Note: The engine is lowered from the engine compartment as a complete unit with the transmission; the two are then separated for overhaul.

Removal
1 Remove the bonnet.
2 Remove the battery and battery tray.
3 Carry out the following operations.
a) Remove the air cleaner assembly.
b) Depressurise the fuel system of Fiat Punto, and disconnect the fuel feed hose at the quick-release connection on the fuel rail.
c) On SOHC (B-valve) engines, disconnect the accelerator cable.
4 Remove the cover from the fuse/relay box on the left-hand side of the engine compartment.
5 Remove the fuse/relay box from its mounting bracket by disengaging the locating lugs at each end. Disconnect the wiring multi-plug connector on the underside of the fuse relay box, and the two mufti-plug connectors on the side of the fuse/relay box mounting bracket (see illustrations). Note that on certain models of Fiat Punto there is only one multi-plug connector on the fuse/relay box mounting bracket.



Remove the fuse/relay box from its mounting bracket.



... and disconnect the three wiring connectors (arrowed)


6 Prise out the grommet and disconnect the brake servo vacuum hose from the front of the servo unit. Release the hose from the retaining clip on the bulkhead.
7 Disconnect the evaporative emission control hose at the quick-release connection on the inlet manifold.
8 On DOHC (16-valve) engines, disconnect the wiring connector at the acceleration sensor, and release the sensor wiring from the cable clips (see illustration).



On DOHC (16-valve) engines of Fiat Punto, disconnect the wiring connector at the acceleration sensor (arrowed)


Manual transmission models

9 Disconnect the gearchange selector cable end fittings from the transmission lever ball-studs (see illustration). Undo the three bolts securing the selector cable support bracket to the transmission and move the bracket and cables to one side.



Disconnect the selector cable end fittings (arrowed) from the transmission lever ball-studs - manual transmission models


10 Unbolt the clutch slave cylinder from the top of the transmission of Fiat Punto then fit a cable-tie around it to prevent the piston from being ejected. Position the cylinder to one side,
11 Disconnect the wiring connector from the reversing light switch on the front of the transmission, then unscrew the nut and disconnect the transmission earth lead from the top of the unit.

Automatic transmission models

12 Disconnect the main wiring harness connector at the top of the transmission, then unscrew the bolt and disconnect the transmission earth lead at the front of the unit (see illustrations).



Disconnect the main wiring harness connector (arrowed) at the top of the transmission...



... then unscrew the bolt (arrowed) and disconnect the transmission earth lead - automatic transmission models



13 Extract the retaining clip and release the selector cable end fitting from the starter inhibitor/reversing light switch (see illustration). Undo the two bolts securing the selector cable support bracket to the transmission and move the bracket and cable to one side.



Extract the retaining clip (arrowed) and release the selector cable end fitting - automatic transmission models



All models of Fiat Punto

14 Firmly apply the handbrake, then jack up the front of the car and support it securely on axle stands. Remove both front roadwheels. In order to remove the engine/transmission assembly in an upright position from under the vehicle, there must be a minimum clearance of approximately 700 mm between the floor and the front crossmember. Additional height is necessary if the assembly is to be lowered onto a trolley.
15 Remove the right-hand wheel arch liner main and centre panels.
16 Carry out the following:
a) Drain me engine oil.
b) Drain the cooling system.
c) On models with automatic transmission, drain the automatic transmission fluid.
d) On models with air conditioning, remove the auxiliary drivebelt.
17 Identify the coolant heater hoses on the bulkhead for position, then loosen the clips and disconnect the hoses (see Illustration). Similarly disconnect the radiator top hose from the radiator of Fiat Punto and thermostat housing.



Disconnect the coolant heater hoses (arrowed) at their bulkhead connections


18 On models with air conditioning, unbolt the air conditioning compressor and secure it in a suitable position clear of the engine as far as the flexible hoses will allow. Do not disconnect the air conditioning refrigerant pipes/hoses of Fiat Punto.
19 On models with automatic transmission, remove the clips and disconnect the transmission fluid cooler hoses at their transmission connections.
20 Remove the exhaust manifold.
21 Undo the bolts securing the exhaust system mounting brackets to the underbody, then move the system to one side.
22 Unscrew the nuts retaining the track rod ends on the swivel hubs and use a balljoint separator tool to disconnect them.
23 Unscrew the two bolts securing the left-hand swivel hub assembly to the front suspension strut, then move the hub assembly outwards.
24 Remove the retaining clip securing the left-hand driveshaft inner CV joint gaiter to the joint body. Pull the driveshaft and spider out of the joint body and move the driveshaft clear of the engine/transmission (see illustration). Suitably cover the joint body and the driveshaft spider to prevent the escape of grease.



Remove the gaiter retaining clip and pull the driveshaft and spider out of the CV joint body


25 Repeat paragraphs 23 and 24 to disconnect the right-hand driveshaft.
26 Using suitable spacers and washers, refit the engine right-hand lifting eye which was previously removed with the exhaust manifold.
27 Attach a suitable hoist to the engine right-hand lifting eye and the left-hand lifting eye on the transmission. To prevent the engine/ transmission assembly tipping backward during removal, a third lifting eye, fabricated from scrap metal or similar should be secured to a suitable location in the vicinity of the alternator. Attach the hoist to the additional eye and evenly take the weight of the engine/transmission of Fiat Punto.
28 Working beneath the car, unscrew the bolts and nuts securing the rear engine mounting to the subframe and transmission, and withdraw the mounting.
29 In the engine compartment, unscrew the nuts securing the right hand engine mounting to the body and to the bracket on the cylinder head. Lift the mounting assembly off the studs and remove it from the engine compartment.
30 Unscrew the centre nut securing the left-hand engine/transmission mounting stud to the bracket on the body.
31 Carefully lower the engine/transmission from the engine compartment taking care not to damage the surrounding components. Ideally lower the unit onto a low trolley so that it may be withdrawn from under the car Fiat Punto. Disconnect the hoist from the engine/transmission assembly.

Separation

32 Rest the engine/transmission assembly on a firm, flat surface, and use wooden blocks as wedges to keep the unit steady.
33 Disconnect all the individual wiring connectors from the various components on the engine and transmission to enable the main engine wiring harness to be removed. Make notes or attach labels to each connector to aid reconnection.
34 Detach the wiring harness support brackets and plastic ducting mountings, release the relevant cable ties and remove the complete harness assembly from the engine/transmission of Fiat Punto.
35 Remove the starter motor.
36 Undo the bolts and remove the support brace linking the transmission to the cylinder block.
37 Unbolt and remove the cover plate from the base of the transmission bellhousing.

Manual transmission models

38 Ensure that both engine and transmission of Fiat Punto are individually supported, than remove the remaining bolts securing the transmission bellhousing to the engine. Note the correct fitted positions of each bolt (and the relevant brackets) to aid refitting.
39 Withdraw the transmission from the engine, ensuring that the weight of the transmission is not allowed to hang on the input shaft while it is engaged with the clutch friction plate.
40 If they are loose, remove the locating dowels from the engine or transmission.

Automatic transmission models

41 Using a socket on the crankshaft sprocket centre bolt, turn the crankshaft in the normal direction of rotation until one of the four torque converter retaining bolts is accessible through the opening at the base of the transmission bellhousing (see illustration). Undo the first retaining bolt, then turn the crankshaft as necessary and undo the remaining three bolts as they become accessible.



Torque converter retaining bolt (arrowed) accessible through the bellhousing opening - automatic transmission models


42 Ensure that both engine and transmission of Fiat Punto are individually supported, then remove the remaining bolts securing the transmission bellhouslng to the engine. Note the correct fitted positions of each bolt (and the relevant brackets) to aid refitting.
43 Make sure that the torque converter is pushed fully onto the transmission shaft, then carefully withdraw the transmission from the engine of Fiat Punto, if they are loose, remove the locating dowels from the engine or transmission.
44 With the transmission removed, secure the torque converter in position by bolting a length of metal bar to one of the bellhousing flange holes.

Connection

45 If the engine and transmission have not been separated.

Manual transmission models

46 Apply a smear of high melting-point grease to the splines of the transmission input shaft. Do not apply too much, otherwise there is a possibility of the grease contaminating the clutch friction plate.
47 Ensure that the locating dowels are correctly positioned in the engine or transmission, and that the release bearing is correctly engaged with the fork.
48 Carefully offer the transmission to the engine, until the locating dowels are engaged. Ensure that the weight of the transmission of Fiat Punto is not allowed to hang on the input shaft as it is engaged with the clutch friction plate.
49 Refit the engine-to-transmission bolts, ensuring that all the necessary brackets are correctly positioned, and tighten them to the specified torque.

Automatic transmission models

50 Ensure that the torque converter is correctly engaged with the transmission, then carefully offer the transmission to the engine, and engage it on the locating dowels. Refit the engine-to-transmission bolts, ensuring that all the necessary brackets are correctly positioned, and tighten them to the specified torque settings of Fiat Punto.
51 Align the torque converter holes with the those in the driveplate, and install the retaining bolts. Tighten the torque converter retaining bolts to the specified torque.

All models

52 Refit the cover plate to the base of the transmission bellhousing,
53 Locate the support brace linking the transmission to the cylinder block, then insert the bolts hand-tight. With all the bolts inserted, tighten them securely,
54 Refit the starter motor.
55 Refit and reconnect the wiring harness to the components on the engine/transmission assembly making sure it is routed correctly.

Refitting

56 Locate the engine/transmission assembly beneath the engine compartment of Fiat Punto and attach the hoist to the fitting eyes.
57 Carefully lift the assembly up into the engine compartment taking care not to damage the surrounding components.
58 Engage the left-hand engine/transmission mounting stud with the mounting, then refit the retaining nut, moderately tightened.
59 Locate the right-hand engine/transmission mounting over the studs, refit the nuts and tighten them to the specified torque. With the engine/transmission assembly now supported, tighten the left-hand mounting nut to the specified torque.
60 Working beneath the vehicle Fiat Punto, refit the rear engine mounting and tighten the bolts to the specified torque.
61 Disconnect the hoist from the engine and transmission lifting eyes and remove the hoist from under the vehicle.
62 The remainder of the refitting procedure is the direct reverse of the removal procedure, noting the following points:
a) Ensure that alt hoses are correctly routed and are secured with the correct hose clips, where applicable. If the hose clips cannot be used again; proprietary worm-drive clips should be fitted in their place.
b) Refill the engine and automatic transmission with the correct quantity and type of lubricant.
c) Refill the cooling system.
d) Where applicable, check and if necessary adjust the accelerator cable.
e) When the engine is started for the first time, check for air, coolant, lubricant and fuel leaks from manifolds, hoses, etc.