1999 FIAT PUNTO ignition

Contents
REPAIRS AND OVERHAUL
Engine and associated systems SOHC (8-valve) petrol engine in-car repair procedures Page 2A«1 DOHC (16-valve) petrol engine in-car repair procedures Page 2B«1 Diesel engine in-car repair procedures Page 2C«1 Engine removal and overhaul procedures Page 2D«1 Cooling, heating and ventilation systems Page 3»1 Fuel system - single-point petrol injection models Page 4A«1 Fuel system - multi-point petrol injection models Page 4B«1 Fuel system - diesel models Page 4C»1 Exhaust and emission control systems Page 4D*1 Starting and charging systems Page SA«1 Ignition system - petrol models Page SB«1 Preheating system - diesel models Page 5C>1
Transmission Clutch Page 6»1 Manual transmission Page 7A«1 Automatic transmission Page 7B*1 Driveshafts Page 8*1
Brakes and suspension Braking system Page 9*1 Suspension and steering Page 10-1
Body equipment Bodywork, trim and Fittings Page 11«1 Body electrical systems Page 12*1
Wiring diagrams Page 12»13
REFERENCE
Dimensions and weights Page REF«1 Conversion factors Page REF*2 Buying spare parts Page REF»3 Vehicle identification Page REF«3 General repair procedures Page REF«4 Jacking and vehicle support Page REF»5 Disconnecting the battery Page REF«5 Tools and working facilities Page REF-6 MOT test checks Page REF»8 Fault finding Page REF»12 Glossary of technical terms Page REF»20
index Page REF»24
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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.

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

Roadside repairs 0.7
I Jump starting will get you out of trouble, but you must correct | whatever made the battery go fiat in the first place. There are three possibilities:

t

The battery has been drained by repeated attempts to start, or by leaving the lights on.

2

The charging system (s not working property (alternator drivebelt slack or broken, alternator wiring fault or alternator Itself faulty).

3

The battery Itself is at fault (ehctrotyte low, or battery worn out).
When jump-starling a car using a booster battery, observe the following precautions:
• Before connecting the booster battery, make sure that the ignition is switched off.
• Ensure that all electrical equipment (lights, heater, wipers, etc) is switched off.
• Take note of any special precautions printed on the battery case.
Jump starting • Make sure that the booster battery Is the same voltage as the discharged one in the vehicle.
• If the battery is being jump-started from the battery in another vehicle, the two vehicles MUST NOT TOUCH each other.
• Make sure that the transmission is in neutral (or PARK. In the case of automatic transmission).
Make sure that the lump leads will not come into contact with the fan. drive-belts or other moving parts of the engine.
Start the engine using the booster battery and run it at idle speed. Switch on the lights, rear window demister and heater blower motor, then disconnect the jump leads in the reverse order of connection. Turn off the lights etc.

Roadside repairs 0.9
Puddles on the garage floor or drive, or obvious wetness under the bonnet or underneath the car, suggest a leak that needs Investigating. It can sometimes be difficult to decide where the leak is coming from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the problem lies.
A
Warning: Most automotive oils and fluids aro poisonous. Wash them off skin, and change out of contaminated clothing, without delay.
Identifying leaks
The smell of 0 fluid leaking from the car may provide a clue to what's leaking. Some fluids are distinctively coloured. It may help to clean the car carefully and to park It over some clean paper overnight as an aid to locating the source of the leak. Remember that some leaks may only occur while the engine is running.
Sump oil
Engine oil may leak from the drain plug...
Antifreeze
Leaking antifreeze often leaves a crystalline oeposit like this.
Oil from filter
A leak occurring at a wheel Is almost certainly brake fluid.
Gearbox oil
Gearbox oil can leak from the seals at the inboard ends of the drivoshafts.
Power steering fluid
Power steering fluid may leak from the pipe connectors on the steering rack.
When ail else falls, you may llnd yourself having to get a tow home - or of course you may be helping somebody else. Long-distance recovery should only be done by a garage or breakdown service. For shorter distances. OIY towing using another car is easy enough, but observe the following points: • Use a proper tow-rope - they are not expensive. The vehicle being towed must display an ON TOW sign in its rear window. • Always turn the Ignition key to the ON position when the vehicle is being towed, so that the steering lock is released, and that the direction indicator and brake lights will work. • Only attach the tow-rope to the towing eyes provided.
• Before being towed, release the handbrake and select neutral on the transmission. • Note that greater-then-usual pedal pressure will be required to operate the brakes, since the vacuum servo unit is only operational with the engine running. • On models with power steering, greater-than-usual steering effort will also be required. • The driver of the car being towed must keep the tow-rope taut at all times to avoid snatching. • Make sure that both drivers know the route before setting off. • Only dnve at moderate speeds and keep the distance towed to a minimum. Drive smoothly and allow plenty of time for slowing down at junctions.
Towing
• On models with automatic transmission, special precautions apply(see Chapter 7B. Section 1). If In doubt, do not tow, or transmission damage may result. • The front towing eye is supplied as part of the tool kit stored in the luggage compart-ment. To fit the eye pnse out the plastic cover from the front or rear bumper using a screwdriver, then screw the eye onto the threaded pin as tightly as possible.

A


Warning: To prevent damage to the catalytic converter, e vehicle must not be push'started, or started by towing, when the engine is at operating temperature. Use jump leads (see Jump starting).

1A»1
Chapter
1
Part A:
Routine maintenance & servicing - petrol models
Contents

Air
filter renewal 18 Automatic transmission filter and fluid change 2B Auxiliary dr cmI
and filter renewal 3 Evaporative loss system check 27 Exhaust system check 8 From brake pad check 5 Fuel filter renewal 17 Headlight beam adjustment 23 Hinge and lock lubrication 22
Hose and fluid leak check 7 Idle speed and CO content check and adjustment .11 Ignition system check 20 Introduction 1 Lambda/oxygen sensor check 25 Manifold mounting check 16 Manual transmission oil level check 26 Manual transmission oil renewal .32 Pollen filter renewal 10 Rear brake shoe check 29 Regular maintenance 2 Road test 24 Spark plug renewal 19 Steering and suspension check 12 Timing belt renewal 30 Underbody sealant check 6 Valve clearance check and adjustment 15
Degrees of difficulty
Easy, suitable for ^ novice with little experience ^
Fairty easy, suitable for beginner with ^ some experience
FaMy difficult, ^ sitable for competent jj^ DIY mechanic ^
Difficult, suitable for experienced DIY aJ mechanic ^
Very difficult, ^ suitable for expert DIY or professional ^
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ia.2 Servicing specifications - petrol models
Lubricants and fluids Refer to end ot Weekly checks on page 0*17
Capacities Engine oil (including filter) 1108 cc engine 3.47 litres 1242 cc (8-valvB) engine 3.74 litres 1242 cc (16-valve) engine 2.80 litres Cooling system 4,6 litres
Manual transmission 5-spee d 1.65 litres 6-spee d 1.87 litres Automatic transmission 1.98 litres Power-assisted steering 0.65 Irtres Fuel tank 47 litres Washer reservoir Wllhouthesdllghl washers 2.5 litres With headlight washers 7.0 litres
Engine Olf niter - Champion F107 Auxiliary drivebelt tension 5.0 mm deflection midway between pulleys Valve clearances - engine cold: Inlet Exhaust 1108 cc and 1242 cc (single-point petrol injection) 0.40±0.05mm 0.50±0.05mm 1242 cc (multi-point petrol Injection 0.40 1 0.05 mm 0.45 1 0.05 mm
Cooling system Antifreeze mixture (50% antifreeze) Protection down to -35"C Note: Refer to antifreeze manufacturer for latest recommendations.
Fuel system Engine idle speed . 900 * 50 rpm CO 0.35 maximum Air filter element: 1108 cc engine with 6-speed transmission -... Champion U647 1108 cc engine (Easl Europe) Champion U648 1242 cc engine (60 models) Champion U647 1242
CO
engine (75.85 and Sporting models) Champion U649 Fuel filler: Up to September 1995 October 1995 onwards 1108 cc engine Champion L213 Champion L225 1242 cc engine (60 models) Champion L213 Champion 1225 1242 cc engine {75 models) Champion L203 Champion L225
Ignition system Ignition liming Refer to Chapter 58 Spark plugs: Type Gap* 1108 cc and 1242 cc (6-valve) engines Champion RC9YCC 0.9 mm 1242 cc (16-valve) engine ,... Champion RA4HCC 0.8 mm The spark plug gap quoted Is Diet recommenced by Champion for their specined plugs listed above. If spar* plugs of any other type ere to be fitted, refer to their manufacturer's recommendations. Brakes Brake pad lining minimum thickness 15 mm Brake shoe friction material minimum thickness 2.0 mm
Torque wrench settings Nm itrfft Automatic transmission lluld drain plug 25 10 Automatic transmission fluid sump bolts 4 3 Manual transmission oil drain plug: Stage 1 12 9 Stage 2 Angle-lighten a further 180" Manual transmission oil filler plug 40 30 Roadwheel bolts 86 83 Spark plugs 27 20 Sump drain plug 10 7

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