1999 FIAT PUNTO AUX

5A»1
Chapters Part A:
Starting and charging systems
Contents
Alternator - brush holder/regulator module renewal 6 Alternator/charging system • testing in vehicle 4 Alternator • removal and refitting 5 Auxiliary drivebelt • removal, refitting and adjustment See Chapter 1A or 1B Battery • condition check See Weekly Checks Battery • removal and refitting 3
Battery - testing and charging 2 Electrical fault finding • general Information See Chapter 12 General Information and precautions 1 Starter motor • removal and refitting 8 Starter motor - testing and overhaul 9 Starting system - testing 7
Degrees of difficulty
Easy, suitable for & novice with Tittle jg experience ^
Fairly easy, suitable ^ for beginner with some experience 3J
Fairly tfifftait, J^ sutable for competent ^ DIYmechanic ^
Difficult, suitable for ^ experienced D!Y mechanic ^
Verydtfficult, jk stitable far expert DfY X or professional ^
Specifications
General System type 12 volt, negative earth
Starter motor Type: Petrol engines Magneti-Marelli pre-engaged Diesel engines Bosch pre-engaged with reduction gear Output: 5A Petrol engines 0.8 kW (1108 cc) or 0.9 kW (1242 cc) Diesel engines 1.7 kW
Battery Capacity: Petrol engines 32 to 50 amp/hr Diesel engines 60 amp/hr Charge condition: Poor 12.5 volts Normal 12.6 volts Good 12.7 volts
Alternator Type Magneti-Marelli Output 65 to 85 amp
Torque wrench settings Nm ibt ft Alternator 60 44 Battery tray 29 21 Oil pressure switch: Petrol engine 32 24 Diesel engine 37 27

5A«2 Starting and charging systems
5.9a Unbolting the alternator upper bracket from the rear of the coolant pump
fl Loosen the pivot bolt and adjustment locknut then unscrew the adjustment bolt and swivel the alternator towards the engine so that the drivebefi may be slipped off the alternator pulley. 9 Unscrew and remove the pivot and adjustment bolts and withdraw the alternator Irom the engine compartment. If preferred the upper alternator bracket may bo unbolted from the rear of the coolant pump {see illustrations).
Refitting 10 Refitting is a reversal ot removal. Refer to Chapter tA or 1B as applicable for details of tensioning the auxiliary drivebeit. On completion lighten the pivot and adjustment botts/nut to the specified torque.
6 Alternator -brush holder/regulator module renewal
%
1 Remove the alternator as described in Section 5. 2 Extract the two small bolts and withdraw the brush box. Note the small plastic grille on the Marelli alternator (see illustrations), 3 Using a steol rule chock the length of the brushes. If less than 5.0 mm the complete brush holder assembly should be renewed. Note: On Bosch alternators it may be possible to obtain the brushes separate//, in which case the brush ieads should be unsoldered
5.9b Removing the pivot bolt and alternator from the engine
from ihe terminals and the new brush leads soldered onto the terminals. 4 Check the slip rings for excessive wear and clean them with a rag soaked in fuel. 5 Pit the new holder using a reversal of the removal procedure but make sure that each brush moves freely.
7 Starting system • & testing
Note: Refer to Ihe precautions given In Safety firstI and in Section I of this Chapter before stoning work. 1 If the starter motor falls to operate when the Ignition key Is turned to the appropriate position, the following possible causes may be to blame. aj The battery is faulty. b) The electrical connections between the switch, solenoid, battery and starter motor are somewhere failing to pass the necessary current from the battery through the starter to earth. c) 77:© solenoid is faulty. d) The starter motor is mechanically or electrically defective. 2 To check the battery, switch on the headlights. If they dim after a few seconds, this indicates that the battery is discharged -recharge (see Section 2) or renew the battery. If the headlights glow brightly, operate the ignition switch and observe the lights. If they
dim, then this indicates that current it reaching the starter motor, therefore the iao8 must lie In the starter motor. If the lights continue to glow brightly (and no clicking sound can be heard from the starter motor solenoid), this indicates that there is a lairt
In
the circuit or solenoid - see following paragraphs, if the starter motor turns siowfy when operated, but the battery is In good condition, then this indicates that either lae starter motor is faulty, or there is considers resistance somewhere in the circuit. 3 If a fault in the circuit is suspected, disconnect the battery ieads (including ihe earth connection to the body), lt» starter/solenoid wiring and tne engine/transmission earth strap. ThoroygWy clean the connections, and reconnect the leads and wiring, ihen use a voltmeter or J«i lamp to check that full battery voltage is available at the battery positive lead connection to the solenoid, and that the earth is sound. Smear petroleum jelly around ttie battory terminals to prevent corrosion > corroded connections are amongst the most frequent causes of electrical system faults. 4 If the battery and all connections are in good condition, check the circuit disconnecting the wire from the solenod blade terminal. Connect a voltmeter or less lamp between the wire end and a good earth (such as the battery negative terminal), ais check that the wire is live when tne ignition switch is turned to the start position. If It is. then the circuit is sound - if not. the circut wiring can be checked as described Chapter 12. Section 2. 5 The solenoid contacts can be checked
Oy
connecting a voltmeter or test lamp across Ihe solenoid. When the ignition switch is turned to the start position, there should b»a reading or lighted bulb, as applicable. II thars is no reading or lighted bulb, the solenoid is faulty and should be renewed. 6 If the circuit and solenoid are proves sound, the fault must lie in the starter motor. In this event, it may be possible to have tre starter motor overhauled by a specialist, but check on the cost of spares before proceeding, as It may prove more economical to obtain a new or exchange motor

Body electrical systems 12*3
3.4 The auxiliary fusebox, located inside the glovebox behind a drop-down panel auxiliary fusebox, which is located inside the glovebox behind a drop-down panel (see Illustration). 5 A blown fuse can be recognised from its melted or broken wire (see illustration). 6 To remove a fuse, first ensure that the relevant circuit is switched off. 7 Using the plastic tool clipped to the main fusebox lid, pull the fuse from its location. 8 Spare fuses are provided in the main fusebox. 9 Before renewing a blown fuse, trace and rectify the cause, and always use a fuse of the correct rating (fuse ratings are specified on the inside of the fusebox cover flap). Never substitute a fuse of a higher rating, or make temporary repairs using wire or metal foil; more serious damage, or even fire, could result. 10 Note that the fuses are colour-coded as follows. Refer to the wiring diagrams for details of the fuse ratings used and the circuits protected. Colour Rating Orange 5A Red 10A Blue 15A Yellow 20A Clear or White 25A Green 30A 11 The radio/cassette player fuse is located In the rear of the unit, and can be accessed after removing the radio/cassette player -refer to Section 12for greater detail.
Relays 12 A relay is an electncally-operated switch, which Is used for the following reasons: 4 A relay can switch a heavy current remotely from the circuit in which the current is flowing, therefore allowing the use of lighter-gauge wiring and switch contacts.
b)
A relay can receive more than one control input, unlike a mechanical switch. c) A relay can have a timer function - for example, the intermittent wiper relay. 13 The main and optional equipment relays are located in the main and auxiliary toseboxes (see Fuses). A number of additional relays may be fitted, depending on model and specification. These are generally mounted
3.5 A blown fuse can be recognised from its melted or broken wire adjacent lo the component being controlled; e.g. the radiator cooling fan relay(s) are mounted on a bracket next the cooling fan itself. 14 The direction Indicator/hazard warning flasher unit is mounted on the underside of the steering column slalk switch unit. It can be accessed by removing the steering column lower shroud panel (see illustration). 15 If a circuit or system controlled by a relay develops a fault, and the relay is suspect, operate the system. If the relay is functioning, it should be possible to hear it click as it is energised, if this is Ihe case, the fault lies with the components or wiring of the system. If the relay is not being energised, then either the relay is not receiving a main supply or a switching voltage, or the relay itself is faulty. Testing is by the substitution of a known good unit, but be careful - while some relays are identical in appearance and in operation, others look similar but perform different functions. 16 To remove a relay, first ensure that the relevant circuit is switched off. The relay can then simply be pulled out from the socket, and pushed back into position.
4 Buibs (exterior lights) -renewal
General 1 Whenever a bulb is renewed, note the following points:
3.14 Removing the direction indlcator/ha2ard warning flasher unit
a) Ensure that the relevant electrical circuit is isolated before removing a bulb. If in doubt, disconnect the battery negative lead before starting work. b) Remember that, if the circuit has just been in use, the bulb may be extremely hot. c) A/ways check the bulb contacts and holder, ensuring that there is clean metal-to-metal contact between the bulb and its live contacts) and earth. Clean off
any
corrosion or dirt before fitting a nevt bulb. d) Wherever bayonet-type bulbs are fitted, ensure that the live contacts) bear firmly against the bulb contact. e) Always ensure that the new bulb is of the correct rating (see Specifications), and that it is completely clean before fitting it; this applies particularly to headlight/foglight bulbs (see following
0 Pay attention to the orientation when fitting multi-filament bulbs (e.g. combined tail/brake light bulbs) • incorrect fitting will cause the filaments to illuminate In the wrong sequence.
Headlight 2 Open the bonnet. Ensure that the headlights are turned off at the stalk switch. Models with single reflector 3 Pull the wiring plug from the rear of the bulb (see illustration). 4 Pull the rubber boot from the rear of the headlight unit (see Illustration).
4.3 Pull the wiring plug from the rear of the bulb 4.4 Pull the rubber boot from the rear of the headlight unit