1995 FIAT PUNTO code

2D»1
Chapter 2 Part D:
Engine removal and overhaul procedures
Contents
Crankshaft - refitting and main bearing running clearance check... 12 Engine overhaul • dismantling sequence 5 Crankshaft • removal and inspection 8 Engine overhaul • general Information .. Cylinder block/crankcase - cleaning and Inspection 9 Engine overhaul - reassembly sequence Cylinder head - dismantling, cleaning inspection and reassembly .. 6 General Information Engine and transmission - removal, separation, connection and refitting 4 Engine and transmission removal • methods and precautions 3 Engine * Initial start-up after overhaul and reassembly 13
Degrees of difficulty
Engine overhaul - general Information 2 11 1 Main and big-end bearings - Inspection and selection 10 Pistons and connecting rods - removal, inspection, refitting and big-end bearing running clearance check 7
Easy, suftable for FaHy easy, suitable ^ FaMy difficult, ^ Difficult, suitable for % Very difficult, ^ novice with littla | for beginner with suitable for competent ^ experienced DIY suitable for expert DIY « experience | some experience ^ HYmechanic mechanic or professional ^
Specifications
Engine codes See Chapter 2A. 2B or ZC.
Cylinder head Camshaft bearing diameters:* Petrol engines: No
1
bearing 24.045 to 24.070 mm No 2 bearing 23.S45 to 23.570 mm No 3 bearing 24.025 to 24.070 mm Diesel engine: No
1
bearing (In right-hand side mount) 29.990to30.015mm No 2 bearing 25.545 to 25.570 mm No 3 bearing 24.045 to 24.070 mm No 4 bearing (in left-hand side mount) 23.990 to 24.015 mm Valve seat angle 45° ±5' Cam follower (tappet) running clearance In head' 0.005 to 0.050 mm Difference between swirl chamber and cylinder head surface (diesel engine only) -0.765 to 0.055 mm '
Refer
to Chapter 2B for camshaft and cam follower specifications on 1242 cc
(16-velve)
petrol engines. Valves Valve stem diameter (Inlet and exhaust): Petrol engines: 1108 cc and 1242 cc (8-valve) engines 6.982 to 7.000 mm 1242
CC
(16-valve) engine 5.974 to 5.992 mm Diesel engine 7.974 to 7.992 mm Valve face angle 45° 30'±5' Valve stem-to-guide clearance: Petrol engines: 1108 cc and 1242 cc(B-valve) engines 0.022 to 0.05B mm 1242 cc (16-valve) engine 0.030 to 0.066 mm Diesel engine 0.030 to 0.066 mm Cam follower (tappet) sJiim sizes 3.20 to 4.70 mm In Increments of 0.05 mm Camshaft Camshaft bearing Journal diameters:' Petrol engines Diesel engine No
1
bearing 24.000 to 24.015 mm 29.945 to 29.960 mm No 2 bearing 23.500 to 23.515 mm 25.500 to 25.515 mm No 3 bearing 24.000 to 24.015 mm 24.000 to 24.015 mm No 4 bearing N/A 23.945 to 23.960 mm Camshaft bearing running clearance* 0.030 to 0.070 mm Camshaft endfloat* 0.070 to 0.250 mm 'Refer to Chapter 2B for camshaft specifications on 1242 cc
(16-valve)
enginss.
20

I
8*4 Driveshafts
3.3 Using pair of circlip pliers, expand the circlip that holds the driveshaft in place
Turbo diesel models 4 Mark the relationship between the joint and the driveshaft using a scriber or a dab of paint. Attach a slide hammer to the dnveshaft nut thread. 5 Draw the joint off the driveshaft using the slide hammer, Use just enough effort to overcome the tension of the internal circlip.
Inboard CV joint removal All models except turbo dieseis 6 Al the inboard end of the driveshaft. use a hammer and centre punch to mark the relationship between Ihe shaft and |olnt. Remove the circlip with a pair of circlip pliers, then using a three-legged puller if required, draw Ihe tripod joint off the end of the driveshaft. Ensure that the legs of Ihe puller bear upon the cast centre section of the joint, not the roller beanngs (see illustration) Turbo diesel models 7 Al the inboard end of Ihe driveshaft. use a hammer and centre punch lo mark the relationship between the shaft and joint. Remove the circlip with a pair of circlip pliers, then carefully slide the CV joint from the end ot the shaft. Take great care to prevenl the
cage and bail bearings from falling out • secure the joint components together with wire or a nylon cable-tie. 8 Remove the washer then slide the flange from the end of the shaft.
Inspection 9 Slide both rubber gaiters off the driveshaft and discard them: It is recommended that new ones are fitted on reassembly as a matter of course. Recover the flexible washers (where fitted), making a note of their fitted positions, to aid correct refitting later. 10 Thoroughly clean the driveshaft splines, and CV joint components with paraffin or a suitable solvent, taking care not to destroy any alignment marks made during removal. 11 Examine Ihe CV joint components for wear and damage: in particular, check the balls and corresponding grooves for pitting and corrosion. If evidence of wear Is visible, then the joint must be renewed. Note that if the outboard CV joint Is to be renewed on turbo diesel models, it must be matched to the driveshaft using the colour-coded paint markings. 12 Where applicable, examine the tripod joint components for wear. Check thai the three rollers are free lo rotate without resistance and are not worn, damaged or corroded. The rollers are supported by arrays of needle bearings: wear or damage will show up as play In the rollers and/or roughness in rotation. If wear is discovered, the tnpod joint must be renewed. 13 Fit a new rubber gaiter (and where applicable, flexible washer) to the inboard end of the driveshaft and secure it In place on the shaft with a clip (see illustration).
Inboard CV joint - refitting
All models except turbo dieseis 14 Using Ihe alignment marks made during removal, fit the tripod joint onto the splines of the driveshaft. Tap It Into position using a soft faced mallet. To ensure that the tripod Joint rollers and driveshaft splines are not damaged, use a socket with an internal diameter slightly larger than I hat of the driveshafl as a drift. Refit the circlip. 15 Slide the gaiter over tho tripod joint and pack the gaiter with grease from the service kit.
3.6 Draw the tripod joint off the end of the driveshaft 3.13 FH s new rubber gaiter to the inboard end of the driveshaft and secure It in place with a clip
Caution: Do not allow grease to come
into
contact with vehicles paintwork, es discolouring may rasutt. Turbo diesel models 16 Slide the flange and washer onto the end of the shaft, then fit the joint Into position on the driveshaft splines, using the alignment marks made during removal. Fit the circlip. ' 17 Pack the gaiter with grease from His service kit, then slide the gaiter over the joint. Briefly lift the lip of the gaiter to expel ail the air from the joint, then secure the gaiter over the joint with a new clip. Caution: Do not allow grease to come
Into
contact with the vehicle's paintwork, as discolouring may result.
Outboard CV joint - refitting 18 Fit a new rubber gaiter to the outboard end of the driveshaft and secure it place with a dp, 19 Pack the CV joint with grease from Ihe service kit, pushing It into the ball grooves and expelling any air that may be trapped underneath. 20 Lubricate the splines of the drive shaft with a smear of grease, then whilst splaying the circlip open with a pair ot circlip pile*, insert the driveshaft into CV joint, observing the alignment marks made during removal. Note: On turbo diesel models, the circlip snaps into the CV Joint groove as Ifte driveshaft is inserted - no circlip pliers are required. Ensure that the circlip snaps securely Into place: pull on the shaft to check that it is held firmly In position. 21 Pack additional grease Into the joint to displace any air pockets, then slide the rubber gaiter over the joint. Briefly lift the lip ol the gaiter to expel all the air from Ihe joint, then secure it In place with a clip. 22 Refit the driveshaft (see Section 2).
4 Intermediate driveshaft - % removal and refitting J;
Note 1: This procedure applies only to turbo diesel engined models. Note 2: The intermediate shaft and
bearing
are not available as separate spares and cac only be renewed as a comptefe assembly.
Removal 1 Firmly apply the handbrake, then jack up the front of Ihe car and support It securely
on
axle stands (see Jacking and vehicle support). Remove the appropriate roadwheei(s). 2 Unbolt the inboard end of the right*hand driveshaft from the intermediate shaft
flange, as
described In Section 2. Suspend the dis-connected end of the driveshaft from a conven-ient point on the subframe, using wire or a cable-tie. to avoid straining the joint and gaiter. 3 Drain the oil from the transmission, with reference to Chapter 1B.

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

Body electrical systems 12*9
3 Undo the mounting screws and lift out the speaker (see Illustration). Unplug the wiring at the connector. 4 Refitting is a reversal of removal,
Rear parcel shelf speakers 5 Working underneath the relevant parcel shetf support bracket, remove the securing screws and lower the loudspeaker from the support bracket. Unplug the wiring at the connector (see illustration). 6 Refitting is a reversal of removal.
11 Radio aerial - J^s removal and refitting ^
Removal 1 Carefully prise off the plastic cap. then remove the securing screws and withdraw the aerial from the roof. 2 Oraw the aerial co-axial cable through the roof aperture and disconnect it. If there is insufficient slack In the aerial cable, remove the courtesy light unit/overhead panel from the inside of the vehicle (as described earlier in this Chapter) to gain access to the cable connector,
Refitting 3 Refitting Is a reversal of removal, but ensure that seal between the aerial housing and the roof panel is in good condition.
12.2 Removing the radio/cassette unit using the special extraction tools
12.3 Disoonnect the wiring plugs from the rear of the unit. Note the bayonet fuse (arrowed) which is a push fit In the rear of the unit
10.3 Lift out the speaker and unplug the wiring at the connector
12 Radio/cassette player -removal and refitting ^
Removal Note: Once the battery has been disconnected, the radio/cassette unit cannot be re-activated until the appropriate security code has been entered. Do not remove the unit unless the appropriate code Is known. 1 Disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual). 2 Insert the special extraction tools supplied with the vehicle into the holes on either side of the radio/cassette unit. Press them home until the Internal clips can be felt to release (see illustration). 3 Pull the unit forwards from the facia, then disconnect the wiring plugs and the aerial lead from the rear of the unit. Note the bayonet fuse, which is a push fit in the rear of the unit, (see illustration).
Refitting A Refitting is a reversal of removal, ensuring that the wiring Is routed freely behind the unit.
13 Speedometer drive cable - % removal and refitting Ss ^
Note: Later vehicles are fitted with an electronic transducer in place of the mechanical speedometer drive. This is mounted on the fransm/ss/on casing; refer to Chapter 7A, Section 3, for details.
Removal 1 Remove the instrument panel as described in Section 7. 2 Working in the engine compartment, unscrew the sleeve securing the cable end to gearbox, then pull the cable from gearbox. 3 Where applicable, release the cable from the brackets in the engine compartment bulkhead, then pull the cable through into the engine compartment. If necessary, pull the cable grommet from the bulkhead.
10.S Lower the loudspeaker from the support brackot and unplug tho wiring at the connector
Refitting 4 Refitting is a reversal of removal, bearing in mind the following points: a} Ensure that the bulkhead grommet is securely seated. b) Refit the instrument panel with reference to Section 7. c) Note that certain models have alignment marks on the cable outer for use when refitting. The marks should be aligned with the bulkhead bracket when the cable is correctly refitted and routed.
14 Switches -removal and refitting ^
Steering column stalk switches Note: On vehicles equipped with sfeezing wheel-mounted radio controls, the column stalk switch unit also incorporates the rotary contacts for the steering wheel switches. Removal 1 Disconnect the battery negative cable and position it away from the terminal. Turn the steering wheel so that the roadwheeis are pointing in the straight-ahead position. 2 Refer to Chapter 10 and remove the steering wheel from the column. 3 Remove the screws and lift off the upper and lower steering column shrouds. 4 Using an Allen key. slacken Ihe clamp ring at the rear of the switch unit (see illustration),
14.4 Using an Allen key, slacken the clamp ring at the rear of the switch unit