Download Fiat Stilo 2001-2007 Workshop Service Manual for Repair –

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Replacing the control arms on a Fiat Stilo is a task that, while not for the faint of heart, can be quite rewarding. The control arms are pivotal components of the vehicle’s suspension system, connecting the wheel hub to the frame of the car and allowing for the up-and-down motion of the wheels while also helping maintain proper wheel alignment. Let’s dive into the process step-by-step, and I’ll make sure to elaborate on each tool and technique used.

### Tools and Materials Needed

1. **Jack and Jack Stands**: A hydraulic floor jack is essential for lifting the vehicle. You’ll also need jack stands to safely support the car once it’s elevated. Safety is crucial here; never work under a vehicle supported only by a jack.

2. **Lug Wrench**: This is a cross-shaped tool that helps you remove the lug nuts from the wheel. Make sure it’s the correct size for the Fiat Stilo’s lug nuts.

3. **Socket Set**: A complete socket set with various sizes, typically metric for European cars, is necessary. You’ll likely need 10mm, 13mm, and 15mm sockets.

4. **Ratchet and Extensions**: A 3/8″ or 1/2″ ratchet will work, and having extensions can help reach those tricky bolts.

5. **Torque Wrench**: This is crucial for ensuring that bolts are tightened to the manufacturer’s specifications, which helps maintain safety and integrity once everything is reassembled.

6. **Pry Bar**: A pry bar can be useful for removing stubborn components or for leveraging parts into place.

7. **Ball Joint Separator**: This tool helps separate the ball joint from the control arm without damaging the components.

8. **Hammer**: A regular hammer can help knock out stubborn parts, while a rubber mallet is useful for gently persuading components without damaging them.

9. **Wrenches**: A set of combination wrenches will be useful, especially for any bolts that are difficult to access with a socket.

10. **Grease**: It’s a good idea to have some grease on hand, particularly if your control arms come with bushings that require lubrication.

11. **Replacement Control Arms**: Make sure you have the right control arms for your Fiat Stilo. Depending on whether you’re replacing the front or rear, the parts may differ.

### Step-by-Step Control Arm Replacement

#### 1. Preparation
Start by parking your Fiat Stilo on a flat, stable surface. Engaging the parking brake is essential for safety. Gather all your tools and materials within reach to avoid running back and forth, which can be both time-consuming and annoying!

#### 2. Lifting the Vehicle
Using the hydraulic floor jack, lift the front or rear of the vehicle as needed. Position the jack under the designated lift points—these are typically found under the frame. Once the vehicle is elevated to a sufficient height, place jack stands under the vehicle to support it securely. Always check that the stands are stable before proceeding.

#### 3. Removing the Wheel
Use the lug wrench to loosen and remove the lug nuts from the wheel that you’re working on. It’s best to do this while the wheel is still on the ground to prevent any spinning. Once the lug nuts are removed, take the wheel off and set it aside.

#### 4. Accessing the Control Arm
Now that you have access to the suspension components, look for the control arm. The control arm will be attached to the chassis at one end and to the wheel hub assembly at the other. you may also need to remove the brake line or the sway bar link, depending on the specific setup of your Fiat Stilo.

#### 5. Disconnecting the Ball Joint
Using the ball joint separator, carefully insert it between the ball joint and the control arm. Once properly positioned, apply pressure to separate the two. If it’s stubborn, a few gentle taps with a hammer can help. Be cautious not to damage the ball joint or the control arm during this process.

#### 6. Removing the Control Arm Bolts
Now, with the ball joint separated, you can turn your attention to the bolts securing the control arm to the chassis. Using the socket set and ratchet, remove these bolts. It’s best to keep track of which bolts came from where, as they can vary in length download Fiat Stilo workshop manual and size.

#### 7. Removing the Control Arm
After the bolts are removed, you should be able to take out the control arm. If it’s stuck, a gentle tap with a hammer or a pry bar can help dislodge it. Inspect the old control arm and the associated bushings for wear; this can give you insight into any additional parts you may need to replace.

#### 8. Installing the New Control Arm
Take your new control arm and position it where the old one was located. Start by loosely threading the bolts into their respective holes. Don’t tighten them just yet; you want to ensure everything is aligned correctly.

#### 9. Reattaching the Ball Joint
Once the control arm is in place and the bolts are snug, it’s time to reattach the ball joint. Position the ball joint into the control arm and secure it in place according to the manufacturer’s specifications, typically with a cotter pin or nut.

#### 10. Tightening Bolts
Now, using your torque wrench, tighten all bolts to the specified torque settings. This information can usually be found in a service manual or online. This step is critical for ensuring the integrity of the suspension system.

#### 11. Reattaching Components
If you removed any brake lines or sway bar links, reattach them now. Make sure everything is securely fastened and double-check your work.

#### 12. Replacing the Wheel
Reattach the wheel, hand-tightening the lug nuts first before lowering the vehicle back to the ground. Once it’s on the ground, use the lug wrench to fully tighten the lug nuts in a crisscross pattern to ensure even pressure.

#### 13. Final Inspection
Before calling it a day, take a moment to inspect your work. Check that all your tools are accounted for and that nothing has been left loose. Make sure the vehicle is stable and that the new control arm is securely in place.

### Conclusion
And there you have it! Replacing the control arm on a Fiat Stilo is a task that requires patience, precision, and a good set of tools. If all goes well, you should notice improved handling and stability once everything is back together and you hit the road. Always remember to take your time, work safely, and refer to a repair manual if you run into any complications. Happy wrenching!
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