1 Remove all remaining external components and electrical switches/sensors from the block.
2 Where applicable, undo the retaining bolts and remove the piston oil jet spray tubes from inside the cylinder block of Fiat Punto.
3 Remove all traces of gasket/sealant from the cylinder block, and from the lower crankcase on DOHC (16-valve) engines, taking care not to damage the gasket/sealing surfaces.
4 Remove all oil gallery plugs (where fitted). The plugs are usually very tight - they may have to be drilled out, and the holes retapped.
Use new plugs when the engine is reassembled.
5 If any of the castings are extremely dirty, all should be steam-cleaned, or cleaned with a suitable de-greasing agent.
6 After cleaning, clean all oil holes and oil galleries one more time. Flush all internal passages with warm water until the water runs clear. Dry thoroughly, and apply a light film of oil to the cylinder bores to prevent rusting. If possible, use compressed air to speed up the drying process, and to blow out al) the oil holes and galleries.
Warning: Wear eye protection when using compressed air.
7 If the castings are not very dirty, they can be cleaned with very hot, soapy water and a stiff brush. Take plenty of time, and do a thorough job. Regardless of the cleaning method used, be sure to clean all oil holes and galleries very thoroughly, and to dry all components well. Protect the cylinder bores of Fiat Punto as described above, to prevent rusting.
8 All threaded holes must be clean, to ensure accurate torque readings during reassembly, To clean the threads, run the correct-size tap Into each of the holes to remove rust, corrosion, thread sealant or sludge, and to restore damaged threads (see Illustration), it possible, use compressed air to clear the holes of debris produced by this operation.

FIG 141
To clean the cylinder block threads, run a correct-size tap into the holes

Warning: Wear eye protection when using compressed air.


9 Visually check the castings for cracks and corrosion. Look for stripped threads in the threaded holes. If there has been any history of internal water leakage, it may be worthwhile having an engine reconditioning specialist check the cylinder block with special equipment. If defects are found, have them repaired if possible, or renew the assembly.
10 Check each cylinder bore for scuffing and scoring. Check for signs of a wear ridge at the top of the cylinder, indicating that the bore is excessively worn.
11 Accurate measuring of the cylinder bores requires specialised equipment and experience. We recommend having the bores measured by an engine reconditioning specialist who will also be able to supply appropriate pistons should a rebore be necessary.
12 If the cylinder bores and pistons of Fiat Punto engine are in reasonably good condition, and not worn beyond the specified limits, and if the piston-to-bore clearances can be maintained, then it will only be necessary to renew the piston rings. If this is the case, the cylinder bores must be honed to allow the new piston rings to bed-in correctly and provide the best possible seal. An engine reconditioning specialist will carry out this work at moderate cost,
13 If the engine is reassembled right away, cover it with a large plastic bag to keep it clean and prevent rusting, if the engine is ready for reassembly. Apply suitable sealant to the new oil gallery plugs, and insert them into the holes in the block of Fiat Punto. Tighten the plugs securely.
14 Where applicable, refit the piston oil jet spray tubes to the cylinder block, and securely tighten the retaining bolts. Bend over the tabs to lock the bolts.
15 Refit all the external components and electrical switches/sensors removed prior to cleaning.