Complete heater Fiat Punto assembly

Warning: On models equipped with air conditioning, do not attempt to remove the complete heater assembly as this entails disconnection of refrigerant tines. Entrust this work to a Fiat dealer, or air conditioning specialist. Note: This is an involved procedure, and it is recommended that the following Section is read thoroughly before commencing work. Plenty of time should be allowed to complete the operation. During dismantling, make notes on the routing of all wiring and cables, and the locations of all fixings, to aid reassembly.

Removal

1 Disconnect the battery negative terminal.
2 Drain the cooling system.
3 Remove the complete facia assembly.
4 Undo the bolts and remove the tubular support beam from the front of the heater assembly (see illustration).



Remove the tubular support beam (arrowed) from the front of the heater assembly



5 Working in the engine compartment, remove the clips and detach the heater coolant hoses from their bulkhead connections.
6 From within the engine compartment, remove the protective plastic caps to expose the two heater assembly mounting studs. Unscrew and remove the nuts from the studs.
7 Label the electrical connections to the heater assembly, to aid correct refitting later, and then unplug them at their connectors. Release the wiring harness from the clips and cable ties on the heater casing.
8 Remove the rubber sleeve connecting the Fiat Punto heater assembly air duct to the floor air duct (see illustration).



Remove the rubber sleeve (arrowed) between the heater and floor air ducts


9 Slacken and remove the three nuts at the top of the unit and lift the heater assembly off its mounting studs.

Refitting

10 Refitting is a reversal of removal, bearing in mind the following points:
a) Make sure that all wiring and cables are routed as noted during dismantling.
b) Make sure that all air ducts are securely reconnected.
c) Refit the facia assembly.
d) On completion, refill the cooling system.

Heater matrix

Removal

11 Remove the complete Fiat Punto heater assembly.
12 Undo the upper and lower retaining bolts and separate the two halves of the heater assembly casing.
13 Undo the bolt and remove the support bracket for the matrix pipes.
14 Undo the bolts and lift off the side cover panel over the matrix pipes.
15 Carefully lift out the matrix, complete with pipes from the heater casing.

Refitting

16 Refitting is a reversal of removal.

Heater blower motor

Removal

17 Working under the facia on the passenger's side, undo the three screws securing the blower motor to the underside of the heater assembly (see illustration).



Undo the three screws (arrowed) securing the blower motor to the underside of the Fiat Punto heater assembly



18 Withdraw the motor from the heater assembly and disconnect the wiring connector (see illustration).



Withdraw the blower motor and disconnect the wiring connector



Refitting

19 Refitting is a reversal of removal.

Heater blower motor resistor

Removal

20 The resistor is located on the underside of the Fiat Punto heater assembly, adjacent to the blower motor.
21 Working under the facia on the passenger's side, disconnect the wiring connector from the resistor.
22 Undo the two screws and remove the resistor from the heater assembly (see illustration).



Undo the two screws and remove the blower motor resistor from the heater assembly


Refitting

23 Refitting is a reversal of removal.

Heater/ventilation control unit

Removal

24 Remove the complete facia assembly.
25 Release the retaining clips or cable clamps and disconnect the three control cables, either at the control unit or at their respective levers on the heater assembly (see illustration).



Control cable retaining clamps (arrowed) on the top of the heater/ventilation control unit


26 Disconnect the control unit wiring connector and remove the unit from the car.

Refitting

27 Reconnect the wiring connector, then reconnect control cables to the control unit or Fiat Punto heater assembly as applicable.
28 Check that the operating levers on the heater assembly move through their full range of travel when moving the respective knobs on the control unit. If necessary, reposition the outer cables in their clips or clamps as required.
29 Refit the facia assembly.