1994 FIAT PUNTO battery replacement

7A«4 Manual transmission
33 Remove lha air cleaner front section and air ducting with reference to Chapter 4C. Also disconnect the injection pump vacuum pipe from the clips on the left-hand end of the cylinder head. This work is necessary in order to fit the engine hoist 34 Support the weight of the engine using a hoist attached to the engine lifting eyes, or alternatively use a trolley Jack and block of wood beneath the engine. 35 Unscrew the nuts securing the downpipe to the exhaust manifold, then lower it and support on an axle stand. Recover the gasket. 36 Unscrew the starter motor mounting bolts and support the starter motor to one side. 37 Disconnect the wiring from the reversing light switch on the front of the transmission. 38 Unscrew the nut and disconnect the earth cable from its stud. 39 Trace the wiring back from the electronic speedometer sensor and disconnect the connector located on the left-hand side ot the engine. If a mechanical speedometer Is fitted unscrew the knurled collar and disconnect the cabte from the transmission. 40 Unbolt and remove the transmission lower cover. 41 Using an Allen key unscrew the bolts securing the inner end of the left-hand driveshaft to the transmission flange. Remove the bolts and recover the spacer plates. Support the driveshaft on an axle stand. 42 Unscrew and remove the bolts securing the left-hand swivel hub assembly to the front suspension strut, then separate the components and support the swivel hub on an axle stand. 43 Move the swrvel hub assembly outwards and support the driveshaft away from Ihe transmission. 44 Using an Allen key unscrew the bolts securing the Inner end of the right-hand driveshaft to the intermediate shaft flange. Remove the bolts and recover the spacer plates. Support the driveshaft on an axle stand. 45 Remove the intermediate driveshaft with reference to Chapter 8. 46 Working beneath the vehicle, unscrew the bolts securing the rear engine mounting to the underbody then unscrew the bolts securing the mounting to the transmission and withdraw the mounting assembly from under the vehicle.
47 Unscrew the bolts securing the left-hand engine/transmission mounting to the body then unscrew Ihe bolts from the transmission and remove the mounting. 48 Support the weight of the transmission on a trolley jack then unscrew the remaining nut and bolts from the bellhousing and pull the transmission away from the engine.

A


Warning: Support the trans-mission to ensure that It remains steady o/i the jack head. Keep the transmission level until the Input shaft
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fully withdrawn from the clutch friction plate.
Refitting 48 Refitting is a reversal of the removal procedure, but note the following points. a) Appiy a smear* of high-meiting-point grease to the clutch friction piate splines; take care to avoid contaminating the friction surfaces. b) Tighten all bolts to the specified torque. c) Fit new clips to secure the driveshaft gaiters to the transmission output shafts. d) Adjust the clutch cable (where applicable) as described In Chapter 6.
4 Manual transmission overhaul -general Infomtatlon
Overhauling a manual transmission is a difficult and Involved Job for the DIY home mechanic. In addition to dismantling and reassembling many small parts, clearances must be precisely measured and, if necessary, changed by selecting shims and spacers. Internal transmission components are also often difficult to obtain, and in many Instances, extremely expensive. Because of this, If the transmission develops a fault or becomes noisy. Ihe best course of action is to have the unit overhauled by a specialist repairer, or to obtain an exchange reconditioned unit. Nevertheless, it is not impossible for the more experienced mechanic to overhaul the transmission, provided the special tools are available, and the Job is done in a deliberate step-by-step manner, so that nothing is overlooked.
The tools necessary for an overhaul include internal and external clrclip pliers, bearing pullers, a slide hammer, a sat of pin punches, a dial test Indicator, and possibly a hydraulic press. In addition, a large, sturdy workbench 8od a vice will be required. During dismantling o1 the transmission, make careful notes of how each component
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fitted, to make reassembly easier and more accurate. Before dismantling the transmission, it will help if you have some idea what area is malfunctioning. Certain problems can be closely related to specific areas In the transmission, which can make component examination and replacement easier. Refer to the Fault Finding Section at the end of this manual for more Information.
5 Reversing light switch -testing, removal and refitting ||
Testing 1 The reversing light circuit is controlled by a plunger-type switch screwed into the front of the transmission casing. If a fault develops, first ensure that Ihe circuit fuse has not blown. 2 To test the switch, disconnect the wiring connector, and use a multimeter (set to the resistance function) or a battery-and-bulb test circuit to check that there is continuity between the switch terminals only when reverse gear is selected. If this is not the case, and there are no obvious breaks or other damage to the wires, the switch is faulty, and must be renewed.
Removal 3 Access to the reversing light switch Is best achieved from under the vehicle. Apply the handbrake then jack up Ihe front of the vehicle and support on axle stands (see Jacking and vehicle support). 4 Disconnect the wiring connector, then unscrew It from the transmission casing.
Refitting 5 Refit the switch and tighten securely. 6 Reconnect the wiring then lower the vehicle to the ground.

Body electrical systems 12*7
5,5 Unclip the plastic cover from the rear of the overhead console 0 Unclip the lens from the support panel (see Illustration). 10 The bulb can be prised from its spring-loaded contacts (see illustration). 11 Fit the new bulb using a reversal of the removal procedure.
Instrument panel gauge Illumination 12 Remove the instrument panel as described In Section 7. 13 The bulbs are a bayonet fit in the rear of the instrument panel (see Illustration). The colour of the bulb casing denotes its wattage - ensure that a replacement bulb of the correct rating is used.
Switch illumination 14 The bulbs that Illuminate the facia-mounted switches are integral with the switch body and cannot be renewed separately.
5.6 Overhead console bulb location 5.9 Unclip the Ions from the support panel A Map reading bulb B Courtesy bulb C Clock illumination bulb
6.3a Unscrew the headlight side securing bolt (arrowed)...
5.10 The bulb can be prised from its spring-loaded contacts (arrowed)
6 Exterior light units • removal and refitting ^ ^
Caution: Ensure that the relevant electrical circuit is isolated be/ore removing a light unit. If In doubt, disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual).
1 Remove the adjacent direction indicator light unit as descnbed in Section 4. 2 Disconnect all wiring from the rear of the light unit at the connectors.
5.13 Tho bulbs are a bayonet fit in the rear of the instrument panel
3 Unscrew the headlight side and upper securing bolts (see illustrations). 4 Withdraw the headlight unit from the vehicle (see illustration).
Refitting 5 Refitting is a reversal of removal. On completion, it Is advisable to hove the headlight beam alignment checked with reference to Section B.
Front direction indicator light 6 The procedure is described as part of the bulb renewal procedure In Section 4. Note that the wiring harness can be disconnected from the light unit without removing the bulb holder (seo illustration).
6.3b ... and upper securing bolts (arrowed) 6.4 Withdraw the headlight unit from the vehicle 6.6 Disconnecting the direction indicator light unit wiring from the bulb holder