engine FIAT UNO 1983 Service Owners Manual

Torque wrench settings (continued)Nm lbf ft
Cylinder head bolts:
903 cc (from engine number 581470), 999 and 1108 cc:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
1299/1301 cc (10 main bolts):
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
1299/1301 cc (4 next to spark plug holes) . . . . . . . . . . . . . . . . . . . . . 30 22
1372 cc (M10):
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
1372 cc (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Engine mounting bracket body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Engine mounting bracket-to-body bolt (1299/1301 cc) . . . . . . . . . . . . . 48 35
Engine mounting bracket-to-transmission nut (1299/1301 cc) . . . . . . . 85 63
Engine mounting nuts:
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 42
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Engine mountings to brackets (1299/1301 cc) . . . . . . . . . . . . . . . . . . . . 23 17
Engine mounting to engine and transmission (999/1108 cc) . . . . . . . . . 60 44
Engine mounting-to-engine bracket bolt (1299/1301 cc) . . . . . . . . . . . 85 63
Flywheel bolts:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 32
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 62
Ignition distributor cover (in crankcase) bolt (1372 cc) * . . . . . . . . . . . . 25 18
Main bearing cap bolts:
999/1108 cc:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59
Manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 20
Mounting bracket to final drive casing (1299/1301 cc) . . . . . . . . . . . . . 95 70
Oil pressure sender unit (1372 cc) * . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 28
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 23
Oil pump backplate screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5
Oil pump mounting bolts:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
1372 cc * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Oil pump shaft driven gear bolt (1372 cc ie only) . . . . . . . . . . . . . . . . . . 83 61
Oil temperature sender unit (1372 cc) * . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
Sump pan fixing screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Timing belt tensioner nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 20
Turbine-to-exhaust manifold and head nut * . . . . . . . . . . . . . . . . . . . . . 29 21
Water pump-to-crankcase bolt (1372 cc) * . . . . . . . . . . . . . . . . . . . . . . 25 18
* Turbo models only
Cooling system
General
Thermostat:
Begins to open:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 90ºC
1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 to 82ºC
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 to 84ºC
Fully open:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100ºC
1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95ºC
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96ºC
Expansion tank pressure cap rating:
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.98 bar
Supplement: Revisions and information on later models 13•9
13

Weber 32 (continued) TLF 4/252 (and 251) TLF 27/251
Exhaust gas CO at idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 2.0% 0.5 to 1.5%
Fast idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.65 to 0.75 mm -
Float level (with gasket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.75 to 27.25 mm 26.75 to 27.25 mm
Float travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.7 to 34.7 mm 33.7 to 34.7 mm
Full power jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm 0.55 mm
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.47 mm 0.45 mm
Idle mixture adjustment port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm 1.50 mm
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 800 rpm 800 to 850 rpm
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 mm 1.05 mm
Needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm 1.50 mm
Pump jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm 0.40 mm
Pump outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm 0.40 mm
Superfeed jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm 0.45 mm
Superfeed mixture jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00 mm 3.00 mm
Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 mm 22 mm
Weber 30/32 DMTE 30/150
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116 cc engine (95 RON unleaded engine)
Exhaust gas CO at idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 2.0%
Float level (with gasket fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 to 7.5 mm
Idle pull-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 to 3.5 mm
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 to 900 rpm
Needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm
Pull down capsule bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm
Primary Secondary
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 1.80
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F30 F30
Idle air jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 0.70
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 -
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.47 0.40
Full power jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 -
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.90 1.05
Main venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 23
Pump discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 -
Pump jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 -
Secondary venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 -
Weber 30/32 DMTE 10/150
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116 cc
Accelerator pump capacity (ten strokes) . . . . . . . . . . . . . . . . . . . . . . . . 8.5 to 12.5 cc
Anti-flooding device (automatic - Y) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.75 to 4.25 mm
Anti-flooding device (mechanical - X) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 to 9.5 mm
Excess fuel discharge orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40
Exhaust gas CO at idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5%
Float setting (fuel level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 to 7.5 mm
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 to 900 rpm
Needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm
Primary and secondary valve plate openings:
X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 to 14.5 mm
Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 to 15.5 mm
Primary valve plate opening (X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.45 to 6.95 mm
Throttle valve plate opening - fast idle (A) . . . . . . . . . . . . . . . . . . . . . . . 0.90 to 0.95 mm
Primary Secondary
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 195
Accelerator pump jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 40
Auxiliary venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 5
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F42 F38
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 70
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 95
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.0 mm 23.0 mm
Solex C 30/32 - CIC8
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116 cc
All calibration as for the Weber 30/32 DMTE 10/150 except for the following:
Primary Secondary
Accelerator pump jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 50
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 190
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.5 40
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 100
Needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 1.6
Supplement: Revisions and information on later models 13•11
13

Ignition timing (in relation to distributor type)
At idle with vacuum hose disconnected and plugged:
Marelli SE101A and Ducellier 525473A . . . . . . . . . . . . . . . . . . . . . . . 2º BTDC
Marelli SE100EX, SE100CX and SE100NX . . . . . . . . . . . . . . . . . . . . . 10º BTDC
Marelli SE101G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3º BTDC
Marelli SE100SX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not available
Centrifugal advance (maximum):
Marelli SE101A and Ducellier 525473A . . . . . . . . . . . . . . . . . . . . . . . 26 to 30º BTDC
Marelli SE100EX and SE100CX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 26º BTDC
Marelli SE100NX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 to 22º BTDC
Marelli SE101G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 to 27º BTDC
Marelli SE100SX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 24º BTDC
Vacuum advance (maximum):
Marelli SE101A, Ducellier 525473A and Marelli SE101G . . . . . . . . . . 12 to 14º BTDC
Marelli SE100NX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 to 16º BTDC
Marelli SE100EX and SE100CX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 to 14º BTDC
Marelli SE100SX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 to 17º BTDC
Digiplex 2 (1372 cc ie)
General
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marelli Digiplex 2 electronic
Spark plug type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RN9YCC or RN9YC
Spark plug electrode gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm
Ignition timing
At 800 to 850 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 to 6º BTDC
Maximum advance (at 4500 to 6200 rpm
with 0.6 bar/8.7 lbf/in
2vacuum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 to 48º BTDC
Component testing values
Ignition coil:
Primary resistance at 23ºC (73ºF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.405 to 0.495 ohms
Secondary resistance at 23ºC (73ºF) . . . . . . . . . . . . . . . . . . . . . . . . . 4320 to 5280 ohms
Engine speed/TDC sensor:
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680 to 920 ohms
Sensor-to-flywheel tooth gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 to 0.8 mm
Microplex (1301 cc Turbo ie)
General
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marelli Microplex electronic
Spark plug type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC7YCC or RC7YC
Spark plug electrode gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm
Rotor arm resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 to 1200 ohms
Ignition timing
At idle with vacuum hose detached:
Up to mid 1988 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 12º BTDC
From mid 1988 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 to 11.5º BTDC
Maximum advance:
Up to mid 1988 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 to 40º BTDC
From mid 1988 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.5 to 35.5 BTDC
Component testing values
Ignition coil:
Primary winding resistance at 20ºC (68ºF) . . . . . . . . . . . . . . . . . . . . . 0.31 to 0.37 ohms
Secondary winding resistance at 20ºC (68ºF) . . . . . . . . . . . . . . . . . . 3330 to 4070 ohms
Engine speed sensor:
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 to 748 ohms
Sensor-to-flywheel tooth gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 1.3 mm
TDC sensor:
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 to 748 ohms
Sensor-to-crankshaft pulley tooth gap . . . . . . . . . . . . . . . . . . . . . . . . 0.4 to 1.0 mm
Microplex (1372 cc Turbo ie)
General
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marelli Microplex electronic ignition
Spark plug type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC7BYC4
Spark plug electrode gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 mm
Supplement: Revisions and information on later models 13•13
13

Ignition timing
At idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8º to 12º BTDC
Maximum advance (at 4000 to 6000 rpm
with 0.377 bars/5.5 lbf/in
2 vacuum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32º to 36º BTDC
Component testing values
Ignition coil:
Primary resistance at 20ºC (68ºF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 to 0.49 ohms
Secondary resistance at 20ºC (68ºF) . . . . . . . . . . . . . . . . . . . . . . . . . 4320 to 5280 ohms
Engine speed sensor:
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 to 748 ohms
Sensor to flywheel teeth clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 1.3 mm
TDC sensor:
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 to 748 ohms
Sensor to crankshaft pulley tooth gap . . . . . . . . . . . . . . . . . . . . . . . . 0.4 to 1.0 mm
Clutch
Pedal height
All later models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 to 146 mm
Driven plate diameter
903, 999 and 1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 mm
1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 mm
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.5 mm
1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 mm
Transmission
General
Type number:
903, 999,1108 and 1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.501.5.10
999 and 1108 (from 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.514
1372 cc, Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.510.5.17
Final drive ratios
903 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.071:1
999 and 1108 cc (except C514 type transmission) . . . . . . . . . . . . . . . . 3.733:1
999 cc (with C514 type transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . 3.866:1
1108 cc (with C514 type transmission) . . . . . . . . . . . . . . . . . . . . . . . . . 3.733:1
1301 cc Turbo ie (without Antiskid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.588:1
1301 cc Turbo ie (with Antiskid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.562:1
1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.353:1
Oil type/specification:
1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fiat ZC 80/S gear oil
Driveshafts
Roadwheels
Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1/2 J x 13
Tyres
Turbo ie
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175/60 HR 13
Pressures:
Front and rear, normal load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 bars
Front, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 bars
Rear, full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 bars
Spare wheel tyre size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50B x 13 FH
Spare wheel tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 bars
1372 cc ie with catalyst (1.4 ie S)
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155/70 SR 13
Pressures:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 bars
Rear - normal load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 bars
Rear - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 bars
13•14 Supplement: Revisions and information on later models

Torque wrench settingsNm lbf ft
Driveshaft flange connecting bolts (Turbo ie) . . . . . . . . . . . . . . . . . . . . . 43 32
Final drive output shaft bearing cover bolts (Turbo ie) . . . . . . . . . . . . . . 24 18
Intermediate shaft support to crankcase (Turbo ie) . . . . . . . . . . . . . . . . 48 35
Braking system (903, 999, 1108, 1116 and 1372 cc)
General
Note:The following items differ, or are additional to those specified in Chapter 8:
Master cylinder bore diameter:
903 cc, 999 cc, 1108 cc and 1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . 19.05 mm
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.65 mm
Vacuum servo diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.4 mm
Hydraulic push rod-to-master cylinder support plate clearance . . . . . . 0.825 to 1.025 mm
Braking system (1301 and 1372 cc Turbo ie)
General
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-wheel discs, ventilated front, solid rear. Vacuum servo. Pressure
regulating valve on rear brakes
Master cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.225 mm
Vacuum servo diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177.8 mm
Front disc brakes
Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240.0 mm
Disc thickness - new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9 to 20.1 mm
Disc thickness - minimum (refinishing) . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6 mm
Disc thickness - minimum (wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2 mm
Minimum thickness of pad friction material . . . . . . . . . . . . . . . . . . . . . . 1.5 mm
Caliper cylinder diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.0 mm
Rear disc brakes
Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227.0 mm
Disc thickness - new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 to 10.9 mm
Disc thickness minimum (refinishing):
1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 mm
1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35 mm
Disc thickness - minimum (wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 mm
Minimum thickness of pad friction material . . . . . . . . . . . . . . . . . . . . . . 1.5 mm
Caliper cylinder diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.0 mm
Torque wrench settingsNm lbf ft
Front caliper cylinder housing mounting bolts . . . . . . . . . . . . . . . . . . . . 52 38
Front caliper support bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 38
Front disc fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Rear caliper support bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Rear caliper cylinder housing mounting bolts . . . . . . . . . . . . . . . . . . . . 52 38
Electrical system
Battery
Turbo ie engine models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Ah
Fuses (903, 999, 1116, 1299/1301 and 1301 cc Turbo ie)
Fuse No. Rating Circuit
1 7.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH tail, RH front parking, rear number plate, check panel
2 7.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH tail, LH front parking, cigar lighting, clock light, heater control
illumination, map reading lamp.
3 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH headlamp main beam
4 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH headlamp main beam and warning light
5 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator cooling fan, econometer and horns
6 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cigar lighter, courtesy lamps, digital clock, stop-lamp switch, clock
and radio
7 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH headlamp dipped beam
8 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH headlamp dipped beam, rear fog warning lamp and indicator
9 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated rear screen and warning lamp
10 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel, stop-lamps, direction indicators, reversing lamps
and warning module
11 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater fan, fan control illumination and digital clock
12 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen wiper, washer pump and rear screen wiper
13 - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare
14 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard warning lamps and indicator
Supplement: Revisions and information on later models 13•15
13

General dimensions, weights and capacities
Dimensions
Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3689 mm
Overall width:
Base and Super models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1558 mm
SX and Turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1562 mm
Height (unladen):
1372 cc (except Turbo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1425 mm
1299/1301 cc (except Turbo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1420 mm
Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1405 mm
All other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1415 mm
Weights (kerb)
Note: 3-door model weights are given. Add 15 kg to the following for 5-door models. Weight will also vary according to the model version.
903 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740 kg
999 cc (45, 45 S and 45 SX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740 to 775 kg
1108 cc (60 S and 60 SX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 760 to 795 kg
1299/1301 cc (70 SX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 770 kg
1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845 kg
1372 cc (1.4 ie S catalyst) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 830 kg
1372 cc ie (70 SX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795 to 845 kg
1732 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925 kg
Capacities
Fuel tank:
1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 litres
All other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 litres
Engine oil (with filter change):
903, 999 and 1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 litres
1116, 1299/1301 and 1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 litres
Transmission:
1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 litres
1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 litres
All other engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 litres
Cooling system:
903, 999 and 1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 litres
1116 and 1299/1301 cc, non-catalyst 1372 cc ie . . . . . . . . . . . . . . . 6.2 litres
1372 cc ie with catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 litres
1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 litres
1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 litres
Supplement: Revisions and information on later models 13•17
13

13•18 Supplement: Revisions and information on later models
Every 9000 miles (15 000 km) or
12 months (whichever comes first)
m mCheck the tyre pressures and their condition
(including the spare)
m mWhere a pad wear warning light is fitted, check its
operation
m mCheck the front brake disc pads for excessive wear
m mCheck the underbody condition (fuel and brakes
pipes, exhaust system, hoses, bushes and gaiters)
m mCheck the condition and tension of drivebelts
m mCheck the engine idle speed and CO emissions
m mCheck the EGR system (If fitted)
m mCheck fluid levels (coolant, brake fluid and
windscreen washer)
m mRenew spark plugs (1372 cc Turbo models)
m mRenew the engine oil and oil filter (non-Turbo
models)
m mCheck the HT leads and connections
m mCheck the condition of all coolant, fuel and
hydraulic hoses and connections
Every 18 000 miles (30 000 km) or
24 months (whichever comes first)
In addition to the items listed for 9000 mile (15 000 km) or 12 months
service
m mCheck the rear brake disc pads for wear (where
applicable)
m mCheck/adjust the valve clearances
m mCheck and tighten (if necessary), inlet and exhaust
manifolds
m mCheck the clutch adjustment (cable operated
models)
m mRenew the fuel filter (where applicable)
m mRenew the air cleaner element
m mRenew the spark plugs and check the HT leads
and connections (all models)
m mWhere applicable, have the ignition and injection
systems checked (special equipment needed)
m mRenew coolant
m mRenew brake fluid
Every 28 000 miles (45 000 km) or
36 months (whichever comes first)
In addition to the items listed for 9000 mile (15 000 km) or 12 months
service
m mCheck Lambda (oxygen) sensors operation (special
equipment needed)
m mCheck fuel evaporation system (where fitted)
m mCheck the transmission oil level
m mCheck the condition crankcase ventilation system
Every 37 000 miles (60 000 km) or
48 months (whichever comes first)
In addition to the items listed for 18 000 mile (30 000 km) or
24 months service
m mCheck the condition of the rear brake shoe linings
m mCheck the condition of the timing belt
Every 65 000 miles (105 000 km)
m
mRenew the timing belt
Every 74 500 miles (120 000 km)
m
mRenew the manual transmission oil
Every 250 miles (400 km), weekly or
before a long journey
m mProceed as described for the earlier models at the
start of this manual
Every 6000 miles (10 000 km) or
12 months (whichever comes first)
m mRenew the engine oil and oil filter (Turbo models
only)
3 Routine maintenance- all models from June 1991
The maintenance intervals in this manual are provided with the
assumption that you, not the dealer, will be carrying out the work.
These are the minimum maintenance intervals recommended by us, for
vehicles driven daily. If you wish to keep your vehicle in peak condition
at all times, you may wish to perform some of these procedures more
often. We encourage frequent maintenance, since it enhances the
efficiency, performance and resale value of your vehicle.
If the vehicle is driven in dusty areas, used to tow a trailer, or driven
frequently at slow speeds (idling in traffic) or on short journeys, more
frequent maintenance intervals are recommended.
When the vehicle is new, it should be serviced by an authorised
dealer to preserve the factory warranty.

4 Engine-
903 and 1299/1301 cc
Sump pan sealing strips (903 cc
engine) - modification
1The design of the sealing strips which go
between the sump pan and the main bearing
caps has been changed. Make sure that the
narrower side of the strip fits into the channel
in the sump pan.
1299 cc engine - description
2In April 1984, a 1299 cc engine was
introduced, progressively replacing the
1301 cc units used previously. The new
engine is identical to the 1301 cc engine
described in Chapter 1, with the exception of
having a slightly shorter stroke.
3However, as of approximately September
1987, the 1299 cc unit was phased out, being
progressively replaced by the 1301 cc engine
used initially.
4As mentioned above, the two engines are
all but identical, so identification of the unit
fitted should not be necessary in practice.
Consult a FIAT dealer if in doubt.
Rocker cover (903 cc engine) -
removal
5Before removing the rocker cover, it will be
necessary to remove the distributor, first.
Refer to Chapter 4 for more details.
Cylinder head (903 cc engine) -
refitting
6Modified cylinder head bolts are fitted to
903 cc models, from engine number 8581470.
When refitting the cylinder head, tighten each
head bolt, as described in Chapter 1, by the
torques and angles shown the Specifications
in this Chapter.
5 Engine-
999 and 1108 cc (FIRE)
Note:Later models are fitted with SPi fuel
injection. Where a procedure refers to a
carburettor, if applicable, replace with throttle
body.
PART A: GENERAL
Description
1Both of these engine types are designated
FIRE (Fully Integrated Robotised Engine),
being largely manufactured and assembled by
computer-controlled mechanical robots.
2The engine is of oversquare design, having
four cylinders and a belt-driven overhead
camshaft.
3The high torque of this engine enableshigher gear ratios to be used with the result
that fuel economy is exceptionally good.
4The cylinder head is of light alloy, while the
cylinder block is cast-iron.
5The camshaft is supported in three
bearings which have detachable caps.
6Valve clearances are maintained by shims
located in the cam followers (tappets).
7The cylinder head is of crossflow type
having the intake manifold (coolant-heated)
and exhaust manifold on opposite sides.
8The pistons have two compression rings
and one oil control ring and are connected to
the connecting rods by means of a gudgeon
pin which is an interference fit in the rod
small-end.
9The crankshaft is supported in five main
bearings. The upper section of the centre
bearing shell retains semi-circular thrust
washers to control crankshaft endfloat.
10The oil pump, which is of gear type, is
Supplement: Revisions and information on later models 13•19
Fig. 13.2 Cross-section view of the 999 and 1108 cc engine (Sec 5A)
Fig. 13.1 Correct method of fitting sump
pan sealing strip (Sec 4)
13

mounted on the front end of the crankshaft
and driven by it.
11The flexible toothed timing belt drives thecamshaft and the coolant pump from a
sprocket on the front end of the crankshaft.
The belt is tensioned by an
eccentrically-mounted pulley.
12The distributor and the fuel pump
(carburettor models) are driven from the
flywheel end of the camshaft. The fuel pump
on fuel injection models is an integral unit
combined with the fuel gauge sender unit and
immersed in the fuel tank.
PART B:
OPERATIONS POSSIBLE
WITH ENGINE IN CAR
Valve clearances - adjustment
1The operations are similar to those
described in Chapter 1, Section 26, but note
that the special tools referred to have differentpart numbers for the FlRE engine -
1860443000 and 1887001000 (photos).
2Remember that the clearance for inlet and
exhaust valves differs see Specifications at
the beginning of this Supplement.
3Counting from the timing cover end of the
engine, the valve sequence is as follows.
Inlet 2-4-5-7
Exhaust 1-3-6-8
Timing belt - renewal #
4Remove the air cleaner.
5Slacken and remove the alternator
drivebelt, then remove the spark plugs.
6Unbolt and remove the timing belt cover.
Note the bolt located at the bottom of the
cover, this can be easily overlooked (photo).
7Unbolt and remove the crankshaft pulley
(photo).
13•20 Supplement: Revisions and information on later models
5B.7 Unscrewing the crankshaft pulley
bolts5B.6 Timing cover lower fixing bolt
removal5B.1B Using a modified C-spanner and
screwdriver to remove a shim
5B.1A Checking a valve clearance
Fig. 13.3 Longitudinal sectional view of the 999 and 1108 cc
engine (Sec 5A)Fig. 13.4 999 and 1008 cc engine lubrication system (Sec 5A)

8Turn the crankshaft sprocket bolt, or
engage top gear and raise and turn a front
roadwheel, until the camshaft sprocket TDC
timing mark is aligned with the mark on the
cylinder head and the crankshaft sprocket
timing mark is aligned with the mark on the oil
pump cover (photos).
9Release the nut on the timing belt
tensioner, move the pulley away from the belt
and retighten the nut to hold the pulley in the
retracted position (photo).
10Slide the drivebelt from the sprockets.
11When refitting the new belt, make sure
that the sprocket timing marks are still in
alignment and fit the belt so that the arrows
on the belt point in the direction of engine
rotation, and the lines of the belt coincide with
the sprocket marks.
12Engage the timing belt with the crankshaft
sprocket first, then place it around the coolant
pump sprocket and the camshaft sprocket
(photo). Finally slip the belt around the
tensioner pulley.
13Release the tensioner nut and push the
pulley against the belt until the belt is quite
taut. Check that the sprocket timing marks
have not moved out of alignment. If they have,
reset them by moving them over the belt
teeth.
14Still applying force to the pulley, tighten its
nut.
15Turn the crankshaft through two complete
turns in the normal direction of rotation and
check that when the centre of the longest runof the belt is gripped between finger and
thumb it can just be twisted through 90º. If
increased tension is required to achieve this,
release the tensioner nut and prise the pulley
against the timing belt. Note: The above
procedure serves only as a rough guide to
setting the belt tension having it checked by a
FIAT dealer at the earliest opportunity is
recommended.
16Refit the timing belt cover, the crankshaft
pulley, alternator drivebelt, spark plugs and
the air cleaner.
Camshaft -
removal and refitting#
Warning: Refer to the beginning
of Section 9 before starting any
work.
17Remove the air cleaner and the fuel pump(carb. models), as described in Section 9 of
this Supplement.
18Remove the distributor (Section 10).
19Remove the timing belt cover.
20Unbolt and remove the camshaft cover,
having first disconnected the HT lead clip
(photos).
21Turn the crankshaft (by engaging top gear
and raising and turning a front roadwheel)
until No. 4 piston is at TDC. The timing mark
on the camshaft sprocket will be in alignment
with the mark on the cylinder head.
22Pass a rod through one of the holes in the
camshaft sprocket to prevent it rotating and
then unscrew the sprocket fixing bolt. Slip the
sprocket from the camshaft and out of the
loop of the belt (photos).
23Mark the camshaft bearing caps as to
position and then unbolt and remove the
Supplement: Revisions and information on later models 13•21
5B.9 Releasing the timing belt tensioner
nut5B.8B Crankshaft sprocket timing mark
and oil pump cover alignment mark
(arrowed)5B.8A Camshaft sprocket timing mark and
cylinder head timing mark in alignment
5B.22B Camshaft sprocket bolt and
washer5B.22A Unscrewing the camshaft sprocket
bolt
5B.20A Camshaft cover HT lead clip5B.12 Fitting the timing belt
5B.20B Removing the camshaft cover
13