Fiat Punto Service and Repair Manual A K Legg tae mimi and Spencer Drayton Models covered (9251-256-1AC1) Fiat Punto Hatchback, including Selecta and special/imited editions Petrol engines: Diesel & Turbo-Diesel engi 1 litre (1108 co) and 1.2 litre (1242 cc) 1.7 litre (1698 cc) Does NOT cover 1.4 litre 1372 co) or 1.6 litre (1581 cc) petrol engines, or Cabriolet © Haynes Publishing 1999 ‘A bockin the Mayes Service and Repalr Manual Series [Al rights reserved No part of this book may be reproduced or trenemittod In any form or by any means, electronic or mechanical, Including ‘hotocopying, recording or by any information storage or retival system, ‘without permission in writing from the copyright holder. san + e5a00 2517 ‘British Library Cataloguing n Publication Data ‘A etlalogue record for hia Books avalal em the Blah tary Pants by JM Haynes & Co Lt, Sparkford Nr Yeowl, Somerset 8422 7), England Haynes Publishing Spero, Nr Yeo, Somerset BA22 7A, England Haymes Mort America Ine 261 Laurance Deve, Newry Park Calta 91220, USA Editions Haynes $4. Tour Aurore a Diese 2,18 Pace des Refit, 82975 PARIS LA DEFENSE Cedex. France Haymes Publishing Nordiska AB Box 1504, 751 45 UPPSALA, SwedenContents LIVING WITH YOUR FIAT PUNTO Introduction Page Satety fist Page 0*6 Roadside repairs if your ear won't start Page 06 Jump starting Page _0*7 Wheel changing : Page 0°8 identifying leaks Page 0-9 Towing Weekly checks Introduction Page_o+10 ‘Underbonnet check points Page 0+10 Engine of level Page 0-11 Coolant level Page 0-12 Brake fuid level Page 0-12 Power steering fuid level Page 0-13 ‘Automatic transmission fui level Page 0-13 ‘Screen washer fluid level Page _0+43 ‘Tyre condition and pressure Page 0-14 Wier blades Page 0-18 Battery Page _0+18 Bulbs and fuses Page 0-16 Lubricants, fluids and tyre pressures Page 0°17 MAINTENANCE Routine maintenance and servicing Fiat Punto petrol models Page thet Maintenance schedule Page 1A: Maintenance procedures _ Page 1As6 Fiat Punto diesel medals Page 18-1 Maintenance schedule : Page 1B+3 Maintenance procedures Page 165Contents REPAIRS AND OVERHAUL Engine and associated systems Petrol engine in-car repair procedures Diesel engine in-car repair procedures Engine removal and general overhaul procedures 2Be4 244 Cooling, heating and ventilation systems ae Fuel system - single-point petrol injection 44 Fuel system - multipoint petrol injection - 4-1 Fuel system diesel z ace Emission control systems - 40-1 Starling and charging systems Bast ignition system - petrol models ‘Bet P reheating system - diesel modals 50s Transmission Clutch Page 6+ Manual transmission a Page Ae ‘Automatic transmission Page 78-1 Driveshafts ae Page 8-4 Brakes and suspension Braking systern Page 9+ Suspension and seeing E Page 10%1 Body equipment Bodywork and fitings Page tte Body electrical systems - Page 12+1 Wiring diagrams Page 12613 REFERENCE Dimensions and weights Page REF+1 Conversion factors 7 - Page REF+2 Buying Spare Parts and Vehicle Identification Page _REF*3 General Repair Procedures ~ Pago REF+4 Jacking and Vehicle Suppor Page REFS Toois and Working Facilities Page REF*6 MOT Test Checks Page REF¢S Fault Finding Page REF*12 Glossary of Technical Terns 7 Page REF*20 Index Page REF+24oa Introduction “Tne Flat Punto range was introduced in March 1994 with 1108 ee, 1242 ce and 1372 ee pettol engines and 1698 ce diasel engine. At frst, models were only valable in 5-doar Hatenback form, however 3 door versions followed in May 1994 and Cabriolet and Automatic Versions in June 1998, At the same time a Turbo diesel mode! was launched. Power-assised steering and ABS were offered as options in October 1884, and the 6-speed §5SX and normally-aspated diesel followed in dune 1995, Flat Punto 88 SX 5-door The Fiat Punto Team Haynes manuals are produced by dedicated and enthusiastic people working in close co-operation. The ‘team responsible for the creation of this book included! Authors ‘Andy Long Spencer Drayton Sub-editor Carole Turk: Editor & Page Make-up Steve Churchill Bob Jex Workshop manager Paul Buckland Photo Scans Paul Tanswell Steve Tanswell Cover illustration & Line Art Roger Healing Wiring diagrams Matthew Marke We hope the book will help you to get the maximum enjoyment from your car. By carrying out routine maintenance as described you will ensure your car's reliability and preserve its resale value. [Al engines covered inthis Manual are fited with single-overhead: camshaft engines, ard all models have fly independent front and rear suspension. The distinguished ines of the bodywork together withthe high level rear bghting have made the Fiat Punto a very popular smal car. Provides that regular servicing is carted out In accordance withthe rmanutacture's recommendations, the Fat Punto should prove reliable lang economical. Te engine compartment is wel-designed, and most ofthe tems needing frequent attention ae easly accessible, Fiat Punto 55 S3-door, Your Fiat Punto Manual ‘The aim of tis manual s to help you get the best value from your vehicle. Itcan do $0 in several ways, It ean help you decide what work must Ge done (even should you choose to gett dane by @ garage), provide information on routine maintenance and servicing, and give 8 Togical course of action and diagnosis when random faults occur However, itis noped that you wil use the manual by tacking the work yourslt.On simpler obs, may even De quicker than booking the ear into a garage and going there twice, to leave and collect it. Perhaps ‘most important. 2 let of money can be saved By avoiding te costs a ‘gavage must charge to cover Is labour and overneads. ‘Tho manual has Grawings and desceptions to show the function of the various components, 60 thatthe layout can be understood. Then the tasks ara described and photographed in a clear step-by-step Acknowledgements Thanks are due to the Champion Spark Plug Company, who supplies the ilustrations of various spark plug conations. Thanks are also due to Sykes-Pickavant Limited, who provided some of the ‘workshop tools, and to al those people at Sparktord wha helped in the production ofthis manual We take great pride in the accuracy of information given inthis ‘manual, but vehicle manufacturers make alterations and design ‘changes during the production run ofa particular vehicie of which they do not inform us. No lability can be accepted by the authors ‘or publishers for loss, damage oF injury caused by any errors in, oF ‘omissions from, the information given.Safety first! o-s \Wesking on your eat can be dangerous “This page shows just some ofthe potential fisks and hazards, with tne aim of eating & Safey-conscious attitude General hazards Scalding + Don't remove the radiator or expansion tank cap while the engine fs Pot, + Engine oh, automatic transmission fd or power steering Muld may also be dangerously hot i the engine has recently been running Burning + Beware of burs fom the exhaust system {and from any part of the engine, Brake discs and drums can also bo extremely hot Immediately ater use, Crushing + Wen working under or near a raced vehicle, always ‘supplement the jk with ae Stands, or use onve-on ramps. Never venture under @ car which Is only supported by a jack. + Take care loosening or tightening high- torque nuts when the vehicle is on stands. Inia loosening and final tightening should be done withthe whoels on the ground Fire + Felis ohyfonmable: ue! vapours oposre 2 Gott onto a ht engine * Do'ot smoke or alow naked igs Gockcing pet igs) ehyahere ner 8 ents Sang wowed or No baw of creating spare tetectaly or by use of ol) *Fetvapbr een ano; 9 dont ‘onon te layer win evi ovr mr napecton Trncler cause’ ire san eect Gerad or herceke Tike ae ten repaeng oF mootving te vnie wiring “eons re ening harcy oa be ‘ate or so ou! and eal Electric shock signton HT ‘ ‘olagecan bey corer copecayio peosie min heat” 3p prole ora pacemaker Dorit fork on or nea the ‘gato sytem ah Beeegie nan or the gon eve on a J + Mains votage is also dangorous. Make ‘sure that any mains-operated equipment is ‘corectly earthed, Mains power porns should be protected by a resiual curent device (FC) cicut breaker Fume or gas intoxication + Exhaust fumes are poisonous; they offen Eantan carbon monoxide, whch is rap fatal inhale. NNover run the engine in a confined space such as a garage withthe doors shut + Fuel vapours also posonous, as are the vapours from some ‘leaning solvents and paint thinners, Poisonous or irritant substances + Avoid skin contact with battery acid and ‘with any Tua, uid or lubricant, especialy antireeze, brake hydraulic fui and Diese! fuel. Don’ syprion them by mouth I such a substance s swallowed oF gets ito the eyes, ‘eek macical ecvice, + Prolonged contact with used engine oil can ‘cause skin cance. Wear gloves or use a barrie roam i necessary. Change out a ot soaked clothes and do not Keep oly rags in your pocket, * Air condlioning refrigerant forms a poisonous gas f exposed to araked lame {including a cigarette}. can also cause skin buras on contact, Asbestos + Asbestos dust can cause cancer inhaled ‘or swallowed. Asbestos may be found I gaskets and in beake and eluteh linings ‘When dealing with sucn components is safest to assume that they contain asbosto. Special hazards Hydroftuoric acid + Tis extremely coos aid is ome ‘when crn ype fey bbe found Inoore Ovinge,o vol ol hoes tee txpoved to orporatres above 800° The TUbber changes ro a cared + schy Subetance comtanng the acd. Once formed, the ac romaine Sangerous for yar It ets onto teak, ray bo necessary fo Snovtate ino im concored = non dealing witha verte which has Suffered afr, or wth conporentssaveged trem auc a veil, wear rolocve gives treed tem aher vse The battery + Batteries contain sulphuric ala, wien attacks clothing, eyes and skin Take care wen topping-up or carrying the batten + The hydrogen gas given off by the battory is highty explosive. Never cause a spark or alow a naked light nearby. Bo careful when Connecting and ciscannecting Dattary charges or jump leads. Air bags “+ Airbags can cause injury if they go oft accidental. Take caro whan removing the Steering wheel and/or facia, Special storage Instructions may apy Diesel injection equipment + Diesel injection pumps supply fuel at very high pressure. Take care wnen working on tho fue injectors anc fuel pipes. Warning: Never expose the hands, face or any other part of the body 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 barr cream to protect your hands when necessary + Do get someone to check periodically ‘hat all is well when working alone on the vehicle. * Do keep loose clothing and longhair well ‘ut of the way of moving mechanical parts. + Do remove ings, wristwatch et, before Working onthe vehicle - especial the ‘lctical syeton, + Do ensure that any ling or jacking ‘equipment has a safe working toad rating ‘adequate forthe job, DON'T + Dori attempt to lit 2 heavy component \which may be beyond your capably - get assistance * Don't rush to finish job, or tke unverified shortcuts. * Don't use a-fting tools which may sp ‘and cause Ijry * Don't leave too or pars ving around ‘where someone can trp over them. Mop Up oll and fuel splls at once * Don't allow children or pots to playin or near a vehicle being worked on.os Roadside repairs The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You wil 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 1 IT it's a model with automatic transmission, make sure the selector isin 'P” or 'N (Open the bonnet and make sure that the battery terminals, are clean and tight. 2 Switch on the headlights and try to start the engine. ithe headlights go very dim when you're tying to start, the. battery is probably fat. Get out of trouble by jump starting (ee next page) using a friend's car. Check the spark plug HT leads are securely connected by pushing them ‘onto the plugs (petro! engine made's) connected I CCheck that electrical connections are secure (withthe ignition switched off) and spray them with @ water depersant spray ike WOO it you suspect a problem dus to dame Check that wiring to the engine compartment components is secutely If your car won’t start even though the starter motor turns as normal Is there fue! in the tank? 5 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 ike those shown in the photos. Pay special attention to the ignition coil wiing connector and HT leads. (Note that Diesel engines don't normally suffer from damp.) Check the securty and condition of the battery terminalsRoadside repairs 0-7 BONNEY 207 starting wit got you out Sermon, | MAINT Sorc es Soe ote th tary hn toon ied 97 Pcetnmt cates merle Fs rig mst ct crt Te arr ras Scere vere alternator itself faulty). ‘The battory itso is at fault When jump-starting a car using a booster battery, observe the following procautions: ¥- Betore connecting the booster battery, make sure thatthe ignition is switehed of, ¥ Ensure that all electrical equioment {ights, neater, 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. Ifthe battery 's being jump-started ‘rom 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), BFF Connect one end ofthe red jump lead to ‘he postive (+ torminal ofthe fat battery BP Connac the other end af the red lead to the postive (+ terminal ofthe Booster battery, Be] Connect one enc ofthe biack jump lead to the negative () terminal ofthe Booster battery ‘Connect the athe’ end ofthe back jump load to a bot or bracket on the engine black, well away from the battery, an the vehicle to be started Make sure that the jump leads will ot ‘come into contact withthe fan, crive- bets or ather moving parts oF the engine. ‘Star the engine using the boaster battery and run iat ole eee, Switen fn tne lights, rear window demistar arc heater blower motor, ten dsconnect the jump leads inthe reverse order of connection. Turn off he lights etcos Roadside repairs Wheel changing Some of the details shown here will vary ‘cording to model. For instance, te location (ofthe spare whoel ane jack is nat the same ‘on all cars, However, the basic principles apply to all vehicles, Preparation When a puncture occurs, stop as soon as itis safe todo so. Park on frm level ground, possible ‘and well out of the way of ater trafic. 1 Use hazard warring ights i necessary Changing the wheel The spare wee ane too ict te Jack are stored inthe luggage compartment Beneath the floor coverng, Unscrew the conta plastic rut to remave the to! holder. | Tur the jack handle clockwise untl the viel raised clear ofthe ground 7 Securely tighten the whee bolts inthe sequence shown. Stow the punctured wineel and tools back in the luggage Compartment ana secure them in position, Note that the wheel bolts should be siackaned and retightened tothe specified torque atthe earliest possible opportunty. Note: When using the space-saver spare whee! do not exceed 50 moh (80 kon) Warning: Do not change a wheel ina situation where you risk being hit by ‘other trafic. On busy roads, try to stop in a lay-by ora gateway. Be wary of passing tratic while changing the wheel ~ it is easy to become distracted by ‘the job in hand. you have one, use a waming tangle to ‘lor other drivers of your presence. ‘Apply the handbrake and engage frst o reverse gear (or Park on mados with ‘automatic transmission, Unscrew the wheel Dols, withdraw the trim and remove the wheel [1 Chook the whee! ciagonay opposite the ‘one being removed ~ a couple of large Stones wl do for this, 1] the ground is sof, use a lat piace ot wood fo spread the load under the jack Locate the jack under the Wangular mare fon the sil next to the wheel to be changed, on tem ground Fit the spare wheel on the pins, and Screw in the bolts. Lightly tighten the Dots with the whoslorace ther lower the Vehicle to the ground Finally... 5) Remove the whee! chocks, Stow the jack and 015 inthe corect locations inthe car Check the tyro pressure on the wheel just fied. If itis tow, orf you don't have a prossure gauge with you, dive siowy to the nearest garage and infate the te 0 the right pressure, Have the damages tyre or whee repaired a 8000 as posse,Roadside repairs o-9 Puddles on the garage foor or drive, or obvious wetness “under the bonnet or lindemeath tne ca, suggest a lek that esos investigating, can sometimes be cfu to (decide where the leak fe coming from, especially it the engine bay is very diy ‘ready. Leaking olor fuid can also be biown Fearwards by the passage of air under the ca. Giving a false impression of whore the problem lis ‘Sump oil Ga Engine oll may leak fram te drain oh, Antifreeze Lanking antiteeze often leaves a crystaline epost ike tis. Warning: Most automotive oils 3nd fluids are poisonous. Wash {them off skin, and change out of ‘contaminated clothing, without ‘olay. ‘or fom the base of the ol filter. Brake fluid ‘leak occurring ata whee! almost certainly brake fu Identifying leaks OTE 7 erat of 2 td leaking om the car ney provide HINT ote 1 wnat toting. Some ads or cstinctvey colored. may hep t0 clean the car and | to,park it over some clean paper as an aid to locating the source of the leak. Remember that some leaks may only ‘occur while the engine is running. ‘Gearbox ol can leak from the seals a the inboard ends ofthe driveshafts, Power steering fluid Power steering fuid may leak from the pipe ‘connectors on the steedng rack When all else fais. you may find yourselt having to get a tow home ~ or of course you may be helping somebody ese. Long-aistance fecovery should only be Gone by a garage or breakdown service, For shorter distances, OY ‘owing using another car eaey enough, But ‘bcerve the following points: T1Use a proper tow-rope ~ they are not expensive. The vehicle being towed must tisplay an ‘ON TOW’ signin its ear window CiAlways turn the ignition key to the ‘on position when the vahice is being towed, so {hat the steering lock s released, and thatthe ‘rection incioator and brake lights wil work. “Only attach the tow-rope to the towing yes provided, Before being towed, release the handbrake {nd geleet neutal on the transmission, Note that greater-than-usual pedal pressure will be required to operate the brakes, since the vacuum servo units only ‘operational vith the engine running. ‘On models with power steering, greater ‘han-usual storing efor wil also be required E The driver of the car Boing towed must Keep the tow-rope taut at all mes to avoid snatohing Make sure that both crvers know the route before setting of Only orive at moderate speeds and keep the distance towed to a minimum. Drive ‘smoothly and allow plenty of tee for slowing ‘down at junctions. On models nith automatic transmission, special precautions apply. if in doubt, do not tow, or transmission damage may rest. Towing The front towing oye is supplied as part of ‘the toolkit stored in the luggage compartment. ‘Toft tha eye prise out the plastic cover from the font or rear bumper using a screwdriver, ‘then screw the eye onto the threaded pin as tightly as possible Fitting the tool kt towing eyeo10 Weekly checks Introduction There are some very simple checks which ‘eed only take a few minutes to cary eu, but which could save you a lot of convenience ‘and expense, These “Weekly checks" requir ne great aki ‘or special tools, and the small amount of me they take to perform could prove to be very wel spent, for example Keeping an eye on tyre condition and pressures, will not only help to stop them wearng out prematurely, ut could aso save your ite Many breaksowns are caused by electical problems, Battery-relaed faults are parveuarly ‘common, and a quick check on a regula basis wil often prevent the majorty ofthese, Underbonnet check points iF your car develops a brake fluid leak, the frst time you might know about itis when Yyour brakes don't work properly. Checking ‘he level regularly wil give aevance warming of this kind of problem, I the ol oF coolant levels run low, the cast of reparring any engine damage vill be far treater than theig the lea, for example, 41.1 litre petrol A Encino i ve! psi B Enoine of er cap C cova exoanson tank Dera fu reseror E Soon washer fuid reser F Betery 41.2 litre petrot A Enoine of ives cipstick B Engine ot titer cap © Coolant excansion tank D Brake tuid reservoirWeekly checks o-1 41.7 litre Turbo diesel A Engine ol level oipstick B Engine oi filer cap © Cooiant expansion tank D erate fuid reservoir E Screen washer fia reservoir F Battery G Power steering fuis reservoir Engine oil level Before you start 7 Make sure that your cars on love! ground, 1 Check the oll evel before the car is crven, brat least 5 minutes after tne engine has bean switched off If the oil level is cracked | immeciately after diving the venice, some of the of wi | . Yomsin'in the oppor engine | The dipsick is brit coloured for easy) Using a clean ag oF paper towel remave components, resulting in an inaccurate identification (eae “Underbonnet check © allo from the dipstick Insert the clean reading on the dipstick! points), Withdraw the dipstick (petrol dipstick into the tube as far as twill go, engine shown) nen withdraw it again. The level should be between the upper and iower marks The correct oil ‘Modem engines place great demands on their ‘ll It is very important thatthe comect ol for Your cars used (See “Lubricants, fuds and tyre pressures") Car Care @ Ifyou have to add ol requenty, you should check whether you have any oll leaks. Piace ‘some ciean paper under the car overnight, land cheek 10" stains in the moxning. I there {are na laaks, the engine may be burning oi (eee *Faut Fining”, ‘@ Always maintain the level between the it more oll 6 needed, remove the oil filer 1dded through the filer cap Upper and lower dipstick marks (see photo 2. cap from the top of the engine (petrol “F aperture (diesel engine shown). Add the Ifthe love is to0 low, severe engine damage engine shown fa litte ata time, checking the level on may oocur. Oi sea failure may result if the the dipstick often. Using a funnel wil hop to engine is overtiled by adding too much ol reduce spilage. Don't overil (see “Car Care")on12 Weekly checks pressure cap when the engine ‘is hot, as there is a very great Coolant level ‘isk of sealing. o not leave Waring: 00 NOT attempt to A remove the expansion tank open containers of coolant about, a poisonous thatthe coolant level is betwoen IN" and *MAX" marks. If topping up is necessary, wat until the engine 1¢ Cold. Stowly unscrew the expansion tank cap to rlaase any pressure present tne cooling ‘system, and remove I (petra engine shown}, the Car Care ‘© Aading coolant should not be necessary fon a reguiar basis. if frequent topping-up Is requied, iis tkely there a lak: Check the radiator, all hoses and joint faces for signs of Staining or wetness, and rectly as necessary, (On diesel engine models, the coolant expansion tank's a different shape, Dut the same procedure apolies 2s fr petal {engine models (see photo 1). The "MIN" and MAX" marks appear onthe side ofthe tank nearest te engine @ It's important that antiroeze is used inthe cooling system al year round, not just during the winter months. Don't top-up with water alone, as the antireeze will became too silted ‘Add a mixture of water and antifreeze to the expansion tank unl the coolant level Is up to the "MAX" mark (ostrol engine shown). The *MIN" ang "MAX" marks appear (on the tank below the filer neck. Brake fluid level A Warning © Brake fluid can harm your eyes and will damage painted ‘surfaces, s.use oxtrome caution hon handling and pouring i. © Do not use fluid that has ‘been standing open for some time, as it absorbs moisture {rom the air, which can cause a dangerous’ loss of braking effectiveness. +. Moke sure that your car is Fine otras HINT] + The tid ievel in the | reservoir will drop slightly as the brake pads wear down, but the uid level must never be allowed to drop below the “MIN" mark. Safety First! (©: the reservoir requires repeates topping- up this is an inaleation of a thid leak ‘Somewhere in the system, which should be investigated immediately, @ if ateak is suspected, the car should not be drivon until the braking system has been Checkod. Never take any risks where brakes The "MIN" and "MAX" marks are Indicated on the side ofthe reservoir. The fluid level must be kept between the marks ata times, Unscrew the reservoir cap and carefully Iitit out of postion, taking care not to damage the level sich feat.nspect the reservoir if the fluid is dirty the hydraulic system should be drained and relied (eee Chapter 1A oF 18}. 2D topaing-up is necessary, frst wine Clean the area around the filer cap to provent cit entering the hydraulc system Corey acd fc taking care nt si itonto the surounding components, Use only the specified fluc: mixing diferent types can cause damage tothe system. After topping-up to the correct level, securely ret the cap and wipe of any spi uid,Weekly checks o«:s Power steering fluid level Before you start: oa For the check to be] Safety First! T 1. Park tha vehicle on level ground Securate, the steering must | @ The need for frequent topping-up indicates Set the steering wheel sraight-ahess. fot be tumed once the | 2 leak, which should be investigated © The engine snould be tured oft ‘engine has been stopped. immediately. Dip the fluid with the reservoir ‘Q When topping-up, use the spectied type Ne ef the bukheas in te enging © capidpsick (do not screw the capinto Do had and do not overll the reser. Samparmont, Wipe loan’ tho. ero postion) When the engine cou, the When te lovel fs cect, securely vf around he ener fer cap then unscrew uid eel shou be up tote MIN mark, tha cap fom thereseror titer hott shoul bon the "MAK mak Automatic transmission C-a — : E=—o50 fluid level Before you start: =o 3 Pak te vehicle on eve round, and wear apply the handbrake femly. Let te engine id, and select "Por "N Safety First! ‘Open the bonnet. Withdraw the If topping up is necessary, add the © The “need for frequent topping-up 1 wansmission dipstick, and wine it with a © spectted fluc via the apstck tube, using indicates a leak, which should be investigated jaan non-lty rag. Re-nser the dipstick a funnel th a fine mesh fer. Take great immodiatey, fully, whoa again and road the fluid evel, care not to introduce dr into the transmission It should be betwaen the two level marks. “There ae two sets of marks. Uso the ‘COOL’ marks if the transmission ie cold (20° to 40°C) forthe HOT marks fits ht (60 to 80°C), Screen washer fluid level ‘Screenwash adattives not only Keep the swingereen clean during foul weather, they also prevent the washer system freezing in cold weather - wich is when you are kel to need it ‘mast, Don't top up using plain water as the Soteenwash will Become too diluted, and wil freeze during cold weather. On no account coolant antifreeze in the washer system - {his could dscolour or damage paintwork ‘The screen washer fluid reservoir i ©) When topping-up the reservoir, add a located on the left-hand side of the © screenwash additive in the quantities engine compartment, next to the battery. recommenced on the bottle, Use of @ Then prise off the cap and pul out the funnel wil prevent spillage, telescopic filer.oa Weekly checks Tyre condition and pressure It is very important that tyres are in good condition, and atthe correct pressure - having tyre faite at any speed is highy dangerous, ‘Tyre wears infuencee by ctiving style= harsh braking and acceleration, or fast comering, will all produce more rapia tyre wear, As a {goneral rule, the front tyres wear out faster than the rears. interchanging the tyes from ‘ont to rear ("rotating te tyes) may result n mors even wear. However, if this i completely effective, you may have the expense of eplacing al four tyres at once! Remove any nails or stones embedded inthe tread before they penetrate the tyre to cause etiaton. i removal of anal does reveal that Tread Depth - visual check ‘The orignal tyres have troad wear safety bands (8), which will appear when the tread depth reaches approximately 1.6 mm, The band postions are indicated by a triangular mark on te tyre sicewal (A), the tye has been punctured, ret the nal ¢o that is point of penetration is marked. Then Immediately change the wheel, and have the tyre repaired by a tyre dealer Regularly check the tyres for damage inthe form of cuts or bulges, especially in the sidewalls. Periogicaly romovo the wheels, {and clean ay dirt or mud from the inside anc ‘outside surfaces. Examine the wheel rns for Signs of rusting, corrosion or otner damage, Light alloy wheels are easily damaged by "kerbing* whilst parking: steel wheels may aso become dented or buckled. Anew whee! is very often te only way to overcome severe damage. Alternatively, tread wear can be ‘monitored with a'simple, Inexpensive device known as a tread depth incicator gauge. Tyre tread wear patterns Now tyres should be balanced when they are fited, but it may become necessary 10 re= Balance them as they wear, ori the Balance ‘weights fitted to the wheel rim should fl of Unbalanced tyres will wear more quickly, 8 wil the steering and suspension components, Wheel imbalance is normally signified by Vibration, particularly at a certain speed (typically around 60 mp). If this vibration is felt oniy through the steering then itis tkely that just the front whole need balancing. I however, the vibration is felt through the wiole car, the rear wheels could be out of balance. Wheel balancing should be caried ‘out by a tyre dealer or garage, Tyre Pressure Check Check the tyre pressures regulary with the tyres cold. Do not adjust the tyre pressures immediately after the vehicle has been used, oran inaccurate setting wil resut ‘Shoulder Wear Underinflation (wear on both sides) ‘Under-inflation will cause overheating ofthe tyre, because the tyre wil flex too much, ans the tread wil not st correcty onthe road surtace. Ths wil cause a loss of grip and ‘excessive wear, not to mention the danger of ‘sudden tyre fare due to heat build-up, (Check and acust pressures Incorrect wheel camber (wear on one side) opair ar renew suspension parts Hard comering Reduce speed! Centre Wear ‘Overinftation (Over-inflation wil cause rapid wear of the centre part of the tyre tread, coupled with Feduced grip, harsher ride, and the danger of shock damage occuring in the tyre casing. Check and act pressures It you sometimes have to inflate your car's tyres to the higher pressures specified for ‘maximum load or sustained high speed, don't forget to reduce the pressures: to normal afterwards. Front tyres may wear unevenly a a resut of whee! misalignment. Most tyre dealers and {garages can check and adjust the wheel Algnment (or "wacking’) fora mocest charge, Incorrect camber or castor pair or renew suspension perts ‘Malfunctioning suspension Repair orranew suspension parts Unbalanced wheel Balance tyres Incorrect toe setting ‘Adjust front whee! alignment Note: The feathored ego ofthe tread which typiies toe wear is best checked by fetWeekly checks oe1s Wiper blades CCheck the condition of the wiper blades if they ae cracked or show any signe of eteroration orf the glass swept areas ‘smeared, renew them. Wiper blades stoula be renewed annually. Don't forget to check the taigate wiper as well To remove a wiper blade, pull the arm fully away from the screen until it locks. Sulvel the blade through 90", press the looking tab with your fingers and slide the blade aut of the a's hooked end, Battery Caution: Before carying out any work on the ‘vehicle battery, read the precautions given in "Safty fret atthe start of tis manual \¥ Make sure thatthe battery try isin good Condition, and that tre clamp is tight Corrosion on te tay, retaining clamp and the battery itself can be removed witha solution of water and baking soda. Thoroughiy rinse all Cleaned areas with water. Any metal parts damaged by corrosion should be covered witha zinc-based primer, then paintec. ¥ Periodically (approximately every three months), check the charge condition of the battery as deserted in Crapter SA iL the battery is lat, and you need to jump Stan your vehicle, see Roadside Repairs. ‘The battery is located on the left-nand side of the engine compartment, The exterior of the battery should be inspected periodealy for damage such as a cracked case oF cover. Hf corresion (white, fully deposits) Ie evidert, remove the cables from the battery terminals, clean them with a smal ‘wire brush then refit them. Automotive stores ‘el a too for claaning the battery post 1D Check tne tghness of bate cares to ensure good electrical connactions, You should not be able to move them, [Also check each cable (8) for cracks and frayed conductors ‘a well a the battery cable clamps 4os Weekly checks Bulbs and fuses Check all external lights and the hor, Refer to the appropriate Sections of Chap- ter 12 for details if any of the ekcuits are found to be inoperative 2 single indeatr taht, Fstop ight or headlight has fale, it i key that bulb has biown and will need to be replaced, Refer to Chapter 12 for detail. I both stop lights have fale, it's possible that the ewitch has faled (see Chapter 9). Visually check all accessible wiring Connectors, hamessas and retaining clips for securiy, and for signs of chafing or damage. Timor han oe eth ral ght ras tei sty totes ne Nos Bown or that tae atau ne cut (eee Ghat 12 The ines ar lated etn {he odoments Way on th fac. Fst unscrew the two sre and sel te tay down Wf you need to check your brake lights and indicators ‘unaided, back up to @ wall or ‘Garage door and operate the lights. The reflected light should show it To replace a blown fuse, imply pul out Using the special plastic too! and ft a new fuse of the correct rating (see Chapter 12. if the fuse blows again, it Is Important that you find out wy - a complete checking procedure is given in Chapter 12Lubricants, fluids and tyre pressures 0-17 Lubricants and fluids 1 (petrol) “Multigrade engine ol, viscosity SAE1SW/40, to API SG/CD or better (Buckhams OXR Premium Petrol Engine Oil, or Duckhams Hypergrade Petrol Engine Oil) Engine (diese!) Multigrade engine oil, viscosity SAE1SWW/40, to API SG/CD or better {Duckhams OXR Premium Diesel Engine Oil, or Duckhams Hyperarade Diesel Engine Oi) Cooling system Ethylene glycol-based antifreeze and soft water (Duckhams Antitreeze & Summer Coolant) Manual gearbox ‘Automatic transmission Braking system Power steering Choosing your engine oil Engines need ol, nt only to wvicate moving parts and minimise wear, but also to maximise ower output and to improve fue! econo. By introducing a simplified and improved range of engine oils, Ducknams has taken ‘away the confusion and mage It easier for you to choose the right ol for your enaine. HOW ENGINE OIL WORKS * Beating friction * Cleaning the engine internally Good quality engine olis clean the inside of your engine, collecting and dispersing Combustion deposits and controling them Lunt they are trapped by the ol iter or flushed but atoll change, OIL CARE - FOLLOW THE CODE To handle and dispose of used engine oll safoly, always: + Avoid skin contact Hypoid gear cil, viscosity SAE8OW to API GL4 (Duckhamss Hypoid Gear Oil 80W GL-4) Dexron type I! automatic transmission flid (ATF) (Duckhams ATF Autotrans ill) Hydraulic fluid to SAE J1703F or DOT 4 (Duckhams Universal Brake & Clutch Fluid) Dexron type ll automatic transmission fluid (ATF) (Duckhams ATF Autotrans il) DUCKHAMS ENGINE OILS. For the griver who demands a premium {quality oll for complete reassurance, We recommend synthetic formula Duekhams {QXxR Premium Engine Oils. For the diver who requires a straight: forward quality engine ol, we recommend ‘Duckhams Hypergrade Engine Oi. For futher Information and advice, cal the Without oi, the moving surfaces inside your sV2ld shin contact ckhams UK Hale on 0800212588. fngine wl uD together est up and mt Feed or tonged uch causing the ngneto seize, Engine ol Coote tan be hanna afm whieh separates these moving ence ct esed ot pare prverting wear ad heat bal. and ompiy packs ina * Cooling hot-spots responsible manner in an Temparatures inside the engin can exceed . 1000" C. The engine ol cculates and acts a8 S¥QE-EE'TSEE the one nearest to you. {octet tnstonng nat rom he hot spas ae ee ae ccm cane otesum, ‘rent fe ground Tyre pressures Front Rear Patrol models (average load) 155/70R19, 165/60R14, 15/65R14, 175/60R14 2009) 190 Peirol models (ly laden} “85/70R13, 165/60R14, 165/6SR14,175/60R14 22 (32) 2.22) Diesel mode's (average load 165/70R19, 165/65R'4, 16/65R14, 175/60R14 2.435) 2009) Diese modes (ly tacon: 165/70R19, 165/65R14, 185/05R14, 175/60R14 2.435) 22 (02)Chapter 1 Part A: Ae Routine maintenance & servicing - petrol models Contents ‘A ter renewal 19 de speed and CO content check and adjustment 2 ‘Aromat ranemisin ter andi change 22 lgniion sytem chock 2 ‘Antiary civebetiy check and renewa) “4 Intensive maintenance 2 Brave hud orev 38 inoaucton i Brace warning amp hack “| Lambda/onyoen sense check 28 Guten adjustment check 15. Manold mounting chec * Goolart rena 30. Manual banemisaon oa lev’ chack a Diveshatt gate chock 10 Manu wanemiscm od renewal % Easton coil sytem check 33 Polen titer raneval * Engine managament ystems chock 22 Rear brake rum check 2» Engine ol and ter renewal 2 Rear trate shoe check . Evaporative oss syst check 2 Roaotest 2 Exhaust system check 9 Spark lig reneval 2 Front orake pad check 5 Stoerng and svapension check ‘8 Foe ier renewal 18. Timing Ba eneckandtenion s Headlight beam adjsiment 24 Ting bel renewal a fing an tock iicaon 23 Ungerbody sealant check 7 Hose ana ha ea check Vale osfance check and acjstment % Degrees of difficulty | aay, sutabitor Fairy easy, stable = Fay cficut, | Diffcut sutabiofor | Veryaifeut, | reveowan te ferbegeeeeath << | guatotercampaten a: | operistoad DY. S| saacitor expert OY SS experience someewerence | DV mecnanc S| mectane ZR] ceprtessons NS 4Ata2_ Servicing specifications - petrol Lubricants and fluids Refer to end of "Weekly Chocks” Capacities Engine ol (including titer: 1108 ec engine 1242 6e engine Cooling system “Manual transmission ‘Automatic transmission Power-assisted steering . Fuel tank Washer reservoir Without headlight washers ‘With headight washers Engine Oi fier Engine ile speed co% ‘Alar drivebel tension Valve clearances - engine cold 1108 cc and 1242 ce (single-point) tet Exhaust 1282 cc (mat-poin) Inlet’ Exhaust Cooling system ‘Anttresze mixture: 50% antiteeze . Note: Refer to anvtreeze manutacturer fr latest recommendations. Fuel system Arter etement 1108 cc engine with 6-speed transmission 1108 ce engine (East Europe) 1242 ce engine (60 models) 1242 ce engine (75 modes} Fue! iter 1108 co engine 1242 ce engine (60 modes) 1242 co engine (75 models) Ignition system gation timing Spark plugs Spark plug electrode gap Brakes Brake pa fining minimum thickness Brake shoo friction material minimum thickness Torque wrench settings Roadwnes bots Spark plugs. Sump drain lug 3.47 tres 3.74 ites 46 ites 1.65 titres 187 ives 1.98 tives 0.85 lives 47 fees 25 tives 7 tives ‘Charnpion F107 {900 50 rpm (0.35 maximum 5.0 mm deflection midway between pulleys 0.40 + 0.05 mm 0.50 + 0.05 mm 0.35 + 0.05 mm 0.40 £0.05 mm Protection dow to -35°C. Champion uB47 Champion UB48 ‘Champion U8? (Champion U89 Champion L213 Ghampion L213 Champion L203 Refer to Chapter 58 ‘Champion ACBYCC 0.9mm 1.5mm 20mm Nm wore 86 6 a 2 10 7Maintenance schedule - petrol 1-3 The maintenance intervals in this manual are provided with the. assumption that you, not the dealer, wil be carrying out the work, “These are the minimum maintenance intervals recommended By us for vehicles even daly. you nish to Keep your vehicle in peak condition at alltimes, you may wish o perform some ofthese procedures more Every 250 miles (400 km) or weekly 1) Refer to “Weekly checks” Every 5000 miles (7500 km) or 6 months - whichever comes first 1 Renew the engine oil and fiter (Section 3) Note: Frequent cil and fiter changes are good for the engine. We recommend changing the ol atthe nteval speciied here, ora least fice a year, ie mileage covered is ess. Every 10 000 miles (15 000 km) or 12 months - whichever comes first Inaction to the tems listed above, cay out the following: TJ Check the operation of the brake warning lamp (Section 4) LA Check the front brake pads for wear (Section 5) Check the rear brake shoes for wear (Section 6) 5 Check the underbody and sealant for damage (Section 7) (2 Hose and fluid leak check (Section 8) 1 Check the condition of the exhaust system and its mountings (Section 9) Check the condition of the driveshaft gaiters. (Section 10) 11 Renew pollen fiter (Section 11) ‘Check exhaust gas content and idle speed (Section 12) Check the steering and suspension components for condition and security (Section 13) Every 20 000 miles (80 000 km) or 2 years - whichever comes first ‘nadion tothe tems sted above, cary out teflon: (LU Check and if necessary adjust the tension of the auxiliary drivebet(s) Section 14) ( Check freeplay and height of clutch pedal (Section 15) Check and if necessary adjust the valve clearances (Section 16) (Check and if necessary tighten inlet and exhaust manifold mountings (Section 17) Renew the fuel filter (Section 18) Renew the air iter element (Section 19) © Renew spark plugs (Section 20) ‘Check condition of HT cables (Section 21) ‘Check engine management system (requires diagnostic equipment) (Section 22) often. We encourage frequent maintenance, because it enhances the sticency, performance and resale value of your vehi When the vehicle is new, it should be service by a factory- authorised dealer sovice department, n order to preserve the factory warranty Every 20 000 miles (30 000 km) or 2 years - whichever comes first (continued) | Lubricate all hinges and locks (Section 23) © Check the headlight beam adjustment (Section 24) 7 Camry out a road test (Section 25) Every 30 000 miles (45 000 km) or 3 years - whichever comes first In adetion to he items sted above, cary out the folowing: Check the operation of the Lambda sensor (Section 26) Co Check and if necessary top-up the manual transmission oil level (Section 27) ‘Check the operation of the evaporative loss system (Section 28) Every 40 000 miles (60 000 km) or 3 years - whichever comes first In ation to the items iste above, cary out he following: ‘Check the rear brake drums for wear (Section 29) ©] Renew the engine coolant (Section 30) J] Check the condition and tension of the timing belt (Gection 31) 1 Automatic transmission inner filter and fluid renewal (Section 32) Every 60 000 miles (90 000 km) or 6 years - whichever comes first In ackttion tothe items lst above, cary out the folowing Check the condition and operation of the crankcase emission control system (Section 33) Every 40 000 miles (60 000 km) Renew the timing belt (Section 34) Note: Although the normal interval for timing belt renewal I 70000 mies (105 000 kr) ti strong recommended that the interval is rediced on vehicles which sre subjected to Intensive use, i, ‘mainly shot journeys or aloof stop: sta cng Every 80 000 miles (120 000 km) Renew the manual transmission oil (Section 35) Every 2 years ] Renew the brake fluid (Section 36) 1Asaa Maintenance & servicing - petrol Underbonnet view - 1108 cc petrol Engin ol iter cap) Engine ol apstick ‘Brake vacuum servo unit ‘Brake fc reservoir Air cleaner cover Coolant expansion tank Windscreen washer uid Front suspension strut upper ‘mounting 8 Ignition col cover 10 Engine wiring connector cover 11 Battery ecu Engine of filer cap Engine ol dipstick Brake vacuura serv unit Brake fui reservoir Aircleanor cover Coolant expansion tank Windscreen washer fuid Front suspension strut upper mounting Ignition eo¥ cover 10 Engine wiring connector cover 11 Battery 12ECUMaintenance & servicing - petrol 11-5 Front underbody view (diesel shown, petrol similar) it ter ‘Sump eran plug Transmission dain plug ‘Bectris cadiing fan unit Leftnand cnveshat Intermediate shat 7 Fight-hand oriveshatt {3 Front suspension lower arms 9. Front ant-rol bar 10 Exhaust downpipe 11 Front brake calipers 12 Rear engine mounting 13 Ragator battom hose. 4A Foal tank Exhaust taipipe and stencer Roar axie Cal springs Rear antirol bar Hlanbrake cables Fear brake pressure regulating Fear shock absorber ower ‘mountings1a Maintenance procedures - petrol 1. Introduction General information This Chapter is designed to help the home mechanic maintan hismher vehicle for safety, ‘economy, long ite and peak performance Te Chapter contains a master maintenance schedule, and Sections dealing specifically with each tak i tha schedule. Visual checks, adjustments, component renewal ang other helpful items are included, Refer to the accompanying illustations of the engine compartment and the underside ofthe vehicle forthe locations of the various components ‘Serving your vehicle in accordance with the mileage/time maintenance schedule ang the folowing Sections wil provide a planned maintenance programme, which should result inva long and reliable service if. This is a ‘comprehensive plan, so maintaining some Items but nat others atthe specified serview intervals, wll not produce the same results, ‘AS you service your vehicle, you will aiscover that many of the procedures can and should - be grouped together, because of the particular procedura being performed, oF because of the proximity of two otherwise unrelated components 10 one another. For ‘example, if the vohicie is raised for any reason, the exhaust can be inspected at the ‘same time as the suspension and steering ‘components. The first step in this maintenance programme is to prepare yourself before the actual work begins. Flead through all the Sections relevant to the work to be carried fut, then make a ist and gather all the parts and tools required. if a problem Is encountered, seek advice from a parts specialist, or @ dealer service department. 2 Intensive maintenance 411, trom the time the vehicle is new, the routine maintenance schedule is folowed ‘closely, and troquent checks are made of fuld levels and high-wear items, as suggested ‘throughout this manual, the engine will be kept in relatively good running condition, and the need for addtional work will be minimised, 2 Itis possible that there willbe times when the engine is running poorly due tothe lack of regular maintenance. Ths is even mote likely if a used vehicle, which has not receives regular and frequent maintenance cheeks, is purchased. In such cases, additional work may need to be carried out, outside of the reguiar maintenance intervals. 8'If engine wears suspected, a compression test (eter to the relevant Part of Chapter 2) will rove valuable information regarding the ‘overall performance of the main internal ‘components, Such a test can be used a8 @ ‘basis to decide on the extent of the work to be carried out. I, or example, a compression test indicates serious internal engine wear, 5000 Mile / 6 Month Service conventional maintenance as descrited in this Chapter will not greatly improve the Performance ofthe engine, and may prove a ‘waste of time and money, unless extensive overhaul works cared ov fst. 44 The folowing series of operations ae those Usually required to improve the porformance ‘of a gonerally poor-tunning engine: Primary operations 4) Clean, inspect and test the battery (See "Wook chacks") 1) Check all the engine-elated ids (See “Wook chocks") ©) Check the condition an tension of the _urlary chvebet) Section 74). ) Renew the spark pugs Section 20. ©) Inspect the ignition HT loads Section 21), 1) Check the condition ofthe air fiter, and renew if necessary (Section 19) @) Check the fue! titer (Section 1). 1) Check the condition ofa hoses, and check for fluid lake (Section 8) Check the exhaust gas emissions (Section 33) 5 If the above operations do not prove fully ctfective, cary out the following secondary ‘operations ‘Secondary operations All tems isted under “Primary operations" ‘lus the folowing: a) Check the charging systom (Chapter 5A) 1) Chock the ignition system (Chepter 5) ©) Check the fu! system (ee relevant Part (of Chapter ) Renew the ignition HT toads (Section 21) 3. Engine oll and fitter renewal 8 1 Frequent olan fiter changes ara the most Important preventative maintenance which can ‘be undertakon by the DIY owner. As engine oi ‘ages, it becomes diluted and contaminated, \which ead to premature engine wear. 2 Betoce starting this procedure, gather all the necessary tools and materials. Also make sure that you have plenty of clean rags and newspapers handy. to mop up any spills, ‘Ideally the engine ol should be warm, as wal drain better, and more bult-up sludge will be removed with I, Take care, however, not to touch the exhaust or anyother hot parts ofthe fengine when working under the vehicle, To avoid any possibilty of scaling, and to protect yourself rom possible skin itants and other harmful contarinants in used engine ol, 11 advisable to wear gloves when carrying ou this ‘work. Access tothe underside ofthe vehicle vl be greatly improved ft can be raised on a It, driven ento ramps, or jacked up and ‘supported on axle stands (s8e “Vacking and vehicle support”). Whichever “method. is chosen, make sure thatthe vehicle remains level ort is at an ange thatthe rain plug is atthe lowest point, 3 Slacken the drain plug about half @ turn Using an Allen key. Position the draining ‘sump while unscrewing ft by hand the last couple of tums. As the plug releases, ‘move it away sharply so that the stream (of oll issuing from the sump runs into the. Container, not up your sleeve! Container under the drain plug, then remove the plug completely (gee Haynes Hint) 4 Allow some time forthe old oil to drain, noting that ¢ may be necessary to reposition the container asthe ol ow slows toa trickle 5 After all the ol has drained, wipe off the Grain plug with a clean rag, then clean the area around the drain plug opening and refit ‘tho plug. Tighten the plug securely. 6 Ifthe iter is also to be renewed, move the ‘container into pasition under the ol fier, ‘hich fs located on the front rghtchand side ‘of the engine (see Mlustration),5000 Mile / 6 Month Service - petrol 14-7 7 Using an ol fiter removal tool if necessary, slacken the fier intially, then unserew it by hand the rest ofthe way. Empty the ol inthe ‘i titer nto the container 8 Use a clean rag to remove allo, cit anc ‘sludge from the filer sealing area on the ‘engine, Check the ol fiter to make sure that the rubber sealing ring has not stuck to the engine. ithas, carefully romove it ‘9 Apply a light coating of clean engine of to ‘the seaing fing onthe newfie, then screw it into position on the engine, Tighten the fiter firmly by hand only - do not use any tots. 40 Remove the old oll and all tools from Under the vehicle then lower the vehicle tothe ‘grouns (if applicabi) 414 Remove the dipstick, then pull out the ot filer cap from the cylinder head cover. Fl the ‘engine, using the correct grade and type of ot (600 “Lubricants fuids and capacities). An oi can spout oF funnel may help to reduce spillage. Pour in haf the specified quantity of fl first, then walt a few minutes forthe ol to fallto the sump. Continue adding oil a small quantity ata time until the level is up to the MAX" mark onthe dipstick. Ref the filer cap. 42 Start the engine and run it for a few minutes; check for leaks around the oll iter seal and the sump drain plug. Note tht there ‘may be a delay of afew seconds before ine ol preseure warming light goes out when the fengine is frst started, a8 the oll circulates ‘through the engine ol galeries and the new ol {iter batore tho pressure buds up, 19. Switon off the engine, and walt a few minutes forthe ol to sete in the sump once 10 000 Mile / 12 Month Service 4. Brake warning lamp & ‘operation check S 4 With the inition key inserted and tumed to the MAR’ position, open the bonnet and Lup with more water. 18 Once the eval n the expansion tank starts to rise, squeeze the radiator top and bottom hoses to help expel any trapped air in the system. Once all the aris expelle, top-up the Coolant level tothe "MAX" mark and ret the expansion tank cap. Ciose ll blood plugs 47. Start the engine and run it untl it reaches Rormal operating temperature, then stop the engine and allow * to coo! 18 Check for leaks, particularly around dlisturbes components. Check the coolant Tevel in the expansion tank, and top-up if necessary, Note thatthe system must be cold before an accurate level's indicated in the ‘expansion tank. Ifthe expansion tank cap is 80.30 Bleed screw located on the top right hand edge of the radiator removed while the engine is stl warm, cover the cap with a thick cloth, and unscrew the cap slowly to gradually relieve the system pressure (a hissing sound wil normally be heard), Wait unt any pressure remaining in the system is released, then continue to tun the cap until it can be removes. Antifreeze mixture 19. The antiraoze should always be renewed at the specified interval. This is necessary ‘ot onty to maintain the antifreeze propartes, but also to prevent corrosion which would otherwise obcut as the corrosion inhibitors become progressively ess effective, 20 Always use an ethylene-glycol based antifreeze which is suitable for use In mixed ‘metal cooling systems. The quantity of antifreeze and levels of protection’ are Indicated in the Specifications. 21 Before adding antiftesze, the cooling system shoulo be completely drained Preferably fished, and all hoses checke for Condition and secur 22 Aor filing with antiveeze, a label shoule be attached tothe expansion tank, stating the type and concentration of antitteeze used, and the date installed. Any subsequent topping-up should be mado with the same type and concentration of antitroeze 23.Do not use engine antifecze in the Wwindscreen/taigate washer systom, as it wi cause damage to the vehicle paintwork. A screenwash additive should be added to the washer system in the quantties stated on the bottle s 1 Refer to Chapter 2A for the procedure necessary to access the timing belt 2 Turn the engine on the crankshaft pulley and inspect the tl length ofthe timing bet for signs of ell contamination and swear of the teeth. In particular check for cracking, Renew the timing bet i necessary, {Ifthe timing bal i in good conaition check its tension with reference to Chapter 2A, ‘81 Timing belt check and tension40 000 Mile / 3 Year Service - petrol sass ‘82 Automatic transmission filter and fluid change 1 Take the vohicl on a short run, to warm the transmission upto operating temperature, 2 Park the car on level ground, ther switch of the ignition and apply the handbrake fry ‘Jack up the front of the vehicle and support securely on axle stands, Note that, when refling and checking the fluid level, the car must be lowered to the ground, and level, to ‘ensure accuracy. 3 Remove the dipstick, then position a Suitable container under the transmission, Unscrew the sump plug and allow the id to ‘rain frat least 10 minutes, Warning: The transmission fluid ‘may be very hot and precautions ‘must be taken to avold scalding. 4 Clean around. the transmission sump mating flange. Unbolt and remove the sump {and remove the gasket, '5 Remove the two bolts and withdraw the transmission Mud iter (see illustration), 6 Fit the new titer, and secure with the two bots. 7 efit tne sump using @ new gasket, then lowor the vehicle tothe aroun 8 Fill the transmission with the specified {uantiy of fuld via tho dipstick tube, using @ ‘unne! witha fina mash titer 8 Run the engine to normal operating temperature, then check the fluid lavel as \escrbed in “Weekly Chocks" 40 D'spose ofthe od ud safely 60 000 Mile / 6 Year Service ‘93 Emission control system check s Refer to Chapter 40. A full check of the ‘emissions control systems must be made by a Fiat dealer. 40 000 Mile Service 32.5 Automatic transmission fluid fiter retaining bolts ‘94 Timing belt renewal Refer to Chapter 28 80 000 Mile Service 96 Manual transmission oll renewal WE 1 Peck te vehicle on a evel surface, if possible ‘over an inspection pit or on a ramp as the filerfevel and arain plugs are accessed trom Under the engine compariment, If necessary [ack up the vehicle and support on axle stands (ee "Jacking and vehicle suppor 2 Wipe clean the area around the fie level ‘ang drain plugs, which are on the front and bottom ofthe transmission (see Iustration) Note: Athough the normal interval for timing ott renewals 70 000 mies (105 000 km), is strong recommended that the interval is ‘duced on vehicles which are subjected to intensive use, se, mainly shor journeys or alot of stop-start driving. The actual belt renewal 3 Using an Allen key, unserew the filer/evel ‘lug and clean it 4 Position a suitable container beneath the transmission, then use the Allen Key to Unscrew the drain plug. Allow the oll to completely drain 85 Wipe clean the drain plug then refit and tighten it 6 Fil the transmission withthe correct grade ‘and quantity of oll, referring to Section 27 von checking the vel. Reft and tighten the fiertevel plug 7 Where applicable lower the vehicle to the round. Interval is tnerefore very much up to the Inciidual owner, That being said, is highly recommended to err onthe ioe of safety, and ‘renew the belt at this ear intarval, beanng in ‘mind the drastic consaquences resulting trom bot fait, ‘35.2 Transmission drain lug location (viewed from under the vehicle 4Atate. Every 2 Years - petrol Every 2 Years § Warning: Brake hydraulic fluid ‘96 Brake fluid renewal ‘can harm your eyes and damage painted surfaces, so use ‘extreme caution when handling ‘and pouring it. Do not use fluid that has ‘been standing open for some time, as It ‘absorbs moisture from the air. Excess ‘moisture can cause @ dangerous loss of ‘broking effectiven 1 Tha procedure is similar to that for the bleeding ofthe hydraulic aystem as described In Chapter 9, except that the brake tlic reservoir should be emptied by siphoning, using a clean poultry baster or similar before starting, and allowance should be made for the old fluid to be expelled when bleeding section ofthe circu 2 Working as described in Chapter 9, open the first bleed screw in the sequence, and pump the brake pedal genty until nearly all the old fluid has been emptied trom the master cylinder reserva Ey Ol hydraulic uid is Invariably much derker_in ‘colour than the new, making ‘easy to distinguish the two. 3 Top-up to the "MAX" level with new fluid, land continue pumping until only the new fic omains in the reservoir, and new fuid can be ‘Seon emerging from the bleed screw. Tighten the screw, and top the reservoir level up tothe “MAX vel ine, 4 Work through all the remaining blosd ‘crews in the sequence unti new fuid can be ‘seen at all of them. Be careful to Keep the linder reservoir topped-up to above level at all tines, or air may enter the system and greatly nerease the length of the task '5 When the operation is complete, check that al bleed screws are securely tightened, and ‘that theie dust caps are refitted. Wash offal ‘races of spilt fuld, and recheck the master cylinder reservoir fi evel {8 Chock the operation of the brakes before taking the car onthe road.Chapter 1 Part B: 1Be1 Routine maintenance & servicing - diesel models 5 at Contents ‘ic fier renewal Auxilary dtvebets) check and renewal Brake tid renewal Brae waming lamp operation check Clutch adjustment chock Coolant renewal Driveshat gait check Emissions control systems check Engine management system check Engine ol ana titer renewal Exhaust system check Front brake pad check Fuel iter renewal Headlight beam adjustment Hinge and lack lubrication Degrees of difficulty 13. Hose and fu teak check 8 16 Idle speed check and adlustment " 30° Intensive maintenance 2 4 Introduction 1 47 Manual transmission i level check 2 25 hanual transmission of renewal 20 40 Pollen fiter renewal 4 27 Rear brake drum check 2 4 Rearbrake shoe check 6 3. Road test 22 9 Steoring and suspension check 5 5 Timing bet cheek and tension 8 12 Timing bat renewal 28 21 Underbody sealant check u 20 Valve clearance check and adjustment 8 Eesiatcke ()Farwewoasse | Falvatiak, | OliaRanbem § )vevatian — @| vice with ile for beginner with suitable for competent experienced DIY S| suitable for expert DIY SS | ostane coneopetmnes | pirmecane S| mec R) Soeecn S) 1Bise Servicing specifications - diesel Lubricants and fluids Fifer to end of Weokly Chocks* Capacities Engine ol including titer) Inoluaing titer 1898 ce non-tubo diesel engine 1698 ce turbo desel engine Cooling system Diesel engines ‘Transmission Marval transmission ‘Non-turbo lesa engine Turbo desel engine Power-nssisted steering Alt medals Fuel tank ‘Al models Washer reservoir without headight washers with neadight washers Engine otter Diesel engines ‘Auxiliary ervebelt tension Valve clearances: 1698 ce engine: Inlet Exhaust Idle speed Allmodels Cooling system Aniresze mixture: 50% antiresze . Note: Refer to antiroaze manufacture for latest recommendations. Fuel system Air fiter element: 1836 ce ciesel engine with Bosch injection 1696 ce cissel engine wth Lucas/CAV injection Fual iter: “1698 ce diesel engine Brakes Brake pad tning minimum thickness Brake Shoe friction material minimum thickness Torque wrench settings Fosdwhee bolts Fal iter to bracket Fualfter bracket to body 4.95 tres 4.84 tres 72 thes 2ar tires 4.98 ives 0.65 tives 47 ees 25 tes To ltres ‘champion C112 5.0 mm deflection midway between pulleys (0.90 mim «0.05 mm (0.35 mm 20.05 mm £880 0.920 rpm Protection down to 35°C (champion U579 Champion Ut (Champion L111 2.5mm 20mm Nm votre 88 6 24 18 18 13Maintenance schedule - diesel 12s ‘The maintenance intervals in this manual are provided withthe assumption that you, not the dealer, wil be carrying out the work. These ar the minimum maintenance intervals recommended by us for vohicis driven daly. Ifyou wish to Keep your vehicle in peak canton at all mes, you may wish to perform some ofthese procedures more Every 250 miles (400 km) or weekly Cl Refer to “Weekly checks” Every 5000 miles (7500 km) or 6 months - whichever comes first C Renew the engine oil and filter (Section 3) Note: Frequent ol and fiter changes are good for the engine. We recommend charging the ol atthe Interval specied hare, or atleast ‘twice a year, ifthe mileage covered ess. Every 10 000 miles (15 000 km) or 12 months - whichever comes first Inaction tothe tems sted above, carryout the folowing: (Cl Check the operation of the brake warming lamp (Section 4) C Gheck the front brake pads for wear (Section 5) check the rear brake shoes for wear (Section 6) Check the underbody and sealant for damage “(Section 7) (© Hose and fluid leak check (Section 8) [O Check the condition of the exhaust system and its mountings (Sect (i Check the condit ~ (Section 10) Check and adjust idle speed (Section 11) ienew fuel filter (Section 12) 5 Renew the air filter element (Section 13) jenew pollen filter (Section 14) ) Check the steering and suspension components for condition and security (Section 15) Every 20 000 miles (30 000 km) or 2 years - whichever comes first In adetion to the ters lst above, cary out the folowing: Cl Check and if necessary adjust the tension of the auxilary drivebetts) (Section 16) (1 Check freeplay and height of clutch pedal (Section 17) LL Check and if necessary adjust the valve clearances (Section 18) 1 Check engine management system (requires: diagnostic equipment) (Section 19) Lubricate all hinges and locks (Section 20) | Check the headlight beam adjustment (Section 21) SJ Canry out a road test (Section 22) often. We encourage frequent maintenance, because it enhances the efcieney, performance and resale value of yaur vehicle When the vehicle Is now, it should be serviced by a factory authorised dealer service department, in order to preserve the factory waranty Every 30 000 miles (45 000 km) or 3 years - whichever comes first ‘radeon tothe items ated above, cory out te folowing (J Check and if necessary top-up the manual transmission oil level (Section 23) Every 40 000 miles (60 000 km) or 3 years - whichever comes first In ation to the items iste above, cary out he following: LI Check the rear brake drums for wear (Section 24) LO Renew the engine coolant (Section 25) 1 Check the condition and tension of the timing bett (Section 26) Every 60 000 miles (90 000 km) or 6 years - whichever comes first In eckiton tothe items listed above, cay out the folowing: (1) Check the condition and operation of the ‘crankcase emission control system (Section 27) Every 40 000 miles (60 000 km) ©) Renew the timing belt (Section 28) Note: Although the normal interval for timing belt renewal is 70 000 miles (105 000 kn), tis strong recommended thatthe interval is reduced on vehicles which are subjected to intensive use, le, ‘mainly short joureys or alo of stop-start cving Every 80 000 miles (120 000 km) | Renew the manual transmission oil (Section 29) Every 2 years LL Renew the brake fluid (Section 30)184 Maintenance & servicing - diesel Underbonnet view - Turbo diesel Engine ol filer oap Engine ol alpstion i fiter Brakelolutch ud reservoir Aircleaner cover Power steenng pump Coolant expansion tank Windscreen washer fis Front suspension stut upper mounting 10 Fue iterheater housing 11 Fuel injection pup 12 Battery 13 Power steering uid reservoir ow fiter Sump dain pug Transmission dain lug Etec coating fan unit Lefchand oriveshat Intermediate shat Right-hand drveshatt Front suspension lower arms Front anol ar 10 Exhaust downpipe 11 Front brake calipers 12 Rear angine mounting 19 Radiator bottom noseMaintenance procedures - diesel iss Rear underbody view - Turbo diesel 1. Introduction General information 1 This Chapter is designed to help the home mechanic maintain hisihar vehicle for safety ‘ecanemy, long life and peak performance 2 Tho Chapter contains a master maintenance schedule, and Sections dealing specifically with each task in the schedule, Visual enecks, adjustments, component renewal and other helpful items are included. Reter to the accompanying illstrations of the engine Compartment and the underside of the vehicle for the locations of the various components 3 Servicing your vehicle in accordance with the mileage/tme maintenance schedule and the folowing Sections wal provide a planned maintenance programme, which shoud result ina long and reliable service Ife. This Is a comprehensive plan, so maintaining some items but not others at the spected service Intervals, wil not procuce the same results 4.As you service your vehicle, you will discover that many of the procedures can ‘and should - be grouped together, because of the particular procadure being performed, or because of the proximity of two otherwise Unrelated components to one another, For ‘example, ithe vohicie i raed for any reason, the exhaust can be inspected at he same time as the suspension and steering components, 5 The first step in this maintenance programme is to prepare yourself before the factual work begins. Read through all the Sections relevant to the work to be carries fut, then make a ist and gather all the parts fand tools required. fa. problem is ‘encountered, seek advice from a parts Specialist, ora dealer service department 2 Intensive maintenance 11, trom the time the vehicle is new, the routine maintenanee schedule is followed ‘closely, and frequent checks are made of fue levels and high-wear items, as suggested ‘throughout this manual, the engine will be opt in relatively good running condition, and the need for adational work wil be minimised, 2 itis possibie that there willbe times when ‘the engine is running poorly du tothe lack of regular maintenance. Ths Is even more Ikely if'a used vehicle, which has not received regular and frequent maintenance checks, Is purchased. In such cases, additional work may need to be carried out, outside of the regular maintenance interval. 3 If engine wears suspected, a compression test (eter to tha relevant Part of Chapter 2) ‘will prove valuable information regarding the overall performance of the man intemal components. Such a test can be used as a ass to decide on the extent of the work to be carried out. If for example, a compression Ful tank Exhaust tallpipe and silencer oar axle Coil springs oar ant-rol bar Handbrake cables Fer brake pressure roguating vaive Roar shock absorber lower ‘mountings test incicates serious internal engine wear, conventional maintenance as described in his Chapter wil_not greatly improve the Performance of the engine, and may prove & waste of time and money, unless extensive overhaul work carted out fst. 4 The folowing series of operations aro those Usually required to improve the performance cof a generally poor-unning engine Primary operations 4) Clean inspect and test the battery (See “Weekly checks 1) Check all the engine-related fds (See "Weekly checks, 6) Check the conation and tension of the auxlary orvebot Section 16, ) Chock the condition ofthe ar fier, andl renew i necessary Section 13) €) Chock the condition ofa hoses, and check for fui lake (Section 8, 1) Chock the engine ile speed setting (Section 71). @) Chock the exhaust gas emissions (Secton 27) 5 If the above operations do not prove fully effective, cary out the following secondary operations: ‘Secondary operations All tems isted under “Primary operations! lus the folowing 4) Check the charging system (Chapter 5A). ») Renew the fue fiter Section 12) and heck the fuel system (see Chapter 4C).186 5000 Mile / 6 Month Service - diesel 3. Engine oil and filter renewal 1 Frequent oll and fiter changes ave the most important preventative maintenance procedures which can be undertaken By the DIY owner. As engine oil ages, it becomes luted and contaminated, which leads to premature engine wear. 2 Before stating this procedure, gather all the necessary tools and materials, Also make sure that you have plenty of clean rags_and newspapers handy, to mop up any spills daly, the engine ot should be warn, as i wil dain batter, and more buit-up sludge wil be removed with i. Take care, however, not to touch the exraust or any ater hot pars ofthe ‘engine when working under the vehicle, To avoid any possibilty of scaling, and to protect yourself from possible skin intants and other harmful contaminants in used engine ol, I _acvsable to wear gloves when canying out tS Work. Access tothe underside of the vehicle wil be greatly improved i tcan be raised on it, ‘devon onto ramps, o jacked up and supperted fon axle stands (see “Jacking and vehicle ‘support. Whichever method is chosen, make ‘sure that the vehicle remain eve, oti at an ‘angle, thatthe dain plugs at tne lowest porn 8 Slacken the drain plug about half a turn Using a 12 mm Alien key (see illustration) Position the draining container under the dain lug, then remove the plug completely (see Haynes Hint) 4 Allow some time for the old oll to drain, noting that it may be necessary to reposition the container asthe ol ow slows toa wickle. 5 Afterall tho oll has drained, wipe off the ‘rain plug with a clean rag, then clean the {area around the drain plug opening and reft ‘the alg, Tahten the plug securely 6 I the fier is also to be renewed, move the Container into position under the ol iter \which is located on the front ight-hand side ofthe engine. 8.74 Using an oil iter removal chain strap, ‘33 Using a 12 mm Allen Key to loosen the ‘engine oll drain plug 7 Using an ol fiter removal tool f necessary slacken the fiterinitally, then unscrew it by hand the rast of the way (see illustrations) Empty the oil in the old iter into the 8 Use a clean rag to remove all il, clit anc sludge from the fier sealing area on the fengine. Check the ol titer to make sure that the rubbor sealing ring has nat stuck to the engin. Wit has, caretuly remove it {9 Appi alight coating of clean engine oll to {the sealing rng on the new iter, then crew t Into position on the eagine. Tighten the fiter firmly by hand only ~ do not use any too's {00 ltustation) 410 Remove the old oil and all tools from Under the vehicle then lower tho vohcle tothe ‘ground ff applicable. 411. Remove the dipstick, then unscrew the of filer cap from tne cylinder hea cover. Fil the engine, sing the comect grade and type of ol (see “Lubricants and fuids", An oll can spout OF funnel may nelp to reduce silage. Pour in half he spectied quantity of ol fst, men wat few minutes for the alto falta tha sump Continue ading oil a small quantity at atime Lntl the tvel sup tothe "MAX" mark on the dipstick, Rot the ier ca, 12 Start the engine and run it for a fow minutes; check for leaks around the oll iter seal and the sump drain plug, Note that there 3:7 Removing the ol fiter sump whilo unscrewing it by hand the fast couple of tums. As the plug releases, move it away sharply so that the stream of oll issuing from the sump ‘uns into the container, not up your sleeve! ‘may bea delay ofa fow seconds before the o pressure warning light goes out when the engine is frst started, a8 the oll circulates through the engine ol galleries and the new ot titer before the pressure builds up. 19 Switch of the engine, and walt a fow minutes forthe ol to settle in the sump once ‘more. Wits the new oi culated and the iter Completely ful, rechack the lavel on the lipstick, nd add more ol as necessary. 14 Dispose of the used engine oF safely, wth reference to “General repair procedures" in the preliminary Sections ofthis manual ‘Note: It is antisocial and llega! to dump oi! ‘down the drain. To find the location of your local ol recyeling ‘bank, call this number tre. 800-6633 66 ‘89 Now oil fiter tightened by hand