FIAT UNO 1983 Service Repair Manual

new oil seal, ensuring that it is correctly
orientated, and drive it squarely into position.
149Refit all disturbed components.
Flywheel - removal,
inspection and refitting#
150If not already done, remove the clutch as
described in Chapter 5.
151Prevent the flywheel from turning by
jamming the ring gear teeth, or by bolting a
strap between the flywheel and the cylinder
block.
152Make alignment marks on the flywheel
and the end of the crankshaft, so that the
flywheel can be refitted in its original position.
153Unscrew the securing bolts and remove
the washer plate, then withdraw the flywheel.
Do not drop it, it is very heavy.
154With the flywheel removed, the ring gear
can be examined for wear and damage.
155If the ring gear is badly worn or has
missing teeth it should be renewed. The old
ring gear can be removed from the flywheel by
cutting a notch between two teeth with a
hacksaw and then splitting it with a cold
chisel. Wear eye protection when doing this.
156Fitting of a new ring gear requires heating
the ring to a temperature of 80ºC (176ºF). Do
not overheat, or the hard-wearing properties
will be lost. The gear has a chamfered inner
edge which should fit against the shoulder on
the flywheel. When hot enough, place the gear
in position quickly, tapping it home ifnecessary, and let it cool naturally without
quenching in any way.
157Ensure that the mating faces are clean,
then locate the flywheel on the rear of the
crankshaft, aligning the previously made
marks on the flywheel and crankshaft.
158Fit the washer plate, and insert the
securing bolts, then prevent the flywheel from
turning as described in paragraph 151 whilst
the bolts are tightened progressively to the
specified torque setting in a diagonal
sequence (photos).
159If applicable, refit the clutch as described
in Chapter 5.
Sump -
removal and refittingÁ
160Drain the engine oil from the sump as
described in Chapter 1.
161Disconnect the lead from the engine oil
level sensor in the sump.
162Unscrew and remove the bolts retaining the
gear linkage mounting bracket (where applicable)
and the clutch housing lower cover bolts.
Remove the cover from the clutch housing.
163Unscrew and remove the sump retaining
bolts and nuts and lower the sump from the
crankcase. Recover the gasket.
164Clean all traces of old gasket from the
sump, crankcase and both oil seal housing
mating surfaces.
165Commence reassembly by applying
sealing compound (FIAT No. 5882442 orequivalent) to the joints between the
crankshaft front and rear oil seal housings and
the mating face of the crankcase (photo).
166Locate the new gasket in position on the
crankcase then fit the sump. As it is fitted it
will need to be twisted to avoid fouling the oil
pump unit. Refit the retaining bolts and nuts
and tighten them to the specified torque
(photos).
167Check that the sump drain plug is refitted
and fully tightened. If the engine is in the car,
top up the engine oil level.
Oil pump - removal,
checking and refittingª
168Drain the engine oil and remove the
sump as described in the previous
sub-Section.
169Unscrew the retaining bolts then
withdraw the oil pump and intake pipe/filter
from its location within the crankcase.
Remove the gasket.
170If oil pump wear is suspected, first check
the cost and availability of new parts and the
cost of a new pump. Then examine the pump
as described below and decide whether
renewal or repair is the best course of action.
171Unscrew the three securing bolts and
remove the oil pump cover (photo). Note that
as the cover is removed, the oil pressure relief
valve components will be released.
172Recover the oil pressure relief valve,
spring and spring seat.
13•46 Supplement: Revisions and information on later models
7B.166C . . . and insert the retaining bolts7B.166B . . . refit the sump . . .7B.166A Locate the new gasket . . .
7B.165 Apply sealant to the front oil seal
housing/cylinder block joint7B.158B . . . tighten the bolts to the
specified torque7B.158A Locate the flywheel, washer plate
and bolts . . .

173Lift the intermediate plate from the oil
pump body.
174The gears can now be removed from the
oil pump body. Inspect them for obvious signs
of wear or damage, and renew if necessary.
175Commence reassembly by lubricating
the gears with clean engine oil, and refitting
them to the casing. Note that the scribed
marks on the top faces of the gears should
face each other with the gears installed
(photo).
176Using a feeler gauge, check that the
clearance between the gears and the pump
body is within the limits given in the Specifica-
tions (photo).
177Using a straight-edge placed across the
top of the pump body and the gears, and a
feeler gauge, check that the gear endfloat is
within the limits given in the Specifications
(photo).
178If either the gear-to-body clearance, or
the gear endfloat is outside the specified
limits, both gears should be renewed.
179Locate the intermediate plate on the
pump body (photo).
180Place the pressure relief valve and spring
over the pressure relief hole in the
intermediate plate, and locate the spring seat
over the boss in the pump cover, then refit the
pump cover, ensuring that the pressure relief
valve components seat correctly (photos).
181Refit and tighten the pump cover
securing bolts.
182Thoroughly clean the mating faces of thepump and crankcase before refitting the
pump. Prime the pump by injecting clean
engine oil into it and turning it by hand.
183Fit the pump using a new gasket, then
insert the securing bolts and tighten them.
184Refit the sump and top up the engine oil
level.
Pistons/connecting rods -
removal and refitting#
185Remove the sump and the cylinder head
as described previously in this Section.
186The big-end caps and connecting rods
normally have identification marks stamped
into their sides, facing the coolant pump side
of the cylinder block. If no marks are present,
use a centre-punch to identify the bearing
caps and the connecting rods for location.187Turn the crankshaft so that No. 1
crankpin is at its lowest point, then unscrew
the nuts and tap off the bearing cap. Keep the
bearing shells in the cap and the connecting
rod if they are to be re-used, taping them in
position if necessary to avoid loss.
188Using the handle of a hammer, push the
piston and connecting rod up the bore and
withdraw it from the top of the cylinder block.
Loosely refit the cap to the connecting rod.
189Repeat the procedure given in
paragraphs 187 and 188 on No. 4 piston and
connecting rod, then turn the crank-
shaft through half a turn and repeat the
procedure on Nos 2 and 3 pistons and
connecting rods.
190The pistons and connecting rods and the
big-end bearings can be examined and if
Supplement: Revisions and information on later models 13•47
7B.176 Check gear-to-body clearance7B.175 Correct alignment of scribed marks
(arrowed) on gears7B.171 Undo the oil pump cover bolts
7B.180C . . . then fit the cover7B.180B Locate spring seat over boss
within pump cover . . .
7B.179 Refitting the intermediate plate7B.177 Checking the gear endfloat
7B.180A Locate pressure relief valve and
spring on the intermediate plate
13

necessary renovated as described later in this
Section.
191Commence refitting as follows.
192Clean the backs of the bearing shells and
the recesses in the connecting rods and
big-end caps.
193Lubricate the cylinder bores with engine
oil.
194Fit a ring compressor to No. 1 piston, theninsert the piston and connecting rod into No. 1
cylinder. With No 1 crankpin at its lowest point,
drive the piston carefully into the cylinder with
the wooden handle of a hammer (photos).
Leave enough space between the connecting
rod and the crankshaft to allow the bearing
shell to be fitted. The piston must be fitted with
the cut-out in the piston crown on the auxiliary
shaft side of the engine, and the cylinder identi-
fication marking on the connecting rod and
big-end cap on the coolant pump side of the
engine - see Fig. 13.21.
195Slide the appropriate bearing shell into
position in the connecting rod big-end, then
pull the connecting rod firmly into position on
the crankpin (photo).
196Press the appropriate bearing shell into
position in the big-end cap (photo).
197Oil the crankpin, then fit the big-end
bearing cap with the cylinder identification
marking on the coolant pump side of the
engine, and tighten the nuts to the specified
torque setting (photos).
198Check that the crankshaft turns freely.
199Repeat the procedure in paragraphs 194
to 198 inclusive on the remaining pistons.
200Refit the cylinder head and the sump.
Pistons/connecting rods -
examination and
renovation
#
201The procedures for inspecting and
renovating the pistons and connecting rod
assemblies are in general the same as thatdescribed for the smaller engines in Sec-
tion 18 of Chapter 1. However, the following
additional points should be noted.
202When renewing a gudgeon pin, first
check the fit in the piston. It should be
possible to fit the gudgeon pin using hand
pressure, but the pin should be a tight enough
fit that it does not drop out under its own
weight. Oversize gudgeon pins are available
as spares if necessary. Use new circlips when
refitting the pistons to the connecting rods.
203Before fitting the pistons to their
connecting rods, weigh each piston and
check that their weights are all within 2.5 g of
each other. If not, the heavier pistons must be
lightened by machining metal from the
underside of the small-end bosses. This
operation must be entrusted to a FIAT dealer
or engine reconditioning specialist.
204The pistons should be fitted to the
connecting rods so that the higher, flat side of
the piston crown is on the side of the
connecting rod with the stamped cylinder
identification number, ie the gudgeon pin is
offset towards the cylinder identification
number see Fig. 13.21.
205The piston rings should be fitted with the
word “TOP” on each ring facing uppermost,
or if no marks are visible, as noted during
removal. If a stepped top compression ring is
being fitted, fit the ring with the smaller
diameter of the step uppermost. The ring end
gaps should be offset 120º from each other.
Use two or three old feeler gauges to assist
13•48 Supplement: Revisions and information on later models
7B.197B . . . and tighten the nuts to the
specified torque
Fig. 13.21 Correct orientation of piston
and connecting rod in engine - 1372 cc ie
and Turbo ie engines (Sec 7B)
1 Auxiliary shaft
2 Cylinder identification markings on
connecting rod and big-end cap
Arrow denotes direction of engine rotation
Note offset gudgeon pin
7B.197A . . . then fit the cap . . .7B.196 . . . and big-end bearing cap . . .
7B.195 Assemble the shell bearing to the
connecting rod . . .7B.194B Tapping a piston into its bore7B.194A Fitting a ring compressor to a
piston

fitting, as during removal. Note that the
compression rings are brittle, and will snap if
expanded too far.
206If new pistons are to be fitted, they must
be selected from the grades available, after
measuring the cylinder bores. Normally, the
appropriate oversize pistons are supplied by
the dealer when the block is rebored.
207Whenever new piston rings are being
installed, the glaze on the original cylinder
bores should be removed using either
abrasive paper or a glaze-removing tool in an
electric drill. If abrasive paper is used, use
strokes at 60º to the bore centre-line, to
create a cross-hatching effect.
Engine/transmission
mountings - renewalÁ
208The engine/gearbox assembly is
suspended in the engine compartment on
three mountings, two of which are attached to
the gearbox, and one to the engine.
Right-hand mounting
209Apply the handbrake, then jack up the
front of the vehicle and support it securely on
axle stands.
210Suitable lifting tackle must now be
attached to the engine in order to support it as
the engine mounting is removed. No lifting
brackets are provided, so care must be taken
when deciding on an engine lifting point. In the
workshop, a right-angled bracket was made up
by bending a suitable piece of steel plate. The
bracket was then bolted to the engine using the
rear right-hand camshaft housing securing bolt
with suitable packing washers.
211Attach the lifting tackle to the bracket on
the engine and just take the weight of the
assembly.
212Working under the vehicle, unbolt the
engine mounting bracket from the cylinder
block, and unbolt the mounting from the
body, then withdraw the bracket/mounting
assembly.
213Unscrew the nut and through-bolt,
counter holding the bolt with a second
spanner or socket, and separate the mounting
from the bracket.
214Fit the new mounting to the bracket, and
tighten the nut to the specified torque, while
counterholding the through-bolt using a
suitable spanner or socket.
215Refit the mounting bracket to the cylinder
block, and tighten the securing bolts to the
specified torque.
216Refit the mounting to the body and
tighten the securing bolts to the specified
torque.
217Disconnect the lifting tackle from the
engine, and remove the engine lifting bracket.
218Lower the vehicle to the ground.
Left-hand mountings
219Apply the handbrake, then jack up the
front of the vehicle and support it securely on
axle stands.
220Suitable lifting tackle must now be
attached to the gearbox lifting bracket inorder to support the weight of the assembly
as the mounting is removed.
221Attach the lifting tackle to the bracket on
the gearbox, and just take the weight of the
assembly.
222Working under the vehicle, unbolt the
mounting bracket from the gearbox, and
unbolt the mounting from the body, then
withdraw the bracket/mounting assembly.
223Proceed as described in paragraphs 213
and 214.
224Refit the mounting bracket to the
gearbox, and tighten the securing bolts to the
specified torque.
225Refit the mounting to the body and
tighten the mounting bolts to the specified
torque.
226Disconnect the lifting tackle from the
engine.
227Lower the vehicle to the ground.
PART C: ENGINE REMOVAL
AND DISMANTLING
Method of removal - general
1The engine (complete with transmission) is
disconnected and lowered downwards
through the engine compartment, then
withdrawn from the front underside of the car.
1372 cc engine/
transmission - removal
and separation
#
Warning: Refer to the beginning
of Section 9 before starting any
work.
2Depressurize the fuel system as described
in Section 9 of this Chapter.
3Disconnect the battery negative lead.
4Mark the position of the hinges on the
underside of the bonnet, then with the aid of
an assistant, unscrew the hinge bolts and lift
the bonnet clear of the car. Store the bonnet
in a safe area.
5Drain the engine coolant.
6Drain the engine and transmission oils.
7Disconnect and remove the air filter.
8Disconnect the coolant hoses from the
engine, including the hose to the inlet
manifold.
9Detach the ignition coil (HT) lead from the
distributor.10Compress the retaining clip and detach
the engine idle speed actuator lead from the
SPi unit (photo).
11Disconnect the brake servo vacuum pipe
from its connector on the inlet manifold.
12Disconnect the throttle cable from the SPi
unit.
13Disconnect the engine speed sensor lead.
14Release and detach the reversing light
lead from the switch on the transmission
(photo).
15Before disconnecting the hydraulic hose
from the clutch slave cylinder, remove the
filler cap from the reservoir and place a piece
of polythene sheet over the filler neck, then
refit the cap; this will help prevent excess fluid
loss. Once disconnected, plug the hose and
its cylinder connection to prevent the ingress
of dirt into the hydraulic system.
16Disconnect the wiring connector from the
alternator.
17Position a clean rag under the fuel supply
and return hose connections to the SPi unit,
then slowly unscrew the hose clips to release
the system pressure; catch fuel leakage in the
rag and dispose of it safely. Detach the hoses
and plug them to prevent ingress of dirt and
any further fuel leakage. Position the hoses
out of the way.
18Detach the wiring connector from the
engine coolant temperature sender unit
(photo).
19Release the retaining clip and detach the
wiring connector from the throttle position
switch. Also detach the associated earth
leads from the cylinder head.
Supplement: Revisions and information on later models 13•49
7C.14 Reversing light switch and lead7C.18 Engine coolant temperature sender
and wiring connector
7C.10 Engine idle speed actuator/SPi unit
lead connection (arrowed)
13

20Release the retaining clip and detach the
wiring connector from the fuel injector
connection (photo).
21Loosen off the front wheel bolts each
side, then raise and support the car at the
front end on axle stands. When raised,
support at a height which will allow the engine
and transmission to be withdrawn from the
underside when fully disconnected. Ensure
that the vehicle is securely supported before
working underneath it.
22Unscrew the wheel bolts and remove the
front roadwheels.
23Release the retaining clips and remove
the underwing shield from the right- and
left-hand front wheel arch.24Relieve the staking, then unscrew and
remove the front hub nut using a socket and
suitable extension. Repeat the procedure on
the opposite front hub.
25Unscrew the retaining nut and disconnect
the tie-rod to steering arm balljoint using a
suitable balljoint separator tool. Repeat the
procedure on the other side.
26Note the direction of fitting, then unscrew
and remove the hub-to-strut retaining bolts
and nuts on each side.
27Unscrew and remove the anti-roll bar-
to-track control arm retaining nuts each side.
28Unscrew and remove the front brake
caliper hydraulic pipe support bracket bolt
each side.29Pull the wheel hub outwards and detach
the driveshaft from it, noting that there may be
a small amount of oil spillage as it is
withdrawn. Repeat the procedure on the
opposite side.
30Disconnect the wiring connector from the
engine oil level sensor lead.
31Unscrew the retaining nuts to detach and
remove the exhaust pipe front section or
alternatively, remove the system complete.
32Unscrew the knurled retaining nut and
detach the speedometer cable from the
transmission (photo).
33Unscrew the retaining nut and detach the
earth strap from the transmission (photo).
34Extract the split pin and detach the gear
selector rod from the transmission pin.
Disconnect the gear engagement and selector
levers from the balljoints.
35The weight of the engine will now need to
be supported from above. Connect a suitable
lift hoist and sling to the engine. When
securely connected, take the weight of the
engine/transmission unit so that the tension is
relieved from the mountings.
36Unscrew and remove the engine and
transmission support mounting bolts at the
points indicated (photos).
37The engine/transmission unit should now
be ready for removal from the vehicle. Check
that all of the associated connections and
13•50 Supplement: Revisions and information on later models
Fig. 13.22 The underwing
shield retaining clips (arrowed)
on the 1372 cc ie and Turbo ie
engines (Sec 7C)Fig. 13.25 Gear engagement
and selector lever balljoints
(arrowed) on the 1372 cc ie and
Turbo ie engines (Sec 7C)Fig. 13.23 Engine oil level
sensor wiring connector
(arrowed) on the 1372 cc ie and
Turbo ie engines (Sec 7C)Fig. 13.24 Disconnect the gear
selector rod at the connection
indicated on the 1372 cc ie and
Turbo ie engines (Sec 7C)
7C.33 Disconnect the transmission earth
strap7C.32 Disconnecting the speedometer
drive cable from the transmission7C.20 Fuel injector wiring connection
7C.36B Transmission rear mounting7C.36A Engine right-hand mounting

fittings are disconnected from the engine and
transmission and positioned out of the way.
Enlist the aid of an assistant to help steady
and guide the power unit down through the
engine compartment as it is removed, If
available, position a suitable engine trolley or
crawler board under the engine/transmission
so that when lowered, the power unit can be
withdrawn from the front end of the vehicle
and moved to the area where it is to be
cleaned and dismantled.
38Carefully lower the engine and
transmission unit, ensuring that no fittings
become snagged. Detach the hoist and
withdraw the power unit from under the
vehicle.
39To separate the engine from the
transmission, unbolt and remove the starter
motor, then unscrew the retaining bolts and
withdraw the transmission from the engine. As
it is withdrawn, do not allow the weight of the
engine or transmission to be taken by the
input shaft.
40To remove the clutch unit, refer to
Chapter 5 for details.
1372 cc Turbo ie
engine/transmission -
removal and separation
#
41The engine and transmission removal and
refitting details for Turbo-engined models are
similar to those described for the non-Turbo
models in the previous sub-Section, but the
following differences should be noted.
42To provide access for the disconnection
of the turbo and related components, first
remove the inlet manifold. Removal of the inlet
manifold and the turbocharger is described in
Section 9 of this Chapter.
43The ignition distributor on the Turbo
engine is driven from the auxiliary shaft and is
mounted at the front of the engine, towards
the timing cover end.
44The right-hand driveshaft has a steady
bearing and this will need to be unbolted and
detached.
Engine dismantling - general
45Refer to Chapter 1, Section 14 for details.
Auxiliary shaft - removal,
inspection and refitting #
46Remove the engine and transmission from
the vehicle as described previously in this
Section part.
47Drain the engine oil and remove the sump
as described in Part B of this Section.
48Remove the oil pump as described in Part
B of this Section.
49Remove the timing belt and the auxiliary
shaft sprocket as described in Part B of this
Section.
50Unscrew the three retaining bolts and
remove the auxiliary shaft cover. Remove the
gasket.
51Withdraw the auxiliary shaft from the
cylinder block.
52Examine the shaft and its bearing bushes
in the cylinder block for signs of excessive
wear and/or damage and renew it if
necessary. Bush renewal is described in
paragraph 79 in this Section.
53The cover gasket and the oil seal should
always be renewed whenever the cover is
removed. To renew the seal, support the
cover on blocks of wood and drive out the old
seal using a suitable drift inserted in the
cut-out in the back of the cover. Clean the
seal location in the housing. Drive the new
seal into place using a suitable metal tube or
socket (photo). The sealing lip must face
towards the cylinder block. Smear the sealing
lips with clean engine oil before installation.
54Commence refitting by lubricating theauxiliary shaft journals with clean engine oil,
then insert the shaft into the cylinder block
(photo).
55Refit the auxiliary shaft cover, using a new
gasket, and tighten the securing bolts
(photos).
56Refit the auxiliary shaft sprocket, timing
belt, cover and crankshaft pulley as described
in Part B of this Section.
57Refit the engine and transmission with
reference to Part D of this Section.
Engine -
complete dismantling#
Warning: Refer to the beginning
of Section 9 before starting any
work.
58Detach and remove the following ancillary
items. Where applicable, refer to the
appropriate Chapter or Section within this
Chapter for more detailed removal instructions.
Engine oil dipstick
Ignition distributor and HT leads
Fuel pump
Alternator
Oil filter
Oil vapour recovery unit
Inlet and exhaust manifolds and associated
fuel injection components (as applicable)
Clutch unit
59Refer to Part B of this Section for details
and remove the timing cover and drivebelt.
60Refer to Part B of this Section for details
and remove the cylinder head unit.
Supplement: Revisions and information on later models 13•51
7C.54 Inserting the auxiliary shaft into the
cylinder block (rear timing belt cover
removed)7C.53 Driving a new oil seal into the
auxiliary shaft cover7C.36C Transmission front mounting
7C.55B . . . and tighten the securing bolts7C.55A Refit the auxiliary shaft cover with
a new gasket . . .
13

61Refer to Part B of this Section for details
and remove the flywheel.
62Refer to the previous sub-Section for
details and remove the auxiliary shaft.
63Refer to Part B of this Section for details
and remove the sump.
64Refer to Part B of this Section for details
and remove the oil pump unit.
65Refer to Part B of this Section for details
and remove the front and rear crankshaft oil
seals.
66Refer to Part B of this Section and remove
the piston/connecting rod assemblies.
67Refer to Part B of this Section for details
and remove the crankshaft and main bearing
assemblies.
Crankshaft and main
bearings - removal#
68Unscrew the securing bolts and remove
the front and rear crankshaft oil seal housings.
Recover the gaskets.
69Check the main bearing caps for identifi-
cation marks and if necessary use a
centre-punch to identify them. Normally the
caps have identifying notches cut into their
top face nearest the timing belt end of the
engine, with the exception of No 5 cap
(flywheel end) which has no marking (photo).
70Before removing the crankshaft, check
that the endfloat is within the specified limits.
Ideally a dial gauge should be used, but
alternatively feeler gauges can be used as
follows. Push the crankshaft as far as possible
towards the timing end of the engine, and
using a feeler gauge, measure the gap
between the rear face of the flywheel
mounting flange on the crankshaft and the
outer face of the thrust washer (photo). Now
push the crankshaft as far as possible in the
opposite direction and take the same
measurement again. The difference between
the two measurements is the crankshaft
endfloat. If the endfloat is outside the
specified limits, new thrustwashers will be
required.
71Unscrew the bolts and tap off the main
bearing caps complete with bearing shells. If
the bearing shells are to be re-used, tape
them to their respective caps.
72Lift the crankshaft from the crankcase.
73Extract the bearing shells from thecrankcase, keeping them identified for
location if they are to be re-used, and recover
the thrust washers from No. 5 main bearing
location.
Engine components -
examination and
renovation
#
74With the engine completely stripped,
clean all the components and examine them
for wear. Each part should be checked and
where necessary renewed or renovated as
described elsewhere in this Section. Renew
main and big-end bearing shells as a matter of
course, unless it is known that they have had
little wear and are in perfect condition.
75If in doubt as to whether to renew a
component which is still just serviceable,
consider the time and effort which will be
incurred should the component fail at an early
date. Obviously the age and expected life of
the vehicle must influence the standards
applied.
76Gaskets, oil seals and O-rings must all be
renewed as a matter of course. FIAT specify
that the main cylinder head bolts should be
renewed after they have been used (ie
tightened) four times - if in any doubt as to the
number of times the bolts have been used,
renew them in any case as a precaution
against possible failure.
77Take the opportunity to renew the engine
core plugs while they are easily accessible.
Knock out the old plugs with a hammer and
chisel or punch. Clean the plug seats, smearthe new plugs with sealant and tap them
squarely into position.
78Clean and examine the cylinder block as
described in paragraphs 2 to 7 of Section 18,
Chapter 1.
79If the auxiliary shaft bushes are
excessively worn or are oval, they must be
renewed. When the new bushes are installed,
they may need to be reamed to suit. The
renewal of the auxiliary shaft bushes is
therefore best entrusted to an engine
reconditioner or FIAT dealer. When the
bushes are renewed, ensure that the oil hole
in each bush is aligned with the oil channel in
the cylinder block.
PART D: ENGINE
REASSEMBLY
Reassembly - general
1Refer to Chapter 1, Section 19.
Crankshaft and main
bearings - refitting#
2Ensure that the crankcase and crankshaft
are thoroughly clean, and that the oilways are
clear. If possible, blow through the oil drillings
with compressed air, and inject clean engine
oil into them.
3Unless they are virtually new, the old main
bearing shells should be renewed. Failure to
do so is a false economy.
4If new bearing shells are being fitted, wipe
away all traces of protective grease.
5Note that there is a tag on the back of each
bearing shell, which engages with a groove in
the relevant seat in the crankcase or bearing
cap.
6Wipe clean the bearing shell locations in the
crankcase with a non-fluffy rag, then lubricate
them and fit the five upper halves of the
bearing shells to their seats. Note that the
centre (No. 3) bearing shell is plain, whereas
all the other shells have oil grooves (photos).
7Fit the thrustwashers to the No. 5 main
bearing shell location, with the grooved side
of each washer facing away from the face of
the cylinder block - ie towards the thrust face
of the crankshaft (photos).
8Wipe the bearing shell locations in the
13•52 Supplement: Revisions and information on later models
7D.6B . . . all others have oil groove7D.6A No. 3 main bearing shell is plain . . .
7C.70 Measuring crankshaft endfloat using
feeler gauge method7C.69 Identification notches on No. 3 main
bearing cap

bearing caps with a soft non-fluffy rag, then fit
the lower halves of the bearing shells to their
seats. Again, note that the centre (No. 3)
bearing shell is plain, whereas all the other
shells have oil grooves (photo).
9Lubricate the crankshaft journals and the
upper and lower main bearing shells with
clean engine oil (photo).
10Carefully lower the crankshaft into the
crankcase (photo). If necessary, seat the
crankshaft using light taps with a
rubber-faced hammer on the crankshaft
balance webs.
11Lubricate the crankshaft main bearing
journals again, the fit the No. 1 bearing cap.
Fit the two securing bolts, and tighten them as
far as possible by hand.
12Fit the No. 5 bearing cap, and as before
tighten the bolts as far as possible by hand.
13Fit the centre and then the intermediate
bearing caps, and again tighten the bolts as
far as possible by hand.
14Check that the markings on the bearing
caps are correctly orientated as noted during
dismantling - ie the identification grooves
should face towards the timing side of the
engine, then working from the centre cap
outwards in a progressive sequence, finally
tighten the bolts to the specified torque
(photo).
15Check that the crankshaft rotates freely.
Some stiffness is to be expected with new
components, but there should be no tight
spots or binding.16Check that crankshaft endfloat is within
the specified limits, as described in paragraph
70 of Part C in this Section.
17Examine the condition of the front and
rear crankshaft oil seals and renew if
necessary with reference to Part B of this
Section. It is advisable to renew the oil seals
as a matter of course unless they are in
perfect condition.
18Lubricate the oil seal lips with clean
engine oil, then carefully fit the front and rear
oil seal housings using new gaskets.
Pistons and connecting rods -
refitting
19Refer to Part B of this Section.
Oil pump - refitting
20Refer to Part B of this Section.
Sump - refitting
21Refer to Part B of this Section.
Flywheel - refitting
22Refer to Part B of this Section. When the
flywheel is bolted in position, refer to Chapter
5 for details and refit the clutch unit.
Auxiliary shaft - refitting
23Refer to Part C of this Section.
Cylinder head - refitting
24Refer to Part B of this Section. Note that
this procedure describes cylinder head
refitting complete with the camshaft housingassembly and manifolds as a complete unit.
Details of refitting the camshaft housing (and
followers) to the cylinder head will be found
separately in Part B.
Timing belt and covers -
refitting
25Refer to Part B of this Section.
Engine/transmission -
reconnection and refitting#
Note: A suitable hoist and lifting tackle will be
required for this operation. New locktabs will
be required for the exhaust
downpipe-to-manifold nuts, and suitable
exhaust assembly paste, will be required when
reconnecting the downpipes to the exhaust
manifold.
26Before attempting to reconnect the
engine to the gearbox, check that the clutch
friction disc is centralised as described in
Chapter 5, Section 8. This is necessary to
ensure that the gearbox input shaft splines
will pass through the splines in the centre of
the friction disc.
27Check that the clutch release arm and
bearing are correctly fitted, and lightly grease
the input shaft splines.
28Mate the engine and gearbox together,
ensuring that the engine adapter plate is
correctly located, and that the gearbox
locates on the dowels in the cylinder block,
then refit the engine-to-gearbox bolts and the
single nut, but do not fully tighten them at this
stage. Ensure that any brackets noted during
Supplement: Revisions and information on later models 13•53
7D.8 Locate the bearing shells into the
main bearing caps . . .7D.7B . . . sliding them into position each
side of the No. 5 main bearing
7DS.14 Tighten the main bearing cap bolts
to the specified torque setting7D.10 Lower the crankshaft into position7D.9 . . . and lubricate the shells
13
7D.7A Locate the thrust washer . . .

removal are in place under the
engine-to-gearbox bolts. Do not allow the
weight of the gearbox to hang on the input
shaft as it is engaged with the clutch friction
disc.
29Refit the starter motor, ensuring that the
wiring harness bracket is in position on the
top bolt.
30Locate the engine/transmission unit at the
front of the car and move it into position under
the engine compartment. Attach the lifting
sling and hoist as during removal.
31Enlist the aid of an assistant to help
steady the combined units as they are raised
into position and to locate the mountings in
the engine compartment.
32Once they are located, tighten the
mountings to the specified torque settings,
then disconnect the lifting hoist and sling.
33The remainder of the refitting and
reconnection procedures are a reversal of the
removal procedure described in Part C. For
further details on reconnecting the
suspension and driveshaft components,
refer to Chapter 7 and Section 13 of this
Chapter.
34Ensure that the exhaust downpipe-to-
manifold connection is clean and renew the
gasket when reconnecting this joint. Use a
smear of exhaust assembly paste on the jointfaces. Use new lockwashers and tighten the
flange nuts securely.
35Ensure that all fuel and coolant
connections are cleanly and securely made.
36Ensure that all wiring connections are
correct and securely made.
37Top up the engine and transmission oil
levels.
38Refill the cooling system.
39Check that all connections are securely
made, then reconnect the battery negative
lead.
Initial start-up after major
overhaul
40Refer to Chapter 1, Section 45.
8 Cooling system
PART A:
999 AND 1108 CC ENGINES
Description
1The operation and function of the cooling
system is essentially as described in Chapter
2 but note the location of the various
components and the routing of the coolant
hoses in Fig. 13.26.
Maintenance
2Topping-up, draining and refilling
procedures are as for 1116 and 1301 cc
engines in Chapter 2, but note that the
coolant capacity is different (see Specifica-
tions).
Thermostat -
removal and refittingÁ
3The thermostat is located on the left-hand
end of the cylinder head, below the
distributor.
4The thermostat cannot be renewed
independently of its housing and if faulty the
complete assembly must be renewed.
5Drain the cooling system.
6Although the thermostat housing can be
removed directly from the cylinder head,
better access is provided if the distributor is
first withdrawn as described in Section 10 of
this Chapter (photo).
7Disconnect the coolant hose from the
thermostat housing and unscrew the housing
flange bolts. Remove the assembly. Note that
it may be necessary to tap it free with a
plastic-faced or wooden mallet if stuck in
place.
8Remove the gasket and clean the mating
surfaces.
9Use a new gasket and bolt the assembly
into position (photo).
10Reconnect the coolant hose, then fill and
bleed the cooling system.
13•54 Supplement: Revisions and information on later models
Fig. 13.26 Cooling system circuit - 999 and 1108 cc engines (Sec 8A)
1 Coolant pump 2 Thermostat 3 Heater matrix
Fig. 13.27 Cooling system thermostat in open and closed positions - 999 and 1108 cc
engines (Sec 8A)8A.9 Fitting the thermostat housing. Note
the new gasket
8A.6 The thermostat housing (shown with
distributor removal) on the 999 cc engine

Coolant pump -
removal and refitting#
11The coolant pump is located on the
crankshaft pulley end of the engine and is
driven by the timing belt.
12The pump cannot be repaired and must
be regarded as disposable.
13Drain the cooling system.
14Remove the timing belt cover and then set
No. 1 piston to TDC. To achieve this, turn the
crankshaft pulley bolt until the camshaft
sprocket timing mark is aligned with the one
on the cylinder head.
15Release the belt tensioner and slip the
timing belt off the camshaft and coolant pump
sprockets.
16Unbolt and remove the coolant pump and
clean the mounting face of all old gasket
material.
17Apply a continuous bead of RTV silicone
sealant (instant gasket) to the mounting face
of the coolant pump and bolt it into position
(photos).
18Check that the camshaft sprocket and the
crankshaft have not been moved and fit the
timing belt to the camshaft and coolant pump
sprockets. The pump sprocket does not
require setting in any particular position
before connecting the timing belt.
19Tension the belt as described in Sec-
tion 5B of this Chapter.
20Fit the timing belt cover.
21After allowing one hour for the gasket
material to cure, refill and bleed the cooling
system.
PART B:
1301 CC TURBO IE ENGINE
Description
1The cooling system on this model has flow
and return connections to the turbocharger,
and is an essential means of cooling the
turbocharger.
2The radiator cooling fan is of two-speed
type, being controlled by a two-stage
thermostatic switch screwed into the radiator
side tank.
3According to the coolant temperature level,
the fan speed is regulated to provide the most
effective cooling.
4The remote cooling system expansion tank
is mounted in the left-hand rear corner of the
engine compartment (photo).
PART C:
1372 CC IE AND 1372 CC
TURBO IE ENGINES
Description
1The cooling system layout and components
for the 1372 cc engines is shown in
Figs. 13.29 and 13.30.
2The system on each engine operates in
essentially the same manner as that
described for the other models in Chapter 2,
but the location of components and the
coolant hose routings differ according to
model. The cooling system expansion tank
location differs according to model, being
either located on the side of the radiator ormounted separately on the side of the inner
wing panel.
3On Turbo models, the cooling system also
assists in cooling the turbocharger.
Maintenance
4The maintenance procedures are
essentially the same as those described for
the other models in Chapter 2.
Cooling system - draining,
flushing and refillingÁ
Warning: Wait until the engine is
cold before starting this
procedure. Do not allow
antifreeze to come into contact
with your skin or painted surfaces of the
vehicle. Rinse off spills immediately with
plenty of water. Never leave antifreeze
lying around in an open container or in a
puddle in the driveway or on the garage
floor. Children and pets are attracted by its
sweet smell. Antifreeze is fatal if ingested.
5Disconnect the battery negative lead.
6Working inside the vehicle, turn the heater
temperature control knob fully to the right,
which will fully open the heater coolant valve.
7With the expansion tank cap removed,
place a suitable container beneath the
radiator bottom hose.
8Loosen the clip and ease the bottom hose
away from the radiator outlet (photo). Allow
the coolant to drain into the container.
9Reposition the container under the front of
the cylinder block, and unscrew the cylinder
block drain plug (photo). Allow the coolant to
drain into the container.
Supplement: Revisions and information on later models 13•55
8A.17B Tightening the coolant pump bolts8A.17A Fitting the coolant pump to the
999 cc engineFig. 13.28 Sectional view of the coolant
pump on the 999 and 1108 cc engines
(Sec 8A)
8C.9 Cylinder block drain plug8C.8 Bottom hose connection to the
radiator8B.4 Topping up the expansion tank with
antifreeze on the 1301 cc engine
13