1999 FIAT PUNTO turbo

8*2 Driveshafts
f Outboard CV joint 3 Driveshaft 6 Flange 2 Gaiter clip A Garter 6 Inboard CV ioint
1.2 Intermediate driveshaft • turbo diesel models 1 Bearing flange 3 Washer S Retaining plate 2 Bearing A Circllp
2.S Extracting the driveshaft from the hub (arrowed) from the CV joint at the carrier transmission
The joints are protected by rubber g&itcrs and are packed with grease, to orovktt permanent lubrication. If wear Is detected in the joint. It can be detached from lii» driveshaft and renewed. Normally, the CV joints do not require additional lubrication, unless they havo been overhauled or lfi» rubber gaiters have been damaged, allotting the greasa to become contaminated. Rater
to
Chapter 1A or 1B for guidance In checking the condition of the driveshaft gaiters. Bolh driveshafts are splined at their outer ends, to accept the wheel hubs, ond ate threaded so that the hubs can be fastened to the driveshafts by means of a large, staked nut.
2 Driveshafts -removal and refitting & ^
Note: A balljoint separator tool will b» required for this operation. A new drivestnf, nut and tmck-rod end nut should be used
on
refitting. In addition, new lower arm
baHj&ot
nuts should be used. Removal 1 Chock the rear wheels, apply the handbrake, then jack up the front of tha vehicle and support on axle stands (see Jacking and vehicle support). Remove th« appropriate roadwheel(6). 2 The front hub must be held stationary
m
order to loosen the driveshaft nut. Ideally, M hub should be held by a suitable tool bolted Into placo using two of the roadwheel nuts, Alternatively, havo an assistant firmly apply the brake pedal to prevent the hub from rotating. Using e socket and extension bar, slacken and remove the driveshaft nut. Recover the washer (where fitted).

A


Warning: The nut Is extremely tight. Discard the nut - a new
one
must be used on refitting. 3 Remove the locking clip and extract the brake caliper hydraulic hose (and where applicable, the brake pad wear indicator cable) from the bracket on the base of the suspension strut. 4 With reference to Chapter 10, Section 3. unbolt the base of the suspension strut from Ihe top of the hub carrier. 5 Temporarily refit the driveshaft nut to the end of the driveshaft, to prevent damage to the driveshaft threads, then using a solt-faced mallet, carefully tap the driveshaft from the hub carrier (see illustration). If the shaft is a tight fit, a suitable hub puller can be used to force the end of the shaft from the hub. Support tha end of the driveshaft • do not allow the end o the driveshaft to hang down as this svill strain the joint components and gaiters. 6 Proceed as follows, according to which driveshaft is to be removed. All models except turbo diesels 7 Remove the driveshaft gaiter clip from the CV joint at the transmission (see Illustration)

Driveshafts 8*3
2.9 On turbo diesel models, unscrew the driveshaft Allen bolts (right-hand driveshaft shown) 2.13 Fitting a new driveshaft nut
then pull the driveshaft away from the plunge cup. Position a container underneath the joint to catch any grease that may escape fdnveshaft grease becomes liquid with use). 6 Remove the driveshaft from under the vehicle. Cover the open plunge cup on the vehicle to prevent the ingress of dirt: use a plastic bag secured with elastic bands. Turbo diesel models 9 Unscrew the six Allen bolts securing the inboard end of the driveshaft to the inter-mediate shaft flange (right hand driveshaft) or gearbox output shaft flange (left hand drive-shaft flange) (see Illustration). Recover tho reinforcement plates (where fitted). 10 Remove the driveshaft from under the vehicle. Cover the exposed flange at the gearbox/intermediate shaft, to prevent the ingress of dirt; use a plastic bag secured with elastic bands. 11 Loosely refit one of the strut lower mounting bolts, to support the hub carrier whilst the driveshaft is out of the vehicle.
Befitting 12 After removing the temporarily-fitted bolt torn the strut mounting, pivot the hub carrier away from the vehicle and push the splined end of the driveshaft Into the hub.
13 Fit a new driveshaft nut, but do not fully tighten it at this point (see illustration). 14 Support the driveshatt with one hand and push the hub carrier back towards the vehicle. All models except turbo diesels 15 Re-engage the tripod at the inboard end of the driveshaft with the plunge cup at the gearbox. Slide the gaiter into position over the joint and briefly lift the lip of the gaiter to expel any air trapped inside. Ensure that the gaiter is seated squarely over the universal joint, then fit a new clip around the centre of the joint to secure it in place. Turbo diesel models 16 Align the inboard end of the driveshaft joint with the intermediate shaft flange. Refit the six driveshaft bolts and tighten them securely. All models 17 Refit the suspension strut-to-hub carrier bolts and tighten them to the correct torque * refer to Chapter 10 for details. 18 Refit the brake caliper hydraulic hose (and where applicable, the brake pad wear indicator cable) to the bracket on the base of the suspension strut. 19 Refit the roadwheel and bolts. 20 Lower the vehicle to the ground and tighten the driveshaft nut to the specified
torque. Stake the rim of the nut into the machined recess in the end of the driveshaft. using a hammer and punch (see illustrations). 21 Tighten the wheel bolts to the specified torque and refit the wheel trim/centre cap.
3 Driveshaft overhaul and rubber gaiter renewal
1 Remove the driveshaft from the vehicle as described In Section 2. 2 Unfasten the remainder of the rubber gaiter securing clips. Slide the gaiters towards the centre of the shaft, away from Ihe joints. Wipe off the majority of the old grease with a rag. Outboard CV joint - removal
All models except turbo diesels 3 Mark the relationship between the joint and the driveshaft using a scriber or a dab of paint. Using pair of circlip pliers, expand the circlip that holds the driveshaft m place and withdraw the shaft from the CV joint. Note that the circlip is captive in tho joint, and need not be removed, unless it appears damaged or worn (see illustration overleaf).
2.20a Tighten the driveshaft nut to the specified torque (roadwheel removed for clarity) 2.20b Stake the rim ot the nut Into the recess in the driveshaft 2.20c Recess machined into end of the driveshaft

I
8*4 Driveshafts
3.3 Using pair of circlip pliers, expand the circlip that holds the driveshaft in place
Turbo diesel models 4 Mark the relationship between the joint and the driveshaft using a scriber or a dab of paint. Attach a slide hammer to the dnveshaft nut thread. 5 Draw the joint off the driveshaft using the slide hammer, Use just enough effort to overcome the tension of the internal circlip.
Inboard CV joint removal All models except turbo dieseis 6 Al the inboard end of the driveshaft. use a hammer and centre punch to mark the relationship between Ihe shaft and |olnt. Remove the circlip with a pair of circlip pliers, then using a three-legged puller if required, draw Ihe tripod joint off the end of the driveshaft. Ensure that the legs of Ihe puller bear upon the cast centre section of the joint, not the roller beanngs (see illustration) Turbo diesel models 7 Al the inboard end of Ihe driveshaft. use a hammer and centre punch lo mark the relationship between the shaft and joint. Remove the circlip with a pair of circlip pliers, then carefully slide the CV joint from the end ot the shaft. Take great care to prevenl the
cage and bail bearings from falling out • secure the joint components together with wire or a nylon cable-tie. 8 Remove the washer then slide the flange from the end of the shaft.
Inspection 9 Slide both rubber gaiters off the driveshaft and discard them: It is recommended that new ones are fitted on reassembly as a matter of course. Recover the flexible washers (where fitted), making a note of their fitted positions, to aid correct refitting later. 10 Thoroughly clean the driveshaft splines, and CV joint components with paraffin or a suitable solvent, taking care not to destroy any alignment marks made during removal. 11 Examine Ihe CV joint components for wear and damage: in particular, check the balls and corresponding grooves for pitting and corrosion. If evidence of wear Is visible, then the joint must be renewed. Note that if the outboard CV joint Is to be renewed on turbo diesel models, it must be matched to the driveshaft using the colour-coded paint markings. 12 Where applicable, examine the tripod joint components for wear. Check thai the three rollers are free lo rotate without resistance and are not worn, damaged or corroded. The rollers are supported by arrays of needle bearings: wear or damage will show up as play In the rollers and/or roughness in rotation. If wear is discovered, the tnpod joint must be renewed. 13 Fit a new rubber gaiter (and where applicable, flexible washer) to the inboard end of the driveshaft and secure it In place on the shaft with a clip (see illustration).
Inboard CV joint - refitting
All models except turbo dieseis 14 Using Ihe alignment marks made during removal, fit the tripod joint onto the splines of the driveshaft. Tap It Into position using a soft faced mallet. To ensure that the tripod Joint rollers and driveshaft splines are not damaged, use a socket with an internal diameter slightly larger than I hat of the driveshafl as a drift. Refit the circlip. 15 Slide the gaiter over tho tripod joint and pack the gaiter with grease from the service kit.
3.6 Draw the tripod joint off the end of the driveshaft 3.13 FH s new rubber gaiter to the inboard end of the driveshaft and secure It in place with a clip
Caution: Do not allow grease to come
into
contact with vehicles paintwork, es discolouring may rasutt. Turbo diesel models 16 Slide the flange and washer onto the end of the shaft, then fit the joint Into position on the driveshaft splines, using the alignment marks made during removal. Fit the circlip. ' 17 Pack the gaiter with grease from His service kit, then slide the gaiter over the joint. Briefly lift the lip of the gaiter to expel ail the air from the joint, then secure the gaiter over the joint with a new clip. Caution: Do not allow grease to come
Into
contact with the vehicle's paintwork, as discolouring may result.
Outboard CV joint - refitting 18 Fit a new rubber gaiter to the outboard end of the driveshaft and secure it place with a dp, 19 Pack the CV joint with grease from Ihe service kit, pushing It into the ball grooves and expelling any air that may be trapped underneath. 20 Lubricate the splines of the drive shaft with a smear of grease, then whilst splaying the circlip open with a pair ot circlip pile*, insert the driveshaft into CV joint, observing the alignment marks made during removal. Note: On turbo diesel models, the circlip snaps into the CV Joint groove as Ifte driveshaft is inserted - no circlip pliers are required. Ensure that the circlip snaps securely Into place: pull on the shaft to check that it is held firmly In position. 21 Pack additional grease Into the joint to displace any air pockets, then slide the rubber gaiter over the joint. Briefly lift the lip ol the gaiter to expel all the air from Ihe joint, then secure it In place with a clip. 22 Refit the driveshaft (see Section 2).
4 Intermediate driveshaft - % removal and refitting J;
Note 1: This procedure applies only to turbo diesel engined models. Note 2: The intermediate shaft and
bearing
are not available as separate spares and cac only be renewed as a comptefe assembly.
Removal 1 Firmly apply the handbrake, then jack up the front of Ihe car and support It securely
on
axle stands (see Jacking and vehicle support). Remove the appropriate roadwheei(s). 2 Unbolt the inboard end of the right*hand driveshaft from the intermediate shaft
flange, as
described In Section 2. Suspend the dis-connected end of the driveshaft from a conven-ient point on the subframe, using wire or a cable-tie. to avoid straining the joint and gaiter. 3 Drain the oil from the transmission, with reference to Chapter 1B.

9«1
Chapter 9
Braking system
Contents
Brake disc - inspection, removal and refitting 4 Brake fluid level check See Weekly checks Brake fluid renewal See Chapter 1A or 1B Brake warning lamp check See Chapter 1A or 1B Front brake caliper - removal, overhaul and refitting 3 Front brake pad check See Chapter 1A or 1B Front brake pads - renewal 2 General information 1 Handbrake - checking and adjustment 9
Handbrake cables - removal and refitting 10 Hydraulic pipes end hoses - renewal 13 Hydraulic system - bleeding 11 Master cylinder - removal and refitting 12 Roar brake shoe check See Chapter 1A or 1B Rear brake shoes - renewal 5 Rear brake drums - removal, inspection and refitting 6 Rear wheel cylinder - removal, overhaul and refitting 7 Stop-light switch - adjustment, removal and refitting 6
Degrees of difficulty

Easy, suitable
far
novice with Sttle
experience ^
Fairly
easy,
suitable ^ (orbeginnerwith ®
some
experience
Fairly difficult, suitable
for
compe«ent ^ CHYmechanlc ^

Difficult, suitable for
experienced DIY « mechanic ^
Very difficult, ^
suitable
for
expert DIY
or professional ^
Specifications
Front disc brakes Type Disc with single-piston sliding calipers Disc diameter Petrol models with single-point Injection 240.0 mm Petrol models with multi-point Injection 257.0 mm Non-turbo diesel models 240.0 mm Turbodieselmodels 257.0 mm Disc thickness (new); Petrol models with single-point injection 10.80 to 11.10 mm Petrol models with multi-point Injection 11.80 to 12.10 mm Non-turbo diesel models 10.80 to 11.10 mm Turbodieselmodels 11.80 to 12.10 mm Minimum disc thickness (wear limit): Petrol models with single-pant Injection 9.20 mm Petrol models with multi-point Injection 10.20 mm Non-turbo diesel models 9.20 mm Turbo diesel models 10.20 mm Maximum disc runout 0.15 mm Brake pad friction material minimum thickness 1.5 mm
Rear drum brakes Drum Inner diameter (new) 180.0 to 180.25 mm Maximum drum diameter (wear limit) 181.35 mm Minimum brake shoe lining thickness 2.0 mm
Torque wrench settings Nm ibf ft
Bfeed
screw 6 4 Brake disc locating studs 12 9 Brake drum locating studs 12 9 Brake pipe and hose unions 14 10 Front caliper mounting bracket-to-hub carrier bolts 53 39 Front caliper-to-caliper bracket guide pin bolts 12 9 fleer wheel cylinder mounting boils 10 7 Roadwheel bolts 85 63

10*1
Chapter 10
Suspension and steering
Contents
Front hub bearings - renewal 2 Front suspension anti-roll bar • removal and refitting 6 Front suspension lower arm - removal and refitting 4 Front suspension lower arm balljolnt - renewal 5 From suspension strut - removal, overhaul and refitting 3 General information 1 Ignition switch/steering column lock - removal and refitting 10 Manual steering gear assembly - removal, overhaul and refitting ... 12 Power steering fluid level check See Weekly checks Power steering gear assembly - removal and refitting 13 Power steering hydraulic system - bleeding 15
Degrees of difficulty
Power steering pump • removal and refitting 16 Rear hub bearings - renewal 7 Rear suspension components- removal, overhaul and refitting 8 Steering and suspension check See Chapter 1A or 1B Steering column - removal, overhaul and refitting 11 Steering gear rubber gaiters - renewal 14 Steering wheel - removal and refitting 9 Track-rod end - removal and refitting 17 Wheel alignment and steering angles • general information 18 Wheel and tyre maintenance and tyre pressure checks See Weekly checks

Easy, suitable for nowoe with little
Jg experience ^

Fakty easy,
suitable for beginner
with
J£>
some experience
^

FaMy difficult,
% suitable for competent ^
DIY mechanic
^

Difficult,
suitable for & experienced DIY « mechsmc ^

Very difficult,
^ suitable for expert
DIY
fij or professional ^
Specifications
Front suspension Type
Rear suspension Type
Steering Type Turns lock-to-lock: Manual Power assisted Toe setting (front)
Roadwheeis and tyres See Weekly checks
Torque wrench settings Front suspension Anti-roll bar bush bracket bolts Driveshaft nut:' All models except turbo diesel (M22 plain) Turbo diesel (M24 with staking and captive washer) Lower arm balljoint to hub carrier Lower arm front bush securing bolt Lower arm rear bush securing bolt Suspension strut damper nut Suspension strut to hub carrier Suspension strut to inner wing
Independent, incorporating transverse lower wishbones and coil spring-over-teiescopic damper strut units. Anti-roll bar fitted to all models.
Independent, incorporating trailing arms with telescopic dampers and coil springs.
Rack-and-pinlon, manual or power assisted, depending on model
4.4 approx. 2.9 approx. 0° (parallel) ± 1a
Nm ibfft
30 22
240 177 280 207 30 22 95 70 70 52 60 44 70 52 50 37