1998 FIAT PUNTO brake

Suspension and steering 10*13
the skill required to use It properly, the checking and adjustment of these settings Is best left to a Fiat dealer or similar expert. Most tyre-fitting shops now possess sophisticated checking equipment. 3 For accurate checking, the vehicle must be at the kerb weight specified in Dimensions and weights. 4 Before starting work, check first that the tyre sizes and types are as specified (see Tyre pressures in Weekly checks), then check tyre pressures and tread wear. Also check roadwheel run-out, the condition of the hub bearings, the steering wheel free play and the condition of the front suspension components (Steering and suspension check in Chapter 1A or
1B).
Correct any faults found. 6 Park the vehicle on level ground, with the front roadwheeis in the straight-ahead position. Rock the rear and front ends to settle the suspension. Release the handbrake and roll the vehicle backwards approximately 1 metre, then forwards again, to relieve any stresses in the steering and suspension components. 6 Two methods are available to the home mechanic for checking the front wheel toe setting. One method is to use a gauge to measure the distance between the front and rear inside edges of the roadwheeis. The other method is to use a scuff plate, in which each front wheel is rolled across a movable plate which records any deviation, or scuff, of the tyre from the straight-ahead position as It moves across the plate. Such gauges are available in relatively-inexpensive form from accessory outlets. It Is up to the owner to decide whether the expense is justified, In view of the small amount of use such equipment would normally receive. 7 Prepare the vehicle 8S described in paragraphs 3 to 5 above.
8 If the measurement procedure is being used, carefully measure the distance between the front edges of the roadwheel rims and the rear edges of the rims. Subtract the front measurement from the rear measurement, and check that the result is within the specified range. If not, adjust the toe setting as described in paragraph 10. 9 If scuff plates are to be used, roll the vehicle backwards, check that the roadwheeis are in the straight-ahead position, then roll it across the scuff plates so that each front roadwheel passes squarely over the centre of its respective plate. Note the angle recorded by the scuff plates. To ensure accuracy, repeat the check three times, and take the average of the three readings, if the roadwheeis are running parallel, there will of course be no angle recorded; If a deviation value Is shown on the scuff plates, compare the reading obtained for each wheel with that supplied by the scuff plate manufacturers. If the value recorded is outside Ihe specified tolerance, the toe setting is incorrect, and must be adjusted as follows. Adjustment 10 Apply the handbrake, then jack up the front of the vehicle and support it securely on axle stands (see Jacking and vehicle support). Turn the steering wheel onto full-left lock, and record the number of exposed threads on the right-hand track-rod. Now turn the steering onto full-right lock, and record the number of threads on the left-hand side. If there are the same number of threads visible on both sides, then subsequent adjustment should be made equally on both sides. If there are more threads visible on one side than the other, it will be necessary to compensate for this during adjustment Note: It is important to ensure that, after adjustment, the same number of threads are visible on the end of each track-rod.
11 First clean the track-rod threads; If they are corroded, apply penetrating fluid before starting adjustment. Release the steering gear rubber gaiter outboard clips, then peel back the gaiters and apply a smear of grease, so that both gaiters are free and will not be twisted or strained as their respective track-rods are rotated. 12 Use a straight-edge and a scriber or similar to mark the relationship of each track-rod to the track-rod end. Working on each track-rod end in tum, unscrew its locking nut. 13 Alter the length of the track-rods, bearing In mind the note in paragraph 10, by screwing them into or out of the track-rod ends. Rotate the track-rod using an open-ended spanner fitted to the flats provided. If necessary, counterhold the track-rod end using a second spanner. Shortening the track-rods (screwing them Into their track-rod ends) will reduce toe-in and increase toe-out. 14 When the setting Is correct, hold the track-rods and securely tighten the locking nuts. Check that the balljoints are seated correctly In their sockets, and count the exposed threads on the ends of the track-rods. If the number of threads exposed is not the same on both sides, then the adjustment has not been made equally, and problems will be encountered with tyre scrubbing in turns; also, the steering wheel spokes will no longer be horizontal when the wheels are in the straight-ahead position. 15 When the track-rod lengths are the same, lower the vehicle to the ground and re-check the toe setting; readjust if necessary. When the setting is correct, tighten the locking nuts. Ensure that the steering gear rubber gaiters are seated correctly and are not twisted or strained, then secure them In position with new retaining clips.
10

Bodywork and fittings
11
*11
securing the motor assembly/winder mechanism to the door 5 Uft the glass out through the window aperture in the top of the door, manipulating the glass past the weatherstrips as it is withdrawn. On 3-door models, it will be necessary to partially remove the weatherstrip from the upper edge of Ihe window aperture, to allow the glass to be withdrawn. Refitting 6 Refitting is a reversal of removal, bearing in mind the following points: a) Ensure that all weather stnps are
securely
seated on the edges of the window aperture. b) Check the operation of the window regulator mechanism before refitting the door inner trim panel. | 0 Refit the door inner trim panel with | reference to Section 14.
1 Door window regulator
Removal 7 Separate the window glass from the regulator mechanism, as described earlier. 6 Fully raise the window glass, and secure the glass In position using suitable tape, or by wedging the glass in position using rags between the glass and the edge of the door • ensure that the glass cannot drop into the door. Alternatively, lift the glass panel out 1 through the window aperture. 9 Where applicable, separate the two halves of the regulator motor wiring connector. I 10 Unscrew the bolts securing the motor assembly/winder mechanism to the door (see Illustration). t1 Unscrew the two upper and the two lower regulator mechanism securing bolts, then manipulate the complete regulator assembly out through the aperture in the door (see illustrations). 12 The winder/motor assembly, together with its associated control cables remains connected to the regulator mechanism (see Illustration), Note: Carefully mark the relationship between the guide rails and the door to ensure correct adjustment on refitting. Refitting
13 Refitting is a reversal of removal, bearing r mind the following points: a) Ensure that all weather strips are securely I seated on the edges of the window aperture
16.11c ... then manipulate the complete regulator assembly out through the aperture in the door b) Check the operation of the window mechanism before refitting the door inner trim panel. c) Refil the door inner tnm panel with reference to Section 14.
19 Facia - ^ removal and refitting 5
Removal 1 Disconnect the batlery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual). 2 Refer to Chapter 12 and carry out Ihe following: a) Remove the instrument panel from the facia.
19.5a Prise open the plastic covers...
18.11b ... and the lower regulator mechanism securing bolts...
assembly
b) Remove the radio/cassette unit from the facia 3 Unscrew the fixings for the storage bin above the radio aperture, then remove the bin from the facia. 4 Remove the steenng wheel (see Chapter 10) and the steering column shroud. 5 Prise open the plastic covers, remove the fixings and lift off the handbrake lever console (see Illustrations). 6 Work around the outside of the centre console and unscrew the fixings. Unclip the gear lever gaiter, lift the centre console over the gear lever, then label and unplug the wiring connector beneath and remove the console from the vehicle. 7 Remove the heater control panel from the facia, with reference to Chapter 3. 8 Unscrew the fixings from the upper and lower edges of the combined ventilation/
19.5b ... remove the fixings...

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*11
15.6 Withdraw the motor assembly through the aperture in the tailgate
Refitting 7 Refitting is a reversal of removal. Refit the wiper arm with reference to Section 16.
16 Windscreen/tailgate washer % system components • ^ removal and refitting ^
Washer fluid reservoir
Removal 1 Ensure that the vehicle is parked on a level surface. Apply the handbrake and chock the rear wheels. Slacken the left hand front roadwheel bolts. 2 Raise the front of the vehicle, rest it securely on axle stands (see Jacking and vehicle support) and remove the left hand front roadwheel. 3 Disconnect the battery negative terminal {refer to Disconnecting the battery In the Reference Section of this manual). 4 Working from the engine bay, remove washer fluid reservoir upper securing screws. 5 Remove the secunng screws and lift off the front and rear sections of the wheel arch liner. 6 Remove fluid reservoir lower securing screws. 7 Disconnect the sviring plugs from the washer pumps, and from the fluid level sensor, where applicable. Label each connector to aid correct refitting later. 8 Disconnect the fluid hoses from the washer tx/mps • if the reservoir still contains fluid, be prepared tor spillage.
16.20a Remove the circllp...
9 Where applicable, release the wiring harness from its clips, and move the harness to one side to allow sufficient clearance to remove the reservoir. 10 Lower the reservoir from under the wheel arch. Refitting 11 Refitting is a reversal of removal.
Washer fluid reservoir and washer pump(s)
Removal 12 Remove the washer fluid reservoir, as described in the previous sub-Section. 13 Disconnect the wiring plug and the fluid hose from the relevant washer pump. 14 Release the spring clip, then pull the washer pump from the reservoir. Where applicable, recover the grommet. Refitting 15 Refitting is a reversal of removal.
IV/nctecreen washer nozzle
Removal 16 Open the bonnet. 17 Working under the bonnet, release the securing tabs using a suitable screwdriver, then push the nozzle from the bonnet. Disconnect the fluid hose, and withdraw the nozzle. Refitting 18 Refitting is a reversal of removal.
housing from the end of the wiper shaft
Tailgate washer nozzle
Removal 19 The tailgate washer nozzle is integral with the wiper motor shaft; remove the wiper motor as described in Section 15. 20 Remove the circllp and then slide the nozzle housing from the end of the wiper shaft (see illustrations). Refitting 21 Refitting is a reversal of removal, but ensure that the fluid hose is securely reconnected.
17 Windscreen wiper motor -removal and refitting ^
Removal 1 Disconnect the battery negative terminal (refer to Disconnecting the battery In the Reference Section of this manual). 2 Refer to Section 18 and remove both wiper arms. 3 Remove the securing screws and plastic clips, and withdraw the cowl panel (see illustrations). 4 Disconnect the motor wiring plug. 5 Slacken and withdraw the motor and linkage securing bolts, then withdraw the assembly from the bulkhead (see illustrations).
17.3a Remove the securing screws and plasUc clips... 17.3b ... and withdraw the cowl panel 17.5a Wiper motor and linkage left-hand ...