Fiat Grande Punto 1.2

The electric power steering column is one of the most common and well-documented failures on the Grande Punto. The torque position sensor inside the column wears out, initially causing a groaning vibration when turning and eventually triggering the steering warning light with full loss of power assistance. A reconditioned column from a specialist typically costs €400-600 fitted, while a new unit from Fiat can exceed €800. Specialist ECU repair companies offer sensor-only repairs for €200-350 which is a cost-effective option. Some owners have managed relay-level repairs for under €50 with basic soldering skills. This issue affects all Grande Punto models built from 2005 onwards and is the single most common MOT/TUV failure point.

The Magneti Marelli IAW 59F/5SF ECU fitted to the 1.2 FIRE engine is vulnerable to a cascading failure. When an ignition coil begins to degrade, it creates a voltage spike that travels back to the ECU and damages the internal coil drivers. The result is persistent misfires on two cylinders, loss of power, and rough running. ECU repair specialists charge €150-300 for a rebuild with lifetime warranty. A replacement ECU costs €300-500 including coding. It is strongly recommended to replace the ignition coil pack at the same time (€40-80) to prevent the new or repaired ECU from being damaged again. This issue typically appears between 60,000 and 120,000 km.

The 5-speed manual gearbox fitted to the Grande Punto 1.2 is known for premature wear of synchronizers and bearings, particularly on 1st/2nd and 3rd/4th gears. Symptoms include crunching when changing gear, difficulty selecting gears, or gears popping out under acceleration. The front input shaft bearing is the most common first failure, which is a relatively affordable fix at €200-400. However, if synchronizers are worn, a gearbox rebuild or replacement is needed at €500-1,500 depending on whether a used or reconditioned unit is fitted. This typically occurs between 80,000 and 130,000 km and is more common on cars that have been driven hard in urban traffic.

At 16-20 years old, corrosion is the biggest threat to Grande Punto longevity. Common rust areas include the rear wheel arches, sills, rear axle subframe, and the back left corner of the engine bay (a known weak point). The rear axle subframe can corrode severely enough to fail MOT/TUV inspection, with replacement costing €500-1,200 including fitting. Sill repairs range from €300-800 per side. Cars from salt-heavy regions (northern Europe, coastal areas) are worst affected. This is often the issue that ultimately makes the car uneconomical to repair.

The door lock mechanism is a well-known weak point. The metal lever connected to the inside door handle gradually wears through the plastic housing it sits in, eventually preventing the door from opening from the inside. This primarily affects the driver's door and rear doors. A replacement lock mechanism costs €60-100, with fitting taking approximately 30 minutes. Some owners have managed temporary repairs by repositioning the worn lever, but replacement is the reliable fix.

The heater blower resistor is a common failure on the Grande Punto. The thermal fuse in the resistor pack fails, often accompanied by melted wiring in the connector. Symptoms range from the fan only working on the highest speed setting to complete failure. The resistor itself is cheap (€10-30) and located in the passenger footwell, making it a straightforward repair. However, if the wiring loom has melted, a wiring repair kit is needed (€30-50 additional), and the root cause (typically a partially seized blower motor drawing excessive current) should be investigated to prevent recurrence.

The windscreen wiper linkage is a known weakness. The ball joint connecting the linkage to the wiper arm can pop off, causing one wiper to stop while the other continues. Alternatively, the wiper motor itself can seize when internal grease dries out. A replacement linkage assembly costs €60-120 and takes about an hour to fit. Re-greasing the motor and linkage can sometimes extend its life temporarily.