1994 FIAT PUNTO Panel

Bodywork and fittings
11
*11
securing the motor assembly/winder mechanism to the door 5 Uft the glass out through the window aperture in the top of the door, manipulating the glass past the weatherstrips as it is withdrawn. On 3-door models, it will be necessary to partially remove the weatherstrip from the upper edge of Ihe window aperture, to allow the glass to be withdrawn. Refitting 6 Refitting is a reversal of removal, bearing in mind the following points: a) Ensure that all weather stnps are
securely
seated on the edges of the window aperture. b) Check the operation of the window regulator mechanism before refitting the door inner trim panel. | 0 Refit the door inner trim panel with | reference to Section 14.
1 Door window regulator
Removal 7 Separate the window glass from the regulator mechanism, as described earlier. 6 Fully raise the window glass, and secure the glass In position using suitable tape, or by wedging the glass in position using rags between the glass and the edge of the door • ensure that the glass cannot drop into the door. Alternatively, lift the glass panel out 1 through the window aperture. 9 Where applicable, separate the two halves of the regulator motor wiring connector. I 10 Unscrew the bolts securing the motor assembly/winder mechanism to the door (see Illustration). t1 Unscrew the two upper and the two lower regulator mechanism securing bolts, then manipulate the complete regulator assembly out through the aperture in the door (see illustrations). 12 The winder/motor assembly, together with its associated control cables remains connected to the regulator mechanism (see Illustration), Note: Carefully mark the relationship between the guide rails and the door to ensure correct adjustment on refitting. Refitting
13 Refitting is a reversal of removal, bearing r mind the following points: a) Ensure that all weather strips are securely I seated on the edges of the window aperture
16.11c ... then manipulate the complete regulator assembly out through the aperture in the door b) Check the operation of the window mechanism before refitting the door inner trim panel. c) Refil the door inner tnm panel with reference to Section 14.
19 Facia - ^ removal and refitting 5
Removal 1 Disconnect the batlery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual). 2 Refer to Chapter 12 and carry out Ihe following: a) Remove the instrument panel from the facia.
19.5a Prise open the plastic covers...
18.11b ... and the lower regulator mechanism securing bolts...
assembly
b) Remove the radio/cassette unit from the facia 3 Unscrew the fixings for the storage bin above the radio aperture, then remove the bin from the facia. 4 Remove the steenng wheel (see Chapter 10) and the steering column shroud. 5 Prise open the plastic covers, remove the fixings and lift off the handbrake lever console (see Illustrations). 6 Work around the outside of the centre console and unscrew the fixings. Unclip the gear lever gaiter, lift the centre console over the gear lever, then label and unplug the wiring connector beneath and remove the console from the vehicle. 7 Remove the heater control panel from the facia, with reference to Chapter 3. 8 Unscrew the fixings from the upper and lower edges of the combined ventilation/
19.5b ... remove the fixings...

11 *12 Bodywork and fittings
switch panel, then remove the panel from the facia (see illustration). Label tho wiring connector to aid refitting, then unplug It. 0 Work along the lower edge of Ihe facia and remove all the securing screws; there are three on the drivers side and three on the passenger side - one is concealed inside the glove compartment, behind a plastic cap. 10 Wilh reference to Chapter 12, remove the cover and open the main fuse box. Where applicable, unscrew the fixings that secure the electronic control unit to Its mounting bracket. Remove the facia mounting bolts located adjacent to the mounting bracket (see illustration). 11 Refer to Chapter 10 and unbolt the steering column from Its support bracket, allowing the column to rest in the footwell. There is no need to slacken the clamp bolt at Ihe base of the steering column to separate it from the steering gear. 12 With reference to Chapter 12, remove front right and left speaker grilles. Remove the two facis upper mounting screws ihat are now exposed. Similarly, prise open the plastic cover from centre of upper edge of the fada and remove the mounting screw behind. 13 Carefully pull whole facia moulding forward away from tho bulkhead slightly. Label all wiring connectors to aid correct refitting later, then unplug Ihem. Check that nothing remains connected between the facia and bulkhead then draw the facia moulding away and remove It from the vehicle.
20.8 Remove the bolt (arrowed) and detach the backrest from the mounting bracket
Refitting 14 Refit the facia by following the removal procedure in reverse, noting the following points: a) Reinstate all electrical connections according to (he labels made during removal and ensure that cables are secured in their clips, using the origins/ routing. b) Ensure thai all ventilation ducting locates correctly over the rear of the grilles before tightening the facia retaining screws. c) On completion, reconnect the battery negative cable and chock the operation of all controls, gauges and Instruments disturbed during the removal process, Including the ventilation/heating system.
20 Seats -removal and refitting JS:
Front seats
Removal

A


Warning: On models with seat belt pre-tonsionors, entrust the work of seat removal to a Flat dealer. DQNOTattempt to remove the seat on vehicles so equipped. 1 The front seats frames are secured to the fioorpan by four bolts. Whero applicable, prise out the caps from the plastic trim panel lo expose the bolt heads. 2 Slide the seat towards the rear of the car to gain access to the two bolts at the front, Ihen slacken and withdraw them. 3 Slide Ihe seat fully forwards and remove the two rearmost bolls. 4 Ufl the seat out of the cabin area.
(arrowed) located adjacent to the control unit mounting bracket Refitting 5 Refil the seat by reversing the remove! procedure. Rear seat back rests
Removal 6 Using the hand straps, raise the seal cushion and lilt it fully forward. 7 The rear seat back rests are mounted or hinged brackets which aro boiled to Ihe fioorpan. To remove both back rests together, first remove the screws and detach the load space carpet panel. 8 Unbolt the back rest panel from the mounting brackets (see illustration). Refitting 9 Refit tho back rests by reversing Ihe removal procedure. Rear seat cushion
Removal 10 Using the hand straps, raise the seat cushion and tilt it fully forward. 11 Remove ihe screws Ihat secure Ihe hinged brackets to tho fioorpan. then lift out the cushion (see illustration}. Refitting 12 Refit the seat cushion by reversing Ihe removal procedure.
20.11 Remove the screws (arrowed) that secure the hinged brackets to the fioorpan

10*1
Chapter 12
Body electrical systems
Contents
Bulbs (exterior lights) - renewal 4 Bulbs (interior lights) - renewal 5 Electrical fault finding - general information 2 Exterior light units - removal and refitting 6 Fuses and relays - general Information 3 General information and precautions 1 Headlight beam alignment • general Information 6 Horn • removal and refitting 9 Instrument panel - removal and refitting 7 Loudspeakers - removal and refitting 10
Degrees of difficulty
Radio aerial - removal and refitting 11 Radio/cassette player • removal and refitting 12 Speedometer drive cable - removal and refitting 13 Switches - removal end refitting 14 Tailgate wiper motor - removal and refitting 15 Windscreen wiper motor - removal and refitting 17 Windscreen/tailgate washer system components • removal and refitting 16 Wiper arm • removal and refitting 18

Easy,
statable for ^
novice with liffle
|| experience ^
Fairly
easy,
suitable for beginner with ^ some experience ^
Fabtycffficiit,
suitable
for competent ^
DIY
mechanic ^

Difficult, suitable for
^ experienced DIY JR mechanic

Very difficult,
A,
suitable
for
expert DIY
Sj or professional ^
Specifications
Bulb ratings Watts Headlights 60/55 Front long range driving light 55 Front fogllght 55 Front direction Indicator light 21 Front sidelight 5 Front direction indicator repeater light 5 Stop light 21 Tall light 5 Rear direction indicator light 21 Reversing light 21 near fogllght 21 Hear number plate light 5 Courtesy light 10 Map reading light 5
1 Genera! information and precautions

A


Warning: fie/Ore carrying out any work on the electrical system, read through the precautions given in Safety first! at the beginning of this manual, and in Chapter 8. The electrical system is of 12-volt negative earth type. Power for the lights and all electrical accessories is supplied by a lead/acid type battery, which is charged by the alternator. This Chapter covers repair and service procedures for the various electrical components not associated with the engine. Information on the battery, alternator and starter motor can be found in Chapter 5. It should be noted that, prior to working on any component In the electrical system, the
battery negative terminal should first be disconnected, to prevent the possibility of electrical short-circuits and/or fires. Caution: Before proceeding, refer to Disconnecting the battery In the Reference Section of this manual for further information.
2 Electrical fault finding-general information
Note: Refer to the precautions given In Safety first! and in Section 1 of this Chapter before starting work. The following tests relate to testing ot the main electrical circuits, and should not be used to test delicate electronic circuits (such as antHock braking systems), particularly where an electronic con fro/ module is used.
General 1 A typical electrical circuit consists of an electrical component, any switches, relays, motors, fuses, fusible links or circuit breakers related to that component, and the wiring and connectors which link the component to both the battery and the chassis. To help to pinpoint a problem in an electrical circuit, wiring diagrams are Included at the end of this manual. 2 Before attempting to diagnose an electrical fault, first study the appropriate wiring diagram, to obtain a more complete understanding of the components included In the particular circuit concerned. The possible sources of a fault can be narrowed down by noting whether other components related to the circuit are operating properly. If several components or circuits fait at one time, the problem Is likely to be related to a shared fuse or earth connection.

Body electrical systems 12*3
3.4 The auxiliary fusebox, located inside the glovebox behind a drop-down panel auxiliary fusebox, which is located inside the glovebox behind a drop-down panel (see Illustration). 5 A blown fuse can be recognised from its melted or broken wire (see illustration). 6 To remove a fuse, first ensure that the relevant circuit is switched off. 7 Using the plastic tool clipped to the main fusebox lid, pull the fuse from its location. 8 Spare fuses are provided in the main fusebox. 9 Before renewing a blown fuse, trace and rectify the cause, and always use a fuse of the correct rating (fuse ratings are specified on the inside of the fusebox cover flap). Never substitute a fuse of a higher rating, or make temporary repairs using wire or metal foil; more serious damage, or even fire, could result. 10 Note that the fuses are colour-coded as follows. Refer to the wiring diagrams for details of the fuse ratings used and the circuits protected. Colour Rating Orange 5A Red 10A Blue 15A Yellow 20A Clear or White 25A Green 30A 11 The radio/cassette player fuse is located In the rear of the unit, and can be accessed after removing the radio/cassette player -refer to Section 12for greater detail.
Relays 12 A relay is an electncally-operated switch, which Is used for the following reasons: 4 A relay can switch a heavy current remotely from the circuit in which the current is flowing, therefore allowing the use of lighter-gauge wiring and switch contacts.
b)
A relay can receive more than one control input, unlike a mechanical switch. c) A relay can have a timer function - for example, the intermittent wiper relay. 13 The main and optional equipment relays are located in the main and auxiliary toseboxes (see Fuses). A number of additional relays may be fitted, depending on model and specification. These are generally mounted
3.5 A blown fuse can be recognised from its melted or broken wire adjacent lo the component being controlled; e.g. the radiator cooling fan relay(s) are mounted on a bracket next the cooling fan itself. 14 The direction Indicator/hazard warning flasher unit is mounted on the underside of the steering column slalk switch unit. It can be accessed by removing the steering column lower shroud panel (see illustration). 15 If a circuit or system controlled by a relay develops a fault, and the relay is suspect, operate the system. If the relay is functioning, it should be possible to hear it click as it is energised, if this is Ihe case, the fault lies with the components or wiring of the system. If the relay is not being energised, then either the relay is not receiving a main supply or a switching voltage, or the relay itself is faulty. Testing is by the substitution of a known good unit, but be careful - while some relays are identical in appearance and in operation, others look similar but perform different functions. 16 To remove a relay, first ensure that the relevant circuit is switched off. The relay can then simply be pulled out from the socket, and pushed back into position.
4 Buibs (exterior lights) -renewal
General 1 Whenever a bulb is renewed, note the following points:
3.14 Removing the direction indlcator/ha2ard warning flasher unit
a) Ensure that the relevant electrical circuit is isolated before removing a bulb. If in doubt, disconnect the battery negative lead before starting work. b) Remember that, if the circuit has just been in use, the bulb may be extremely hot. c) A/ways check the bulb contacts and holder, ensuring that there is clean metal-to-metal contact between the bulb and its live contacts) and earth. Clean off
any
corrosion or dirt before fitting a nevt bulb. d) Wherever bayonet-type bulbs are fitted, ensure that the live contacts) bear firmly against the bulb contact. e) Always ensure that the new bulb is of the correct rating (see Specifications), and that it is completely clean before fitting it; this applies particularly to headlight/foglight bulbs (see following
0 Pay attention to the orientation when fitting multi-filament bulbs (e.g. combined tail/brake light bulbs) • incorrect fitting will cause the filaments to illuminate In the wrong sequence.
Headlight 2 Open the bonnet. Ensure that the headlights are turned off at the stalk switch. Models with single reflector 3 Pull the wiring plug from the rear of the bulb (see illustration). 4 Pull the rubber boot from the rear of the headlight unit (see Illustration).
4.3 Pull the wiring plug from the rear of the bulb 4.4 Pull the rubber boot from the rear of the headlight unit

12*4 Body electrical systems
4.5 Squeeze the retaining spring-clip lugs, and release the clip from the rear erf the bulb
5 Squeeze the retaining spring-clip lugs, and release Ihe clip Irom the rear of the bulb {see illustration) 6 Withdraw the bulb (see illustration). Models with twin reflectors 7 Unclip Ihe cover from the rear of the headlight unit. Note that the light unit houses three bulbholders; one tor the combined main/dipped beam bulb, one for the long range main beam bulb and one for the sidelight bulb. 8 Pull Ihe wiring plug from the rear ol Ihe bulb. 9 Squeeze the retaining spring-clip lugs, and release tho clip from the rear of the bulb 10 Withdraw Ihe bulb. All models 11 When handling the new bulb, use a tissue
4.21 Unhook the light unit spring clip from the recess in the inner wing
4 6 Withdraw Ihe bulb
or clean cloth, to avoid touching Ihe glass wilh Ihe lingers; moisture and grease from the skin can cause blackening and rapid failure of this type of bulb. If the glass is accidentally touched, wipe it clean using methylated spirit. Avoid knocking or shaking the bulb as this may weaken the filament. 12 Install the new bulb, using a reversal of the removal procedure, ensuring that its locating tabs are correctly located in tho light unit cut-outs. Secure the bulb in position with Ihe retaining clip.
Sidelight
Models with single reflector 13 Open the bonnet. Ensure Ihat the sidelights are turned off at ihe stalk switch. 14 Twist the bulbholder lo release it from the rear of tho light unit (see illustration) 15 The bulb is a push fit in the bulbholder. 16 Fit the new bulb using a reversal of the removal procedure. Models with twin reflectors 17 Unclip the cover from Ihe rear of Ihe headlight unit. Note that Ihe light unit houses three bulbholders; one for the combined main/ dipped beam bulb, one for the long range main beam bulb and one (or the sidelight bulb. 18 Twist the bulbholder to release il from the rear of the light unit. 19 The bulb is a push fit in the bulbholder. 20 Fit Ihe new bulb using a reversal of the removal procedure.
4.14 Twist the bulbholder to release it from tho rear of tho light unit
Front direction indicator 21 Open the bonnet. Unhook tho light unit spring clip from the recess in the innsr wing, directly behind ihe indicator lighl unit (see illustration). 22 Pull the light unit forwards liom its housing. 23 Twist ihe bulbholder anti-clockwise and withdraw It from the light unit (see illustration). 24 The bulb is a bayonet fit in the bulbbdoer. 25 Fit the new bulb, then refil tho fight assembly using a reversal of Ihe remove! procedure. Ensure that the pegs on the side ol the lighl unit engage with the lugs in the side of the headlight unit and the body panel (see illustration). Hook the retaining spring clip securely Into the recess in the Inner
wing.

Front direction indicator
side
repeater 26 Slide the light unit towards the from
ol
the vehicle slightly, then insert a plastic Implement behind the rear edge of the unit and lever it oul ot the wing aperture (see illustration). 27 Withdraw the light unit. Ihen twist the bulbholder anti-clockwise to release
H
from the light unit (see illustration). 28 The bulb is a push fit in the bulbholder. 29 Fit the new bulb using a reversal of trie removal procedure.
4.26 Slide the light unit towards the front
of
the vehicle slightly, then Insert a plastic implement behind the rear edge
4.23 Twist the bulbholder anticlockwise and withdraw It from the light unit
4.25 Ensure that the pegs (arrowed) on tho sido of tho tight unit engage with the lugs In the side of the headlight unit and the body panel

Body electrical systems 12*5
4.27 Withdraw the tight unH, then twist the bulbholder anti-clockwise to release it from the light unit
Front fogllght 30 Access to the rear of the fogllght units can be gained by via removable hatches in plastic inner wheel arch liners. 31 Turn the steering wheel to angle the roadwheel away from the rear of the relevant fogllght. 32 Reach through the wheel arch liner and disconnect the wiring from the rear of the fogllght unit at the connector (see illustration). 33 Unscrew the rear cover from the foghghl unit by turning it anticlockwise (see Illustration). 34 Unplug the flying lead from the push-fit connector inside of the rear cover. Release Ihe spring clip, and withdraw the bulb from the rear of the light unit (see illustrations). 35 Fit the new bulb using a reversal of Ihe removal procedure, ensuring that the recess In the bulb flange engages with the lug in the bulbholder.
Rear light cluster bulbs 38 Open the tailgate. Working from within the loadspace. prise the plastic caps from the rear pillar trim panel (see illustration). 37 Using the special socket provided with the vehicle's toolkit, unscrew the rear light cluster securing bolts (see illustrations). 38 Pull the light cluster away from the bodywork. Unplug the electrical wiring at the connector (see illustrations).
4.37b ... unscrew the rear light cluster securing bolts (arrowed)
4.32 Disconnect the wiring from the rear 4.33 Unscrew the rear cover from the of the fogtight unit at the connector fogllght unit by turning It anticlockwise
4.38a Pull the light cluster away from the 4.38b ... unplug the electrical wiring at bodywork... the connector