regulator
Removal 11 Remove Ihe air cleaner and air duel as described In Section 2. 12 Using a marker pen. make alignment marks between the regulator cover end the throttle body, then undo the four retaining
screws. As the screws are loosened, place a rag over the cover to catch any fuel spray which may be released. 13 Lift off the cover, then remove the spring and withdraw the diaphragm, noting Its correct fitted orientation. Remove all traces of dirt, and examine the diaphragm for signs of splitting. If damage Is found, it will be necessary to renew the complete upper throttle body assembly. Refitting 14 Refitting is a reversal of removal ensuring that the diaphragm and cover are fitted the correct way round, and that the retaining screws are securely tightened,
Idle control stepper motor
Removal 15 Disconnect the battery negative terminal (refer to Disconnecting the battery In the Reference Section of this manual), then remove the air cleaner and air duct as described in Section 2. 16 Using a crosshead screwdriver, unscrew the mounting screws and remove the stepper motor from the throttle body. Recover the gaskei (see illustration). 17 Clean the unit and check for damage and wear. Refitting 18 When refitting the unit use a new gasket and make sure that the plunger is inserted correctly using the following procedure. Insert the unit and refit the mounting screws loosely. Reconnect the wiring then switch on the ignition several times so that the unit centralises itself. Finally fully tighten the mounting screws to the specified torque. Note: The mounting screws are covered with a locking agent and must be renewed every time they are removed 19 Leave the battery negative terminal disconnected for about 20 minutes - the injection/ignition ECU will position the Idle control stepper motor correctly the first time the engine is started. Reconnect the battery negative terminal.
Throttle potentiometer
Removal 20 Remove the air cleaner and air duct as described in Section 2. 21 Disconnect the wiring from the throttle potentiometer. 22 Using an Allen key unscrew the mounting screws then withdraw the unit from the throttle body (see Illustration). Note: The mounting screws ere covered with a locking agent and must be renewed every time they are removed. Refitting 23 When refitting the unit make sure that the pin Is correctly engaged, and tighten the mounting screws to the specified torque. 24 If a Rat test Instrument is available, the
operation of the throttle potentiometer can be checked at this stage. Before connecting the wiring first turn Ihe ignition key to position MAR and wait a few seconds, then return the key to the STOP position, Reconnect the wiring and connect the test instrument. Turn the Ignition key to the MAR position and cancel the error that will appear. The throttle position Indicated should be between 0° and 4°. If greater than this, check thai the accelerator cable is correctly adjusted however If the correct reading cannot be obtained renew the unit.
Inlet air temperature sensor
Removal 25 Remove the throtlle body assembly as described earlier In this Section. 28 Extract the plastic pins and remove the press-fit cover from the top of the throttle body. 27 Invert the cover then unscrew the mounting screws and remove the Inlet air temperature sensor from the cover. Refitting 28 Refining Is a reversal of removal.
Manifold absolute pressure (MAP) sensor
Removal 29 The manifold absolute pressure sensor is located on the left-hand side of the bulkhead. 30 Unscrew the mounting screws and remove the sensor from the bulkhead, Disconnect the wiring and vacuum pipe. Refitting 31 Refitting is a reversal of removal, but check the condition of the vacuum pipe and renew it if necessary.
Coolant temperature sensor
Removal 32 The coolant temperature sensor Is located on the left-hand side of the inlet manifold. Drain the cooling system as described In Chapter 1A before removing it. 33 Disconnect the wiring. 34 Unscrew the sensor and remove It from the Inlet manifold. If using a socket take care not to damage Ihe wiring connector on the sensor. Refitting 35 Refitting Is a reversal of removal bui tighten Ihe sensor to the specified torque. Do not exceed the specified torque otherwise the unit may be damaged.
Crankshaft TDC sensor
Removal 36 The crankshaft TDC sensor Is located on the front side of the crankshaft pulley. Firmly apply the handbrake, then jack up the front of the car Bnd support It securely on axle stands (see Jacking end vehicle support). Remove 5.22 Throttle potentiometer mounting screws