FIAT 1999-2003 PUNTO Petrol Workshop Repair & Service Manual

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Contents LIVING WITH YOUR FIAT PUNTO Safety first! Introduction to the Fiat Punto Roadside repairs If your car won't start Page Jump starting Page o-a Wheel changing Page O-g Identifying leaks Page 0-10 Towing Page 0-10 Weekly checks Introduction Page 0-11 Underbonnet check pOints Page 0-11 Engine oil level Page 0-12 Automatic transmission fluid level Page 0-12 Coolant level Page 0-13 Brake fluid level Page 0-13 Tyre condition and pressure Page 0-14 Electrical systems Page 0-15 Washer fluid level Page 0-15 Battery Page 0-16 Wiper blades Page 0-16 Lubricants and fluids Page 0-17 Tyre pressures Page 0-18 MAINTENANCE Routine maintenance and servicing Servicing specifications Page 1-2 Maintenance schedule Page 1-3 Maintenance procedures Page 1-6

-~ .---~ .. -- . REPAIRS & OVERHAUL Engine and associated systems SOHC (8-valve) engine in-car repair procedures DOHC (16-valve) engine in-car repair procedures Engine removal and overhaul procedures Cooling, heating and air conditioning systems Fuel and exhaust systems Emissions control systems Starting and charging systems Ignition system Transmission Clutch Manual transmission Automatic transmission Driveshafts Brakes and suspension Braking system Suspension and steering Body equipment Bodywork and fittings Body electrical systems Wiring diagrams REFERENCE Dimensions and weights Conversion factors Buying spare parts Vehicle identification General repair procedures Jacking and vehicle support Disconnecting the battery Tools and working facilities MOT test checks Fault finding Glossary of technical terms Index ------=--=--== Contents Page 2A-1 Page 28-1 Page 2C-1 Page 3-1 Page 4A-1 Page 48-1 Page 5A-1 Page 58-1 Page 6-1 Page 7A-1 Page 78-1 Page 8-1 Page 9-1 Page 10-1 Page 11-1 Page 12-1 Page 12-20 Page REF-2 Page REF-3 Page REF-4 Page REF-4 Page REF-5 Page REF-6 Page REF-6 Page REF-7 Page REF-9 Page REF-13 Page REF-20 Page REF-25

0-4 Advanced driving Advanced driving Many people see the words 'advanced driving' and believe that it won't interest them or that it is a style of driving beyond their own abilities. Nothing could be further from the truth. Advanced driving is straightforward safe, sensible driving - the sort of driving we sh ould all do every time we get behind the wheel. An average of 10 people are killed every day UK roads and 870 more are injured, some usly. Lives are ruined daily, usually ause somebody did something stupid. ing like 95% of all accidents are due an error, mostly driver failure. mes we make genuine mistakes - _ ..... .",., does. Sometimes we have lapses of on. Sometimes we deliberately For many people, the process of 'learning to drive' doesn't go much further than learning how to pass the driving test because of a common belief that good drivers are made by 'experience' . Learning to drive by 'experience' teaches three driving skills: o Quick reactions. (Whoops, that was close!) o Good handling skills. (Horn, swerve, brake, horn). o Reliance on vehicle technology. (Great stuff this ASS, stop in no distance even in the wet...) Drivers whose skills are 'experience based' generally have a lot of near misses and the odd accident. The results can be seen every day in our courts and our hospi'lal casualty departments. Advanced drivers have learnt to control the risks by controlling the position and speed of their vehicle. They avoid accidents and near misses, even if the drivers around them make mistakes. The key skills of advanced driving are concentration, effective all-round observation, anticipation and planning. When good vehicle handling is added to these skills, all driving situations can b approached and negotiated in a saf methodical way, leaving nothing to chance. Concentration means applying your mind' safe driving, completely excluding anyth that's not relevant. Driving is usually the m dangerous activity that most of us underta in our daily routines. It deserves our' attention. Observation means not just looking, b seeing and seeking out the information fou' in the driving environment. Anticipation means asking yourself what happening, what you can reasonably expec to happen and what could happe unexpectedly. (One of the commonest woro used in compiling accident reports 'suddenly' .) Planning is the link between seel~ something and taking the appropria' action. For many drivers, planning is missing link. If you want to become a safer and more s driver and you want to enjoy your driving contact the Institute of Advanced Motons www.iam.org.uk, phone 0208 996 96 write to lAM House, 510 Chiswick Hig London W4 SRG for an information pa

- " Working on your car 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 exhaust 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 always supplement the lack with axle stands, or use drive-on ~sic~§~~~L)) 'amps. l(( Never venture under a car which is only supported by a jack. • Take care if loosening or tightening high- 'orque nuts when the vehicle is on stands. 'litial loosening and final tightening should be done with the wheels on the ground. Fire • Fuel is highly flammable; fuel vapour is explosive. • Don't let fuel spill onto a hot engine. • Do not smoke or allow naked lights ncluding pilot lights) anywhere near a · ehicle being worked on. Also beware of creating sparks electrically or by use of tools). • Fuel vapour is heavier than air, so don't .. ork 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 'epairing or modifying the vehicle wiring. • Keep a fire extinguisher handy, of a type o.(litable for use on fuel and electrical fires. Electric shock L, f? • Ignition HT oltage can be =angerous, -'!Specially to t'" --' -eople with heart f = 'oblems or a ::.ace maker. Don't ork on or near the ) ~ -:'lition system with f '\ '" € engine running or ) J \ ~ \ -e 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 oil- 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 such components it is safest to assume that they contain asbestos. 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, wristwatch 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. ------------------------- - Safety first! 0-5 Special hazards Hydrofluoric acid • This extremely corrosive acid is formed when certain types of synthetic rubber, found in some a-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. If it 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 steering 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 other part of the body • to injector spray; the fuel can penetrate the skin with potentially fatal results. 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 tools 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.

0-6 Introduction A five-speed manual transmission is fitted to all models except the Sporting and Speedgear versions. Sporting models are equipped with a six-speed manual transmission, whereas Speedgear models utilise a CVT automatic transmission which can also be operated manually with six-speed or seven-speed sequential gear selection. A wide range of standard and optional equipment is available within the Punto range including central locking, electric windows, an electric sunroof, an anti-lock braking system with traction control and supplementary restraint system. For the home mechanic, the Punto is a straightforward vehicle to maintain, and most of the items requiring frequent attention are easily accessible. Your Fiat Punto Manual Fiat Punto Dynamic The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs, it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The new Fiat Punto range was introduced in October 1999 in 3-door and 5-door Hatchback layout. Although mechanically similar in some areas to the previous Punto range, the new version has been completely redesigned with significant improvements in comfort, handling and performance. The Punto range is available with two sizes of petrol engines, and a turbocharged or normally-aspirated diesel engine. Covered in this manual are the popular 1.2 litre SOHC (a-valve) and DOHC (16-valve) petrol units. Both engines feature multi-point fuel injection and are equipped with an extensive range of emissions control systems. The engines are of a well-proven design and have been used extensively in a range of Fiat vehicles. Fully-independent front suspension is fitted, with semi-independent torsion beam suspension used at the rear. Electrically-operated power steering is standard equipment on most models and is available as an option on others. The manual has drawings and descriptions to show the function of the various components, so that their layout can be understood. Then the tasks are described and photographed in a clear step-by-step sequence. References to the 'left' or 'right' are in the sense of a person in the driver's seat, facing forward. Acknowledgements Thanks are due to Draper Tools Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual. Fiat Punto Speedgear We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for los~ damage or injury caused by any errors in, or omissions from, the information given. _. ~ .. _- - -- = .. -- .. ---. -- . .., ..... ---- ~

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 D If it's a model with automatic transmission, make sure the selector is in P or N. D Open the bonnet and make sure that the battery terminals are clean and tight. D 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. Roadside repairs 0-7 If your car won't start even though the starter motor turns as normal D Is there fuel in the tank? D 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 connectors and HT leads. A Check that the spark plug HT leads are B '.. and at the ignition coils. securely connected at the spark plugs ... C Check the condition and security of critical wiring connectors such as those at the ignition coils . .. Check that electrical connections are secure (with the ignition switched off) and spray them with a water dispersant spray like WO-40 if you suspect a problem due to damp. D .. . and camshaft position sensor. E Check the condition and security of the battery terminals.

o-a Roadside repairs Jump starting When jump-starting a car using a booster battery, observe the following precautions: V Before connecting the booster battery, make sure that the ignition is switched off. V Ensure that all electrical equipment (lights, heater, wipers, etc) is switched off. V Take note of any special precautions printed on the battery case. Connect one end of the red jump lead to the positive (+) terminal of the flat battery ----------~ V Make sure that the booster battery is the same voltage as the discharged one in the vehicle. V If the battery is being jump-started from the battery in another vehicle, the two vehicles MUST NOT TOUCH each other. V Make sure that the transmission is in neutral (or PARK, in the case of automatic transmission). Connect the other end of the red lead to the positive (+) terminal of the booster battery. r----- r- ~-----------------------------~ - . _ of trouble, but you must correct ;; Jump starting will get you out MIN whatever made the battery go flat in the first place. There are three possibilities: 1 The battery has been drained by repeated attempts to start, or by leaving the fights on. 2 The charging system is not working properly (alternator drivebelt slack or broken, alternator wiring fault or alternator itself faulty). 3 The battery itself is at fault (electrolyte low, or battery worn out). Connect one end of the black jump lead to the negative (-) terminal of the booster battery Connect the other end of the black jump lead to a bolt or bracket on the engine block, well away from the battery, on the vehicle to be started. I Make sure that the jump leads will not come into contact with the fan, drive- belts or other moving parts of the engine. 6 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. -_ •.

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FIAT 1999-2003 PUNTO Petrol Workshop Repair & Service Manual

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