1999 FIAT PUNTO ECU

o.6 Roadside repairs
The following pages are Intended to help In dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair Information In the main chapters.
If your car won't start
and the starter motor
doesn't turn
If your car won't start
even though the starter
motor turns as normal
tf it's a model with automatic transmission, make sure the selector is in P or N. Open the bonnet and make sure that the battery terminals are clean and tight. Switch on the headlights and try to start the engine. If the headlights go very dim when you're trying to start, the battery is probably flat. Get out of trouble by Jump starting (see next page) using a friend's car.
• Is there fuel In the tank? • Is there moisture on electrical components under the bonnet? Switch off the ignition, then wipe off any obvious dampness with a dry cloth. Spray a water-repellent aerosol product (WD-40 or equivalent) on ignition and fuel system electrical connectors like those shown in the photos. Pay special attention to the ignition coil wiring connector and HT leads. (Note that Diesel engines don't normally suffer from damp.)

A

Check that the spark plug HT leads are securely connected by pushing them onto the plugs (petrol engine models).
B

Check that the wiring to the engine compartments is securely connected.
C

Check the security and condition of the battery terminals,
Check that electrical connections are secure (with the ignition switched off) and spray them with a water dispersant spray tike WD40II you suspect a problem due to damp

o«8
Roadside repairs
Wheel changing
Some of the details shown horo will vary according to model. For Instance, the location of the spare wheel and jack is not the same on all cars. However, the basic principles apply to aii vehicles-
Preparation
• When a puncture occurs, stop as soon as it Is safe to do so. • Park on firm level ground. If possible, and v/etl out of the way of other traffic. • Use hazard warning lights if necessary.
Changing the wheel
A
Warning: Do not change a wheel (n a situation where you risk being hit by another vehicle. On busy roads, try to stop in a fay-by or a gateway. Be wary of passing traffic white changing the wheel - it Is easy to becomo distracted by the job in hand.
If you have one, use a warning triangle to alert other drivers of your presence. Apply the handbrake and engage first or reverse gear (or P on models with automatic transmission).
• Chock the wheel diagonally opposite the one being removed - a couple of largo stones will do for this. G If the ground is soft, use a flat piece of wood to spread the load under the iack.

I

Tbe spare wheel and tools (Including the jack) are stored
In
the luggage compartment beneath the floor covering. Unscrew the central plastic nut to remove the tool holder.
Slacken each wheel bolt by a half turn Locale the jack under the triangular mark on the 6)11 next to the wheel to be changed, on firm ground

4

Turn the Jack handle clockwise until the wheel Is raised clear of the ground Unscrew the wheel bolts, withdraw the trim and remove the whed
6

Fit Ihe spare wheel on the pins, and screw In the bolts. Lightly lighten tho bolts with the wheelbrace then lowor the vehicle to the ground
Finally...
Securely lighten the wheel bolts in Ihe sequence shown. Note that the wheel bolts should be slackened and retightened to the specified torque at the earliest possible opportunity.
• Remove l)>e wheel chocks.
• Stow the punctured wheel, jack and tools in the correct locations in the car. • Check the tyre pressure on the wheel just fitted. If it is low. or It you don't have a pressure gauge with you, drive slowly to the nearest garage and inflate the tyre to Ihe right pressure.
D When using tho space-saver spare wheel, do not exceed 50 mph (SO kph). C Have the damaged tyre or wheal repaired as soon as possible.

o*i2 Weekly checks
Engine oil level
Before you start • Make euro that your cor is on level ground. • Check ihe oil level oefore ihe cor is driven, or at least 5 minutes alter the engine has been switched off.
HHifffl If tho oil Is checked rTf"™^ Immediately after driving the IHlAIT vehicle,
some
of the oil will " remain In the upper engine components, resulting in on inaccurate reading on the dipstick!
The correct oil Modern engines place great demands on their oil. It Is very important that the correct oil for your car is used
Lubricants and fluids).
Car Care • If you have to add oil frequently, you should check whother you have any oil leaks. Place some clean paper under the car overnight, and check for stains In the morning. If there are no leaks, the engine may be burning oil.
• Always maintain the level between the upper and lower dipstick marks (see pholo 2). If Ihe level Is too low
sqvoio
engine damage may oecur. Oil seal failure may result if tho engine is overfilled by adding too much oil.

I

Tho dipstick is brightly coloured for easy identification (seo Under bonnet check points). Withdraw the dipstick (petrol engine shown).

3

If more oil is needed, remove the oil filler cap Irom the top of the ongine (petrol engine shown).
SI i J

2

Using a clean rag or paper towel remove all oil from the dipstick. Insert the clean dipstick into the tube as far as it will go, then withdraw it again. The level should be between the upper and lower marks.

4

Oil Is added through the filler cap aperture (diesel engine shown). Add the oil a little at a time, checking the level on the dipstick often. Using a funnel will help to reduce spillage. Don't overfill (see Car Care).
Coolant level
A
Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a very great risk of scalding. Do not leave open containers of coo/ant about, as It is poisonous.
Car Care • With a sealed-type cooling system, adding coolant should not be necessary on a regular basis. If frequent topping-up is required, it is likely there Is a leak. Check the radiator, all hoses and Joint faces for signs of staining or wetness, and roctify as necessary.
• It is important that antifreeze is used in the cooling system all year round, not just during the winter months. Don't top-up with water alone, as the antifreeze will become too diluted.
H Check that the coolant level is between I the MIN and MAX marks, il topping up is necessary, wait until tho engine is cold. Slowly unscrew the expansion tank cap to release any pressure present in the cooling system, and remove it (petrol engine shown).

2

On diesel engine models, Ihe ooolant expansion tank is a different shape, but Ihe same procedure applies as for petrol engine models (see photo 1). Tho MlN and MAX marks appear on the side of tlie tank neorosl the engine.

3

Add a mixture of water and antifreeze to the expansion tank until the coolant level is up to the MAX mark (petrol engine shown), The MIN and MAX marks appear on the tank below the filler neck.

Weekly checks 0.13
Brake fluid level
A
Warning: • Brake fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouting it.
• Do not use fluid that has been standing open for so mo time, as It absorbs moisture from the air, which can cause a dangerous loss of braking effectiveness.
Mpmna * Make sure that your car Is I on level ground. HiNTi * Th* ffftt 'eve/ In the reservoir will drop slightly as

I

The MIN and MAX marks are indicated on the side of Ihe reservoir The fluid level must be kept between the marks at all times.

2

11 topping-up is necessary, first wipe clean the area around the filler cap to prevent dirt entering the hydraulic system.
the brake pads wear down, but the fluid level must never be allowed to drop below the "MIN" mark.
Safety First! • If the reservoir requires repeated topping* up this is an indication of a fluid leak somev/here In the system, which should be investigated immediately.
• If a leak is suspected, the car should not be driven until the braking system has been checked. Never take any risks where brakes are concerned.
Unscrew the reservoir cap and carefully lift it out of position, taking care not to damage the level switch float. Inspect the reservoir: if the fluid Is dirty Ihe hydraulic system should be drained and refilled (see Chapter 1A or 1B).

4

Carefully add fluid, taking care not to spill it onto the surrounding components, Use only the specified fluid; mixing different types can cause damage to the system. After topping-up to the correct level, secureiy refit the cap and wipe off any spilt fluid.
Power steering fluid level
Before you start: •Park the vehicle on level ground. • Set the steering wheel straight-ahead. •
The
engine should be turned off.

I

The reservoir is located on the right-hand side of the bulkhead in the engine compartment. Wipe clean the area around the reservoir filler cap then unscrew It from the reservoir.
For the check to be accurate, the steering must HlHT; not be turned once the engine has been stopped.


2

Dip the fluid with the reservoir cap/ dipstick (do not screw the cap into position). When the engine is cold, the fluid level should be up to Ihe MIN mark (B): when hot. it should be on the MAX mark (A).
Safety First! • The need for frequent topping-up indicates a leak, which should be investigated immediately.

3

When topping-up, use the specified type of lluid and do noi overfill the reservoir. When the level is correct, securely refit the cap.

o«i6 Weekly checks
Battery
Caution: Before carrying out any work on the vehicle battery, read the precautions given In "Safety first" at the start of this manual. • Make sure thai the battery tray is in good condition, and that the clamp Is tight. Coirosion on the tray, retaining clomp and the battery itself can be removed with a solution of water and baking soda, Thoroughly rinse all cleaned areas with water. Any metal parts damaged by corrosion should be covered with a zinc-based primer, then painted. • Periodically (approximately every three months), check the charge condition of the battery as described In Chapter SA. • If the battery Is flat, and you need to jump start your vehicle, see Roadside Repalrz.
Battery corrosion can be kept to a minimum by applying o layer of petroleum Jelly to the clamps and terminals after they are reconnected
fin %

I

The battery is located on the left-hand side of the engine compartment, The exterior of the battery should be inspected penodlcaily for damage such as a cracked case or cover.

2

Check the tightness of battery clamps (A) to ensure good electrical connections. You should not be able to move them. Also check each cable (B) for cracks and frayed conductors.

3

If corrosion (while, fluffy deposits) is evident, remove the cables from the battery terminals, clean them with a small wire brush, then refit them. Automotive stores sell a tool for cleaning the battery post...
as well as the battery cable clamps
Electrical systems
• Check all external lights and the horn. Refer to the appropriate Sections of Chapter 12 for details if any of the circuits are found to be Inoperative,
• Visually chock all accessible wiring connectors, harnesses and retaining clips for security, and for signs of chafing or damage.
fffjffflg^ " y°u A**^ check your "T™*! broke lights and Indicators ,HllMT[ unaided, back up to a wall or garage door and operate the lights. The reflected light shouid show
If
they are working property.

I

I? a single indicator light, stop-light or headlight has failed, it Is likely that a bulb has blown and will need to be replaced. Refer to Chapter 12 for details. If both stop-lights have failed, it is passible that the switch has failed (see Chapter 9).

2

If more than one Indicator light or tail light has failed It is likely that either a fuse has blown or that there is a fault tn the circuit (see Chapter 12). The fuses are located behind the oddments tray on ihe facia. First unscrew the two screws and swivel Ihe tray down.

3

To replace a blown fuse, simply pull it out using the special plastic tool and fit a new fuse of tho correct rating (see Chapter 12). If the fuse blows again, it is importont that you find out why - a complete checking procedure Is given in Chapter 12.

Maintenance schedule - petrol models 1A.3
The maintenance Intervals in this manual are provided with the assumption that you, not the dealer, will be carrying out the work. These axe the minimum maintenance intervals recommended by us for vehicles driven daily.
if you wish to keep your vehicle in peak condition at all times, you may wish to perform some of these procedures more often. We encourage frequent maintenance, because it enhances the efficiency.
performance and resale value of your vehicle. When the vehicle Is new, it should be serviced by a factory-authorised dealer service department, In order to preserve the factory warranty.
Every 250 miles (400 km) or weekly Q Refer to Weekly checks
Every 5000 miles (7500 km) or
6 months - whichever comes first • Renew the engine oil and filter (Section 3)
Note: Frequent oil and fitter changes am good tor the engine. We recommend changing the oil at the mileage specified here, or at least
twice
a year if the mileage covered Is a less.
Every 10 000 miles (15 000 km) or
12 months - whichever comes first
In
addition to the items listed above, cany out the following: Q Check the operation of the brake warning lamp (Section 4) • Check the front brake pads for wear (Section 5) • Check the underbody and sealant for damage (Section 6) • Hose and fluid leak check (Section 7) • Check the condition of the exhaust system and its mountings (Section 8) • Check the condition of the driveshaft gaiters (Section 9) • Renew pollen filter (Section 10) • Check exhaust gas content and idle speed (Section 11) • Check the steering and suspension components for condition and security (Section 12)
Every 20 000 miles (30 000 km) or
2 years - whichever comes first
In
addition to the Items listed above, carry out the following: • Check and if necessary adjust the tension of the auxiliary drlvebelt(s) (Section 13) • Check the freeplay and height of the clutch pedal (Section 14) • Check and if necessary adjust the valve clearances (Section 15) HI Check and if necessary tighten inlet and exhaust manifold mountings (Section 16) • Renew the fuel filter (Section 17) D Renew the air filter element (Section 18) O Renew the spark plugs (Section 19) • Check the condition of the HT cables (Section 20) • Check the engine management system (Section 21) Q Lubricate all hinges and locks (Section 22) O Check the headlight beam adjustment (Section 23) • Carry out a road test (Section 24)
Every 30 000 miles (45 000 km) or
3 years - whichever comes first In addition to the items listed above, cany out the following: • Check the operation of the Lambda sensor (Section 25) • Check and if necessary top-up the manual transmission oil level (Section 26) • Check the operation of the evaporative loss system (Section 27) • Automatic transmission inner filter and fluid renewal (Section 28)
Every 40 000 miles (60 000 km) or
4 years - whichever comes first In addition to the items fisted above, carry out the following: • Check the rear brake shoes for wear (Section 29) • Renew the timing belt (Section 30)"
*Noto: Although the normal interval for timing belt renewal is 70 000 miles (105 000 km), It is strongly recommended that the belt Is renewed at 40 000 miles (60 000 km) on vehicles which are subjected to Intensive use, ie. malniy short Journeys or a let of stop-start driving. The actual belt renewal Interval Is therefore very much up to the individual owner, but bear in mind that severe engine damage will result if the belt breaks.
Every 60 000 miles (90 000 km) or
6 years - whichever comes first in addition to the items listed above, cany out the following: • Check the condition and operation of the crankcase emission control system (Section 31)
Every 80 000 miles (120 000 km) • Renew the manual transmission oil (Section 32)
Every 2 years
(regardless of mileage) • Renew the engine coolant (Section 33) • Renew the brake fluid (Section 34)

ia«4 Component location - petrol models
Underbonnet view -1108 cc engine model
1 Engine oil filler
cap
2 Engine oil dipstick 3 Brake vacuum servo unit 4 Brake fluid
reservoir
5 Air cleaner
cover
6 Coolant expansion lank 7 Windscreen washer fluid reservoir 8 Front suspension strut upper mounting 9 Ignition coil cover 10 Engine wiring connector cover 11 Battery 12 ECU
Underbonnet view - 1242 cc (8-valve) engine model
1 Engine oil tiller
cap
2 Engine oil dipstick 3 Brake vacuum servo unit 4 Brake fluid
reservoir
5 Air cleaner cover 6 Coo/ant expansion tank 7 Windscreen washer
fluid
reservoir 8 Front suspension strut upper mounting 9 Ignition coil cover 10 Engine wiring connector cover 11 Battery 12 ECU

Component location - petrol models 1A.5
Underbonnet view - 1242 cc (16-valve) engine model
1
Engine
olt filler
cap
2
Engine
oil dipstick 3
Brake
fluid
reservoir
4
Power
steering fluid reservoir 5
Engine
wiring connector cover 6
Windscreen
washer
fluid
reservoir 7 Battery 8
Coolant
expansion
tank
9 Air cleaner
cover
10 Resonator 11 ECU
1
Oil filter
2
Sump
drain plug 3
Transmission
drain plug A
Electric
cooling Ian unit 5
Left-hand driveshaft
6
Intermediate shaft
7
Right-hand driveshaft
B
Front
suspension lower arms 9
Front
anti-roll
bar
10
Exhaust
downpipe 11
Front
brake calipers (2
Rear engine
mounting IS Radiator bottom hose
Front underbody view (diesel model shown, petrol model similar)