1999 FIAT PUNTO ECO mode

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

Maintenance procedures - petrol models ia./
Every 5000 miles (7500 km) or 6 months
3 Engine oil and filter renewal Ja*
1 Frequent oil and filter changes are the most important preventative maintenance which can be undertaken by the DIY owner. As engine oil ages, it becomes diluted and contaminated, which leads to premature engine wear. 2 Before starting this procedure, gather all Ihe necessary tools and materials. Also make sure that you have plenty of clean rags and newspapers handy, to mop up any spills. Ideally, the engine oil should be warm, as It
will
drain better, and more built-up sludge will
be
removed with it. Tske care, however, not to touch the exhaust or any other hot parts of the engine when working under the vehicle. To avoid any possibility of scalding, and to protect yourself from possible skin irritants end other harmful contaminants in used engine oils, it Is advisable to wear gloves when carrying out this work. Access to the underside of the vehicle will be greatly Improved if it can be raised on a lift, driven onto ramps, or jacked up and supported on axle stands (see Jacking and vehicle support). Whichever method is chosen, make sure that
the
vehicle remains level, or if it is at an angle, that the drain plug Is at the lowest point. 3 Slacken the drain plug about half a turn using an Allen key. Position the draining container under the drain plug, then remove
the plug
completely (see Haynes Hint). 4 Allow some time for the old oil to dram, noting that it may be necessary to reposition
the
container as the oil flow slows to a trickle. 5 After all the oil has drained, wipe off the drain plug with a clean rag, then clean the area around the drain plug opening and refit
(MB
HiNT '
Keep the drain plug pressed Into the sump white unscrewing it by hand the last couple of turns. As the plug releases, move it away sharply so that the stream
of
oil Issuing from the sump runs into the container, net up your sleeve.
the plug. Tighten the plug securely. 6 It the filter is also to be renewed, move the container into position under tho oil filter, which is located on the front right-hand side of the engine (see illustration). 7 Using an oil filter removal tool if necessary, slacken the filter initially, then unscrew It by hand the rest of the way. Empty the oil in the old filter into the container. 8 Use a clean rag to remove all oil, dirt and sludge from the filter sealing area on the engine. Check the old filter to make sure that the rubber sealing ring has not stuck to the engine. If it has. carefully remove It. 9 Apply a light coating of clean engine oil to the sealing ring on the new filter, then screw it into position on the engine. Tighten the filter firmly by hand only • do not use any tools. 10 Remove the old oil and all tools from under the vehicle then lower the vehicle to the ground (if applicable).
3.6 Oil filter location (viewed from above)
11 Remove the dipstick, then pull out the oil filler cap from the cylinder head cover. Fill the engine, using the correct grade and type of oil (see Weekly checks). An oil can spout or funnel may help to reduce spillage. Pour In half the specified quantity of oil first, then wail a few minutes for the oil to fall to the sump. Continue adding oil a small quantity at a time until the level is up to the MAX mark on the dipstick. Refit the filler cap. 12 Start the engine and run it for a few minutes: check for leaks around the oil filter seal and the sump drain plug. Note that there may be a delay of a few seconds before the oil pressure warning light goes out when the engine is first started, as the oil circulates through the engine oil galleries and the new oil filter before (he pressure builds up. 13 Switch off the engine, and wait a few minutes for the oil to settle In the sump once more. With the new oil circulated and the filter completely full, recheck the level on the dipstick, and add more oil as necessary. 14 Dispose of the used engine oil safely, with reference to General repair procedures in the reference Sections of this manual.
Every 10 000 miles (15 000 km) or 12 months
4 Brake warning lamp ag operation check J§
1 With the ignition key inserted and turned to the MAR position, open the bonnet and depress the button on the top of the brake ftuid reservoir cap (see illustration). 2 As the button is depressed, the brake warning lamp on the instrument panel should Illuminate. 3 If the lamp fails to illuminate, check the operation of the level switch using a continuity tester, then refer to Chapter 12, Section 5, wd check the instrument panel bulb.
5 Front brake pad check
1 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 the front roadwheels, 2 Using a steel rule, measure the thickness of the friction material of the brake pads on both front brakes- This must not be less than 1.5 mm. Check the thickness of the pad friction material through the hole on the front of the caliper (see illustration). 3 For a comprehensive check, the brake pads 4.1 Depress the button on the top of the brake fluid reservoir cap

ia«8 Every 10 000 miles - petrol models
5.2 Check the thickness of the pad friction material through the hole on the front of the caliper should be removed and cleaned. The operation of the caliper can then
bIbo
be checked, and the condition of the brake disc itself can be fully examined on both sides. Refer to Chapter 9 for further Information. 4 If any pad's friction material is worn to the specified thickness or less, all four psds must tie renewed as a set. Refer to Chapter 9. 5 On completion refit the roadwheels and lower the car to the ground
6 Underbody sealant check
I
1 Jack up the front and rear of the car and support It securely on axle stands (see Jacking and vehicle support). Alternatively position the car over an inspection pit. 2 Check the underbody. wheel housings and side sills for rust and/or damage to the under-body sealant. If evident, repair as necessary.
7 Hose and fluid leak check ^
I
1 Visually Inspect the engine joint laces, gaskets and seals for any signs of water or oil leaks. Pay particular attention to the areas around the camshaft cover, cylinder head, oil (liter and sump joint faces. Bear in mind that.
A leak In the cooling system will usually show up as white or rust~coloured deposits on the area adjoining the leak
over a period of time, some very slight seepage from these areas is to be expected -what you are really looking for is any indication of a serious leak (see Haynes Hint). Should a leak be found, renew the offending gasket or oil seal by refemng to the appropriate Chapters in this manual. 2 Also check the security and condition of all the engine-related pipes and hoses. Ensure that all cable-ties or securing clips ore In place and In good condition, Clips which are broken or missing can lead to chafing of the hoses, pipes or wiring, which could cause more serious probioms In the luture. 3 Carefully check the radiator hoses and heater hoses along their entire length. Renew any hose which is cracked, swollen or deteriorated, Cracks will show up better if the hose is squeezed. Pay close attention to the hose clips that secure the hoses to the cooling system components. Hose clips can pinch and puncture hoses, resulting in cooling system leaks. 4 Inspect all 'he cooling system components {hoses. |olnt faces etc.) for leaks. A leak in the coolmg system will usually show up as white-or rust-coloured deposits on the area adjoining the leak. Where any problems of this nature are found on system components, renew the component or gaskel with reference to Chapter 3. 5 Where applicable, inspect the automatic transmission fluid cooler hoses for leaks or deterioration. 6 With the vehicle raised, inspect the fuel tank and filler neck for punctures, cracks and other damage. The connection between the filler neck and tank Is especially critical. Sometimes a rubber filler neck or connecting hose will leak due to loose retaining clamps or deten orated rubber. 7 Carefully check all rubber hoses and metal fuel lines leading away Irom the fuel tank. Check for loose connections, deteriorated hoses, crimped lines, and other damage. Pay particular attention to the vent pipes and hoses, which often loop up around the fitter neck and can become blocked or crimped. Follow the lines to the front of the vehicle, carefully inspecting them all the way. Renew damaged sections as necessary. 8 From within tne engine compartment,
check the security of all fuel hose attachments and pipe unions, and inspect the fuel hoses and vacuum hoses for kinks, chafing and deterioration. 9 Where applicable, check the condition of the power steering fluid hoses and pipes.
8 Exhaust system check fe
1 With the engine cold (at least an hour after the vehicle has been driven), check the complete exhaust system from the engine to the end of the tailpipe. The exhaust system is most easily checked with the vehicle raised on a hoist, or suitably supported on axle stands (see Jacking and vehicle support), so that the exhaust components are readily visible and accessible. 2 Check the exhaust pipes and connections for evidence of leaks, severe corrosion and damage. Make sure thai all brackets and mountings are in good condition, and that all relevant nuts and bolts are tight, Leakage at any of the Joints or in other parts of the system will usually show up as a black sooty stain in the vicinity of the leak. 3 Rattles and other noises can often bo traced to the exhaust system, especially the brackets and mountings. Try to move the pipes and silencers. If the components are able to come Into contact with the body or suspension parts, secure the system with new mountings Otherwise separate the joints {if possible) and twist the pipes as necessary to provide additional clearance.
9 Driveshaft gaiter check
9.1 Checking the condition of a driveshaft gaiter
1
1 With the vehicle raised and securely supported on stands (see Jacking and vehicle support), turn the steering onto full lock, then s'owly rotate the roadwheel. Inspect the condition of Ihe outer constant velocity (CV) joint rubber garters, squeezing the gaiters to open out the folds. Check for signs of cracking, splits or deterioration of the rubber, which may allow the grease to escape, and lead to water and grit entry into the joint. Also check the security and condition of the retaining clips. Repeat these checks on the Inner CV joints (see Illustration), If any damage or deterioration Is found, the gaiters should be renewed (see Chapter 8, Section 3). 2 At the same time, check the general condition of (he CV joints themselves by first holding (he driveshaft and attempting to rotate the wheel. Repeat this check by holding the inner joint and attempting to rotate the driveshaft. Any appreciable movement indicates wear in the joints. wear In the driveshaft splines, or a loose driveshaft retaining nut

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

Every 20 000 miles - petrol models 1A.13
20 Ignition system check
81
21 Engine management system check

A


Warning: Voltages produced by an electronic ignition system are considerably higher than those produced by conventional ignition systems. Extreme care must be taken when working on the system with the Ignition switched on. Persons with surgically-Implanted cardiac pacemaker devices should keep well clear of the ignition circuits, components and test oquipment. 1 The ignition system components should be checked for damage or deterioration as follows.
General component check 2 The spark plug (HT) leads should be checked whenever new spark plugs are fitted. 3 Pull the leads from the plugs by gripping
the end
fitting, not the lead, otherwise the lead connection may be fractured.
Ensure that the leads are i numbered before removing i them, to avoid confusion when refitting
4 Check Inside the end fitting for signs of corrosion, which will look like a white crusty powder. Push the end fitting back onto the spark plug, ensuring that it is a tight fit on the plug. if not, remove the lead again and use pliers to carefully crimp the metal connector inside the end fitting until it fits securely on the
end
of the spark plug. 5 Using a clean rag, wipe Ihe emlre length of the lead to remove any built-up dirt and grease. Once the lead is clean, check for bums, cracks and other damage. Do not bend the lead excessively, nor pull the lead lengthways - the conductor inside might break. 6 Disconnect the other end of the lead from the ignition coll. Again, pull only on the end fitting. Check for corrosion and a tight fit in the
same
manner as the spark plug end. Refit the bad securely on completion. 7 Check the remaining leads one at a time, in
ihe same
way. 8 if new spark plug (HT) leads are required, purchase a set for your specific car and engine. 9 Even with the ignition system In first-class condition, some engines may still occasionally experience poor starting attributable to damp ignition components. To disperse moisture, a water-dispersant aerosol should be liberally
Ignition timing -
check
and adjustment 10 Check the ignition timing as described In Chapter 58.
1 This check is part of the manufacturer's maintenance schedule, and Involves testing Ihe engine management system using special dedicated test equipment. Such testing will allow the test equipment to read any fault codes stored in the electronic control unit memory. 2 Unless a fault is suspected, this test te not essential, although it should be noted that it is recommended by the manufacturers. 3 If access to suitable test equipment is not possible, make a thorough check of all ignition, fuel and emission control system components, hoses, and wiring, for security and obvious signs of damage. Further details of the fuet system, emission control system and ignition system can be .found In the relevant parts of Chapters 4 and 5.
22 Hinge and lock lubrication %
1
1 Lubricate the hinges of the bonnet, doors and tailgate with a light general-purpose oil. Similarly, lubricate ail latches, locks and lock strikers. At the same time, check the security and operation of all the locks, adjusting them If necessary (see Chapter 11). 2 Lightly lubricate the bonnet release mechanism and cable with a suitable grease.
23 Headlight beam adjustment % & ^
1 Accurate adjustment of the headlight beam is only possible using optical beem-setting equipment, and this work should therefore be carried out by a Fiat dealer or service station with the necessary facilities. In an emergency, however, the following procedure will provide an acceptable light pattern. 2 Position the car on a level surface with tyres correctly inflated, approximately 10 metres in front of. and at right-angles to, a wall or garage door, 3 Draw a horizontal line on the wall or door at headlamp centre height. Draw a vertical line corresponding to the centre line of the car, then measure off a point either side of this, on the horizontal line, corresponding with the headlamp centres. 4 Switch on the main beam and check that the areas of maximum illumination coincide with the headlamp centre marfcs on Ihe wall, if not. turn the adjustment screw located on the upper inside edge of the headlight unit to adjust the beam laterally, and the adjustment screw located on the upper outside edge of the headlight unit to adjust the beam
vertically. On models with electric headlight adjustment, make sure that it is set at its basic setting before making the adjustment.
24 Road test
Instruments and electrical equipment 1 Check the operation of all Instruments and electrical equipment. 2 Make sure that all instruments read correctly, and switch on all electrical equipment in turn, to check that it functions properly.
Steering and suspension 3 Check for any abnormalities in the steering, suspension, handling or road feel. 4 Drive the vehicle, and check that there are no unusual vibrations or noises. 5 Check that the steering feels positive, with no excessive sloppiness, or roughness, and check for any suspension noises when cornering and driving over bumps.
Drivetrain 6 Check the performance of the engine, clutch (where applicable), transmission and driveshafts. 7 Listen for any unusual noises from the engine, clutch and gearbox/transmission. 8 Make sure that the engine runs smoothly when Idling, and that there Is no hesitation when accelerating. 9 Check that, where applicable, the clutch action Is smooth and progressive, that the drive is taken up smoothly, and that the pedal travel is not excessive. Also listen for any noises when the clutch pedal is depressed. 10 On manual gearbox models, check that all gears can be engaged smoothly without noise, and that the gear lever action is not abnormally vsgue or notchy. 11 On automatic transmission models, check that all Ihe gear positions can be selected with the vehicle at rest, if any problems are found, they should be referred to a Flat dealer. 12 Listen for a metallic clicking sound from the front of the vehicle, as the vehicle is driven slowly in a circle with the steering on full-lock. Carry out this check in both directions. If a clicking noise is heard, this Indicates wear in a drtveshaft joint, In which case renew the joint if necessary.
Check the braking system 13 Make sure that the vehicle does not pull to one side when braking, and that the wheels do not lock prematurely when braking hard. 14 Check that there is no vibration through the steering when braking. 15 Check that the handbrake operates correctly without excessive movement of the lever, and that It holds the vehicle stationary on a slope.

Maintenance procedures - petrol models 1A.15
Every 40 000 miles (60 000 km) or 4 years
29 Rear brake shoe check
1 Chock the front wheels then Jack up the rear of Ihe car and support it on axle stands (see Jacking and Vehicle Support). Remove the rear roadwheels. 2 Using the inspection hole at the edge of the brake drum, check that the linings are not worn below Ihe minimum thickness given in the Specifications (see illustration). If necessary use a torch. 3 If the friction material on any shoe is worn down to the specified minimum thickness or
less,
all four shoes must be renewed as a set. 4 At the same time check for signs of brake
Kutti
leakage. 5 For a comprehensive check, the brake drum should be removed and cleaned. This
will allow the wheel cylinders to be checked, and the condition of the brake drum itself to be fully examined (see Chapter 9). 6 Refit the lubber plugs then lower the car to the ground.
30 Timing belt renewal
Refer to Chapter 2A or 2B. Note: Although the norma/ interval for timing belt renewal is 70 000 miles (105 000 km), it is strongly recommended that the interval Is reduced on vehicles which are subjected to intensive use. ie, mainly short journeys or a lot of stop-start driving. The actual belt renewal interval is therefore very much up to the individuaf owner. That being said, it is highly recommended to err on the side of safety, and
29.2 Check the thickness of the shoe friction material through the hole on the edge of the drum (arrowed)
renew the belt at 40 000 miles (60 000 km), bearing in mind the drastic consequences resulting from belt failure.
Every 60 000 miles (90 000 km) or 6 years
31 Emission control system check
Refer to Chapter 4D. A full check of the emissions control systems must be made by a Fiat dealer.
Every 80 000 miles (120 000 km)
32 Manual transmission all renewal S
1 Park the vehicle on a level surface, if possible over an inspection pit or on a ramp as the filler/level and drain plugs are accessed from order
the
engine compartment. If necessary
Jack
ip the vehicle and support on axle stands (see
Jacking and vehicle
support). 2 Wipe clean the area around the filler/leval And drain plugs, which are on the front and bottom of the transmission (see illustration).
3 Using an Allen key. unscrew the filler/level plug and clean it. 4 Position a suitable container beneath the transmission, then use the Allen key to unscrew the drain plug. Allow the oil to completely drain. 5 Wipe clean the drain plug then refit and tighten It. 6 Fill the transmission with ihe correct grade and quantity of oil, referring to Section 26 when checking the level. Refit and lighten the filler/level plug. 7 Where applicable lower the vehicle to the ground. 32.2 Transmission drain plug location (viewed from under the vehicle)
Every 2 years (regardless of mileage)
33 Coolant renewal
I
Cooling system draining

A


Warning: Walt until the engine Is cold before starting this pro-cedure. Do not allow antifreeze to come In contact with your skin, or with the painted surfaces of the vehicle. Rinse off spills immediately with plenty of water.
Ndver
leave antifreeze lying around In an open container, or fn a puddle In the
driveway or on the garage floor. Children and pets are attracted by its sweet smell, but ant/freeze can be fatal if ingested. 1 With the engine completely cold, cover the expansion tank cap with a wad of rag. and slowly turn the cap anticlockwise to relieve the pressure in the cooling system (a hissing sound will normally be heard). Wait until any pressure remaining in the system is released, then continue to tum the cap until it can be removed. 2 Position a suitable container beneath the radiator bottom hose connection, then release the retaining clip and ease the hose from the radiator stub (see illustration). If the hose 33.2 Disconnecting the radiator bottom hose to drain tho coolant

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

A


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

1B.2
Servicing specifications - diesel models
Lubricants and fluids Refer to end of Weekly checks on page 0*17
Capacities Engine oil (including filter) Non-turbo diesei engine 4.95 litres Turbo diesel engine 4.84 litres Cooling system 7.2 litres
Manual transmission Non-turbo diesel engine 2.37 litres Turbo diesei engine t .98 litres Power-assisted steering 0.65 litres
Fuel tank 47 litres Washer reservoir Without headlight washers 2.5 litres With headlight washers 7.0 litres
Engine Oil fitter Engine Idle speed: Non-turbo diesel engine Turbo diesel engine Auxiliary drivebelt tension ...... Valve clearances • engine cold: Inlet Exhaust
Champion C112
8l0«40rpm 900 ± 20 rpm 5.0 mm deflection midway between pulleys
0.30 mm * 0.05 mm 0.35 mm ± 0.05 mm
Cooling system Antifreeze mixture: 50% antifreeze Protection down to-35°C Note: Refer to antifreeze manufactuivr for latest recommendations.
Fuel system Air filter element: Non-turbo diesel engine (with Lucas/CAV Injection) Champion U611 Turbo diesel engine (with Bosch Injection) Champion U579 Fuel filter Champion L120
Brakes Brake pad lining minimum thickness 1-5 mm Brake shoe friction material minimum thickness 2.0 mm
Tyre pressures See end of Weekly checks on page 0*18
Torque wrench settings Fuel filter bracket to body ..... « Fuel filter to bracket i........ Manual transmission oil drain plug: Non-turbo diesel engine: Stage 1 Stage 2 Turbo diesel engine Manual transmission oil filler plug Roadwheel bolts
Nm Ibfft 18 13 24 18
12 9 Angle-tighten a further 180® 46 34 46 34