1995 FIAT PUNTO bayonet

9*6 Braking system
5.4a Detaching the tower return spring
S Rear brake shoes -renewal ji,

A


Warning: Renew BOTH sets of rear brake shoos at the same time • NEVER renew the shoes on onty one wheel, as uneven braking may result.

A


Warning: Before sterling work, refer to tho warning given at the beginning of Section 2, concerning the dangers of asbestos dust. 1 Remove the rear brake drums, as described In Section 6. 2 Working on one side ot the vehicle, brush the dirt and dust tram tho brake backpiate and drum. Avoid inhaling the dust, as it may contain asbestos, which Is a health hazard, 3 Note the position of each shoe, and the location of the return and steady springs. Also
5.6 Unhook the self-adjuster mechanism roturn spring from the leading brake shoe
5.7b ... and remove it
5.4b Detaching the upper return spring from tho leading ...
make a note oi the adjuster component locations, to aid refitting later. Il is advisable, at this stage to wrap a stout rubber band or a cable-tie over Ihe wheel cylinder, to prevent the pistons from being accidentally ejected. 4 Detach tha upper and lower return springs from both brake shoes (see illustrations). 5 Unhook the sell-adjuster mechanism return spring Iroin the leading brake shoe (see illustration). Remove the hold-down cup and spring from the leading shoe. The spring cups are a bayonet-style fit • use a large pair of pliers to depress and Ihen turn the cup through 90", while holding Ihe pin from behind the backpiate. Remove the pin. 6 Carefully pull the leading brake shoe away from the backpfaie and remove It (see Illustration). 7 Using a suitable pair of pliers, unhook the self-adjuster mechanism from the trailing shoe and remove it (see Illustrations).
away from the backpiate and remove it
5.8a Remove the hold-down cup and spring from the trailing shoe
5.4c ... and trailing brake shoes
8 Remove the hold-down cup and spring from the trailing shoe, using a large pair of pliers, as described for the leading shoe. Remove the pin. Lift the trailing shoe away from the backpiate and disconnect the handbrake cable from the brake shoe lever (see illustration). 9 Thoroughly ciean the surface of tru-backpiate using brake component cleaner lo remove all traces of dust and old lubricant. Examine all components for signs o4 corrosion. 10 Apply brake grease sparingly to the shoe contact surfaces of tho brake backpiate (see Illustration). 11 Connect tha handbrake cable to the Iwr on the trailing brake shoe, locate the trailing shoe on the backpiate and secure In position with the pin, hold down spring and cup. Usnj pliers, turn the cup through 90" and men release It. to lock it in position.
5.7a Unhook the solf-adjuster mochanism from the trailing shoe...
5.6b Lift the trailing shoe away from the backpiate...

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

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*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

12*8 Body electrical systems
6.10 Front foglamp beam adjustment screw (arrowed)
Front direction indicator side repeater light 7 The procedure is described as pari of the bulb renewal procedure In Section 4.
Front foglight 8 Remove the hatch from the wheel arch liner and unplug Ihe wiring Irom the rear of the foglamp unit. 9 The front foglamps are secured to tho valence by three screws • one directly above the light unit, accessed from the front and two accessed Irom below the valence. Once these ere removed, the foglamp can be removed via the hatch in the wheel arch liner. 10 Refitting is a reversal of removal. On complellon, it Is advisable to check the foglight beam alignment. If necessary, the beam may be altered using the adjustment screw (see Illustration)
Rear light cluster 11 The procedure is described as part of the bulb renewal procedure in Section 4.
7 Instrument panel -removal and refitting
Removal 1 Disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual). 2 Remove the securing screws from 1he instrument panel surround.
9.2 Unplug the wiring from the hom at tho connector (arrowed)
7.3a Carefully pull the panel oway from the facia 3 Carefully pull tho panel away from (he facia. Label each bundle of electrical cables carefully to old refitting later end then unplug them nt the connectors (see illustrations). Where a mechanical speedometer drive is fitted, disconnect the dnve coble from the rear of the instrument panel, 4 The individual gauges are Illuminated by filament bulbs. These are a bayonet fit In the rear of the Instrument panel and can be removed individually by rotating them through a quarter turn and withdrawing them • refer to Section 5 for details.
Refitting 5 Refit the instrument panel by following the removal procedure in reverse
8 Headlight beam alignment -general information
Accurate adjustment ot the headlight beam is only possible using optical beam-setting equipment, and this work should therefore be carried out by a Fiat dealer or suitably-equipped workshop. Incorrectly adjusted headlamps can dazzle other drivers and cause accidents. Certain models are equipped with a headlight aim adjustment switch, located on the facia, which allows the aim of tho headlights lo be adjusted to compensate lor tho varying loads carried in the vehicle. The switch should be positioned according to Ihe
9.3 Unscrew the securing bolt (arrowed) and remove the horn sounder
7.3b Label and then unplug the wiring connectors load being carried in the vehicle - refer to lie vehicle's handbook for details.
9 Horn -removal and refitting
Removal 1 The horn is mounted on the lower edge o! the front left hand wing, behind Ihe front bumper moulding. To gain access, remove the screws and detach the hatch from the wheel arch linor. 2 Reach through the aperture in the wheel arch liner and unplug the wiring Irom the hom st the connector (see Illustration). 3 Unscrew the securing boll (see Illustration) and remove the horn sounder.
Refitting 4 Refit the hom by following the removal procedure in reverse.
10 Loudspeakers -removal and refitting §;
1 Ensure that the radio/cassette unit is switched off.
Facia mounted front speakers 2 Remove the screw and lift off the
facia
grfle (see illustration).
10.2 Remove tho screw and lift off the facia grille

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