1997 FIAT PUNTO Check

FIAT
PUNTO
1994 to Oct 1999 (L to V registration) Petrol & Diesel
Haynes Service and Repair Manual
expert22 fl/ia http://rutracker.org
Includes Roadside Repairs and MOT Test Checks

Contents
LIVING WITH YOUR FIAT PUNTO
Introduction to the Rat Punto Page 0-4 Safety lirstl Page 0*5
Roadside repairs If your car won't start Page 0*6 Jump starting Page 0*7 Wheel changing Page 0«8 Identifying teaks Page 0*9 Towing Page 0*9
Weekly checks Introduction Page 0*10 Underbonnet check points Page 0»10 Engine oil level Page 0*12 Coolant level Page 0*12 Brake fluid level Page 0*13 Power steering fluid level Page 0"13 Tyre condition and pressure Page 0*14 Automatic transmission fluid level Page 0«1S Screen washer fluid level Page 0«1S Wiper blades Page 0*15 Battery Page 0*16 Electrical systems Page 0-16
Lubricants and fluids Page 0*17
Tyre pressures Page 0*18
MAINTENANCE
Routine maintenance and servicing Rat Punto petrol models Page 1A«1 Servicing specifications Page 1A«2 Maintenance schedule Page 1A«3 Maintenance procedures Page 1A«6 Fiat Punto diesei models Page 1B-1 Servicing specifications Page 1B«2 Maintenance schedule Page 1B«3 Maintenance procedures Page 1B«5
expert22 fl/ia http://rutracker.org

Contents
REPAIRS AND OVERHAUL
Engine and associated systems SOHC (8-valve) petrol engine in-car repair procedures Page 2A«1 DOHC (16-valve) petrol engine in-car repair procedures Page 2B«1 Diesel engine in-car repair procedures Page 2C«1 Engine removal and overhaul procedures Page 2D«1 Cooling, heating and ventilation systems Page 3»1 Fuel system - single-point petrol injection models Page 4A«1 Fuel system - multi-point petrol injection models Page 4B«1 Fuel system - diesel models Page 4C»1 Exhaust and emission control systems Page 4D*1 Starting and charging systems Page SA«1 Ignition system - petrol models Page SB«1 Preheating system - diesel models Page 5C>1
Transmission Clutch Page 6»1 Manual transmission Page 7A«1 Automatic transmission Page 7B*1 Driveshafts Page 8*1
Brakes and suspension Braking system Page 9*1 Suspension and steering Page 10-1
Body equipment Bodywork, trim and Fittings Page 11«1 Body electrical systems Page 12*1
Wiring diagrams Page 12»13
REFERENCE
Dimensions and weights Page REF«1 Conversion factors Page REF*2 Buying spare parts Page REF»3 Vehicle identification Page REF«3 General repair procedures Page REF«4 Jacking and vehicle support Page REF»5 Disconnecting the battery Page REF«5 Tools and working facilities Page REF-6 MOT test checks Page REF»8 Fault finding Page REF»12 Glossary of technical terms Page REF»20
index Page REF»24
expert22 rjijr http://rutracker.org

Safety first! 0.5
Working on your ear can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude.
General hazards
Scalding • Don't remove the radiator or expansion tank cap while the engine is hot. • Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running.
Burning • Beware of burns from the exhau3t system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use.
Crushing • When working under or near a raised vehicle. ~ always supplement the ' ' -jack with axle stands, or use ... drive-on i'j ramps. kr Never venture ™ under
a
car
vv/j/ch
Is only supported by a jack. • Take card if loosening or tightening high-torque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground.
Fire • Fuel Is highly flammable; fuel vapour is explosive. • Don't (et fuel spill onto a hot engine. • Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of toots). • Fuel vapour is heavier than air, so don't work on the fuel system with the vehicle over an inspection pit. • Another cause of fire is an electrical overload or short-circuit. Take care when repainng or modifying the vehicle wiring. • Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires.
Electric shock x ^ ^ ? , • Ignition HT _ " voltage can be ^ dangerous, ~ especially to > people with heart problems or a pacemaker. Don't work on or near the f^ ignition system with fT") the engine running or ' J ' J the Ignition switched on.
• Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker.
Fume or gas intoxication • Exhaust fumes are poisonous: they often contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine in a confined space such as a garage with the doors shut, • Fuel vapour is also poisonous, as are the vapours from some cleaning solvents and paint thinners.
Poisonous or irritant substances • Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don't syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice. « Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream If necessary. Change out of oll-soaked clothes and do not keep oily rags in your pocket. • Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame {including a cigarette). It can also cause skin burns on contact.
Asbestos • Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found In gaskets and in brake and clutch linings. When dealing with soch components It is safest to assume that they contain asbestos.
Special hazards
Hydrofluoric acid • This extremely corrosive acid is formed when cerlam types of synthetic rubber, found In some O-rings, oil seals, fuel hoses etc. are exposed to temperatures above 400;C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years, tfit gets onto the skin, it may be necessary to amputate the limb concerned. • When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use.
The battery • Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. • The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads.
Air bags • Air bags can cause injury if they go off accidentally. Take care when removing the steenng wheel and/or facia. Special storage instructions may apply.
Diesel injection equipment • Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes.

A


Warning: Never expose the hands, face or any otfterpart of the body to injector spray; the fuel can penetrate the skin with potentially fatal results.
Remember...
DO • Do use eye protection when using power tools, and when working under the vehicle. • Do wear gloves or use barrier cream to protect your hands when necessary. • Do get someone to check periodically that all is well when working alone on the vehicle. • Do keep loose clothing and long hair well out of the way of moving mechanical parts. • Do remove rings, wrtstwatch etc. before working on the vehicle - especially the electrical system, • Do ensure that any lifting or jacking equipment has a safe working load rating adequate for the job.
DON'T • Don't attempt to lift a heavy component which may be beyond your capability - get assistance. • Don't rush to finish a job. or take unverified short cuts. • Don't use ill-fitting toots which may slip and cause injury. • Don't leave tools or parts lying around where someone can trip over them. Mop up oil and fuel spills at once. • Don't allow children or pets to play In or near a vehicle being worked on.

o.6 Roadside repairs
The following pages are Intended to help In dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair Information In the main chapters.
If your car won't start
and the starter motor
doesn't turn
If your car won't start
even though the starter
motor turns as normal
tf it's a model with automatic transmission, make sure the selector is in P or N. Open the bonnet and make sure that the battery terminals are clean and tight. Switch on the headlights and try to start the engine. If the headlights go very dim when you're trying to start, the battery is probably flat. Get out of trouble by Jump starting (see next page) using a friend's car.
• Is there fuel In the tank? • Is there moisture on electrical components under the bonnet? Switch off the ignition, then wipe off any obvious dampness with a dry cloth. Spray a water-repellent aerosol product (WD-40 or equivalent) on ignition and fuel system electrical connectors like those shown in the photos. Pay special attention to the ignition coil wiring connector and HT leads. (Note that Diesel engines don't normally suffer from damp.)

A

Check that the spark plug HT leads are securely connected by pushing them onto the plugs (petrol engine models).
B

Check that the wiring to the engine compartments is securely connected.
C

Check the security and condition of the battery terminals,
Check that electrical connections are secure (with the ignition switched off) and spray them with a water dispersant spray tike WD40II you suspect a problem due to damp

o«8
Roadside repairs
Wheel changing
Some of the details shown horo will vary according to model. For Instance, the location of the spare wheel and jack is not the same on all cars. However, the basic principles apply to aii vehicles-
Preparation
• When a puncture occurs, stop as soon as it Is safe to do so. • Park on firm level ground. If possible, and v/etl out of the way of other traffic. • Use hazard warning lights if necessary.
Changing the wheel
A
Warning: Do not change a wheel (n a situation where you risk being hit by another vehicle. On busy roads, try to stop in a fay-by or a gateway. Be wary of passing traffic white changing the wheel - it Is easy to becomo distracted by the job in hand.
If you have one, use a warning triangle to alert other drivers of your presence. Apply the handbrake and engage first or reverse gear (or P on models with automatic transmission).
• Chock the wheel diagonally opposite the one being removed - a couple of largo stones will do for this. G If the ground is soft, use a flat piece of wood to spread the load under the iack.

I

Tbe spare wheel and tools (Including the jack) are stored
In
the luggage compartment beneath the floor covering. Unscrew the central plastic nut to remove the tool holder.
Slacken each wheel bolt by a half turn Locale the jack under the triangular mark on the 6)11 next to the wheel to be changed, on firm ground

4

Turn the Jack handle clockwise until the wheel Is raised clear of the ground Unscrew the wheel bolts, withdraw the trim and remove the whed
6

Fit Ihe spare wheel on the pins, and screw In the bolts. Lightly lighten tho bolts with the wheelbrace then lowor the vehicle to the ground
Finally...
Securely lighten the wheel bolts in Ihe sequence shown. Note that the wheel bolts should be slackened and retightened to the specified torque at the earliest possible opportunity.
• Remove l)>e wheel chocks.
• Stow the punctured wheel, jack and tools in the correct locations in the car. • Check the tyre pressure on the wheel just fitted. If it is low. or It you don't have a pressure gauge with you, drive slowly to the nearest garage and inflate the tyre to Ihe right pressure.
D When using tho space-saver spare wheel, do not exceed 50 mph (SO kph). C Have the damaged tyre or wheal repaired as soon as possible.

do Weekly checks
Introduction
There are some very simple checks which need only take a few minutes to carry out, but which could save you a lot of inconvenience and expense.
These Weekly checks require no great skill or special lools, and the small amount of lime they take to perform could prove to be very well spent, for example;
P Keeping an eye on tyre condition and pressures, will not only help to stop them wearing out prematurely, but could also save your life.
C Many breakdowns are caused by electacai problems. Battery-relalod faults are particularly common, and a quick check on a regular basis will ofton prevent the majority of these.
• If your car develops a brake fluid teak, the first time you might know about it is when your brakes don't work properly. Checking the level regularly will give advance warning of this kind of problem.
• If the oil or coolant levels run low. the cost of repairing any engine damage will be far greater than fixing the leak, for example.
Underbonnet check points
4 1.1 litre petrol
A Engine oil level dipstick Q Engine oil filler cap C Cooteof expansion tank P Brake fluid reservoir E Screen washer fluid reservoir p Battery
< 1.2 litre
m (8-valve) petrol
^ 1 A Engine oII level dipstick
B Engine otl tiller cap
fi i: c Coolant expansion tank
D Brake fluid reservoir
E Screen washer fluid reservoir
F Battery

Weekly checks o.n
Ulllllli
B
4 1.2 litre (16-valve) petrol
A Engine oil level dipstick
B Engine oil fitter cap 0 Coolant expansion tank D 8rake fluid reservoir £ Screen ivasfter fluid reservoir P Battery G Power steenng fluid reservoir
B

4
1.7 litre Turbo diesel
A Engine otl level dipstick B Engine oil filler cap Q Coolant expansion tank Q Brake fluid reservoir E Screen washer fluid reservoir F Battery
G Power steering fluid reservoir