1994 FIAT PUNTO Workshop Manual

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.

Lubricants and fluids 0.17
Lubricants and fluids
Engine Petrol Multigrade engine oil, viscosity SAE15W/40, to API SG/CD or better (Duckhams QXR Premium Petrol Engine Oil, or Duckhams Hypergrade Petrol Engine Oil) Diesel Multigrade engine oil, viscosity SAE15W/40, to API SG/CD or better Duckhams QXR Premium Diesel Engine Oil, or Duckhams Hypergrade Diesel Engine Oil) Cooling system Ethylene glycol-based antifreeze and soft water (Duckhams Antifreeze & Summer Coolant) Manual gearbox Hypoid gear oil, viscosity SAE80W to API GL4 (Duckhams Hypoid Gear Oil SOW GL-4) Automatic transmission Dexron type II automatic transmission fluid (ATF) (Duckhams ATF Autotrans III) Braking system Hydraulic fluid to SAE J1703F or DOT 4 (Duckhams Universal Brake & Clutch Fluid) Power steering Dexron type II automatic transmission fluid (ATF) (Duckhams ATF Autotrans Hi)
Choosing your engine oil
Engines need oil. not only to lubricate moving parts and minimise wear, but also to maximise power output and to Improve fuel economy. By introducing a simplified and improved range of engine oils. Duckhams has taken away the confusion and made it easier for you lo choose the right oil for your engine.
HOW ENGINE OIL WORKS
• Beating friction Without oil. the moving surfaces inside your engine will rub together, heat up and melt, quickly causing the engine to seize. Engine oil creates a film which separates these moving parts, preventing wear and heat build-up.
• Cooling hot-spots Temperatures Inside the engine can exceed 1000°
C.
The engine oil circulates and acts as a coolant, transferring heat from the hot-spots to the sump.
• Cleaning the engine internally Good quality engine oils clean the Inside of your engine, collecting and dispersing combustion deposits and controlling them until they are trapped by the oil niter or flushed out at oil change.
OIL CARE - FOLLOW THE CODE To handle and dispose of used engine oil safety, always: • Avoid skin contact with used engine oil. Repeated or prolonged contact can be harmful. • Dispose of used oil and empty packs In a responsible manner In an authorised disposal site. tti Call 0800 663366 to find qIqq f £ the one nearest to you. Never tip oil down drains or onto the ground.
DUCKHAMS ENGINE OILS For the driver who demands a premium quality oil for complete reassurance, we recommend synthetic formula Duckhama QXR Premium Engine Oils. For the driver who requires a straight-forward quality engine oil, we recommend Duckhams Hypergrade Engine Ote.
For further information and advice, call the Duckhams UK Helpline on 0800 212988.
^SGCKHAMS

o.i8 Tyre pressures
Tyre pressures (cold)
Front Hear Petrol models (average load): 155/70R13.165/60R14,16S/65R13.165/65R14,175/60R14 2.0(29) 1.9(28) 165/65R14 78Q (M+-S) 2.5(36) 2.2(32) 185/55/R14 2.4(35) 2.0(29) 135/80B13,135/80B14 (space-saver spare tyre) 2.8(41) 2.8(41)
Petrol models (fully laden): 155/70R13,165/60R14.165/65R14,175/60R14 2.2 (32) 2.2 (32) 165/65R14 78Q (M+S) 2.5(36) 2.2(32) 185/55/R14 2.4(35) 2.2(32) 135/80B13,135/80B14 (space-saver spare tyre) 2.8 (41) 2.8 (41)
Diesel models (average load): 165/70R13.165/65R14,175/60R14 2.4(35) 2.0(29) 135/80B13.135/80B14 (space-saver spare tyre) 2.8(41) 2.8(41)
Diesel models (fully laden): 165/70R13,165/65R14,175/60R14 2.4 (35) 2.2 (32) 135/80B13,135/80B14 (space-saver spare tyre) 2.8 (41) 2.8 (41)

1A»1
Chapter
1
Part A:
Routine maintenance & servicing - petrol models
Contents

Air
filter renewal 18 Automatic transmission filter and fluid change 2B Auxiliary dr cmI
and filter renewal 3 Evaporative loss system check 27 Exhaust system check 8 From brake pad check 5 Fuel filter renewal 17 Headlight beam adjustment 23 Hinge and lock lubrication 22
Hose and fluid leak check 7 Idle speed and CO content check and adjustment .11 Ignition system check 20 Introduction 1 Lambda/oxygen sensor check 25 Manifold mounting check 16 Manual transmission oil level check 26 Manual transmission oil renewal .32 Pollen filter renewal 10 Rear brake shoe check 29 Regular maintenance 2 Road test 24 Spark plug renewal 19 Steering and suspension check 12 Timing belt renewal 30 Underbody sealant check 6 Valve clearance check and adjustment 15
Degrees of difficulty
Easy, suitable for ^ novice with little experience ^
Fairty easy, suitable for beginner with ^ some experience
FaMy difficult, ^ sitable for competent jj^ DIY mechanic ^
Difficult, suitable for experienced DIY aJ mechanic ^
Very difficult, ^ suitable for expert DIY or professional ^
expert22 fl/ia http://rutracker.org

ia.2 Servicing specifications - petrol models
Lubricants and fluids Refer to end ot Weekly checks on page 0*17
Capacities Engine oil (including filter) 1108 cc engine 3.47 litres 1242 cc (8-valvB) engine 3.74 litres 1242 cc (16-valve) engine 2.80 litres Cooling system 4,6 litres
Manual transmission 5-spee d 1.65 litres 6-spee d 1.87 litres Automatic transmission 1.98 litres Power-assisted steering 0.65 Irtres Fuel tank 47 litres Washer reservoir Wllhouthesdllghl washers 2.5 litres With headlight washers 7.0 litres
Engine Olf niter - Champion F107 Auxiliary drivebelt tension 5.0 mm deflection midway between pulleys Valve clearances - engine cold: Inlet Exhaust 1108 cc and 1242 cc (single-point petrol injection) 0.40±0.05mm 0.50±0.05mm 1242 cc (multi-point petrol Injection 0.40 1 0.05 mm 0.45 1 0.05 mm
Cooling system Antifreeze mixture (50% antifreeze) Protection down to -35"C Note: Refer to antifreeze manufacturer for latest recommendations.
Fuel system Engine idle speed . 900 * 50 rpm CO 0.35 maximum Air filter element: 1108 cc engine with 6-speed transmission -... Champion U647 1108 cc engine (Easl Europe) Champion U648 1242 cc engine (60 models) Champion U647 1242
CO
engine (75.85 and Sporting models) Champion U649 Fuel filler: Up to September 1995 October 1995 onwards 1108 cc engine Champion L213 Champion L225 1242 cc engine (60 models) Champion L213 Champion 1225 1242 cc engine {75 models) Champion L203 Champion L225
Ignition system Ignition liming Refer to Chapter 58 Spark plugs: Type Gap* 1108 cc and 1242 cc (6-valve) engines Champion RC9YCC 0.9 mm 1242 cc (16-valve) engine ,... Champion RA4HCC 0.8 mm The spark plug gap quoted Is Diet recommenced by Champion for their specined plugs listed above. If spar* plugs of any other type ere to be fitted, refer to their manufacturer's recommendations. Brakes Brake pad lining minimum thickness 15 mm Brake shoe friction material minimum thickness 2.0 mm
Torque wrench settings Nm itrfft Automatic transmission lluld drain plug 25 10 Automatic transmission fluid sump bolts 4 3 Manual transmission oil drain plug: Stage 1 12 9 Stage 2 Angle-lighten a further 180" Manual transmission oil filler plug 40 30 Roadwheel bolts 86 83 Spark plugs 27 20 Sump drain plug 10 7

Maintenance schedule - petrol models 1A.3
The maintenance Intervals in this manual are provided with the assumption that you, not the dealer, will be carrying out the work. These axe the minimum maintenance intervals recommended by us for vehicles driven daily.
if you wish to keep your vehicle in peak condition at all times, you may wish to perform some of these procedures more often. We encourage frequent maintenance, because it enhances the efficiency.
performance and resale value of your vehicle. When the vehicle Is new, it should be serviced by a factory-authorised dealer service department, In order to preserve the factory warranty.
Every 250 miles (400 km) or weekly Q Refer to Weekly checks
Every 5000 miles (7500 km) or
6 months - whichever comes first • Renew the engine oil and filter (Section 3)
Note: Frequent oil and fitter changes am good tor the engine. We recommend changing the oil at the mileage specified here, or at least
twice
a year if the mileage covered Is a less.
Every 10 000 miles (15 000 km) or
12 months - whichever comes first
In
addition to the items listed above, cany out the following: Q Check the operation of the brake warning lamp (Section 4) • Check the front brake pads for wear (Section 5) • Check the underbody and sealant for damage (Section 6) • Hose and fluid leak check (Section 7) • Check the condition of the exhaust system and its mountings (Section 8) • Check the condition of the driveshaft gaiters (Section 9) • Renew pollen filter (Section 10) • Check exhaust gas content and idle speed (Section 11) • Check the steering and suspension components for condition and security (Section 12)
Every 20 000 miles (30 000 km) or
2 years - whichever comes first
In
addition to the Items listed above, carry out the following: • Check and if necessary adjust the tension of the auxiliary drlvebelt(s) (Section 13) • Check the freeplay and height of the clutch pedal (Section 14) • Check and if necessary adjust the valve clearances (Section 15) HI Check and if necessary tighten inlet and exhaust manifold mountings (Section 16) • Renew the fuel filter (Section 17) D Renew the air filter element (Section 18) O Renew the spark plugs (Section 19) • Check the condition of the HT cables (Section 20) • Check the engine management system (Section 21) Q Lubricate all hinges and locks (Section 22) O Check the headlight beam adjustment (Section 23) • Carry out a road test (Section 24)
Every 30 000 miles (45 000 km) or
3 years - whichever comes first In addition to the items listed above, cany out the following: • Check the operation of the Lambda sensor (Section 25) • Check and if necessary top-up the manual transmission oil level (Section 26) • Check the operation of the evaporative loss system (Section 27) • Automatic transmission inner filter and fluid renewal (Section 28)
Every 40 000 miles (60 000 km) or
4 years - whichever comes first In addition to the items fisted above, carry out the following: • Check the rear brake shoes for wear (Section 29) • Renew the timing belt (Section 30)"
*Noto: Although the normal interval for timing belt renewal is 70 000 miles (105 000 km), It is strongly recommended that the belt Is renewed at 40 000 miles (60 000 km) on vehicles which are subjected to Intensive use, ie. malniy short Journeys or a let of stop-start driving. The actual belt renewal Interval Is therefore very much up to the individual owner, but bear in mind that severe engine damage will result if the belt breaks.
Every 60 000 miles (90 000 km) or
6 years - whichever comes first in addition to the items listed above, cany out the following: • Check the condition and operation of the crankcase emission control system (Section 31)
Every 80 000 miles (120 000 km) • Renew the manual transmission oil (Section 32)
Every 2 years
(regardless of mileage) • Renew the engine coolant (Section 33) • Renew the brake fluid (Section 34)

ia«4 Component location - petrol models
Underbonnet view -1108 cc engine model
1 Engine oil filler
cap
2 Engine oil dipstick 3 Brake vacuum servo unit 4 Brake fluid
reservoir
5 Air cleaner
cover
6 Coolant expansion lank 7 Windscreen washer fluid reservoir 8 Front suspension strut upper mounting 9 Ignition coil cover 10 Engine wiring connector cover 11 Battery 12 ECU
Underbonnet view - 1242 cc (8-valve) engine model
1 Engine oil tiller
cap
2 Engine oil dipstick 3 Brake vacuum servo unit 4 Brake fluid
reservoir
5 Air cleaner cover 6 Coo/ant expansion tank 7 Windscreen washer
fluid
reservoir 8 Front suspension strut upper mounting 9 Ignition coil cover 10 Engine wiring connector cover 11 Battery 12 ECU

Component location - petrol models 1A.5
Underbonnet view - 1242 cc (16-valve) engine model
1
Engine
olt filler
cap
2
Engine
oil dipstick 3
Brake
fluid
reservoir
4
Power
steering fluid reservoir 5
Engine
wiring connector cover 6
Windscreen
washer
fluid
reservoir 7 Battery 8
Coolant
expansion
tank
9 Air cleaner
cover
10 Resonator 11 ECU
1
Oil filter
2
Sump
drain plug 3
Transmission
drain plug A
Electric
cooling Ian unit 5
Left-hand driveshaft
6
Intermediate shaft
7
Right-hand driveshaft
B
Front
suspension lower arms 9
Front
anti-roll
bar
10
Exhaust
downpipe 11
Front
brake calipers (2
Rear engine
mounting IS Radiator bottom hose
Front underbody view (diesel model shown, petrol model similar)