1994 FIAT PUNTO washer fluid

Suspension and steering 10*5
3,9s Withdraw the coll spring, complete with the compressors ... 3.9b ... then withdraw the dust cover and bump rubber 3.9c Fully dismantled strut
10 With the strut assembly now dismantled, examine all the components tor wear, damage or deformation. Check the rubber com-ponents for deterioration. Renew any of the components as necessary. 11 Examine tho damper for signs of fluid teakage. Check the damper rod for signs of pitting along its entire length, and check the stjul body for signs of damage. White holding fc
in an
upright position, test the operation of
Ihe
stmt by moving Ihe damper rod through a fut stroke, and then through short strokes of
SO
to 100 mm. In both cases, the resistance Id should be smooth and continuous. If the resistance is jerky, or uneven, or if there is any wsible sign of wear or damage to the strut, renewal is necessary. Note that the damper cannot be renewed independently, and if leakage, damage or corrosion Is evident, the complete strut/damper assembly must be renewed {in which case, the spring, upper mounting components, bushes, and associated components can be transferred to
Ihe
new strut). 12 If any doubt exists about the condition of
Ihe
coil spring, carefully remove the spring compressors, and check the spring for distortion and signs of cracking. Renew the spring if it is damaged or distorted, or if there isany doubt about its condition. a Warning: Coil springs are /j\ classified by their height when '
11
• undor load • this Is indicatod by a
coloured
paint marking on the side of the
coll windings (either green or yellow). All coll springs fitted to tho vehicle must be of the same classification to ensure the correct ride height. 13 Clamp the strut body in a vice, as dunng dismantling, then refit the lower spring seat rubber (where fitted), dust cover and bump rubber. 14 Ensure that the coil spring is compressed sufficiently to enable the upper mounting components to be fitted, then fit the spring over the damper rod. ensuring that the lower end of the spring is correctly located In the recess on the lower spring seat (soe illustration). 15 Refit the upper spring seat and upper mounting plate ensuring that the top end of
the spring is correctly located on the upper spring seat. Note that when the strut is reassembled, the orientation marking on the upper rubber mounting must be positioned in relation to the metal section of the upper mounting plate as shown, to maintain the correct front wheel castor setting (see illustration). 10 Fit the new damper rod top nut together with its washer and bush, then tighten the nut to the specified torque, counterholding the damper rod in a manner similar to that used during dismantling. Note that a suitable crows-foot adapter will be required to tighten the damper rod top nut to the specified torque. 17 Remove the spring compressors. Where applicable, refit the protective plastic cap over the damper rod top nut.
Refitting 18 Manoeuvre the strut assembly into position under the wheel arch, passing the locating stud clip through the holes in the body turret. Note that when the strut is refitted, the orientation marking on the upper mounting plate rubber mounting must be positioned in relation to the vehicle as shown, to maintain the correct front wheel castor setting • refer to illustration 3.15. Fit the upper mounting bolts, and tighten them to the specified torque (see illustration). 19 Engage Ihe lower end of the strut with the
3.14 Ensure that the lower end of the spring is correctly located in the recess (arrowed) on the lower spring seat
3.15 Correct positioning of the suspension strut upper mounting components A Left hand mounting for vehicles with manual steering B Left hand mounting tor vehicles with power-assisted steering C To front of vehicle O Orientation marking 3.18 Fit the strut upper mounting bolts, and tighten them to the specified torque

Bodywork and fittings
11
*5
8.2 Release the fixings and lower the trim panel away from the tailgate
Refitting 7 The pumper is refitted by following the removal procedure In reverse.
8 Tailgate- ^ removal and refitting
Removal 1 Disconnect the battery negative tormina) {refer to D/sconnecf/ng the battery In the Reference Section of this manual}. 2 Release the press stud fixings and extract ihe screws, then lower the trim panel away from the tailgate (see illustration). 3 Working inside the tailgate, disconnect all wiring harness connectors and unbolt the earth leads. Check for any other wiring connectors which must be disconnected to facilitate tailgate removal. Note: Carefully label each wiring harness connector (o aid correct refitting. 4 Tie a length of cord to the wiring harness, then bind the loose ends of the cabling together using PVC tape. Prise the winng harness grommets from the upper edge of the tailgate, then feed the wiring through the aperture in the tailgate. Untie the cord from the harness, but leave it In place In the tailgate, to aid refitting later. 5 Where applicable, remove the fluid hose from the tailgate washer nozzle, as described in Chapter 12. Section 16. then tie a length of
8.2a Lever off the balljoint spring clip...
8.8 Slacken and unscrew the bolts (arrowed) securing the hinges to the tailgate
cord to the hose and draw it out of the tailgate, using the same procedure carried out on the wiring harness. 8 Have an assistant support the tailgate in the open position. 7 Detach the upper ends of the support stmts from the tailgate as described in Section 9. 8 Slacken and unscrew the bolts securing tho hinges to the tailgate (seo illustration), then lift the tailgate from the vehicle.
Refitting 9 Refitting is a reversal of removal, bearing in mind the following points. a) Tie the cord to the wiring harness and use It to pull the harness through the aperture and into the tailgate. Where applicable, repeat the procedure on the washer fluid hose. b) Do not fully tighten the hinge bolts until the tailgate adjustment has been checAed, as described in the following paragraphs.
Adjustment 10 Close the tailgate carefully, in case the alignment is Incorrect, which may cause scratching on the tailgate or the body as the tailgate is closed, and check for alignment with the adjacent panels. If necessary, slacken the bolts that secure the hinges to the bodywork and re-align the tailgate to suit. Once the tailgate is correctly aligned, tighten the hinge bolts securely.
9.2b ... and then prise strut balljoint from the stud on tho taitgate
11 Check that the tailgate fastens and releases In a satisfactory manner. If adjustment Is necessary, slacken the striker plate retaining bolts, and adjust the position of the lock to suit (see Section 10). Once the lock is operating correctly, securely tighten the striker plate retaining bolts. 12 If necessary, adjust the protrusion of the rubber buffers at the lower edge of the tailgate, by screwing them in or out as appropriate.
9 Tailgate strut - ^ removal and refitting
Removal 1 Open the tailgate and support it using suitable wooden props. 2 At the upper end of each strut, lever off the balljoint spring clip. Compress tho strut slightly by hand and then prise strut balljoint from the stud on the tailgate (see illustrations),

A


Warning: The strut may still be under tension and could extend suddenly once detached from Its mountings. 3 At the lower end of the strut, unbolt the joint Irom the bodywork. Refitting 4 Refitting is a reversal of removal.
10 Tailgate lock components -removal and refitting ^
Lock and cylinder assembly Removal 1 With the tailgate held In the fully open position, slacken and unscrew the bolts securing the lock assembly to tho lower edge of tho tailgate (soo illustration). 2 Carefully withdraw the lock assembly, together with tne lock cylinder (see Illustration).
10.1 Unscrew the bolts (arrowed) securing the lock assembly to the lower edge of the tailgate

Body electrical systems 12*11
15.6 Withdraw the motor assembly through the aperture in the tailgate
Refitting 7 Refitting is a reversal of removal. Refit the wiper arm with reference to Section 16.
16 Windscreen/tailgate washer % system components • ^ removal and refitting ^
Washer fluid reservoir
Removal 1 Ensure that the vehicle is parked on a level surface. Apply the handbrake and chock the rear wheels. Slacken the left hand front roadwheel bolts. 2 Raise the front of the vehicle, rest it securely on axle stands (see Jacking and vehicle support) and remove the left hand front roadwheel. 3 Disconnect the battery negative terminal {refer to Disconnecting the battery In the Reference Section of this manual). 4 Working from the engine bay, remove washer fluid reservoir upper securing screws. 5 Remove the secunng screws and lift off the front and rear sections of the wheel arch liner. 6 Remove fluid reservoir lower securing screws. 7 Disconnect the sviring plugs from the washer pumps, and from the fluid level sensor, where applicable. Label each connector to aid correct refitting later. 8 Disconnect the fluid hoses from the washer tx/mps • if the reservoir still contains fluid, be prepared tor spillage.
16.20a Remove the circllp...
9 Where applicable, release the wiring harness from its clips, and move the harness to one side to allow sufficient clearance to remove the reservoir. 10 Lower the reservoir from under the wheel arch. Refitting 11 Refitting is a reversal of removal.
Washer fluid reservoir and washer pump(s)
Removal 12 Remove the washer fluid reservoir, as described in the previous sub-Section. 13 Disconnect the wiring plug and the fluid hose from the relevant washer pump. 14 Release the spring clip, then pull the washer pump from the reservoir. Where applicable, recover the grommet. Refitting 15 Refitting is a reversal of removal.
IV/nctecreen washer nozzle
Removal 16 Open the bonnet. 17 Working under the bonnet, release the securing tabs using a suitable screwdriver, then push the nozzle from the bonnet. Disconnect the fluid hose, and withdraw the nozzle. Refitting 18 Refitting is a reversal of removal.
housing from the end of the wiper shaft
Tailgate washer nozzle
Removal 19 The tailgate washer nozzle is integral with the wiper motor shaft; remove the wiper motor as described in Section 15. 20 Remove the circllp and then slide the nozzle housing from the end of the wiper shaft (see illustrations). Refitting 21 Refitting is a reversal of removal, but ensure that the fluid hose is securely reconnected.
17 Windscreen wiper motor -removal and refitting ^
Removal 1 Disconnect the battery negative terminal (refer to Disconnecting the battery In the Reference Section of this manual). 2 Refer to Section 18 and remove both wiper arms. 3 Remove the securing screws and plastic clips, and withdraw the cowl panel (see illustrations). 4 Disconnect the motor wiring plug. 5 Slacken and withdraw the motor and linkage securing bolts, then withdraw the assembly from the bulkhead (see illustrations).
17.3a Remove the securing screws and plasUc clips... 17.3b ... and withdraw the cowl panel 17.5a Wiper motor and linkage left-hand ...