1996 FIAT PUNTO Valve

ia«4 Component location - petrol models
Underbonnet view -1108 cc engine model
1 Engine oil filler
cap
2 Engine oil dipstick 3 Brake vacuum servo unit 4 Brake fluid
reservoir
5 Air cleaner
cover
6 Coolant expansion lank 7 Windscreen washer fluid reservoir 8 Front suspension strut upper mounting 9 Ignition coil cover 10 Engine wiring connector cover 11 Battery 12 ECU
Underbonnet view - 1242 cc (8-valve) engine model
1 Engine oil tiller
cap
2 Engine oil dipstick 3 Brake vacuum servo unit 4 Brake fluid
reservoir
5 Air cleaner cover 6 Coo/ant expansion tank 7 Windscreen washer
fluid
reservoir 8 Front suspension strut upper mounting 9 Ignition coil cover 10 Engine wiring connector cover 11 Battery 12 ECU

Component location - petrol models 1A.5
Underbonnet view - 1242 cc (16-valve) engine model
1
Engine
olt filler
cap
2
Engine
oil dipstick 3
Brake
fluid
reservoir
4
Power
steering fluid reservoir 5
Engine
wiring connector cover 6
Windscreen
washer
fluid
reservoir 7 Battery 8
Coolant
expansion
tank
9 Air cleaner
cover
10 Resonator 11 ECU
1
Oil filter
2
Sump
drain plug 3
Transmission
drain plug A
Electric
cooling Ian unit 5
Left-hand driveshaft
6
Intermediate shaft
7
Right-hand driveshaft
B
Front
suspension lower arms 9
Front
anti-roll
bar
10
Exhaust
downpipe 11
Front
brake calipers (2
Rear engine
mounting IS Radiator bottom hose
Front underbody view (diesel model shown, petrol model similar)

ia«6 Component location - petrol models
Rear underbody view (diesel model shown, petrol model similar)
1 Fuel
tank
2
Exhaust
tailpipe
and
silencer 3
Rear axle
4 Coll
springs
5
Rear
anti-mil
bar
6
Handbrake cables
T
Rear brake pressure
regulating
valve
S
Rear
shock absorber lower mountings
Maintenance procedures
1 Introduction
This Chapter is designed to help the home mechanic maintain his/her vehicle (or safety, eoonomy, long life and peak performance. The Chapter contains a master maintenance schedule, and Sections dealing specifically with each task in the schedule. Visual checks. ad}ustments, component renewal and other helpful Items are included. Refer to the accompanying Illustrations of the engine compartment and tho underside of the vehicle for the locations of the various components. Servicing your vehicle in accordance with ihe mlleaget/time maintenance schedule and the following Sections will provide a planned maintenance programme, which should result m a long and reliable service life. This Is a comprehensive plan, so maintaining some Items but not others at the specified service Intervals, will not produce the same results. As you service your vehicle, you will discover that many of the procedures can, and should, be grouped together, because of the particular procedure being performed, or because of the proximity of two otherwise-unrelated components to one another. For example, if the vehicle Is raised for any reason, the exhaust can be inspected at the same time as the suspension and steering components. The first step in this maintenance programme is to prepare yoursell before tne
actual work begins. Read through all the Sections relevant to the work to be carried out, then make a list and gather all the parts and tools required. If a problem is encountered, seek advice from a parts specialist, or a dealer service department.
2 Regular maintenance
1 If. from the time the vehicle is new, the routine maintenance schedule is followed closely, and frequent checks are made of fluid levels and high-wear items, as suggested throughout this manual, the engine will be kept in relatively good running condition, and the need for additional work will be minimised. 2 II is possible that there will be times when the engine rs running poorly due to the lack of regular maintenance. This is even more likely If a used vehicle, which has not received regular and frequent maintenance checks, is purchased. In such cases, additional work may need to be carried out. outside of the regular maintenance intervals. 3 If engine wear is suspected, a compression test (refer to the relevant Part of Chapter 2) will provide valuable information regarding the overall performance of the main internal components. Such a test can be used as a basis to decide on the extent of the work to bo carried out. II, for example, a compression test indicates serious internal engine wear, conventional maintenance as described in this
Chapter will not greatly improve the performance of the engine, and may prove a waste of time and money, unless extensive overhaul work is carried out first. 4 The following series of operations are those usually required to improve the performance of a generally poor-running engine:
Primary operations a) Cloan, inspect and test the battery
(See
Weekly checks), b) Check alt the engine-related fluids (See Weekly checks). c) Check the condition and tension of the auxiliary drivebeft($) (Section 13). d) Renew the spark plugs (Section 19). e) Inspect the ignition HT leads (Section 20). 0 Check the condition of the air filter, and renew if necessary (Section 18). g) Check the fuel filter (Section 17). h) Check tho condition of ell hoses, and check for fluid leaks (Sect/on 7). i) Check theexhaust
gas emissions (Section 11).
5 If the above operations do not prove fully effective, carry out the following secondary operations;
Secondary operations All items listed under Primary operations, plus the following; e) Check the charging system (Chapter 5K Section 4). b) Check the ignition system (Chapter 58). c) Check tho fuel system (see relevant Part of Chapter
4).
d) Renew the ignition HT leads (Section 20)

ia.io Every 20 000 miles - petrol models
the front of the car and support It securely on axle stands (see Jacking and vehicle support}. 4 Remove the nght-hand front wheel. 5 Remove the inner cover from under the right-hand wheeiarch for access to the right-hand side of the engine. 0 Using a socket on the crankshaft sprocket boll, rotate the crankshaft so that the full length of the auxiliary drlvebelt(s) can be examined. Look for cracks, splitting and fraying on the surface of the belt: check also for signs of glazing (shiny patches) and separation of the belt plies. If damage or wear Is visible, the relevant belt should be renewed. 7 If the condition of the belt Is satisfactory, check Ihe drivebeit tension as described below.
Renewal
Alternator drivebeit Note: On certain models with power steering but without air conditioning, it will be necessary to remove the power steering pump drivebeit ffrst, as described below. 8 Where fitted, undo the bolts and remove the belt guard from the alternator. 9 Loosen the pivot and adjustment bolts then swivel the alternator towards the engine and slip off the drivebeit. 10 Unbolt and remove the crankshaft sensor from Ihe front of the engine (refer to Chapter 4A. Section 5, if necessary). 11 Remove the drivebeit from the engine. 12 When renewing a drivebeit. ensure that the correct type is used. Fit the belt around the two pulleys then swivel the alternator outwaids to take up any slack in the betL Adjust the tension correctly as described below. Power steering pump drivebeit 13 Slacken the bolts securing the power steering pump to the mounting bracket. 14 Slacken the adjusting bolt locknut and turn the adjusting boit until all the tension is removed from the drivebeit. 15 Undo the bolts and remove the pultey guard from the power steering pump then slip the drivebeit off (he pulleys. 18 Ensuring that the correct type of drivebeit is used, fit the belt around the pulleys and turn the adjusting bolt to just take up the slack in the belt. Adjust the tension correctly as described below. Air conditioning compressor drivebeit 17 Remove the alternator and power steering pump dnvebelts as described previously. 18 Slacken the bolts securing the compressor to the mounting bracket. 19 Slacken the adjusting bolt locknut and turn the adjusting bolt until alt the tension is removed from the drivebeit, then slip the belt off the pulleys. 20 Ensuring lhat the correct type of drivebeit is used, fit the belt around the pulleys and turn the adjusting bolt to just take up the slack In the belt. Adjust the tension correctly as described below.
15.7 Checking a valve clearance with a feeler blade
Tensioning 21 Correct tensioning of the belt will ensure that it has a long life. A belt which Is too slack will slip and perhaps squeal. Beware, however, of overtightening, as this can cause wear in the alternator, power steering pump or air conditioning compressor bearings. Note: Fiat recommend use of their special tensioning tool however the fallowing procedure will set the tension correctly. 22 The belt(s) should be tensioned so that, under firm thumb pressure, there is approximately 5.0 mm of free movement at the mid-point between the pulleys. To adjust the alternator drivebeit, slightly tighten the adjustment bolt then swivel the alternator outwards until tne beft tension Is correct. Fully tighten the adjustment bolt followed by the pivot bolt then refit the rpm sensor. 23 On models with power steering and/or air conditioning, fit the relevant drivebeit over the pulleys then turn the adjusting bolt until the tension is correct. Secure the adjusting bolt by tightening Ihe locknut, then tighten the remaining mounting bolts. Refit any remaining dnvebelts and all the components removed. 24 Refit the inner cover and wheel, lower the vehicle to the ground, then reconnect the battery negative terminal,
14 Clutch adjustment check
Refer to Chapter 8. Section 2.
15.11 Using a modified C-spanner and e screwdriver to remove a shim
15 Valve clearance check ^ and adjustment S
Note: The following procedure Is not applicable to 1242 cc,
16-vatve
engines which utilise self-adjusting hydraulic tappets. 1 The importance of having the valve clearances correctly adjusted cannot be overstressed, as they vitally affect the performance of the engine. Adjustment should only be necessary when the valve gear has become noisy, after engine overhaul, or when trying to trace the cause of power loss. The clearances are checked as follows. The engine must be cold for the check to be accurate. 2 Apply the handbrake then jack up the right* hand front of the vehicle and support on an axle stand (see Jacking and vehicle support). Engage 4th gear. The engine can now be rotated by turning the right-hand front road wheel. 3 Remove all spark plugs as described In Section 19. 4 Remove the camshaft cover as described In Chapter 2A. 5 Each valve clearance must be checked when the high point of the cam lobe is pointing directly upward away from the cam follower. 6 Check the clearances In the firing order 1-3-4-2. No
1
cylinder being at the timing bell end of the engine. This will minimise the amount of crankshaft rotation required. 7 Insert the appropriate feeler blade between the heel of the cam and the cam follower shim of the first valve (see illustration). II necessary alter the thickness of the feeler blade until it is a stiff, sliding fit. Record the thickness, which will, of course, represent the valve clearance for this particular valve. 8 Tum the engine, check the second valve clearance and record it. 9 Repeat the operations on all the remaining valves, recording their respective clearances. 10 Remember that the clearance for Inlet and exhaust valves differs • see Specifications. Counting from the timing cover end of the engine, the valve sequence is: tnlet 2-4-5-7 Exhaust 7-3-6-$ 11 Where clearances are incorrect, the particular shim will have to be changed. To remove the shim, turn the crankshaft until the high point of the cam Is pointing directly upward. The cam follower will now have to be depressed so that the shim can be extracted. Special tools are available from your Fiat dealer to do the job, otherwise you will have to make up a forked (ever to locate on the rim of the cam follower. This must allow room for the shim to be prised out by means of the cut-outs provided in the cam follower rim {see illustration). 12 Once the shim is extracted, establish its thickness and change It for a thicker or thinner one to bring the previously recorded

Every 20 000 miles - petrol models ia-h
clearance within specification. For example, if the measured valve clearance was 1.27 mm too great, a shim thicker by this amount will be required. Conversely, if the clearance was 1.27 mm too small, a shim thinner by this amount will be required. 13 Shims have their thickness (mm) engraved on them; although the engraved side should be fitted so as not to be visible, wear still occurs and often obliterates the number. In this case, measuring their thickness with a metric micrometer is the only method to establish their thickness (see illustration). t4 In practice, if several shims have to be changed, they can often be interchanged, so avoiding the necessity of having to buy more new shims than is necessary. 15 If more than two or three valve clearances are found to be incorrect, it will be more convenient to remove the camshaft for easier removal of the shims. 16 Where no clearance can be measured, even with the thinnest available shim in position, the valve will have to be removed and the end of its stem ground off squarely. This will reduce its overall length by the minimum amount to provide a clearance. This job should be entrusted to your dealer as it is important to keep the end of the valve stem square. 17 On completion, refit the camshaft cover and gasket, air cleaner and duct, and spark plugs. 18 lower the vehicle to the ground.
16 Manifold mounting check
Refer
1O
Chapters 4A. 48 and 4D and check tne tightness of the nuts and bolts securing the inlet and exhaust manifolds.
17
Fuel
filter renewal I I
Warning: Before carrying out the !\ f°llow'n9 operation, refer to the precautions given In Safety firstI A
15.13 Shim thickness is marked on the tower face (here 4.20 mm) at the beginning of this manual, and follow them Implicitly. Petrol Is a highly-dangerous and volatile liquid, and the precautions necessary when handling it cannot be overstressed. Note: 1242 cc (8-vatve) engine mode's from 1998 onwards are equipped with a modified fuel system incorporating a fuel fitter integral with the fuel pump. On these engines fuel filter renewal is not required. 1 The fuel filter is situated underneath the rear of the vehicle, on the right-hand side of the fuel tank (see illustration). To gain access to the filter, chock the front wheels, then jack up the rear of the vehicle and support it on axle stands (see Jacking and vehicle support). 2 Unscrew the bolt securing the filter to its support bracket. 3 Noting the fitted position of the filter body, release the retaining clips and disconnect the fuel hoses from the filter. The correct position is indicated by an arrow marked on ihe filter body 4 Remove the filter from the vehicle. Dispose safely of the old filter; it will be highly flammable, and may explode if thrown on a fire. 5 Locate the new filter into position, ensuring that the arrow on the filter body is pointing in the direction of the fuel flow, as noted when removing the old filter. The flow direction can otherwise be determined by tracing the fuel hoses back along their length. 6 Connect the fuel hoses to the filter and lighten the clips, then locate it in the support bracket and tighten the mounting bolt.
17.1 Fuel filter location on tho right-hand side of the fuel tank 7 Start the engine, check the filter hose connections for leaks, then lower the vehicle to the ground.
18 Air fitter renewal
I
f f 08 cc and 1242 cc (8-valve) engines 1 Prise open the spring clips and withdraw the air cleaner cover a little way from the main body (see illustration). Leave the cover attached to the hot air tube and inlet duct. 2 Lift out the filter element (see illustration). 3 Remove any debris that may have collected inside the air cleaner and wipe the inner surfaces clean. 4 Fit a new air filter element In position, ensuring that the edges are securely seated. 5 Refit the air cleaner top cover and snap the retaining clips into position.
1242 cc (16-valve) engines 6 Undo the three bolts securing the front of Ihe air cleaner cover to the main body. Lift the cover up at the front, disconnect the rear retainers and move it clear of the main body {see illustration). Leave the cover attached to the hot air tube and inlet duct. 7 Lift out the filter element (see illustration). 8 Remove any debris that may have collected inside the air cleaner and wipe the inner surfaces clean.
18.1 Prise open the spring clips... . and remove the filter element (8-valve engines)
18.6 Undo the three bolts (arrowed) and disconnect the air cleaner cover rear retainers (16-vatve engines)

1A.12
Every 20 000 miles - petrol models
18.7 Lift up the cover and remove the filter element (18-va!ve engines) 9 Fit a new air (liter element In position, ensuring that the edges are securely seated 10 Refit the air cloaner cover, engage the rear retainers and secure with the three bolts.
19 Spark plug renewal
1 The correct functioning of the spark plugs is vital for the correct running and efficiency of the engine. It is essential that the plugs fitted are appropnate for the engine (a suitable type is specified at the beginning of this Chapter. If this type is used and the engine Is In good condition, the spark plugs should not need attention between scheduled replacement intervals Spark plug cleaning Is rarely necessary, and should not be attempted
19.2a Disconnecting tho HT leads from Iho spark plugs on 8-valve engines ...
19.4 Removing the spark plugs
unless specialised equipment Is available, as damage can easily be caused to the firing ends. 2 To remove the plugs first remove the air cleaner assembly (8-vaive engines) or the a»r cleaner, resonator and inlet air duct (16-valve engines) with reference to Chapter 4A or 4B. if the marks on the original-equipment spark plug (HT) leads cannot be seen, mark the leads 1 to 4, to correspond to the cylinder the lead serves (No 1 cylinder is at the timing belt end of the engine). Pull the leads from the plugs by gripping the end fitting, not the lead, otherwise the lead conneciion may be Iractured (see illustrations) 3 It is advisable to remove the dirt from the spark plug recesses using a clean brush, vacuum cleaner or compressed air before removing the plugs, to prevent dirt dropping into the cylinders. 4 Unscrew the plugs using a spark plug spanner, suitable box spanner or a deep socket and extension bar (see illustration). Keep the socket aligned with the spark plug • If it is forcibly moved to one side, the ceramic insulator may be broken off. As each plug is removed examine 4 as fallows. 5 Examination of the spark plugs will give a good Indication of the condition of the engine. If the Insulator nose of the spark plug Is clean and white, with no deposits, this is Indicative of a weak mixture or too hot a plug (a hot plug transfers heal away from the electrode slowly, a cold plug transfers heat away quickly). 6 If the tip and insulator nose are covered with hard black-looking deposits, this
19.2b ... and on 16-valve engines
19.9 Ad|ustlng a spark plug electrode gap
indicates that the mixture Is too rich. If the plug is black and oily, then It is likely that the engine is fairly worn, as well as the mixture being too rich. 7 If the Insulator nose is covered with light tan to greyish-brown deposits, then the mixture Is correct and it is likely that (he engine Is in good condition. 6 The spark plug electrode gap is of considerable importance as, if it Is too large or too small, the size of the spark and its efficiency will be seriously impaired. The gap should be set to the value given in the Specifications at the beginning of this Chapter. 9 To set the gap. measure it with a feeler blade and then bend open, or closed, the outer plug elect/ode until the correct gap l9 achieved. The centre electrode should never be bent, as this may crack the insulator and cause plug I allure, if nothing worse. If using feeler blades, the gap is correct when the appropriate-size blade is a firm sliding fit (see illustration). 10 Special spark plug electrode gap adjusting tools are available from most motor accessory shops, or from some spark plug manufacturers, 11 Before fitting the spark plugs, check that the threaded connector sleeves are tight, and that the plug exterior surfaces and threads are clean (see Haynes Hint). 12 Remove the rubber hose (If used), and tighten the plug to the specified torque using the spark plug socket and a torque wrench, Refit the remaining spark plugs In the same manner. 13 Connect the HT leads In their correct order, and refit any components removed for access.
It is very often difficult to insert spark plugs into their holes without cross-threading them. To, avoid this possibility, fit a short length of Si 16 Inch Internal diameter rubber hose over the end of the spark plug. The flexible hose acts as a universal Joint to help align the plug with the plug hole. Should the plug beginto cross-thread, the hose will slip on the spark plug, preventing thread damage to the cylinder head

ia.16 Every 2 years - petrol models
joint has not been disturbed for some time, if will bo necessary to gently manipulate the hose to break the joint. Do not use excessive force, or the radiator stub could be damaged. Allow the coolant to drain Into the container. 3 Certain models are fitted with cooling system bleed plugs, which should be opened to aid the draining process and help prevent airlocks. These are located on the top right hand edge of the radiator, on the heater Inlet hose and additionally, on 16-valve engines, on the heater outlet hose (see illustrations). If the coolant has been drained for a reason other than renewal, then provided It is ciean and less than two years old, it can be re-used, though this is not recommended. 4 Once ail the coofant has drained, reconnect the hose to the radiator and secure it in position with the retaining clip.
Cooling system flushing 5 If coolant renewal has been neglected, or If the antifreeze mixture has become diluted, then in time, Ihe cooling system may gradually lose efficiency, as the coolant passages become restricted due to rust, scale deposits, and other sediment. The cooling system efficiency can be restored by flushing the system clean. 6 The radiator should be flushed Independently of the engine, to avoid contamination. Radiator flushing 7 To flush the radiator disconnect the top and bottom hoses and any other relevant hoses from the radiator, with reference to Chapter 3. 8 Insert a garden hose into the radiator top inlet. Direct a flow of clean v/ater through the radiator, and continue flushing until clean water emerges from the radiator bottom outlet. 9 If after a reasonable period, the water still does not run clear, the radiator can be flushed wilh a good propnetary cooling system
cleaning agent. It is important that their manufacturer's Instructions are followed carefully. If the contamination is particularly bad, insert the hose in the radiator bottom outlet, and reverse-flush the radiator. Engine flushing 10 To flush the engine, remove the thermostat as described In Chapter 3 then temporarily refit the thermostat cover. 11 With the top and bottom hoses disconnected from the radiator, insert a garden hose into the radiator top hose. Direct a clean flow of water through the engine, and continue flushing until clean water emerges from the radiator bottom hose. 12 On complotion of flushing, refit the thermostat and reconnect the hoses with reference to Chapter 3,
Cooling system filling 13 Before attempting to fill the cooling system, make sure that all hoses and clips are in good condition, and that the clips are tight. Note that an antifreezo mixture must be used all year round, to prevent corrosion of the engine components (see below). 14 Remove the expansion tank filler cap. and fill the system by slowly pouring the coolant Into the oxpansion lank to prevent airlocks from forming. Ensure that all bleed plugs/screws are open. 15 If the coolant Is being renewed, begin by pouring in a couple of litres of v/ater, followed by the correct quantity of antifreeze, then top-up with more water. 16 Once the level in the expansion tank starts to rise, squeeze the radiator top and bottom hoses to help expel any trapped air In the system. Once all the air is expelled, top-up the coolant level to the MAX mark and refit the expansion tank cap. Close all bleed plugs. Continue the filling procedure as follows according to engine type.
1108 cc and 1242 cc (8-vaive) engines 17 Start the engine and run it until tt reaches normal operating temperature, then stop the engine and allow it to cool. 18 Chock for teaks, particularly around disturbed components. Check the coolant level in the expansion tank, and top-up H necessary. Note that the system must be coW before an accurate level Is indicated in the oxpansion tank. If the expansion tank cap is removed while the engine Is still warm, cover Ihe cap with a thick cloth, and unscrew the cap slowly to gradually relieve the system pressure (a hissing sound will normally be heard). Wall until any pressure remaining In the system is released, then continue to turn the cap until It can be removed. 1242 cc (16-valve) engines 19 Remove the expansion tank filler cap. start the engine and run it at Idling speed for two to three minutes. Allow the engine to continue running until the electric cooling fan operates, but during this time, briefly in-crease the engine speed to 2000 to 3000 rpm every 30 seconds. Maintain the coolant level in the expansion tank to the MAX mark during tliis procedure, adding more coolant as necessary. 20 On models without air conditfoning, wilh the engine still idling, carefully unscrew the bleed plug on the top of the radiator. Increase the engine speed until fluid emerges from the bleed plug, then close the plug and return the engine to idle.

A


Warning: Take suitable pre-cautions against scalding when opening the bleed plug as the coolant will be very hot. 21 On all models, allow the engine to continue running at idle for a further five minutes. After this time, switch the engine ofl, allow it 1o cool completely and when cool

1B»1
Chapter
1
Part B:
Routine maintenance & servicing - diesel models
Contents
Air filter renewal 13 Auxiliary drivebelt(s) check and renewal 16 Brake fluid renewal 2d Brake warning lamp operation check 5 Clutch adjustment check 17 Coolant renewal 27 Drtv«shaft gaiter check 10 Emissions control systems check 25
Engage
oil and filter renewal 3 Exhaust system check 9 Front brake pad check 6
Fuel
fitter renewal 12 Fuel Filter water draining 4 Headlight beam adjustment 20
Hinge and lock lubrication 19 Hose and fluid leak check 6 Idle speed check and adjustmenl 11 Introduction ... 1 Manual transmission oil level check 22 Manual transmission oil renewal - 26 Pollen filter renewal 14 Rear brake shoe check 23 Regular maintenance 2 Road test 21 Steering and suspension check 15 Timing belt renewal 24 Underbody sealant check 7 Valve clearance check and adjustment 16
^m
Degrees of difficulty
Easy, sutable for % Fairly easy, suitable FaHycifficult, i'. Difficult, suitable fa Very difficult, novice with irttte % for beginner with suitable for competent experienced DIY
1
suitable for expert DIY * or professional jQ experience some experience DIY mechanic mechanic 1
suitable for expert DIY * or professional jQ