Fiat Punto Petrol Service and Repair Manual: Oct 1999 to July 2003 (Haynes Manuals)

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  • and not forgetting ... We don't just publish car manuals, you know! In addition to the hundred and fifty million car and bike manuals we have sold worldwide, Haynes also produce a wide range of practical books and manuals on subjects such as home DIY, computing, caravanning, cycling and driving tuition - and there's our innovative and highly successful Family Series as well. No matter what the subject, our essential no-nonsense, easy-to-follow approach remains the same.

    We also publish and distribute hundreds of books and DVDs covering general motoring and transport subjects, including all aspects of motorsport, classic cars, sports cars, motorcycling, military vehicles, aviation, model cars, cycling, golf, history and much, much more.

    Check out our website at www.haynes.co.uk to find your nearest stockist or to view or download our online catalogue. All Haynes publications are available variously through car accessory shops, book stores and mail order outlets.

    Haynes Publishing, Sparkford, Yeovil, Somerset BA22 7JJ, England Telephone 01963442030. E-mail sales@haynes.co.uk. Website www.haynes.co.uk

    Sweden 018124016. USA 805498-6703. Australia 6139763-8100

    Illegal Copying It IS the policy of Haynes Publishing to actively protect ItS CopYrights and Trade Marks. Legal action Will be taken against anyone who unlawfully copies the cover or contents of this Manual. This Includes all forms of unauthorised copying including digital , mechanical , and electronic In any form. Authorisation from Haynes Publishing will only be provided expressly and In writing. Illegal copying will also be reported to the appropriate statutory authorities In whichever JUrisdiction the offence takes place.

  • 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 should 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 ca