1994 FIAT PUNTO Lit

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
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.

Safety first! 0.5
Working on your ear can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude.
General hazards
Scalding • Don't remove the radiator or expansion tank cap while the engine is hot. • Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running.
Burning • Beware of burns from the exhau3t system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use.
Crushing • When working under or near a raised vehicle. ~ always supplement the ' ' -jack with axle stands, or use ... drive-on i'j ramps. kr Never venture ™ under
a
car
vv/j/ch
Is only supported by a jack. • Take card if loosening or tightening high-torque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground.
Fire • Fuel Is highly flammable; fuel vapour is explosive. • Don't (et fuel spill onto a hot engine. • Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of toots). • Fuel vapour is heavier than air, so don't work on the fuel system with the vehicle over an inspection pit. • Another cause of fire is an electrical overload or short-circuit. Take care when repainng or modifying the vehicle wiring. • Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires.
Electric shock x ^ ^ ? , • Ignition HT _ " voltage can be ^ dangerous, ~ especially to > people with heart problems or a pacemaker. Don't work on or near the f^ ignition system with fT") the engine running or ' J ' J the Ignition switched on.
• Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker.
Fume or gas intoxication • Exhaust fumes are poisonous: they often contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine in a confined space such as a garage with the doors shut, • Fuel vapour is also poisonous, as are the vapours from some cleaning solvents and paint thinners.
Poisonous or irritant substances • Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don't syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice. « Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream If necessary. Change out of oll-soaked clothes and do not keep oily rags in your pocket. • Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame {including a cigarette). It can also cause skin burns on contact.
Asbestos • Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found In gaskets and in brake and clutch linings. When dealing with soch components It is safest to assume that they contain asbestos.
Special hazards
Hydrofluoric acid • This extremely corrosive acid is formed when cerlam types of synthetic rubber, found In some O-rings, oil seals, fuel hoses etc. are exposed to temperatures above 400;C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years, tfit gets onto the skin, it may be necessary to amputate the limb concerned. • When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use.
The battery • Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. • The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads.
Air bags • Air bags can cause injury if they go off accidentally. Take care when removing the steenng wheel and/or facia. Special storage instructions may apply.
Diesel injection equipment • Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes.

A


Warning: Never expose the hands, face or any otfterpart of the body to injector spray; the fuel can penetrate the skin with potentially fatal results.
Remember...
DO • Do use eye protection when using power tools, and when working under the vehicle. • Do wear gloves or use barrier cream to protect your hands when necessary. • Do get someone to check periodically that all is well when working alone on the vehicle. • Do keep loose clothing and long hair well out of the way of moving mechanical parts. • Do remove rings, wrtstwatch etc. before working on the vehicle - especially the electrical system, • Do ensure that any lifting or jacking equipment has a safe working load rating adequate for the job.
DON'T • Don't attempt to lift a heavy component which may be beyond your capability - get assistance. • Don't rush to finish a job. or take unverified short cuts. • Don't use ill-fitting toots which may slip and cause injury. • Don't leave tools or parts lying around where someone can trip over them. Mop up oil and fuel spills at once. • Don't allow children or pets to play In or near a vehicle being worked on.

Roadside repairs 0.7
I Jump starting will get you out of trouble, but you must correct | whatever made the battery go fiat in the first place. There are three possibilities:

t

The battery has been drained by repeated attempts to start, or by leaving the lights on.

2

The charging system (s not working property (alternator drivebelt slack or broken, alternator wiring fault or alternator Itself faulty).

3

The battery Itself is at fault (ehctrotyte low, or battery worn out).
When jump-starling a car using a booster battery, observe the following precautions:
• Before connecting the booster battery, make sure that the ignition is switched off.
• Ensure that all electrical equipment (lights, heater, wipers, etc) is switched off.
• Take note of any special precautions printed on the battery case.
Jump starting • Make sure that the booster battery Is the same voltage as the discharged one in the vehicle.
• If the battery is being jump-started from the battery in another vehicle, the two vehicles MUST NOT TOUCH each other.
• Make sure that the transmission is in neutral (or PARK. In the case of automatic transmission).
Make sure that the lump leads will not come into contact with the fan. drive-belts or other moving parts of the engine.
Start the engine using the booster battery and run it at idle speed. Switch on the lights, rear window demister and heater blower motor, then disconnect the jump leads in the reverse order of connection. Turn off the lights etc.

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.