1999 FIAT PUNTO check oil

Suspension and steering 10*3
2.10 Using a slide hammer to extract the hub 2.11 Wheel bearing components / Hub carrier 2 Wheel bearing 3 Circlip
Owners wishing to attempt the work them-
selves
should proceed as follows. 10 Mount tho hub carrier firmly In a bench vice. Attach a slide hammer to the hub flange and extract the hub. together with the inner bearing race, If it has remained attached to the hub. Unbolt and remove the heat shield
(see
Illustration). 11 Mount the hub carrier horizontally in the rice, then remove tho bearing retaining circlip. Using a suitable length of tubing as a drift, drive Ihe bearing outer race from the carrier (see Illustration). Note that a flange on the outboard side of the carrier means that the bearing can only be driven out in one direction. 12 Support the inner bearing race, if it has remained attached to the hub, then press or drive the hub from the race. Alternatively, pull trie bearing race from the hub using a suitable Iw or three-legged puller. 13 Before Installing the new bearing, thoroughly clean the bearing location in the tub carrier. U Fit the new bearing from the Inboard side the hub: press or drive the bearing into position, applying pressure only to the bearing oiler race. Oo not lubricate the mating surface
ol the
bearing In an attempt to ease installation. 15 Fit the bearing retaining circlip to its 700ve in the hub carrier, then refit the heat
shield and tighten the retaining screw securely. 16 Support the outer face of the hub carrier across the jaws of a bench vice. 17 Carefully press or draw the hub into the bearing, noting that the bearing inner race must be supported during Ihis operation, to prevent It from being separated from the outer race. This can be achieved using a suitable socket, threaded rod, washers and a length of bar (see Illustration). 18 On completion, check that the hub rotates freely in the hub carrier without resistance or roughness.
2.17 Typical method of drawing the hub into the wheel bearing using improvised tools
Refitting 19 Reconnect the outboard end of the drive-shaft to the hub as described In Chapter 8. Ensure that the driveshaft nut is tightened to the correct torque and adequately staked. Ideally, for safety reasons due to the very high torque of the driveshaft nut, carry out final tightening and staking of the nut after refitting the roadwheel and lowering the car to the ground. 20 Reconnect the hub carrier to the lower arm balljoint, then fit a new clamp bolt nut. Tighten tho nut to the specified torque. 21 Engage the hub carrier with the suspension strut, then refit the securing bolts and nuts, tightening them to the specified torque. 22 Reconnect the steering track-rod balljoint to the hub carrier steering arm. Use a new nut and tighten it to the specified torque. 23 Refer to Chapter 9 and refit the brake disc and caliper. 24 Where applicable, fit the ABS wheel sensor into its mounting hole and tighten the securing screw. 25 Refit the roadwheel, and tower the vehicle to the ground. 26 Have the front wheel alignment checked by a Fiat dealer or a tyre specialist at the earliest opportunity.

Suspension and steering 10*5
3,9s Withdraw the coll spring, complete with the compressors ... 3.9b ... then withdraw the dust cover and bump rubber 3.9c Fully dismantled strut
10 With the strut assembly now dismantled, examine all the components tor wear, damage or deformation. Check the rubber com-ponents for deterioration. Renew any of the components as necessary. 11 Examine tho damper for signs of fluid teakage. Check the damper rod for signs of pitting along its entire length, and check the stjul body for signs of damage. White holding fc
in an
upright position, test the operation of
Ihe
stmt by moving Ihe damper rod through a fut stroke, and then through short strokes of
SO
to 100 mm. In both cases, the resistance Id should be smooth and continuous. If the resistance is jerky, or uneven, or if there is any wsible sign of wear or damage to the strut, renewal is necessary. Note that the damper cannot be renewed independently, and if leakage, damage or corrosion Is evident, the complete strut/damper assembly must be renewed {in which case, the spring, upper mounting components, bushes, and associated components can be transferred to
Ihe
new strut). 12 If any doubt exists about the condition of
Ihe
coil spring, carefully remove the spring compressors, and check the spring for distortion and signs of cracking. Renew the spring if it is damaged or distorted, or if there isany doubt about its condition. a Warning: Coil springs are /j\ classified by their height when '
11
• undor load • this Is indicatod by a
coloured
paint marking on the side of the
coll windings (either green or yellow). All coll springs fitted to tho vehicle must be of the same classification to ensure the correct ride height. 13 Clamp the strut body in a vice, as dunng dismantling, then refit the lower spring seat rubber (where fitted), dust cover and bump rubber. 14 Ensure that the coil spring is compressed sufficiently to enable the upper mounting components to be fitted, then fit the spring over the damper rod. ensuring that the lower end of the spring is correctly located In the recess on the lower spring seat (soe illustration). 15 Refit the upper spring seat and upper mounting plate ensuring that the top end of
the spring is correctly located on the upper spring seat. Note that when the strut is reassembled, the orientation marking on the upper rubber mounting must be positioned in relation to the metal section of the upper mounting plate as shown, to maintain the correct front wheel castor setting (see illustration). 10 Fit the new damper rod top nut together with its washer and bush, then tighten the nut to the specified torque, counterholding the damper rod in a manner similar to that used during dismantling. Note that a suitable crows-foot adapter will be required to tighten the damper rod top nut to the specified torque. 17 Remove the spring compressors. Where applicable, refit the protective plastic cap over the damper rod top nut.
Refitting 18 Manoeuvre the strut assembly into position under the wheel arch, passing the locating stud clip through the holes in the body turret. Note that when the strut is refitted, the orientation marking on the upper mounting plate rubber mounting must be positioned in relation to the vehicle as shown, to maintain the correct front wheel castor setting • refer to illustration 3.15. Fit the upper mounting bolts, and tighten them to the specified torque (see illustration). 19 Engage Ihe lower end of the strut with the
3.14 Ensure that the lower end of the spring is correctly located in the recess (arrowed) on the lower spring seat
3.15 Correct positioning of the suspension strut upper mounting components A Left hand mounting for vehicles with manual steering B Left hand mounting tor vehicles with power-assisted steering C To front of vehicle O Orientation marking 3.18 Fit the strut upper mounting bolts, and tighten them to the specified torque

Suspension and steering
10*195

5 Front suspension >,•> tower arm balljoint -renewal ^
The balljoint is integral with the suspension ower arm (see Illustration). If the balljoint is worn or damaged, the complete lower arm oust be renewed as described In Section 4.
6 Front suspension ^ anti-roll bar -
removal and refitting s^
Removal 1 Chock the rear wheels, apply the handbrake, then jack up the front of the vehicle and support securely on axle stands •we Jacking and vehicle support). If required, wove the relevant roadwheels. 2 Refer to the Chapter 4D and unbolt the hnt section of the exhaust pipe. 3 Unscrew the bolts securing the anti-roll bar mountings to the suspension lower arms on ether side of the vehicle. Similarly, unscrew
ine
bolts securing the anti-roll bar mountings lo the suspension sub-frame (refer to the Derations in Section 4). 4 lower the anti-roll bar away from the underside of the vehicle. 5 Inspect the rubber bushes for cracks or ietertoratlon, If renewal Is necessary, slide the dd bushes from the bar, and fit the now items, using soapy water as a lubricant. Do rot apply grease or oil as this will attack the •ifiber. 9 Check the anti-roll bar for signs of damage, war or serious corrosion. Refitting 7 Refitting Is a reversal of removal, bearing In
mnd
the following points: sj
D'rw
up the holes af the ends of the anti-roll bar with those on the suspension iov/erarm. til
Tighten
all fixings to the specified torque, but do not do this until the vehicle is resting on its roadwheels, and the suspension has been settled, or damage to the bushes may result.
7.5 Slacken and remove the rear hub nut
5.1 Front suspension lower arm balljoint
7 Rear hub bearings -renewal
Note: 77ie bearing will be destroyed during the removal operation, and a new rear hub/ bearing assembly must be used on refitting -the old hub cannot be re-used. A new rear hub nut must be used on refitting. 1 The rear hub bearings are integral with the hubs themselves, and cannot be renewed separately, tf the bearings require renewal, the complete hub assembly must be renewed as follows. 2 Chock the front wheels, then jack up the rear of the vehicle and support securely on axle slands (see Jacking and vehicle support). Remove the appropriate rear roadwheel. 3 Remove the brake drum as described In Chapter 9. Do not depress the brake pedal whilst the brake drum is removed. 4 Prise the dust cap from the hub. using a mallet and punch. 5 Slacken and remove the hub nut and recover the washer/spacers (see illustration). Caution: The nut Is tightened to a very high torque. Use a long extension bar to remove the nut and ensure that you have access to torque wrench capable of tightening the new nut to the speclfiod torque setting, before removing the existing nut 6 Withdraw Ihe hub and bearing assembly from the stub axle, and recover the inner washer. Discard the hub nut - a new one must be used on refitting.
1
8.3 Slacken and withdraw the damper lower retaining bolt (arrowed)
7 Thoroughly clean tho stub axle, then slide the inner washer and new hub assembly into position. 8 Fit the outer washer, then thread a new hub nut onto the end of the stub axle by hand - do not fully tighten the nut at this stage. 9 Refit the brake drum (Chapter 9). 10 Tighten the hub nut to the specified torque, then check that the hub spins smoothly and freely. Carefully tap the dust cap into position over the nut. 11 Refit the roadwheel, then lower the vehicle to the ground and tighten the road-wheel bolts to the specified torque.
8 Rear suspension components -removal, overhaul and refitting ^
1 Chock the front wheels, then jack up the rear of the vehicle and support on axle stands (see Jacking and vehicle support). Remove the relevant rear roadwheel.
Damper
Removal 2 Using a trolley jack positioned under the trailing arm, raise the trailing arm to take the strain from the damper. 3 Slacken and withdraw the damper lower retaining boll (see Illustration). 4 Lower the jack and allow the damper to separate from the trailing arm. Take care to avoid displacing the coil spring. 5 Slacken and withdraw the damper upper retaining bolt (see illustration). 6 Lower the damper away from the suspension subframe. Refitting 7 Refitting is a reversal of removal. Tighten the damper upper and lower retaining bolts to the specified torque, but delay this operation until the full weight vehicle is resting on the road-wheels • this prevents the damper bushes from being strained.
Coil spring
Removal 8 With reference to the previous sub-Section.
8.5 Slacken and withdraw the damper upper retaining bolt (arrowed)

Suspension and steering 10*8
9.1 Prise the horn centre pad from the steering wheel hub unbolt the lower end of the damper from the trailing arm. 9 Lower the trailing arm gradually using a trolley jack, until the coil spring Is released from its lower seat on the trailing arm and its upper seat on the subframe. Make a note of the orientation of the coll spring, to aid correct refitting later. Refitting 10 Refitting is a reversal of removal, lighten the damper lower retaining bolt to the specified torque. Trailing arm Note: The rear stub axles are integral with the trailing arm assemblies and cannot be renewed separately. Removal 11 With reference to Chapter 9. carry out the following: a) Remove the brake drum, shoes and adjuster assembly. b) Unbolt the brake hose union from the
rear
of the wheel cylinder. c) Unbolt the brake pipe mounting bracket from the trailing arm. 12 Refer to Section 7 and remove The rear hub and beanng assembly. 13 With reference to the relevant sub-Section, unbolt the lower end of Ihe damper from the trailing arm. 14 Raise the trailing arm using a trolley jack so that the coll spring Is compressed, then slacken and withdraw the trailing arm front mounting bolL 15 With reference to the previous sub-Section, gradually lower the trailing arm using a trolley lack and remove the coll spring. 16 Allow Ihe trailing arm to hang down, then pull the leading edge of the arm down from its mounting bracket. Refitting 17 Refitting Is a reversal of removal. Tighten all suspension fixings to the specified torque settings, but delay this operation until the full weight vehicle is resting on the roadwheeis -this prevents the damper and trailing arm bushes from being strained. 18 On completion, bleed the brake hydraulic system and adjust the operation of the handbrake, with reference to Chapter 9.
9.2 Unplug the wiring from the centre pad at the connector(s)
9 Steering wheel - % removal and refitting ^
Note: This procedure does not apply to vehicles fitted with an airbag A Warning: For safety reasons, owners are strongly advisod to entrust to an authorised Fiat dealer any work which involves disturbing the airbeg system components. The airbag inflation devices contain explosive material and legislation exists to control their handling and storage. In addition, specialised test equipment Is needed to check thet the alrbag system Is fully operational following reassembly.
Removal 1 Ensure that the ignition is switched off, then prise the horn centre pad from the steering wheel hub. Use the blade of a screwdriver, padded with PVC tape to protect the steering wheel (see illustration) 2 Unplug the horn and (where applicable) radio/cassette control switch wiring from the centre pad at the connectors) (see illustration) 3 Turn the steering wheel to its centre position, so that the roadwheeis are pointing straight ahead. 4 Make alignment marks between the steering wheel and the end of the steering column shaft, to aid correct refitting later, 5 Relieve the staking and then slacken and remove tne steenng wheel securing nut (see
9.5 Slacken and remove the steering wheel securing nut Illustration). Discard the nut as a new item must used on refitting. 6 Lift the steering wheel off the column splines. If it is tight, tap il near the centre, usrg the palm of your hand, or twist it from
side to
side, whilst pulling upwards to release il ton the shaft splines. If the wheel is particular tight, a suitable puller should be used.
Refitting 7 Before commencing refitting, lightly eca. Ihe surfaces of the direction indicator cancelling mechanism with grease. 8 Refitting is a reversal of ren>oval.
bearing a
mind the following points: a) Use a new steering wheel
securing not
and tighten it to the specified
torque.
Ensure that its outer collar
Is adequate^
staked to the column shaft
using a
hammer and punch (see Illustrations). b) Ensure that the direction Indicator
swiith
is in the central (cancelled/off)
position,
otherv/ise the sivitch may be damaged X the wheel Is refitted. c) Align the marks made on the
wheel and
Ihe steering column shaft during removeI 9 Note that if necessary, the position of tf* steering wheel on the column shaft cant* | altered in order to centralise the wheel (enstn that the front roadwheeis aro pointing
In the
straight-ahead position), by moving the vMti the required number of splines on the
sfcafc
Fine adjustment can be carried out by adjusting the length of both track-rwa simultaneously, but this operation is best entrusted to a Rat dealer or tyre specialist
9.8a Fit a new steering wheet securing nut... 9.3b ... and stake it to the steering column shaft using o hammer and punch

10*10 Suspension and steering
12.8 Slacken and remove the two steering goar-to-subirame bolts (arrowed) 8 Disconnect the universal joint at the base of the steering column from the steering gear pinion. Note the position of tho safety clip • this must be refitted In the same position on reassembly. 9 Remove Ihe steering column from the vehicle.
Overhaul 10 The hoight adjustment mechanism can be removed by removing the nut from the end of the pivot shaft and withdrawing it. 11 The upper and lower bushes are held in position by staking at the ends of the column tube. Relieve the staking using a mallet and punch to extract the bushes. 12 Check for excessive radial and axial play In the universal joints at both ends of the lower steering column. The lower section of the steering column may be renewed separately if required, by slackening the clamp bolt and detaching It from the upper section. 13 If the vehicle has been Involved in an accident, check for deformation In all ol the steering column components, particularly the mounting bracket and centre tube. Renew as required.
Refitting 14 Refitting the steering column is by following the removal procedure in reverse. Tighten all fixings to Ihe specified torque setting.
12 ManuaJ steering fk gear assembly -removal, overhaul and refitting
Removal 1 Firmly apply the handbrake, then jack up the front of the car and support it securely on axie stands (see Jacking and vehicle support). Remove the front road wheels. 2 Disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual). 3 With reference to Section 11. slacken the clamp boil at the base of steering column lower universal |o!nt, to separate it rrom the steering gear pinion.
12.9 Unbolt the rear engine mountlng-to-subframe bolts (arrowed) 4 Remove the safety clip from the steering gear pinion, noting Its fitted position to aid correct refitting later. Lift off the sound insulating pad. 5 Refer to Section 17 and dotach the track* rod end bailjoints from the hub carriers, using a balljoint splitter. 6 Working underneath the vehicle, remove the clips and detach the gear selection cable and the reverse gear inhibitor cable from the steenng gear. 7 Delach the gear selector rod from the top of the steering gear, 8 Slacken and remove the two steering gear-to-subframe bolts (see Illustration) 9 Support the underside of the transmission using a trolley jack, then unbolt the rear engine mountlng-to-subframe bolts (see illustration) 10 With reference to Chapter 4D. unbolt the front section of the exhaust pipe from the catalytic converter. 11 Unclip the plastic steenng gear pinion cup from ihe bulkhead. 12 Withdraw the steenng gear through the wheel arch.
Refitting 13 Refitting is a reversal of removal, noting the following: a) Tighten all fixings lo the specified torque settings. b) On completion, have the front wheel alignment checked at the earliest opportunity by a Fiat dealer or a tyro specialist.
13.10 Disconnect the fluid delivery and return pipes (arrowed) from the power steering gear
13 Power steering * gear assembly - J removal and refitting ^
Removal 1 Chock the rear wheels, apply tN handbrake, then jack up the front ot thi vehicle and support securely on axle standi (see Jacking and vehicle support). Remove both front roadwheels to improve access. 2 Disconnect the battery negative terminal (refer to Disconnecting the battery In tto Reference Section of this manual). 3 With reforence to Section 11, slacken ihe clamp bolt at the base of steering cohimn lower universal joint, to separate ll from Ihe steering gear pinion. 4 Remove the safety clip from the steenng gear pinion, noting its fitted position lo aid correct refitting later. Lift off the sound Insulating pad. 5 Refer to Section 17 and detach the track-rod end bailjoints from the hub carriers, usty a balljoint splitter. 6 Working underneath the vehicle, ranwvi the clips and detach the power steering fluid pipe from the steering gear casing. 7 With reference to Chapter 40, unboil lbs front section of the exhaust pipe from the manifold and catalytic converter/intermediate silencer (as applicable). 8 Refer to Chaptor 7A and disconnect the gear selector rod from the relay rod Disconnect the relay rod from the mounting on the top of the steering gear casing. 9 Drain as much fluid as possible from the power steering reservoir, using a pipette or
an
old poultry baster. 10 Slacken the unions and disconnect the fluid delivery and return pipes from the power steering gear. Be prepared for an amount
erf
fluid loss - position a container underneath the unions and pad the surrounding area wth absorbent rags (see Illustration). 11 Slacken and remove the two sleeting gear-to-subframe bolts (see illustrations). 12 Support the engine and tronsmission assembly using either blocks of wood positioned under the transmission casing,
or a
lifting beam positioned across the engine
bay

13.11a Slacken and remove the right-hand...

11 *2 Bodywork and fittings
on vehicles with wax-based underbody protective coating, or the coating will be removed. Such vehicles should be inspected annually, preferably just prior lo Winter, when the underbody should be washed down, and any damage to the wax coating repaired. Ideally, a completely fresh coat should be applied. It would also be worth considering the use of such wax-based protection for injection into door panels, sills, box sections, etc, as an additional safeguard against rust damage, where such protection Is not provided by the vehicle manufacturer. After washing paintwork, wipe off with a chamois feather to give an unspotted clear finish. A coat of clear protective wax polish wilt give added protection against chemical pollutants in the air. If the paintwork sheen has duiled or oxidised, use a cleaner/polisher combination to restore the brilliance of the shine. This requires a little effort, but such dulling Is usually caused because regular washing has been neglected. Care needs to be taken with metallic paintwork, as special non-abrasive cleaner/polisher is required to avoid damage to the finish, Always check that the door and ventilator opening drain holes and pipes are completely clear, so that water can be drained out. Brightwork should be treated In the same way as paintwork. Windscreens and windows can be kept clear of the smeary film which often appears, by the use of proprietary glass cleaner. Nover use any form of wax or other body or chromium polish on glass.
Maintenance -upholstery and carpets
Mats and carpets should be brushed or vacuum-cleaned regularly, to keep them free of grit. If they are badly stained, remove them from the vehicle for scrubbing or sponging, and make quite sure they are dry before refitting. Seats and interior trim panels can be kept clean by wiping with a damp cloth. If they do become stained (which can be more apparent on light-coloured upholstery), use a little liquid detergent and a soft nail brush lo scour the grime out of the grain of the material. Do not forget to keep the headlining clean in the same way as the upholstery. When using liquid cleaners inside the vehicle, do not over-wet the surfaces being cleaned. Excessive damp could get Into the seams and padded interior, causing stains, offensive odours or even rot.
If the Inside of the vehicle gets wet accidentally, tt Is worthwhile taking some trouble to dry ft out property, particularly where carpets an involved. Do not leave oil or electric heaters inside the vehicle for this purpose.
4 Minor body damage -repair
Repairs of minor scratches In bodywork If the scratch Is very superficial, and does not penetrate to the metal of the bodywork, repair is very simple. Lightly rub the area of the scratch with a paintwork renovator, or a very fine cutting paste, to remove loose paint from the scratch, and to clear the surrounding bodywork of wax polish, Rinse the area with clean water. Apply touch-up paint to ihe scratch using a fine paint brush; continue to apply fine layers of paint until the surface of the paint In the scratch Is level with the surrounding paintwork. Allow Ihe new paint at least two weeks to harden, then blend it Into the surrounding paintwork by rubbing the scratch area with a paintwork renovator or a very fine cutting paste. Finally, apply wax polish. Where the scratch has penetrated right through to the metal of the bodywork, causing the metal to rust, a different repair technique Is required. Remove any loose rust from the bottom of the scratch with a penknife, then apply rust-inhibiting paint to prevent the formation of rust in the future. Using a rubber or nylon applicator, fill the scratch with bodystopper paste. If required, this paste can be mixed with cellulose thinners to provide a very thin paste which is ideal for filling narrow scratches. Before the stopper-paste in Ihe scratch hardens, wrap a piece of smooth cotton rag around the top of a finger. Dip the finger in cellulose thinners, and quickly sweep it across the surface of the stopper-paste in the scratch: this will ensure that the surface of the stopper-paste is slightly hollowed. The scratch can now be painted over as described earlier In this Section.
Repairs of dents in bodywork When deop denting of the vehicle's bodywork has taken place, the first task is to put) the dent out. until the affected bodywork almost attains rts onginal shape. There is little polnl in trying to restore Ihe original shape completely, as the metal in the damaged area will have stretched on impact, and cannot be reshaped fully to its original contour. It Is better to bring the level of the dent up to a point which is about 3 mm below the level of the surrounding bodywork. In cases where Ihe dent is very shallow anyway, It is not worth trying to pull it out at all. If the underside of the dent is accessible, it can be hammered out gently from behind, using a mallet with a wooden or plastic head, Whilst doing this, hold a suitable block of wood firmly against (he outside of Ihe panel, to absorb the impact from the hammer blows and thus prevent a large area of the bodywork from being 'belled-out".
Should the dent be In a section of (I* bodywork which has a double skin, or seme other factor making It Inaccessible from behind, a different technique is called for. Dull several small holes through the metal inside Ihe area - particularly in the deeper section. Then screw long self-tapping screws Into the holes, just sufficiently for them to gain a good purchase in the metal. Now the dent can be pulled out by pulling on the protruding heads of the screws with a pair of pliers. The next stage of the repair Is the removal of the paint from the damaged area, and from an inch or so of the surrounding 'sound' bodywork. This is accomplished most easily by using a wire brush or abrasive pad on a posver drill, although it can be done just as effectively by hand, using sheets of abrasive paper. To complete the preparation for filling, score the surface of the bare metal wflhi screwdriver or the tang of 8 file, or alternatively, drill small holes In the affected area. This will provide a really good 'key' for the filler paste. To complete the repair, see the Section on filling and respraying.
Repairs of rust holes or gashes in bodywork Remove all paint from the affected area, and from an inch or so of the surrounding 'sound' bodywork, using an abrasive pad
or a
wire brush on a power drill. If these are not available, a few sheets of abrasive paper wil do the job most effectively. With the paint removed, you will be able to judge the severity of the corrosion, and therefore decide whether to renew the whole panel (if this is possible) or to repair the affected area. New body panels are not as expansive as most people think, and it is often quicker and more satisfactory to fit a new panel than to attempt to repair large areas of corrosion. Remove all fittings from Ihe affected area, except those which will act as a guide to ttie original shape of the damaged bodywork (eg headlight shells etc). Then, using tin snips
or a
hacksaw blade, remove all loose metal snd any other metal badly affected by corrosion. Hammer the edges of the hole inwards, in order to create a slight depression for the filer paste. Wire-brush the affected area to remove tha powdery rust from the surface of the remaining metal. Paint Ihe affected area with rust-inhibiting paint, if the beck of the rusted area is accessible, treat this also. Before filling can take place, ft will be necessary to block the hole in some
way.
TNs can be achieved by the use of aluminium cr plastic mesh, or aluminium tape. Aluminium or plastic mesh, or glass-fibre matting, is probably the best material to use for a large hole. Cut a piece to tha approximate size and shape of tho hole to b« filled, then position it In the hole so that its edges are below the level of the surrounding bodywork. It can be retained in position by

Bodywork and fittings
11
*3
several blobs of filler paste around its periphery. Aluminium tape should be used for small or very narrow holes. Pull a piece off the roll, trim it to the approximate size and shape required, then pull off the backing paper (if used) and stick the tape over the hole; it can be overlapped if the thickness of one piece is Insufficient. Burnish down the edges of the tape with the handle of a screwdriver or similar, to ensure that the tape is securely attached to the metal underneath.
Bodywork repairs -filling and respraying Before using this Section, see the Sections on dent, deep scratch, rust holes and gash repairs. Many types of bodyfiller are available, but generally speaking, those proprietary kits which contain a tin of filler paste and a tube of resin hardener are best for this type of repair. A wide, flexible plastic or nylon applicator will be found invaluable for imparting a smooth and well-contoured finish to the surface of the filler. Mix up a little filler on a clean piece of card or board • measure the hardener carefully (follow the maker's instructions on the pack), otherwise the filler will set too rapidly or too slowly. U3ing the applicator, apply the filler paste to the prepared area; draw the applicator across the surface of the filler to achieve the correct contour and to level the surface. As soon as a contour that approximates to the correct one is achieved, stop working the paste - if you carry on too long, the paste will become sticky and begin lo 'pick-up' on the applicator. Continue to add thin layers of filler paste at 20-minute Intervals, until the level of the filler is just proud of the surrounding bodywork. Once the filler has hardened, the excess can be removed using a metal plane or file. From then on, progressively-finer grades of abrasive paper should be used, starting with a 40-grade production paper, and finishing with a 400-grade wet-and-dry paper. Always wrap the abrasive paper around a flat rubber, cork, or wooden block • otherwise the surface of the filler will not be completely flat. During the smoothing of the filler surface, the wet-and-dry paper should be periodically rinsed in water. This will ensure that a very smooth finish is imparled to the filler at the final stage. At this stage, the dent should be surrounded by a ring of bare metal, which in turn should be encircled by the finely feathered' edge of the good paintwork. Rinse the repair area with clean water, until all of the dust produced by the rubbing-down operation has gone. Spray the whole area with a light coat of primer - this will show up any imperfections In the surface of the filler. Repair these imperfections with fresh filler paste or bodystopper, and once more smooth the surface with abrasive paper. Repeat this
spray-and-repair procedure until you are satisfied that the surface of the filler, and the feathered edge of the paintwork, are perfect. Clean the repair area with clean water, and allow to dry fully.
flflfl^gl tf txxfystopper is used, it can WiMiiBi be mixed with cellulose Hi NT thinners to form a really thin 1 1 paste which is Ideal for filling small holes.
The repair area Is now ready for final spraying. Paint spraying must be carried out in a warm, dry, windless and dust-free atmosphere. This condition can be created artificially if you have access to a large indoor working area, but If you are forced to work in the open, you will have to pick your day very carefully. If you are working indoors, dousing the floor In the work area with water will help to settle the dust which would otherwise be in the atmosphere. If the repair area is confined to one body panel, mask off the surrounding panels; this will help to minimise the effects of a slight mis-match in paint colours. Bodywork fittings (eg chrome strips, door handles etc) will also need to be masked off. Use genuine masking tape, and several thicknesses of newspaper, for the masking operations. Before commencing to spray, agitate the aerosol can thoroughly, then spray a test area (an old tin. or similar) until the technique is mastered. Cover the repair area with a thick coat of primer; the thickness should be built up using several thin layers of paint, rather than one thick one. Using 400-grade wet-and-dry paper, rub down the surface of the pnmer until it is really smooth. While doing this, the work area should be thoroughly doused with water, and the wet-and-dry paper periodically rinsed in water. Allow to dry before spraying on more paint. Spray on the top coat, again building up the thickness by using several thin layers of paint. Start spraying at one edge of the repair area, and then, using a side-to-side motion, work until the whole repair area and about 2 inches of the surrounding original paintwork is covered. Remove all masking material 10 to 15 minutes after spraying on the final coat of paint. Allow the new paint at least two weeks to harden, then, using a paintwork renovator, or a very fine cutting paste, blend the edges of the paint into the existing paintwork. Finally, apply wax polish.
Plastic components With the use of more and more plastic body components by the vehicle manufacturers (eg bumpers, spoilers, and in some cases major body panels), rectification of more serious damage to such items has become a matter of either entrusting repair work to a specialist in this field, or renewing complete components. Repair of such damage by the
DIY owner is not really feasible, owing to the cost of the equipment and materials required for effecting such repairs. The basic technique involves making a groove along the line of the crack in the plastic, using a rotary burr In a power drill. The damaged part is then welded back together, using a hot-air gun to heat up and fuse a plastic filler rod Into the groove. Any excess plastic is then removed, and the area rubbed down to a smooth finish. It is important that a filler rod of the correct plastic is used, as body components can be made of a variety of different types (eg polycarbonate, ABS, polypropylene). Damage of a less senous nature (abrasions, minor cracks etc) can be repaired by the DIY owner using a two-part epoxy filler repair material. Once mixed in equal proportions, this is used in similar fashion to the bodywork filler used on metal panels. The filler is usually cured in twenty to thirty minutes, ready for sanding and painting. If the owner is renewing a complete component himself, or If he has repaired it with epoxy filler, he will be left with the problem of finding a suitable paint for finishing which is compatible with the type of plastic used. At one time, the use of a universal paint was not possible, owing to the complex range of plastics encountered In body component applications. Standard paints, generally speaking, will not bond to plastic or rubber satisfactorily. However, it is now possible to obtain a plastic body parts finishing kit which consists of a pre-pnmer treatment, a primer and coloured top coat. Full Instructions are normally supplied with a kit, but basically, the method of use is to first apply the pre-pnmer to the component concerned, and allow It to dry for up to 30 minutes. Then the primer is applied, and left to dry for about an hour before finally applying the special-coloured top coat. The result is a correctly-coloured component, where the paint will flex with the plastic or rubber, a property that standard paint does not normally possess.
5 Major body damage -repair
Where serious damage has occurred, or large areas need renewal due to neglect, it means that complete new panels will need welding-in, and this is best left to professionals. If the damage is due to Impact, it will also be necessary to check completely the alignment of the bodyshell, and this can only be carried out accurately by a Fiat dealer using special jigs. If the alignment of the bodyshell is not corrected, the car's handling may be seriously affected. In addition, excessive stress may be Imposed on the steering, suspension, tyres or transmission, causing abnormal wear or even complete failure.

11 *12 Bodywork and fittings
switch panel, then remove the panel from the facia (see illustration). Label tho wiring connector to aid refitting, then unplug It. 0 Work along the lower edge of Ihe facia and remove all the securing screws; there are three on the drivers side and three on the passenger side - one is concealed inside the glove compartment, behind a plastic cap. 10 Wilh reference to Chapter 12, remove the cover and open the main fuse box. Where applicable, unscrew the fixings that secure the electronic control unit to Its mounting bracket. Remove the facia mounting bolts located adjacent to the mounting bracket (see illustration). 11 Refer to Chapter 10 and unbolt the steering column from Its support bracket, allowing the column to rest in the footwell. There is no need to slacken the clamp bolt at Ihe base of the steering column to separate it from the steering gear. 12 With reference to Chapter 12, remove front right and left speaker grilles. Remove the two facis upper mounting screws ihat are now exposed. Similarly, prise open the plastic cover from centre of upper edge of the fada and remove the mounting screw behind. 13 Carefully pull whole facia moulding forward away from tho bulkhead slightly. Label all wiring connectors to aid correct refitting later, then unplug Ihem. Check that nothing remains connected between the facia and bulkhead then draw the facia moulding away and remove It from the vehicle.
20.8 Remove the bolt (arrowed) and detach the backrest from the mounting bracket
Refitting 14 Refit the facia by following the removal procedure in reverse, noting the following points: a) Reinstate all electrical connections according to (he labels made during removal and ensure that cables are secured in their clips, using the origins/ routing. b) Ensure thai all ventilation ducting locates correctly over the rear of the grilles before tightening the facia retaining screws. c) On completion, reconnect the battery negative cable and chock the operation of all controls, gauges and Instruments disturbed during the removal process, Including the ventilation/heating system.
20 Seats -removal and refitting JS:
Front seats
Removal

A


Warning: On models with seat belt pre-tonsionors, entrust the work of seat removal to a Flat dealer. DQNOTattempt to remove the seat on vehicles so equipped. 1 The front seats frames are secured to the fioorpan by four bolts. Whero applicable, prise out the caps from the plastic trim panel lo expose the bolt heads. 2 Slide the seat towards the rear of the car to gain access to the two bolts at the front, Ihen slacken and withdraw them. 3 Slide Ihe seat fully forwards and remove the two rearmost bolls. 4 Ufl the seat out of the cabin area.
(arrowed) located adjacent to the control unit mounting bracket Refitting 5 Refil the seat by reversing the remove! procedure. Rear seat back rests
Removal 6 Using the hand straps, raise the seal cushion and lilt it fully forward. 7 The rear seat back rests are mounted or hinged brackets which aro boiled to Ihe fioorpan. To remove both back rests together, first remove the screws and detach the load space carpet panel. 8 Unbolt the back rest panel from the mounting brackets (see illustration). Refitting 9 Refit tho back rests by reversing Ihe removal procedure. Rear seat cushion
Removal 10 Using the hand straps, raise the seat cushion and tilt it fully forward. 11 Remove ihe screws Ihat secure Ihe hinged brackets to tho fioorpan. then lift out the cushion (see illustration}. Refitting 12 Refit the seat cushion by reversing Ihe removal procedure.
20.11 Remove the screws (arrowed) that secure the hinged brackets to the fioorpan