General information

1 A one-piece exhaust system of Fiat Punto is fitted comprising a front pipe, intermediate silencer and rear silencer. The front pipe is connected to the exhaust manifold downpipe by means of a flange joint, and contains a flexible section to cater for engine movement. A catalytic converter is fitted to all models, and is an integral part of the exhaust manifold.
2 The system is suspended throughout its entire length by rubber mountings.
3 The intermediate and rear silencers can be individually renewed by cutting the original system at a specified distance from the front pipe flange joint. The new section is then secured by a clamping sleeve which is supplied as part of the new front or rear section.

Component renewal

Exhaust manifold and catalytic converter of Fiat Punto

4-5 Firmly apply the handbrake, then jack up the front and rear of the car and support it securely on axle stands.
6 Using a tape measure, measure rearwards from the flat surface of the front pipe-to-mainfold downpipe flange, and suitably mark the system 1974.0 mm from the flange. This will be the cutting point for renewal of the intermediate or rear silencer.
7 Unscrew the nuts and disconnect the front pipe flange from the manifold downpipe. Recover the gasket.
8 Undo the bolts securing the front and rear exhaust system mounting brackets to the underbody. Lower the system and suitably support it.
9 Using a hacksaw, cut through the system at the point previously marked, then remove the front pipe and intermediate silencer or the tailpipe and rear silencer, as applicable.
10 Remove any burrs from the remaining section at the cutting point, then slide the clamping sleeve into position. Locate the new section in place in the clamping sleeve.
11 Refit the bolts securing the front and rear mounting brackets to the underbody and tighten them to the specified torque.
12 Reconnect the front pipe flange to the manifold downpipe using a new gasket, and tighten the nuts to the specified torque.
13 Align the two exhaust system sections of Fiat Punto so that there is adequate clearance between the system and vehicle underbody, then securely tighten the clamping sleeve nut.
14 On completion, lower the car to the ground.

Heat shields of Fiat Punto

15 Undo the bolts securing the front and rear exhaust system mounting brackets to the underbody. Lower the system and suitably support it.
16 The heat shields are secured to the underbody by an assortment of nuts, bolts and retaining clips. Remove the relevant attachments and withdraw the heat shield(s) from their location.
17 Refit the heat shield(s), and exhaust system mounting brackets, tightening the bracket retaining bolts to the specified torque.