1999 FIAT PUNTO steering wheel adjustment

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...

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

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

12*10 Body electrical systems
14.5 Remove the switch unit the steering column and unplug the wiring connectors 14.9 Carefully lever the switch body out of the facia, using a flat btaded instrument
14.10 Unplug the wiring from tho rear of the switch body at the connector
5 Pull the switch unit along ihe steering column slightly, then label and unplug the wiring connectors from the rear of the unit (sec Illustration). 6 Remove the switch unit from the steering column Refitting 7 Refitting is reversal of removal • ensure that the steering column/roadwheels are still in the straight-ahead position. On completion, ensure that the direction indicator cancelling mechanism lunations correctly.
Headlamp beam adjustment switch 8 Disconnect the battery negative cable and position il away from the terminal. 9 Carefully lever the switch body out of the facia, using a flat bladed instrument. Pad the
15 Refitting is a reversal of removal. Courtesy light/door ajar warning switches 16 Disconnect the battery negative terminal (refer to Disconnecting the battery in thf Reference Section of this manual). 17 Open the door to expose the switch
in
the door 8-plHar. 18 Remove the secunng screw, then remove the rubber gaiter (where applicable) ant) withdraw the switch from the door pillar. Disconnect the wiring connector as tl becomes accessible.
Tape the wiring to the
door
i m | pillar, or tie a length of
string
HlNTi to the wiring, to retrieve itttit falls back Into the door pillar.
14.14 Remove the screws and lift the switch bank from the rear of the facia panel
facia with a small piece of card to prevent the Instrument blade from damaging it (see illustration). 10 Unplug the wiring Irom Ihe rear of the switch body at Ihe connector (see illustration). 11 Refitting is a reversal of removal
Stop-light switch 12 Refer to the information in Chapter 9
Centre console switches 13 With reference to Chapter 11, Section 19, remove the combined air ventilation/switch panel from the facia. 14 Remove the screws and lift Ihe switch bank from Ihe rear of the panel (see illustration),
19 Refitting Is a reversal of removal, but ensure that the rubber gaiter is securely seated over the switch.
Electric window switches 20 Refer to the information given
In
Chapter It, Section 14.
15 Tailgate wiper motor - & removal and refitting ^
Removal 1 Disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual), 2 Remove the tailgate inner trim panel with reference to Chapter 11, Section 8. 3 Remove the wiper arm with reference to Section 18. 4 Working inside the tailgate, unplug tlx tailgate wiper motor wiring at Ihe connector and disconnect the washer hose at
1he
union (see illustrations). 6 Unscrew the bolts securing the motor mounting bracket to the tailgate (see illustration). 6 Withdraw the motor assembly through tte aperture in the tailgate (see illustration).
15.4a Working inside the tellgate, unplug tho tailgate wiper motor wiring at the connector...
. and disconnect tho washer hose at the union 15.5 Unscrew the bolts securing the motor mounting bracket to the tailgate