SOHC (8-valve) engines

Removal of inlet manifold of Fiat Punto

1 Disconnect the battery negative terminal.
2 Remove the air cleaner assembly.
3 Drain the cooling system.
4 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.
5 Disconnect the wiring connectors from the camshaft position sensor and crankshaft TDC sensor (see illustration).



Camshaft position sensor (A) and crankshaft TDC sensor (B) wiring connectors - SOHC (8-valve) engines


6 Disconnect the wiring connectors from the intake air temperature/pressure sensor, and engine coolant temperature sensor of Fiat Punto (see illustration).



Intake air temperature/pressure sensor wiring connector (arrowed) – SOHC (8-valve) engines


7 Disconnect the wiring connector and fuel vapour hose from the evaporative emission control solenoid (see illustrations).



Disconnect the wiring connector...



... and fuel vapour hose from the evaporative emission control solenoid - SOHC (8-valve) engines


8 Release the retaining clip and disconnect the coolant hose from the rear of the manifold.
9 Disconnect the crankcase ventilation system hose from the right-hand side of the manifold (see illustration)



Disconnect the crankcase ventilation system hose from the right-hand side of the manifold – SOHC (8-valve) engines


10 Remove the throttle body assembly of Fiat Punto.
11 Remove the fuel rail and injectors.
12 Release the clips and disconnect the fuel injector wiring duct from the slots on the camshaft cover. Move the wiring duct and associated cables clear of the inlet manifold.
13 Release the wiring harness from the clips at the rear of the manifold.
14 Undo the manifold retaining nuts bolts, and remove the manifold from the cylinder head. Remove the sealing rings and obtain new rings for refitting.

Refitting the inlet manifold of Fiat Punto

15 Refitting is a reverse of the removal procedure, noting the following points:
a) Ensure that the manifold and cylinder head mating surfaces are clean and dry, and fit new manifold sealing rings. Refit the manifold and securely tighten its retaining nuts.
b) Ensure alt relevant hoses and wiring are
reconnected to their original positions and are securely held (where necessary) by the retaining clips.
c) Refit the fuel rail and injectors, and the throttle body assembly.
d) On completion, refill the cooling system.

DOHC (16-valve) engines

Removal of inlet manifold of Fiat Punto

16 Disconnect the battery negative terminal.
17 Remove the air cleaner assembly.
18 Drain the cooling system.
19 Depressurise the fuel system.
20 Disconnect the fuel supply pipe at the quick-release connector in the centre of the fuel rail. Release the fuel supply pipe from the retaining clips on the manifold and move it to one side.
21 Disconnect the evaporative emission control system fuel vapour hose at the quick-release connector on the manifold right-hand side (see illustration).



Disconnect the evaporative emission control vapour hose at the quick-release connector - DOHC (16-valve) engines


22 Release the clip and disconnect the vacuum hose from the rear of the inlet manifold (see illustration).



Release the clip and disconnect the vacuum hose from the rear of the manifold - DOHC (16-valve) engines


23 Rotate the wiring connector locking catches and disconnect the two wiring connectors from the top of the ECU. Undo the nut and release the earth lead from the ECU front mounting stud.
24 Open the cable clip and free the ECU wiring harness from the throttle body (see illustration).



Open the clip and free the ECU wiring harness from the throttle body - DOHC (16-valve) engines


25 Disconnect the wiring connectors from the engine coolant temperature sensor, throttle valve actuator, evaporative emission control solenoid and fuel injector harness (see illustrations).



Disconnect the wiring connectors at the engine coolant temperature sensor and throttle valve actuator of Fiat Punto (arrowed)...



... and at the evaporative emission control solenoid and fuel injector harness (arrowed) - DOHC (16-valve) engines


26 At the right-hand end of the manifold, disconnect the wiring connector from the intake air temperature/pressure sensor.
27 Disconnect the crankcase breather hose from the pipe stub behind the throttle body (see illustration).



Disconnect the crankcase breather hose from the pipe stub behind the throttle body - DOHC (16-valve) engines


28 Release the clip and disconnect the coolant hose from the rear of the manifold (see illustration).



Release the clip and disconnect the coolant hose from the rear of the manifold - DOHC (16-valve) engines


29 Release the spark plug HT leads from the manifold upper support bracket, then undo the bolt securing the support bracket to the cylinder head extension of Fiat Punto (see illustration).



Undo the bolt securing the inlet manifold support bracket to the cylinder head extension - DOHC (16-valve) engines


30 Detach the engine wiring harness from the two clips at the rear of the manifold.
31 Undo the eight retaining bolts and remove the manifold from the cylinder head (see illustrations).



Undo the eight retaining bolts (arrowed)...



... and remove the inlet manifold from the cylinder head - DOHC (16-valve) engines


32 Remove the sealing rings and obtain new rings for refitting (see illustration)



Renew the inlet manifold sealing rings prior to refitting - DOHC (16-valve) engines


Refitting the inlet manifold of Fiat Punto

33 Refitting is a reverse of the removal procedure, noting the following points:
a) Ensure that the manifold and cylinder head mating surfaces are clean and dry, and fit new manifold sealing rings. Refit the manifold and securely tighten its retaining bolts.
b) Ensure all relevant hoses and wiring are reconnected to their original positions and are securely held (where necessary) by the retaining clips.
c) On completion, refill the cooling system.