1995 FIAT PUNTO cap

Bodywork and fittings
11
*7
12.4 Adjusting the extension of the bonnet pin
12 Bonnet lock components - ^ removal and refitting H
Latch and release lever assembly
Removal 1 Secure the bonnet In the fully open position using the stay. Mark the relationship between the latch and the surface of the bonnet using a soft pencil or marker pen. 2 Slacken and unscrew the bolts, then lower the latch assembly away from the bonnot. Refitting 3 Refitting is a reversal of removal. Use the alignment markings made during removal to aid accurate refitting. Note that the mounting holes are slotted to allow adjustment if required. On completion, tighten the bolts securely. 4 The extension of the bonnet pin may be adjusted in necessary, by slackening the locknut and turning the pin with a flat-bladed screwdriver (see illustration).
Striker plate
Removal 5 Mark the relationship between the striker plate and the bodywork using a soft pencil or marker pen. The striker plate can then be removed by slackening and withdrawing the three securing bolts and unhooking the release cable from the operating lever. Refitting 6 Refitting is a reversal of removal. Use the alignment markings made during removal to aid accurate refitting. Note that the mounting holes are slotted to allow adjustment if required. On completion, tighten the bolts securely.
Suffers 7 If necessary, adjust the protrusion of the rubber buffers on the front crossmember, (located above each headlamp unit) by screwing them in or out as appropriate. When the rubber buffers are correctly adjusted, there should be just enough free movement to
14.3a Remove the screw .
allow the bonnet to be closed and locked easily, without using excessive force, but not enough to allow the bonnet to rattle when secured in the locked position.
13 Bonnet release cable -removal and refitting I
Removal 1 Secure the bonnet in the fully open position. With reference to Section 12, detach Ihe bonnet release cable from the striker plate operating lever. 2 Unscrew the cable clip from above the nght hand headlamp unit. 3 Working around the engine bay, extract the release cable from its securing clips. 4 In the drivers footweil, extracl Ihe fixings and lower the sound insulation panel (where fitted) away from the underside of the steering column/facia. 5 Push the bonnet release handle towards the bulkhead slightly, then free the release cable end fitting from its recess in the handle. Lift the cable inner up, pass the end fitting through the larger hole and withdraw it from the handle. Extract the release cable outer from the mounting bracket by carefully pulling down on the plastic collar. 6 Release the cable from the remaining clips under the facia, then carefully pull the entire cable through the bulkhead grommet Info the engine bay.
14.3b ... then prise out the door grab handle moulding
Refitting 7 Refit the cable by reversing the removal process. On completion, close the bonnet to check that it locks securely, then check the operation of tho release mechanism. If adjustment is required, this can be achieved by repositioning the slotted plastic collar fitted to the cable outer sheath, in the mounting lug on the underside of the striker plate.
14 Door inner trim panel -removal and refitting I
Removal Note: This section describes the removal of the front door trim panel; the procedure for removing the rear door trim panel is essentially the same, 1 Disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual). 2 With reference to Section 17. remove the trim panel from the rear of the door mirror fixings. 3 Lift off the caps and remove the screw, then prise out the door grab handle moulding (see Illustrations) 4 Prise the electric window/mirror adjustment switch from the armrest and unplug the wiring connector(s). Label them to aid correct refitting later (see illustrations).
14.4a Prise the electric window/mirror adjustment switch from the armrest... 14.4b ... and unplug the wiring connector

11
*8 Bodywork and fittings
14.5a Unscrew the door panel securing screws, located on the edge of the armrest moulding... 5 Unscrew Ihe door panel securing screws, located on Ihe edge of the armrest moulding and around the outside edge of the door trim panel - note that some are concealed beneath plastic caps (see illustrations). 6 Using a Suitable forked tool inserted between the door end the trim panel, release Ihe press-stud clips located around Ihe edge of Ihe panel. Ihen lift the trim panel upwards. Recover the locking knob Inm collars (see illustrations). 7 Pull the panel from the door, noting that Ihe lower window aperture weatherstrip is integral with the trim panel and must bo released from the door as the panel Is withdrawn. B If work Is lo be earned out nn the door Internal oomponenls. it will be necessary to remove the plastic soaling sheet from tho inside ot the door Starl ol one comer of the sheet and carefully peel il away, using a sharp blade to split the sealant bead (see (lustration).
j
14.8a Release the press-stud clips located around the edge of tho panel...
trim collars from above...
14.5b ... and around the outside edge of the door trim panel
9 Store Ihe detached sealing sheet such that it cannot become contaminated with dust: this will allow it to be re-used later.
Refitting 10 Refilling Is a reversal of removal, bearing in mind the following points:
a) Ensure that the sealing sheet is correctly refitted, press it on firmly to ensure that it is adequately sealed around its edges. It should be possible fo use the origins} sealant, but if necessary, new sealant can be obtained from a Fiat dealer. b) Before refitting the trim panel, feed the electric window switch wlnng through the aperture in the front of Ihe panel. c) Make sure that the weatherstrip engages securely with the edge of the door as the panel Is refitted.
i4,6b ... then lift the trim panel upwards...
14.6d ... and below tho panel
15 Door- & removal and refitting is
Note: 7?ws procedure is applicable both to
the
front and rear doors.
Removal Note: A new door check strap rolbpin
win
be requited on refitting. 1 Disconnect the battery negative terminal (refer to O/sconoecf/ng fhe battery In Ihe Reference Section of this manual). 2 Unplug Ihe multiway electrical connector from the inner edge of the door. 3 Have an assistant support the door, then unscrew the door hinges centre bolts, and hit the door from the vehicle.
Refitting 4 Refitting is a reversal of removal. On completion, tighten the hinge centre bolts securely.
Adjustment 5 Close the door carefully, In case the alignment is incorrect, which may cause scratching on the door or the body BS the door is closed, and check the fit ot the door with the surrounding panels. 6 II adjustment Is required, loosen the hinge-to-body securing bolts (the bolt holes are elongated to allow lor adjustment) and move the hinges as required to achieve satisfactory alignment. Tighten the securing bolls securely on completion. 7 Check the operation of the door lock. If necessary, slacken the securing bolts, and adjust Ihe position of Ihe lock striker on the body pillar to achieve satisfactory alignment-Tighten the bolts securely on completion,
16 Door handle and lock components -removal and refitting ^
1 Ensure that the door window glass is in the fully closed position, then disconnect ihe battery negative terminal (refer to Drscoryiecfrrg fhe battery In the Reference Section of this
•
m-i -14.8 Carefully peel the sealing sheet away, using a sharp blade to spilt the sealant bead

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

12*2 Body electrical systems
3 Electrical problems usually stem from simple causes, such as loose or corroded connections, a faulty earth connection, a blown fuse, a melted lusible link, or a fautty relay {refer to Section 3 for details of testing relays). Visually inspect the condition of all (uses, wires and connections in a problem circuit before testing the components. Use the wiring diagrams lo determine which terminal connections will need to be checked, in order to pinpoint the trouble-spot. 4 The basic tools required for electrical fault-finding include a circuit tester or voltmeter (a 12-volt bulb with a set of lest leads can also be used for certain tests}; a self-powered test light (sometimes known as a continuity tester); an ohmmeter (to measure resistance): a battery and set of tesi leads: and a lumper wire, preferably with u circuit breaker or fuse incorporated, which can be used to bypass susoect wires or electrical components. Before attempting to locate a problem with tost instruments, use the wiring diagram to determine where to make the connections. 5 To find the source of an intermittent wiring fault (usually due to a poor or dirty connection, or damaged wiring Insulation), a wiggle test can be performed on the wiring. This involves wiggling the wiring by hand, to see if tha fault occurs as the wiring Is moved. It should be possible to narrow down the source of the fault to a particular section of wiring. This method of testing can be used in conjunction with any of the tests descnbed in the following sub-Sections. 6 Apart from problems due to poor connections, two basic types of fault can occur in an electrical circuit - open-circuit, or short-circuit. 7 Open-circuit faults are caused by a break somewhere in the circuit, which prevents current from flowing. An open-circuit fault will prevent a component from working, but will not cause the relevant circuit fuse to blow 8 Short-circuit faults are caused by a shod somewhere in the circuit, which allows Die current flowing In the circuit to escape along an alternative route, usually to earth. Short-circuit faults are normally caused by a breakdown in wiring insulation, which allows a feed wire to touch either another wire, or an earthed component such as the bodysheli. A short-circuit fault will normally cause the relevant circuit fuse to blow.
Finding an open-circuit 9 To check for an opon-circuit, connect one lead of a circuit tester or voltmoter to either the negative battery terminal or a known good earth. 10 Connect the other lead to a connector in the circuit being tested, preferably nearest to the batter/ or luse. 11 Switch on the circuit, bearing In mind that some circuits are live only when tho ignition switch is moved to a particular position. 12 If voltage is present (Indicated either by
3.2 Main fuse box, located on the driver's side of the facie the toster bulb lighting or a voltmeter reading, as applicable), this means that tho section of Ihe circuit between the relevant connector and the battery is problem-free. 13 Continue to check the remainder ot the circuit in the same fashion. 14 When a point is reached at which no voltage Is present, the problem must lie between that point and the previous test point with voltage. Most problems can be traced to a broken, corroded or loose connection.
Finding a short-circuit 15 To check for a short-circuit, first disconnect the load(s) from the circuit (loads are the components which draw current from a circuit, such as bulbs, motors, heating elements, etc). 16 Remove the relevant luse Irom the circuit, and connect a circuit tester or voltmeter to the luse connections. 17 Switch on the circuit, beanng in mind that some circuits are live only when the ignition switch is moved to a particular position. 18 If voltage is present (indicated either by the tester bulb lighting or a voltmeter reading, as applicable), this means that there Is a short-circuit. 19 If no voltage is present, but the fuse still blows with the load(s) connected, this indicates an internal fault in the load(s).
Finding an earth fault 20 The battery negative terminal Is connected to 'earth' - the metal of the engine/transmission and the car body - and
I
IK
J 3.3 To gain access to the fuses, remove the screw and pull the stowage bin away from the facia
most systems are wired so that they only receive a positive feed, the current returning via the metal of Ihe car body. This means that the component mounting and the body form part of that circuit. Loose or corroded mountings can therefore cause a range of electrical faults, ranging from total failure ot a circuit, to a puzzling partial fault. In particular, lights may shine dimly (especially when another circuit sharing the same earth port In operation), motors (eg wiper motors v Ihe radiator cooling fan motor) may run slowly, and Ihe operation of one circuit may have an apparently-unrelated effect on another. Ncie that on many vehicles, earth straps axe uses between certain components, such as the engine/transmission and the body, usually whore there is no metal-to-metal contact between components, due to flexible rubber mountings, etc. 21 To check whether a component $ properly earthed, disconnect Ihe battery, and connect one lead of an ohmmeter to a kwwi good earth point. Connect the other lead to the wire or earth connection being tested. Tha resistance reading should be zero; if not. check the connection as follows. 22 If an earth connection Is thought to be faulty, dismantle the connection, and clean pack to bare metal both the bodysheli and ite wire terminal or the component earth connection mating surface. Be careful to remove all traces of dirt and corrosion, then use a knife to trim away any palm, so thai a clean metal-to-metal joint Is mads. On reassemoly, tighten the joint fasteners securely: if a wire terminal Is being refitted, use serrated washers between tho terminal and the bodysheli. to ensure a clean and secure connection. When the connection is remade, prevent the onset ot corrosion in the future by applying a coat of petroleum idly
or
stlicone-based grease, or by spraying on (a: regular intervals} a proprietary ignition eoater, or a water-aispersant lubneant.
3 Fuses and relays -general information
Fuses 1 Fuses are designod to break a circuit when a predetermined current is reached, in order to protect the components and wiring wttioh could be damaged by excessive current How. Any excessive current flow will be due to a fault in the circuit, usually a short-circuit (see Section 2). 2 The main fuses are located in the fusefcox on the driver's side of the facia (see illustration). 3 To gain access to the fuses, remove tne screw and pull the stowage bin moulding away from the facia (see illustration). 4 Additional fuses and circuit-breakers are located In the engine compartment, and in an

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

12*6 Body electrical systems
4.39a Remove the screws...
39 Remove the screws and separate the bulbholder from the lens unit (see Illustrations). 40 The bulbs are a bayonet (it in the bulbholder (s&e Illustration), 41 Fit the new bulb using a rovorsal of the removal procedure. Note that the stop/tall light bulb has offset locking pins, to ensure correct orientation.
Rear number plate light 42 Remove the securing screws, and lower the light unit lens from the tailgate handle (see Illustration), 43 The bulb Is a push fit In the light unit. 44 Fit the new bulb using a reversal of the removal procedure.
5.3a On models with a manually oporated sunroof, remove the sunroof crank handle
5.3b Carefully prise out the pfestic caps...
from the lens unit
5 Bulbs (interior lights) -renewal
General 1 Whenever a bulb is renewed, note Ihe following points: a) Ensure that the relevant electrical circuit is Isolated before removing a bulb. If
In
doubt, disconnect the battery negative terminal (refer to Disconnecting the battery In the Reference Section of this manual) before starting work. b) Remember that, if the light has just been in use, the bulb may be extremely hot. c) Always check the bulb contacts and holder, ensuring that there is clean metal-to-metal contact between the bulb and its live contacts) and earth, dean off any corrosion or dirt before fitting a new bulb. d) Wherever bayonet-type bulbs are fitted, ensure that the live contact(s) bear (irmly 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.
Courtesy light 2 On Punto S models (except those with a manually operated sunroof end/or theft alarm) access to the courtesy light bulb can gained by unclipping the lens from the roof lining. The bulb can then be prised from its spring loaded contacts.
5.3c ... and remove the screws that secure the overhead console to the roof
buibhoidai
/ ' fl B 4.42 Remove the securing screws, and lower the light unit lens from the tailgate handle 3 On all other variants, carefully prise out the plastic caps and remove the screws that secure the overhead console lo the roof. Note: On models fitted with a manually operator sunroof, it will be necessary to remove
the
screw and detach the sunroof crank
handle
from its shaft, before the overhead console can be removed (see illustrations). A Unplug Ihe wiring from the console at the connector (see illustration). 5 Unciip the plastic cover from the rear ol the overhead console (see illustration). 6 Carefully prise the bulb from the spring contacts (see Illustration). 7 Fit the new bulb using a reversal of the removal procedure.
Luggage compartment light 8 The light unit is located under 1he left hand parcel shelf support panel.
5.4 Unplug Ihe wiring from (he console at the connector

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