1998 FIAT PUNTO Instrument

4A*2 Fuel system - single-point petrol Injection models
2.4a Disconnect the large breather hose... ziecessary when handling it cannot be mrstressed. Note that residual pressure
wttf
remain in the tuei lines long after the wh/cte was last used, When disconnecting any fuel line, first depressurise the fuel
system
(see Section 8).
2 Air cleaner and intet system • removal and refitting
1
Accelerator cable -removal, refitting and adjustment l
Removal 1 Remove the air cleaner element as described in Chapter 1A. 2 Disconnect the outer section from the hot
air
tube and the inlet air duct and remove it
from
the engine compartment. 3II necessary remove the inlet air duct. 4 Disconnect Ihe large and small breather
roses
from the inner section of the air cleaner, tftsn unscrew the retaining nuts and lift the section from the throttle body (see lustrations).
5
Recover the sealing ring. Check the ring for condition and renew it if necessary.
6
Wipe clean the inner surfaces of both the merand outer sections of the air cleaner. Refitting 7 Refitting Is a reversal ol removal but renew
tie
element
H
necessary.
3 Inlet air temperature regulator -removal and refitting
Removal t
The
thermostatically-controlled cold air flap cpener is located in the air cleaner outer ttsrig section. To check the unit, disconnect
ire air
inlet duct with the engine cold and use imrrorto check that the flap Is positioned to aJmit only hot air from the shroud on the utaust manifold. Next, warm up the engine
and
check that the flap moves to admit only sett air from the inlet duct. If the unit is faulty fl must be renewed.
2
Remove the air cleaner element as •senbod in Chapter
1
A.
kickdown cable adjustment as described in Chapter 7B before adjusting the accelerator cable • in its rest position the accelerator pedal should have approximately 8.0 mm free travel.
5 Engine management system components -removal and refitting I
2.4b ... and the small breather hose ...
3 Unscrew the retaining screw and remove the regulator from the air cleaner outer section.
Refitting 4 Refitting is a reversal of removal.
Removal 1 Remove the air cleaner and air inlet ducting as desenbed in Section 2. 2 To release the cable from the throttle body, unscrew the outer cable locknuts, then disengage the inner cable from the throttle cam, and release the outer cable from its mounting bracket. 3 Working under the instrument panel inside the vehicle, unhook the cable from the fork at the top of the pedal arm. 4 Release the bulkhead grommet and withdraw the accelerator cable from Inside the engine compartment.
Refitting and adjustment 5 Refitting is a reverse of the removal process, but adjust the cable (by means of the outer cable locknuts) so that there is only a very small amount of free play present at the throttle body end of the inner cable. Have an assistant depress the accelerator pedal, and check that the throttle cam opens fully and returns to the at-rest position, then secureJy tighten the cable locknuts. On Selecta models, check the
Note: Refer to the warning given in Section 1 before proceeding. Throttle body assembly
Removal 1 Remove the air cleaner and air duct as desenbed in Section 2. 2 Disconnect the wiring connectors from the throttle potentiometer, idle control stepper motor, inlet air temperature sensor and the injector wiring loom connector situated on the front of the throttle body. 3 Depressurise the fuel system with reference to Section 8, then release the retaining clips and disconnect the fuel feed and return hoses from the throttle body assembly, if the original Fiat retaining clips are still fitted, cut the clips and discard them; replace them with standard luel hose clips on refitting. 4 Slacken the accelerator cable locknuts, then disengage the inner cable from the throttle cam and froe tho outer cable from its retaining bracket. Position the cable clear of the throttle body. 5 Disconnect the EVAP purge valve hose, and the MAP sensor hose from the rear of the throttle body. 6 Slacken and remove the four bolts securing the throttle body assembly to tho Inlet manifold, then remove the assembly along with its insulating spacer. Refitting 7 Refitting is a reversal of the removal pro-cedure, bearing in mind the following points: a) Examine the insulating spacer for signs of damage, and renew //necessary, b) Ensure that the throttle body, inlet manifold and insulating spacer ma ting surfaces are clean and dry, then fit the throttle body and spacer, and securely tighten the retaining bolts.
2.4c ... then remove the retaining nuts. 2.4d ... and remove the air cleaner inner section

4A*2 Fuel system - single-point petrol Injection models
motor c) Ensure that all hoses are correctly reconnected and, where necessary, that their retaining clips are securely tightened. d) Adjust the accelerator cable as described In Section 4.
Fuel injector Note: If a faulty Injector Is suspected, before condemning the Injector, it is worth vying the effect of one of the proprietary Injector cleaning treatments. Removal 8 Remove the air cleaner and air duct as described In Section 2. 9 Disconnect the wiring then unscrew the mounting screws and remove Ihe Injector from the throttle body. Refitting 10 Refitting is a reversal of removal.
Fuel pressure regulator
Removal 11 Remove Ihe air cleaner and air duel as described In Section 2. 12 Using a marker pen. make alignment marks between the regulator cover end the throttle body, then undo the four retaining
screws. As the screws are loosened, place a rag over the cover to catch any fuel spray which may be released. 13 Lift off the cover, then remove the spring and withdraw the diaphragm, noting Its correct fitted orientation. Remove all traces of dirt, and examine the diaphragm for signs of splitting. If damage Is found, it will be necessary to renew the complete upper throttle body assembly. Refitting 14 Refitting is a reversal of removal ensuring that the diaphragm and cover are fitted the correct way round, and that the retaining screws are securely tightened,
Idle control stepper motor
Removal 15 Disconnect the battery negative terminal (refer to Disconnecting the battery In the Reference Section of this manual), then remove the air cleaner and air duct as described in Section 2. 16 Using a crosshead screwdriver, unscrew the mounting screws and remove the stepper motor from the throttle body. Recover the gaskei (see illustration). 17 Clean the unit and check for damage and wear. Refitting 18 When refitting the unit use a new gasket and make sure that the plunger is inserted correctly using the following procedure. Insert the unit and refit the mounting screws loosely. Reconnect the wiring then switch on the ignition several times so that the unit centralises itself. Finally fully tighten the mounting screws to the specified torque. Note: The mounting screws are covered with a locking agent and must be renewed every time they are removed 19 Leave the battery negative terminal disconnected for about 20 minutes - the injection/ignition ECU will position the Idle control stepper motor correctly the first time the engine is started. Reconnect the battery negative terminal.
Throttle potentiometer
Removal 20 Remove the air cleaner and air duct as described in Section 2. 21 Disconnect the wiring from the throttle potentiometer. 22 Using an Allen key unscrew the mounting screws then withdraw the unit from the throttle body (see Illustration). Note: The mounting screws ere covered with a locking agent and must be renewed every time they are removed. Refitting 23 When refitting the unit make sure that the pin Is correctly engaged, and tighten the mounting screws to the specified torque. 24 If a Rat test Instrument is available, the
operation of the throttle potentiometer can be checked at this stage. Before connecting the wiring first turn Ihe ignition key to position MAR and wait a few seconds, then return the key to the STOP position, Reconnect the wiring and connect the test instrument. Turn the Ignition key to the MAR position and cancel the error that will appear. The throttle position Indicated should be between 0° and 4°. If greater than this, check thai the accelerator cable is correctly adjusted however If the correct reading cannot be obtained renew the unit.
Inlet air temperature sensor
Removal 25 Remove the throtlle body assembly as described earlier In this Section. 28 Extract the plastic pins and remove the press-fit cover from the top of the throttle body. 27 Invert the cover then unscrew the mounting screws and remove the Inlet air temperature sensor from the cover. Refitting 28 Refining Is a reversal of removal.
Manifold absolute pressure (MAP) sensor
Removal 29 The manifold absolute pressure sensor is located on the left-hand side of the bulkhead. 30 Unscrew the mounting screws and remove the sensor from the bulkhead, Disconnect the wiring and vacuum pipe. Refitting 31 Refitting is a reversal of removal, but check the condition of the vacuum pipe and renew it if necessary.
Coolant temperature sensor
Removal 32 The coolant temperature sensor Is located on the left-hand side of the inlet manifold. Drain the cooling system as described In Chapter 1A before removing it. 33 Disconnect the wiring. 34 Unscrew the sensor and remove It from the Inlet manifold. If using a socket take care not to damage Ihe wiring connector on the sensor. Refitting 35 Refitting Is a reversal of removal bui tighten Ihe sensor to the specified torque. Do not exceed the specified torque otherwise the unit may be damaged.
Crankshaft TDC sensor
Removal 36 The crankshaft TDC sensor Is located on the front side of the crankshaft pulley. Firmly apply the handbrake, then jack up the front of the car Bnd support It securely on axle stands (see Jacking end vehicle support). Remove 5.22 Throttle potentiometer mounting screws

4A*2 Fuel system -
single-point
petrol Injection models
2.8 Undo tho two bolts securing the resonator to the camshaft cover
8 Undo the two bolts securing the resonator to the camshaft cover (see illustration) 9 Release ihe wiring loom support clip from the slot on the side of the resonator lower extension, then lift the resonator off the camshaft cover (see illustrations). Disconnect Ihe crankcase breather hose from the underside of tho resonator and remove the resonator from the engine. 10 Undo the nuts secunng the sides of the air cleaner to the mounting brackets at the front of the engino. 11 Release the hose clip and disconnect the inlet air duct from the throttle body. 12 Release the crankcase ventifation hose from the pipe stub on the camshaft cover then remove the air cleaner and inlet air duct assembly from the engine (see illustration).
Refitting 13 Refitting is a reversal of removal but renew the air cleaner element as described In Chapter
1 A,
if necessary.
Inlet air temperature regulator -liWfii' I
2.9o Release the wiring support clip (arrowed) from the slot on the resonator lower extension ...
the shroud on the exhaust manifold. Next, warm up tho engine and check that the flap moves to admit only cold air from the Inlet duct. If the unit is faulty it must be renewed. 2 Remove the air cleaner element as described in Chapter
1
A. 3 Unscrew tha retaining screw and remove tho regulator from the air cleaner outer section.
Refitting 4 Rofitting is a reversal of removal.
I
Removal 1 The thermostatically-controlled cold air flop opener, fitted to 8-valve engines, is located in the air cleaner outer cos>ng section. To check lha unit, disconnect the atr inlet duct with the engine cold and use a mirror to check that the flap Is positioned to admit only not air from
2.12 Removing the air cleaner and Inlet air duct assembly
4 Accelerator cable -removal, refitting and adjustment
1242 cc (8-valve) engines
Removal 1 Remove Ihe air cleaner as described In Section 2. 2 To release the cable from the throttle body, unscrew the outer cable locknuls, then disengage the inner cable from the throttle cam, and release the outer cable from its mounting bracket, 3 Wording under the instrument panel inside the vehicle, unhook the cable from tho fork at the top of the pedal arm. 4 Release the bulkhead grommel and withdraw tho accelerator cable from inside Ihe engine compartment. Refitting and adjustment 5 Refitting is a reverse of the removal process, but ad|ust the cable (by means of the outer cable locknuts} so that there Is only a very small amount of free play present at the throttle body end of the inner cablo. Have an assistant depress the accelerator pedal and check that the throttlo cam opens fully and returns to the at-rest position, then securely tighten the cable locknuts.
1242 cc (16-valve) engines
Removal 6 Dlsconnoel the battery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual), 7 Remove the resonator, air cleaner and Inlet air duct as described in Section 2.
camshaft cover
8 Undo the engine management ECU mounting bracket bolts, release the ECU wiring loom from Ihe support clips and move tho ECU and wiring loom to one side for access to the accelerator cable. 9 Free the accelerator inner cable from the throttle cam, remove the outer cable spring clip, then pull the outer cable out from its mounting bracket rubber grommet (see illustration). 10 Trace the cable back to its entry point in the engine compartment bulkhead and undo the bulkhead support bracket mounting bolt. 11 Working back along the length of the cable, free It from any retaining clips or ties, noting its correct routing. 12 Working under the instrument panel Inside the vehicle, unhook the cable from the fork at the top of the pedal arm. 13 Release the bulkhead support bracket and withdraw the accelerator cable from inside the engino compartment. Refitting end adjustment
14 Refitting is a reverse of the removal process, but adjust the cable as follows before refitting the outer cable spring clip. 16 Ensuring that the throttle cam is fully against its stop, gently pull the cable out of its grommet until all free play Is removed from the inner cable. 16 With the cable held in this position, lit the spring clip to tho first outer cable groove visible in front of the mounting brackot rubber grommet. This should leave a small amount of freeplay in tho inner cable which is necessary to ensure correct throttle operation.
4.9 Accelerator outer cable spring clip (arrowed)

Fuel system - diesel models 4C*3
2.7a Unscrew the bolt... 2.7b ... and remove the Inlet air duct assembly
2.9b ... remove the air cleaner body...
Non-turbo models 2 Disconnect the intermediate air duct from
the
sir cleaner cover and the resonance box. 3 Disconnect the inlet duct from the resonance box and unbolt It from the front of
the
engine compartment. 4 Unscrew tho mounting nuts and remove the resonance box. Note the location of the special spacers. 6 If necessary unbolt and remove the support Brackets for the resonance box. Turbo models 6 Disconnect the intermediate air duct from the air cleaner cover and front Inlet air duct assembly. 7 Unbolt and remove the inlet oir duct tssembty (see illustrations). 6 Disconnect the air ducts from between the
air
cleaner and turbocharger. and between the turbocharger and Inlet manifold.
2.9c ... and spacers
9 Unscrew the mounting nuts and remove the air cleaner body. Note the location of the special spacers (see illustrations).
Refitting 10 Refitting is a reversal of the removal procedure.
3 Accelerator cable -removal, refitting and adjustment
Removal 1 Remove the air inlet ducting as described in Section 2. 2 Working In Ihe engine compartment, remove the cylindrical spring clip, and release the Inner cable from the lever (see illustration).
2.9a Unscrew the mounting nuts...
3 Pull the outer cable from the grommet in the fuel injection pump bracket (see illustration). 4 Release the cable from the remaining clips and brackets in the engine compartment, noting Its routing. 5 Working under the Instrument panel inside the vehicle, unhook the cable from the fork at the top of the pedal arm. 6 Release the bulkhead grommet and withdraw the accelerator cable from inside the engine compartment.
Refitting 7 Refitting Is a reversal of removal, but ensure that the cable is routed as noted before removal, and on completion, adjust the cable as follows.
Adjustment 8 Remove the spring clip from the accel-erator outer cable (see illustration). Ensuring that the control lever Is against its stop, gently pull the cable out of Its grommet until all Iree play is removed from the inner cable. 9 With the cable held In this position, refit the spring clip to the last exposed outer cable groove in front of the rubber grommet and washer. When the clip is refitted and the outer cable is released, there should be only a small amount of free play in the inner cable. 10 Have an assistant depress the accelerator pedal, and check that the control lever opens lulty and returns smoothly to its stop.
4C
32 Remove the spring clip and release the inner cable 3.3 Removing the outer cable 3.8 Removing the spring clip Irom the accelerator outer cable

Fuel system - diesel models
4C*3

7.4 Unscrew the access screw from the 7.5 Dial gauge and adapter (Bosch) rear of the Injection pump (Bosch)
7 Injection timing ^ (Bosch fuel injection pump) -checking and adjustment ^
Caution: Some of the Injection pump uttlngs and access plugs may be sealed ty the manufacturers at the factory, using
paint
or locking wire and lead seals. Do not
disturb
the seals If the vehicle is still within the warranty period, otherwise the warranty will be invalidated. Also do not attempt the timing procedure unless
accurate
Instrumentation Is available. Note: To check the injection pump timing a special
timing
probe and mounting bracket is required. Without access to this piece of
tquipment.
injection pump timing should be intrusted to a Fiat dealer or other suitably
eqwpped
specialist. 1
H
the Injection timing is being checked with ffie pump in position on the engine, rather rian as part ot the pump refitting procedure, disconnect the battery negative terminal (refer to
Disconnecting
the battery in the Reference S«ction of this manual), and remove the air rtel ducting from the front of the engine. 2 Unscrew the union nuts and disconnect the injector pipes from the Injection pump and injectors. Counterhold the unions on the pump, while unscrewing the pipe-to-pump irion
nuts.
Remove the pipes as a set. Cover open unions to keep dirt out, using small plastic bags, or fingers cut from discarded
ibut clean!)
rubber gloves. 3 Referring to Chapter 2C, set the engine at
TDC on
cylinder No 1. 4 Unscrew the access screw, situated In the centre of the four injector pipe unions, from the rear of the Injection pump (see illustration). As the screw Is removed, position a suitable container beneath the
pump
to catch any escaping fuel, Mop up any tpilt fuel with a clean cloth. 5 Screw the adapter into the rear of the pump
and
mount the dial gauge in ihe adapter (see •ustration). If access to the special Fiat *Japter cannot be gained, they can be purchased from most good motor factors. Position the dial gauge so that its plunger is at
Ifce
mid-point of its travel and securely tighten Ite adapter locknut. 6 Slowly rotate the crankshaft first back then towards whilst observing the dial gauge, to ctotermlne when the Injection pump piston is
a',
the bottom of Its travel (BDC), When the pston Is correctly positioned, zero the dial
7 Rotate the crankshaft slowly in the correct direction until the TDC timing marks are tfjned on both the crankshaft, camshaft and rjecbon pump sprockets.
6
The reading obtained on the dial gauge should be equal to the specified pump timing measurement given in the Specifications at ew start of this Chapter, If adjustment is necessary, slacken the fronl and rear pump mounting nuts/bolts and slowly rotate the
pump body until the point is found where the specified reading Is obtained. When the pump is correctly posilioned, tighten both its front and rear mounting nuts and bolts securely. 9 Rotate the crankshaft through one and three quarter rotations in the normal direction of rotation. Find the injection pump piston BDC as described in paragraph 6 and zero the dial gauge. 10 Rotate the crankshaft slowly in the correct direction of rotation until the TDC marks are aligned. Recheck the timing measurement. 11 If adjustment is necessary, slacken the pump mounting nuts and bolts and repeat the operations In paragraphs 8 to 10. 12 When the pump timing Is correctly set, unscrew the adapter and remove the dial gauge. 13 Refit the screw and sealing washer to the pump and tighten it securely. 14 If the procedure is being carried out as part of the pump refitting sequence, proceed as described in Section 5, 15 If the procedure is being carried out with the pump fitted to the engine, refit the injector pipes tightening their union nuts to the specified torque setting. Reconnect the battery and refit the air inlet ducting. 16 Start the engine, and check for any leakage at the luel unions. To enable the engine to start it may be necessary to loosen the injector union nuts while turning tho engine on the starter motor in order to purge trapped air. 17 Check and if necessary adjust the idle speed as described in Chapter 1B.
8.4 Removing the injection pump timing inspection plug (Lucas)
8 injection timing ^ (Lucas fuel injection pump) - ^ checking
and
adjustment ^
Caution: Some of the injection pump settings and access plugs may be sealed by the manufacturers at the factory, using paint or locking wire and lead seo/s. Do not disturb the seals if the vehicle Is still within the warranty period, otherwise tho warranty will be Invalidated. Also do not affempf the timing procedure unless accurate instrumentation is available.
Note: To check the Injection pump timing a speciai timing probe and mounting bracket Is required. Without access to this piece of equipment, injection pump timing should be entrusted to a Fiat dealer or other suitably equipped specialist. 1 If the injection timing is being checked with the pump tn position on the engine, rather than as part of the pump refitting procedure, disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual), and remove the air inlet ducting from the front of the engine. 2 Unscrew the union nuts and disconnect the injector pipes from the Injection pump and In-jectors. Counterhold the unions on the pump, while unscrewing the pipe-to-pump union nuts. Remove the pipes as a set. Cover open unions to keep dirt out. using smalt plastic bags, or fingers cut from discarded (but clean!) rubber gloves. 3 Referring to Chapter 2C, set the engine at TDC on cylinder No 1, then turn the crank-shaft backwards (anti-clockwise) approx-imately a quarter of a turn. 4 Unscrew the access plug from the guide on the top of the pump body and recover the sealing washer (soe Illustration). Insert the special liming probe Into the guide, making sure it Ib correctly seated against the guide seating washer surface. Note: The timing probe must be seated against the guide sealing washer surface and not the upper lip of the guide for the measurement to be accurate. 5 Mount the bracket on the pump guide (using adapter tool) and securely mount the dial gauge {dial test indicator) In the bracket
expert22 fl/i* http://rutracker.org

Fuel system - diesel models 4C*3
14.6 Nuts securing the exhaust downpipe to the exhaust manifold 14.8 Disconnecting the oil return pipe from tho turbocharger
13 Turbocharger -description and precautions
Description A turbocharger 1$ fitted to TDS, TD and SX models. It increases engine efficiency by raising the pressure In the inlet manifold above atmospheric pressure. Instead of the air simply being sucked Into the cylinders. It Is forced in. Additional fuel is supplied by the injection pump in proportion to the increased air inlet. Energy for the operation of the turbocharger comes from the exhaust gas. The gas flows through a specially-shaped housing (the turbine housing) and In so doing, spins the turbine wheel. The turbine wheel is attached lo a shaft, at the end of which is another vaned wheel known as the compressor wheel, The compressor wheel spins in Its own housing, snd compresses the inlet air on the way to the inlet manifold. Boost pressure (the pressure in the Inlet manifold) is limited by a wastegate, which diverts Ihe exhaust gas away from the turbine wheel In response to a pressure-sensitive actuator. A pressure-operaled switch operates a warning light on the instrument panel in the event of excessive boost pressure developing. The turbo shaft is pressure-lubricated by an oil feed pipe from the main oil gallery The shaft floats on a cushion of oil. A drain pipo returns the oil to the sump.
Precautions The turbocharger operates at extremely high speeds and temperatures. Certain precautions must be observed, to avoid premature failure of the turbo, or injury to the operator. Do not operate the turbo with any of its parts exposed, or with any of ils hoses removed. Foreign objects falling onto the rotating vanes could cause excessive
damage, and (if ejected) personal injury. Do not race the engine immediately after start-up, especially if it Is cold. Give the oil a few seconds lo circulate. Always allow the engine to return to idle speed before switching il off - do not blip the throttle and switch off, as this will leave the turbo spinning without lubrication. Allow the engine to idle lor several minutes before switching off after a high-speed run. Observe the recommended intervals for oil and filter changing, and use a reputable oil of the specified quality. Neglect of oil changing, or use of Inferior oil, can cause carbon formation on the turbo shaft, leading to subsequent failure.
14 Turbocharger -removal and refitting
8 Disconnect the oil return pipe from the turbocharger (see Illustration). 9 Unscrew the bolt securing the mounting bracket to the cyfindar block. 10 Unscrew the mounting nuts and withdraw the turbocharger from the studs in Ihe exhaust manifold. Recover the gasket. II It Is to be refitted, store the turbocharger carefully, and plug its openings to prevent dirt ingress.
Refitting 11 Refitting Is a reversal of removal, bearing in mind the fallowing points: a) if a new turbocharger Is being fitted, change the engine oil and filter. b) Tighten ail nuts and bolts to the specified torque. c) Before starting the engine, prime the turbo lubrication circuit by disconnecting the stop solenoid iead at the injection pump, and cranking the engine on the starter for three ten-second bursts.
Removal 1 Remove the battery as described in Chapter 5A. 2 Unbolt and remove the relay guard and bracket from the left-hand side of Ihe engine. 3 Remove the air cleaner and ducting as descnbed in Section 2. 4 Loosen the clips and remove the air outlet duct between tho turbocharger and inlet manifold. Also disconnect the air inlet duct from the turbocharger. 6 Appty the handbrake, then jack up tho front of the vohicle and support on axle stands (see Jacking and vehicle support). 6 Bend back the locking tabs (if fitted) and unscrew the nuts securing the exhaust downpipe lo the exhaust manifold (see Illustration). Disconnect the downpipe from the exhaust system (refer to Part 4D) end remove it from under the vehicle. Recover tne gasket. 7 Unscrew ihe union nut and disconnect the oil supply pipe from the turbocharger. Recover the copper ring and tape over the end of the pipe 10 prevent dust entry.
15 Turbocharger -examination and renovation l
1 With the turbocharger removed, inspect the housing for cracks or other visible damage. 2 Spin the turbine or the compressor wheel, to verify that the shaft is intact and to feel for excessive shake or roughness. Some play is normal, since in use, the shaft is floating on a film of oil. Check that the wheel vanes are undamaged. 3 The wastegate and actuator are Integral, and cannot be checked or renewed separately. Consul! a Flat dealer or other specialist If it is thought that testing or renewal is necessary. 4 If tho exhaust or induction passages are ail* contaminated, Ihe turbo shaft oil seals have probably failed. 6 No DIY repair of the turbo is possible. A new unit may be available on an exchange basis,

5A«2 Starting and charging systems
Maintenance-free battery -charging Note: The following is intended as a guide only. Always refer to the manufacturer's recommendations (often printed on a label attached to the battery) before charging a battery. 13 This battery type takes considerably longer lo fully recharge than the standard type, the time taken being dependent on the extent of discharge, but it can take anything
up
to three days. 14 A constant voltage type charger is required, tooe set, when connected, to 13.9 to 14.9 votts wth a charger current below 25 amps. Using
mis
method, the battery should be usable within three hours, giving a voltage reading of 12.5 vofts. but this Is for a partially discharged battery and, as mentioned, full charging can
take
considerably longer. 15 If Ihe battery is to be charged from a fully discharged state {condition reading loss lhan 12.2 volts), have it recharged by your FIAT dealer or local automotive electrician, as Ihe charge rate is higher and constant super-vision during charging Is necessary.
3 Battery -removal and refitting
Note: Refer to Disconnecting the battery in ifte Reference Section of this manual before proceeding.
Removal 1 Slacken the clamp bolts and disconnect the ctamp from the battery negative (earth) terminal. 2 Remove the insulation cover (where fitted)
and
disconnect the positive terminal lead(s) in
Die same
way. 3 At the base of the battery, unscrew the bolt from the battery holding clamp plate and remove the clamp plate (see Illustration). A Remove the battery from Ihe engine compartment. 5 II necessary the mounting tray may be removed by unscrewing the bolts. On diesel models it will be necessary to remove the relay guard bolts as well.
Refitting 6 Refitting is a reversal of removal but make sure that the positive terminal is connected first followed by the negative terminal.
4 Alternator/charging system - >%•> testing in vehicle
Note: Refer to the warnings given in Safety first! and in Section 1 of this Chapter before starting work. 1 If the ignition warning light fails to Illuminate when the ignition is switched on, first check the alternator wiring connections for security. If satisfactory, check that the warning light bulb has not blown, and that the bulbholder is secure in its location in the instrument panel. If the light still fails to illuminate, check the continuity of the warning light feed wire from the alternator to the bulbholder. If all is satisfactory, the alternator is at fault and should be renewed or taken to an auto-electrician for testing and repair. 2 If the ignition warning light Illuminates when the engine Is running, stop the engine and check that the drivebelt is correctly tensioned (see Chapter 1A or 18) and that the alternator connections are secure. If all is so far satisfactory, have the alternator checked by an auto-electrician. 3 If the alternator output is suspect even though the warning light functions correctly, the regulated voltage may be checked as follows. 4 Connect a voltmeter across the battery terminals and start the engine. 5 Increase the engine speed until the voltmeter reading remains steady; the reading should be approximately 12 to 13 volts, and no more than 14 volts. 6 Switch on as many electrical accessories (eg. the headlights, heated rear window and heater blower) as possible, and check that the alternator maintains the regulated voltage at around 13 to 14 volts. 7 If ihe regulated voltage is not as stated, the fault may be due to worn brushes, weak brush springs, e faulty voltage regulator, a faulty diode, a severed phase winding or worn or damaged slip rings. The alternator should be renewed or taken to an auto-electrician for testing and repair.
3.3 Removing the battery clamp plate
5 Alternator -removal and refitting
Removal 1 Disconnect the battery negative terminal {refer to Disconnecting the battery In the Reference Section of this manual). 2 Firmly apply the handbrake, then jack up the front of the car and support it securely on axle stands (see Jacking and vehicle support). Remove tho right-hand front roadwheel. 3 Remove Ihe Inner cover from under the right-hand wheelarch for access to tho right-hand side of the engine. 4 Disconnect the cables from the rear Of the alternator (see illustration).
Petrol models 5 Loosen the pivot and adjustment bolts then swivel the alternator towards the engine and slip off the drivebelt. Note that the position of the rpm sensor will prevent complete removal of the drivebelt from the crankshaft puiley. 6 Unscrew and remove the pivot and adjustment bolts then unscrew the upper slot-mounted bolt. Withdraw the alternator from the engine (see illustrations).
Diesel models 7 For additional working room, unclip and remove the upper timing belt cover then unbolt and remove the lower timing belt cover.
5.4 Cable connections on the rear of the alternator
5.6a Alternator adjustment and pivot bolts (petrol engine) B Adjuster bolt C Pivot bolt 5.6b Removing the alternator (petrol engine)

9*4 Braking system
3.5 Unscrew the caliper upper guide pin bolt and remove tho caliper body (torn the bracket
3 Front brake caliper -removal, overhaul and refitting ^

A


Warning: Before starting work, refer to the warnings at the beginning of Sections 2 and 11 concerning the dangers of handling asbestos dust and hydraulic fluid.
Removal 1 Chock the rear wheels, apply the handbrake, then |ack up the front of the vehicle and support it on axle stands {see Jacking and vehicle support). Remove the appropriate front roadwheel. 2 Remove the brake pads as described In Section 2. 3 To minimise fluid loss dunng the following operations, remove the master cylinder reservoir cap. then
tig hi en
it down onto a piece of polythene, to obtain an airtight seat. Alternatively, use a brake hose clamp to seal off the flexible hose running to the caliper.

A


Warning: Do not use an ordinary G-clamp or mole grips for this purpose, as these can easily damage the hydraulic hose Internally, possibly leading to failure. 4 Clean the area surrounding the brake hose union, then slacken ft using a ring spanner. It won't be possible to separate the union completely without twisting the hose ai this slage.
3.7 Unscrew the two securing bolts (arrowed) and remove the caliper mounting bracket from the hub carrier
5 On petrol models without ABS, unscrew the caliper upper guide pin bolt using a hex bit or Allen key and remove the caliper body from the bracket (see illustration). 6 Hold the brake hose and rotate the caliper to unscrew the hose union from the caliper body. Cover the open ends of the union and the caliper fluid inlet, to prevent dirt Ingress. Alternatively, Ihe flexible brake hose may be separated from the rigid brake pipe, at the bracket mounted on the Inner wheel arch. 7 If desired, the caliper mounting bracket can be removed from the hub carrier after unscrewing ihe two securing bolts (see Illustration) but note that locking compound must be applied to the bolt threads on refitting.
Overhaul Note: Before commencing work, ensure that the appropriate caliper overhaul kit
Ss
obtained. 8 With the caliper on the bench, wipe away all (races of dust and dirt, but avoid inhaling the dust, as It
Is
a health hazard. 9 Place a small block of wood between the caliper body and tho piston, to act as padding. Remove the piston by applying a Jet of low pressure compressed air (such as that pioduced by a tyre foot pump) to the fluid inlel port.

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Warning: Protect your hands and eyes when using compressed air In this manner • brake fluid moy be ejected under pressure when the pisfon pops out of Its bore. 10 Peel the dusi seal from the piston, then use a soft, blunt instrument (ie not a screwdriver) to extract the piston seal from the caliper bore. 11 Thoroughly clean all components, U9tng only methylated spint or clean hydraulic fluid, Never use mineral-based solvents such as petrol or paraffin, which will attack Ihe hydraulic system rubber components. 12 The caliper piston seal, the dust seal and the bleed nipple dust cap, a/e oniy available as part of a seat kit. Since the manufacturers recommend that the piston seal and dust seal are renewed whenever they are disturbed, all of these components should be discarded on disassembly and new ones fitted on reassembly as a matter of course. 13 Carefully examine all parts of the caliper assembly, looking for signs of wear or damage. In particular, the cylinder bore and piston must be free from any signs of scratches, corrosion or wear. If there is any doubt about ihe condition of any part of the caliper, the relevant port should be renewed Note that the piston surface is plated, and must not be polished with emery or similar abrasives to remove corrosion or scratches. In addition, the pistons are matched to the caliper bores and can only be renewed as a part of a complete caliper assembly. 14 Check that the threads in the caliper body and the mounting bracket are in good condition, Check that both guide pins are
undamaged, and (when cleaned) a reasons^' tight sliding fit In the mounting bracket bores. 15 UsecompressedairtOblow clear the IkuJ passages. Warning: Wear eye protection when using compressed
air.
16 Before commencing reassembly, en$vr« that all components are spotlessly-clean
and
dry. 17 Soak the new piston seal m clean hydraulic fluid, and fit it to the groove
In
tftt cylinder bore, using your fingers only (rift tools) to manipulate it into place. 18 Fit the new dust seal inner ftp to tne cylinder groove, smear clean hydraulic Hud over the piston and caliper cylinder
bore, and
twist ihe pfaton into the dust seal. Press tne piston squarely Into the cylinder, then sildt the dust seal outer lip to tho groove in we piston
Refitting 19 Where applicable, refit the caliper mounting bracket to thB hub earner. Ccaitto threads ol the mounting bolts with locking compound, then tighten them to the speclfed torque. 20 Hold the brake hose and rotate Ihe calip* to screw the hose union back Into the caliper body. 21 On petrol models without ABS, place the caliper In position on the bracket and tighter the caliper upper guide pin bolt to the specified torque. 22 Relit ihe brake pads as described m Section 2. 23 On all models, tighten the brake hose-to-callper union securely. 24 Check that the caliper slides smoothly
on
its guide pins. 25 Where applicable, remove the polytbste from the master oyhnder rasarvoir cap, or remove tho clomp from the fluid hose, ai applicable. 26 Bleed tho hydraulic fluid circuit as desenbed m Section 11. Note that if rootMf part of the system has been disturbed, < should only be necessary to bleed tha relevant front circuit, 27 Depress the brake pedal repeatedly to bring ihe pads into contact with ihe brake disc, and ensure that normal pedal
pressure is
restored. 28 Refit the roadwheel, and lower tha veti'cfc lo ihe ground.
4 Brake disc -
inspection,
removal
and
refitting
Inspection 1 Firmly apply the handbrake, then jaefcup the front of the car and support It securely
oft
axle stands (see Jacking and vehicle
support1,.
Remove the front roadwhesls.
expert22 f
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