1999 FIAT PUNTO diesel fuel pump

Safety first! 0.5
Working on your ear can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude.
General hazards
Scalding • Don't remove the radiator or expansion tank cap while the engine is hot. • Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running.
Burning • Beware of burns from the exhau3t system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use.
Crushing • When working under or near a raised vehicle. ~ always supplement the ' ' -jack with axle stands, or use ... drive-on i'j ramps. kr Never venture ™ under
a
car
vv/j/ch
Is only supported by a jack. • Take card if loosening or tightening high-torque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground.
Fire • Fuel Is highly flammable; fuel vapour is explosive. • Don't (et fuel spill onto a hot engine. • Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of toots). • Fuel vapour is heavier than air, so don't work on the fuel system with the vehicle over an inspection pit. • Another cause of fire is an electrical overload or short-circuit. Take care when repainng or modifying the vehicle wiring. • Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires.
Electric shock x ^ ^ ? , • Ignition HT _ " voltage can be ^ dangerous, ~ especially to > people with heart problems or a pacemaker. Don't work on or near the f^ ignition system with fT") the engine running or ' J ' J the Ignition switched on.
• Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker.
Fume or gas intoxication • Exhaust fumes are poisonous: they often contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine in a confined space such as a garage with the doors shut, • Fuel vapour is also poisonous, as are the vapours from some cleaning solvents and paint thinners.
Poisonous or irritant substances • Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don't syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice. « Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream If necessary. Change out of oll-soaked clothes and do not keep oily rags in your pocket. • Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame {including a cigarette). It can also cause skin burns on contact.
Asbestos • Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found In gaskets and in brake and clutch linings. When dealing with soch components It is safest to assume that they contain asbestos.
Special hazards
Hydrofluoric acid • This extremely corrosive acid is formed when cerlam types of synthetic rubber, found In some O-rings, oil seals, fuel hoses etc. are exposed to temperatures above 400;C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years, tfit gets onto the skin, it may be necessary to amputate the limb concerned. • When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use.
The battery • Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. • The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads.
Air bags • Air bags can cause injury if they go off accidentally. Take care when removing the steenng wheel and/or facia. Special storage instructions may apply.
Diesel injection equipment • Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes.

A


Warning: Never expose the hands, face or any otfterpart of the body to injector spray; the fuel can penetrate the skin with potentially fatal results.
Remember...
DO • Do use eye protection when using power tools, and when working under the vehicle. • Do wear gloves or use barrier cream to protect your hands when necessary. • Do get someone to check periodically that all is well when working alone on the vehicle. • Do keep loose clothing and long hair well out of the way of moving mechanical parts. • Do remove rings, wrtstwatch etc. before working on the vehicle - especially the electrical system, • Do ensure that any lifting or jacking equipment has a safe working load rating adequate for the job.
DON'T • Don't attempt to lift a heavy component which may be beyond your capability - get assistance. • Don't rush to finish a job. or take unverified short cuts. • Don't use ill-fitting toots which may slip and cause injury. • Don't leave tools or parts lying around where someone can trip over them. Mop up oil and fuel spills at once. • Don't allow children or pets to play In or near a vehicle being worked on.

ib-4 Component location - diesel models
Underbonnet view - turbo diesel model
1 Engine oil filter
cap
2 Engine oil dipstick 3 Oil
tilter
4 Brake/clutch fluid
reservoir
5 Air cleaner
cover
6 Power steering pump 7 Coolant expansion
tank
8 Windscreen washer
fluid
reservoir 9 Front suspension strut upper mounting 10 Fuel filter/heater
housing
11
Fuel
injection pump 12 Battery 13 Power steering fluid reservoir
Front underbody view - turbo diesel model
1 Oil
fitter
2 Sump drain plug 3 Transmission drain plug 4 Electric cooling fan unit 5 Left-hand
driveshaft
6 Intermediate
shaft
7 Bight-hand
driveshaft
8 Front suspension lower arms 9 Front anti-roll
bar
10 Exhaust downpipe 11 Front brake calipers 12
Rear
engine mounting 13 Radiator bottom hose
expert22 fl/ia http://rutracker.org

ib-8 Every 10 000 miles - diesel models
10.1 Checking the condition of a driveshaft gaiter
9 Exhaust system check
1 With the engine cold {at least an hour after tho vehicle has been driven), check ihe 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 oorrosion and damage. Make sure that 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 tho system will usually show up as a black sooty stain in the vicinity ot the leak. 3 Rattles and other noises can often be Iracod 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.
10 Driveshaft gaiter check
I
1 With the vehicle raised and securely supported on stands (see Jacking and vehicle support), turn the steering onto lull lock, then slowly rotate the roadwheel. Inspect the condition ol the outer constant velocity (CV) joint rubber gaiters, squeezing the gaiters to open out the folds. Check for signs ot cracking, splits or detenoration 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 the CV joints themselves by first holding the 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 Ihe driveshaft splines, or a loose driveshaft retaining nut.
11 Idle speed check and adjustment
1 The usual type of tachometer (rev counter), which works from ignition system pulses, cannot be used on diesel engines. A
diagnostic socket is provided for the use of Flat test equipment, but this will not normally be available to the home mechanic. If it Is not felt that adjusting the Idle speed by ear 19 satisfactory, It will be necessary to purchase or hire an appropriate tachometer, or else leave tho task to a Fiat dealer or other suitably equipped specialist, 2 Before making adjustments, warm up the engine to normal operating temperature. Make sure that the accelerator cable is correctly adjusted (see Chapter 4C). 3 The adjustment must be made with all electrical components (Including the cooling fan) switched off. It the fan comes on dunng the adjustment, wait until it switches off automatically before proceeding. 4 The idle adjustment screw Is located on the top of the fuel injection pump (see illustration). To adjust the idie speed loosen the locknut and turn the screw as required then tighten the locknut. 5 On completion switch off the engine.
12 Fuel filter renewal i
1 The fuel filter is located on the bulkhead in the engine compartment. An electrically-operated heater is located between the filter and tlw housing, 2 Position a suitable container under the fuel filler. Loosen tho bleed screw on the top of the filter, then disconnect the wiring from Ihe water sensor and loosen the water drain screw on the bottom of the filter. Allow the fuel to drain completely (see illustration). 3 Tighten the drain and bleed screws, then Use an oii niter strep to loosen the fuel filter {see illustration).
12.2 Loosening the bleed screw on the top of the fuel filter
11.4 fdie speed adjustment 1 Locknut 2 Adjustment screw

2C«1
Chapter 2 PartC:
Diesel engine in-car repair procedures
Contents
Auxiliary drivebelts - removal and refitting See Chapter 1B Camshaft cover - removal and refitting 6 Camshaft oil seal - renewal 7 Camshaft - removal and refitting See Chapter 20 Crankshaft oil seats - renewal 8 Cylinder compression test « 3 Cylinder head - dismantling and overhaul See Chapter 20 Cylinder head - removal and refitting 9 Engine mountings - inspection and renewal 11 Engine oil and fitter - renewal See Chapter 18 Engine oil level check See Weekly checks
Degrees of difficulty
Flywheel * removal, inspection and refitting 10 General information 1 Location of TDC on No 1 cylinder 2 Oil cooler - removal and refitting 14 Oil pump and pick-up tube • removal, Inspection and refitting 13 Sump • removal and refitting 12 Timing belt and covers • removal and refitting 4 Timing belt tensioner and sprockets - removal, Inspection and refitting 5 Valve clearance check and adjustment See Chapter 1B

Easy,
suitable for novice
with Irttle
|| experience g^
FaMy
eesy,
suitable ^
forbeglnnerwilti
some experience ^
Falrtydfficult, ^ suitable
for
competent DIYmechanic ^

Difficult, suitable
for & experienced DIY mechanic ^
Very
difficult,
^ suitable
for
expert
DfY
jR or professional ^
Specifications
General Engine code:' 1698 cc non-turbo engine 176.B3.000 1698 cc turbo engine: Up to 1997 t76.A3.00aor176.A5.000 1997 onward 176.A3.000or176.B7.000 •Note: See Vehicle Identification for the location of the code marking on the engine. Bore 82.6 mm Stroke 79.2 mm Compression ratio: Non-turbo engine 20.5:1 Turbo engine 19:1 Firing order 1-3-4-2
No 1
cylinder location Timing belt end of engine Titling belt tension See text
Lubrication system Oi pump type By-rotor driven from front of crankshaft Outer rotor-to-houslng clearance 0.080 to 0.186 mm Axial clearance 0.025 to 0.056 mm
Torque wrench settings Nm ibf ft Camshaft cover 10 7 Camshaft sprocket 11B 87 Crankshaft sprocket centre bolt 190 140 Cylinder head: Stage 1 50 37 Stage 2 100 74 StageS Angle-tighten a furtfier 90" Stage 4 Angle-tighten a further 90° CySnder head front bolts 30 22 Flywheel 142 105
Fuel
injection pump sprocket 49 36 Inlet and exhaust manifolds 25 18 Sump 10 7 Timing belt tensioner and idler 44 32

2C*2 Diesel engine in-car repair procedures
1 General information
Using this Chapter Chapter 2 is divided Into four Parts; A. 8, C and 0. Repair operations that cart be carried out with the engine in the vehicle are described In Part A, SOHC (B-valve) petrol engines. Part B, DOHC (16-valve) petrol engines and Part C. diesel engines, Part D covers the removal of the engine/transmission as a unit, and describes the engine dismantling and overhaul procedures. In Parts A. 8 and C. the assumption Is made that the engine is installed in Ihe vehicle, with all anciliaries connected If the engine has been removed for overhaul, the preliminary dismantling information which precedes each operation may be ignored.
Engine description Both normally aspirated (non-turbo) and turbocharged diesel engines are fitted to the Punto range. The engines together with their codes are given in the Specifications at the start of lhis Chapter. The engines are water-cooled, single-overhead camshaft. In-line lour cylinder units with cast-iron cylinder blocks and aluminium-alloy cylinder heads. The engine is mounted transversely at the front of the vehicle, with the transmission bolted to the left-hand side of the engine. The cylinder head carries the camshaft which is driven by a toothed timing belt. It also houses the inlet and exhaust valves which are closed by single coll valve springs and run in valve guides pressed into the cylinder head. The valves are operated by cam followers fitted over each valve, and the clearances are adjusted by shims positioned between the followers and the camshaft lobes. The camshaft is supported by four bearings • the end bearings are machined in the cylinder head and the remaining bearings have caps bolted to the cylinder head. The cylinder head contains integral oiiways which supply and lubricate the camshaft and followers and it also Incorporates renewable swirl chambers. The crankshaft Is supported by five main bearings, and endfloat Is controlled by a thrust bearing fitted on the rear main bearing. All diesel engines are fitted with a brake servo vacuum pump dnven from the left-hBnd end of the camshaft. Engine coolant is circulated by a pump, driven by the auxiliary drivebeit. For details of the cooling system refer to Chapter 3. Lubricant is circulated under pressure by a pump, driven from the front of the crankshaft. Oil is drawn from the sump through a strainer, and then forced through an externally-mounted, replaceable screw-on filter. From there, it is distributed to the cylinder head.
where il lubncates the camshaft journals and followers, and also to the crankcase, where it lubricates the main bearings, connecting rod big- and small-ends, gudgeon pins and cylinder bores. Oil jets are fitted to the base of each cylinder bore - these spray oil onto the underside of the pistons, lo Improve cooling. An oil cooler is also fitted to reduce the temp-erature of oil before it re-enters the engine.
Repair operations possible with the engine in the car The following work can be carried out with the engine in the can a) Compression pressure - testing b) Auxiliary drivebeit - removal and refitting (refer to Chapter rej c) Valve clearances • checking and adjustment (refer to Chapter 1B) d) Camshaft cover - removal and refitting e) Tim/ng belt and covers • removal and refitting 0 Timing belt tensioner and sprockets -removal and refitting g) Cylinder head - removal and refitting' h) Camshaft and cam followers - removal end refitting' I) Camshaft oil seal - renewal j) Crankshaft oil seals - renewal k) Flywheel • removal, inspection and refitting I) Engine mountings - inspection and renewal m)Sump • removal and refitting n) Oil pump and pick-up tube assembly -removal, inspection and refitting 'Cylinder head dismantling procedures are detalfed In Chapter 2D, with details of camshaft and cam follower removal. Note: It ts possible to remove the pistons and connecting rods (after removing the cylinder nead and sump) without removing the engine. However, this is not recommended. Work of this nature is more easily and thoroughly completed with the engine on tho bench as described in Chapter 2D.
2 Location of
TDC
on ^ No
1
cylinder ||
General information 1 The camshaft and fuel Injection pump are driven by the crankshaft, by means of sprockets and a timing belt. All three sprockets rotate in phase with each other and this provides the correct valve and injection pump timing as the engine rotates. When the timing bell is removed during servicing or repair, it is possible for the camshaft, injection pump and crankshaft to rotate independently of each other and the correct timing Is then lost.
2 It Location of TDC on cylinder No
1
6 Remove the air inlet ducting as described ft Chapter 4C, Section 2. 7 Remove the heater glow plugs with reference to Chapter 5C. Due to the high compression ratio of diesel engines this Is necessary to allow the engine to be turned by hand. 8 Unscrew the mounting bolts and move the coolant expansion tank to one side for access to the timing covers. Release the hose from the clips on Ihe camshaft cover. 9 Release the toggle clips and remove the upper timing cover (see illustration),
2.9 Removing the upper timing cover