FIAT UNO 1983 Service User Guide
Manufacturer: FIAT, Model Year: 1983, Model line: UNO, Model: FIAT UNO 1983Pages: 303, PDF Size: 10.36 MB
Page 11 of 303
Routine maintenance0•11
Engine compartment (air cleaner removed for clarity) on 55S model
1 Strut upper mounting
2 Washer fluid reservoir
3 Brake fluid reservoir
4 Ignition coil5 Throttle cable
6 Carburettor
7 Battery
8 Timing belt cover9 Distributor
10 Oil filler cap
11 Radiator electric cooling
fan12 Radiator
13 Coolant expansion tank
14 Front mounting
15 Clutch operating cable
Page 12 of 303
0•12Routine maintenance
View of front end from below on
55S model
1 Tie-rod end
2 Track control arm
3 Lower mounting
4 Gearchange control rods
5 Exhaust pipe
6 Driveshafts
7 Transmission
8 Sump drain plug
9 Disc caliper
10 Front mounting
11 Horns
12 Radiator
13 Oil filter
View of rear end from below
1 Suspension trailing arm
2 Fuel tank filler hose
3 Rear axle beam
4 Rear silencer
5 Spring seat
6 Expansion box
7 Handbrake cable
8 Fuel tank support strap
9 Fuel tank
10 Handbrake cable adjuster
Page 13 of 303
Lubricants and Fluids0•13
Component or system Lubricant type/specification
1 EngineMultigrade engine oil, viscosity SAE 15W/40, meeting API-SG or CCMC
G2/G3 specification (or equivalent multigrade engine oil with viscosity
rating suitable for ambient temperature in which vehicle is operated -
see owner’s handbook)
2 Transmission:
1372 cc Turbo ie model FIAT ZC 80/S gear oil
All other models FIAT ZC 90 gear oil
3 Cooling systemEthylene glycol based antifreeze
4 Brake and clutch hydraulic system(s)Hydraulic fluid to DOT 3 or 4, or SAE J1703C
5 Driveshaft CV joints and steering rackLithium based molybdenum disulphide
General greasingMulti-purpose lithium based grease
Page 14 of 303
0•14Conversion Factors
Length (distance)
Inches (in) x 25.4 = Millimetres (mm) x 0.0394 = Inches (in)
Feet (ft) x 0.305 = Metres (m) x 3.281 = Feet (ft)
Miles x 1.609 = Kilometres (km) x 0.621 = Miles
Volume (capacity)
Cubic inches (cu in; in3) x 16.387 = Cubic centimetres (cc; cm3) x 0.061 = Cubic inches (cu in; in3)
Imperial pints (Imp pt) x 0.568 = Litres (l) x 1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt) x 1.137 = Litres (l) x 0.88 = Imperial quarts (Imp qt)
Imperial quarts (Imp qt) x 1.201 = US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)
US quarts (US qt) x 0.946 = Litres (l) x 1.057 = US quarts (US qt)
Imperial gallons (Imp gal) x 4.546 = Litres (l) x 0.22 = Imperial gallons (Imp gal)
Imperial gallons (Imp gal) x 1.201 = US gallons (US gal) x 0.833 = Imperial gallons (Imp gal)
US gallons (US gal) x 3.785 = Litres (l) x 0.264 = US gallons (US gal)
Mass (weight)
Ounces (oz) x 28.35 = Grams (g) x 0.035 = Ounces (oz)
Pounds (lb) x 0.454 = Kilograms (kg) x 2.205 = Pounds (lb)
Force
Ounces-force (ozf; oz) x 0.278 = Newtons (N) x 3.6 = Ounces-force (ozf; oz)
Pounds-force (lbf; lb) x 4.448 = Newtons (N) x 0.225 = Pounds-force (lbf; lb)
Newtons (N) x 0.1 = Kilograms-force (kgf; kg) x 9.81 = Newtons (N)
Pressure
Pounds-force per square inch x 0.070 = Kilograms-force per square x 14.223 = Pounds-force per square inch
(psi; lbf/in2; lb/in2) centimetre (kgf/cm2; kg/cm2) (psi; lbf/in2; lb/in2)
Pounds-force per square inch x 0.068 = Atmospheres (atm) x 14.696 = Pounds-force per square inch
(psi; lbf/in
2; lb/in2)(psi; lbf/in2; lb/in2)
Pounds-force per square inch x 0.069 = Bars x 14.5 = Pounds-force per square inch
(psi; lbf/in
2; lb/in2)(psi; lbf/in2; lb/in2)
Pounds-force per square inch x 6.895 = Kilopascals (kPa) x 0.145 = Pounds-force per square inch
(psi; lbf/in
2; lb/in2)(psi; lbf/in2; lb/in2)
Kilopascals (kPa) x 0.01 = Kilograms-force per square x 98.1 = Kilopascals (kPa)
centimetre (kgf/cm
2; kg/cm2)
Millibar (mbar) x 100 = Pascals (Pa) x 0.01 = Millibar (mbar)
Millibar (mbar) x 0.0145 = Pounds-force per square inch x 68.947 = Millibar (mbar)
(psi; lbf/in
2; lb/in2)
Millibar (mbar) x 0.75 = Millimetres of mercury (mmHg) x 1.333 = Millibar (mbar)
Millibar (mbar) x 0.401 = Inches of water (inH
2O) x 2.491 = Millibar (mbar)
Millimetres of mercury (mmHg) x 0.535 = Inches of water (inH
2O) x 1.868 = Millimetres of mercury (mmHg)
Inches of water (inH
2O) x 0.036 = Pounds-force per square inch x 27.68 = Inches of water (inH2O)
(psi; lbf/in2; lb/in2)
Torque (moment of force)
Pounds-force inches x 1.152 = Kilograms-force centimetre x 0.868 = Pounds-force inches
(lbf in; lb in) (kgf cm; kg cm) (lbf in; lb in)
Pounds-force inches x 0.113 = Newton metres (Nm) x 8.85 = Pounds-force inches
(lbf in; lb in)(lbf in; lb in)
Pounds-force inches x 0.083 = Pounds-force feet (lbf ft; lb ft) x 12 = Pounds-force inches
(lbf in; lb in)(lbf in; lb in)
Pounds-force feet (lbf ft; lb ft) x 0.138 = Kilograms-force metres x 7.233 = Pounds-force feet (lbf ft; lb ft)
(kgf m; kg m)
Pounds-force feet (lbf ft; lb ft) x 1.356 = Newton metres (Nm) x 0.738 = Pounds-force feet (lbf ft; lb ft)
Newton metres (Nm) x 0.102 = Kilograms-force metres x 9.804 = Newton metres (Nm)
(kgf m; kg m)
Power
Horsepower (hp) x 745.7 = Watts (W) x 0.0013 = Horsepower (hp)
Velocity (speed)
Miles per hour (miles/hr; mph) x 1.609 = Kilometres per hour (km/hr; kph) x 0.621 = Miles per hour (miles/hr; mph)
Fuel consumption*
Miles per gallon (mpg) x 0.354 = Kilometres per litre (km/l) x 2.825 = Miles per gallon (mpg)
Temperature
Degrees Fahrenheit = (°C x 1.8) + 32 Degrees Celsius (Degrees Centigrade; °C) = (°F - 32) x 0.56
* It is common practice to convert from miles per gallon (mpg) to litres/100 kilometres (l/100km), where mpg x l/100 km = 282
Page 15 of 303
1
903 cc engine
Type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four cylinder in-line, liquid cooled, overhead valve. Transversely
mounted with end-on transmission
General
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.0 mm (2.56 in)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.0 mm (2.68 in)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903 cc (55 cu in)
Compression ratio:
900 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 : 1
900 ES models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 : 1
Maximum power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 kW at 5600 rev/min (45 bhp)
Maximum torque (DIN):
900 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Nm at 3000 rev/min (49 lbf ft)
900 ES models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Nm at 3000 rev/min (51 lbf ft)
Compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 to 10.35 bar (135 to 150 lbf/in2)
Maximum pressure difference between cylinders . . . . . . . . . . . . . . . . . 0.69 bar (10 lbf/in2)
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 - 4 - 2 (No. 1 at crankshaft pulley end)
Chapter 1 Engine
For modifications, and information applicable to later models, see Supplement at end of manual
Part 1: General
Crankcase ventilation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Major operations possible without removing the engine
from the car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Part 2: 903 cc engine
Cylinder head - dismantling and decarbonising . . . . . . . . . . . . . . . . 17
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine - complete dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine - complete reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine - dismantling (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine - initial start-up after overhaul or major repair . . . . . . . . . . . . 24
Engine - method of removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine - reassembly (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine - refitting ancillary components . . . . . . . . . . . . . . . . . . . . . . . 21
Engine - removing ancillary components . . . . . . . . . . . . . . . . . . . . . 15
Engine mountings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine/transmission - reconnection . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine/transmission - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine/transmission - removal and separation . . . . . . . . . . . . . . . . . 13
Examination and renovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fault finding - all engines . . . . . . . . . . . . . . . . . . . . See end of Chapter
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pistons/connecting rods - removal and refitting . . . . . . . . . . . . . . . . 9Sump pan - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Timing chain and sprockets - removal and refitting . . . . . . . . . . . . . 6
Valve clearances - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Part 3: 1116 cc and 1301 cc engines Camshaft and camshaft carrier - removal and refitting . . . . . . . . . . 27
Cylinder head - dismantling and decarbonising . . . . . . . . . . . . . . . . 39
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine - complete dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Engine - complete reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Engine - dismantling (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Engine - initial start-up after major overhaul . . . . . . . . . . . . . . . . . . . 45
Engine - method of removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Engine - reassembly (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Engine ancillary components - refitting . . . . . . . . . . . . . . . . . . . . . . . 43
Engine ancillary components - removal . . . . . . . . . . . . . . . . . . . . . . 37
Engine mountings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Engine/transmission - reconnection and refitting . . . . . . . . . . . . . . . 44
Engine/transmission - removal and separation . . . . . . . . . . . . . . . . . 35
Examination and renovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fault finding - all engines . . . . . . . . . . . . . . . . . . . . See end of Chapter
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Pistons/connecting rods - removal and refitting . . . . . . . . . . . . . . . . 32
Sump pan - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Timing belt - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Valve clearances - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Valve clearances - checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1•1
Specifications Contents
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
Page 16 of 303
Cylinder block and crankcase
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast-iron
Bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.000 to 65.050 mm (2.5591 to 2.5610 in)
Diameter of camshaft bearing bores in crankcase timing gear end:
Grade B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.505 to 50.515 mm (1.9882 to 1.9886 in)
Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.515 to 50.525 mm (1.9886 to 1.9890 in)
Grade D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.705 to 50.715 mm (1.9960 to 1.9964 in)
Grade E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.715 to 50.725 mm (1.9964 to 1.9968 in)
Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.420 to 46.450 mm (1.8275 to 1.8287 in)
Flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.921 to 35.951 mm (1.4142 to 1.4154 in)
Maximum cylinder bore taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm (0.0006 in)
Maximum cylinder bore ovality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm (0.0006 in)
Pistons and piston rings
Piston diameter:
Grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.940 to 64.950 mm (2.5566 to 2.5570 in)
Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.960 to 64.970 mm (2.5574 to 2.5578 in)
Grade E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.980 to 64.990 mm (2.5582 to 2.5586 in)
Oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2, 0.4, 0.6 mm (0.008, 0.016, 0.024 in)
Piston clearance in cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.070 mm (0.0020 to 0.0028 in)
Piston ring groove width:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.785 to 1.805 mm (0.0703 to 0.0711 in)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.015 to 2.035 mm (0.0793 to 0.0801 in)
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.975 to 3.977 mm (0.1566 to 0.1567 in)
Piston ring thickness:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.728 to 1.740 mm (0.0680 to 0.0685 in)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.978 to 1.990 mm (0.0779 to 0.0784 in)
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.925 to 3.937 mm (0.1545 to 0.1550 in)
Piston ring groove clearance:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 to 0.077 mm (0.0018 to 0.0030 in)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 to 0.057 mm (0.0010 to 0.0022 in)
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.052 mm (0.0008 to 0.0020 in)
Piston ring end gap:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.45 mm (0.0098 to 0.0177 in)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 to 0.35 mm (0.0078 to 0.0137 in)
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 to 0.45 mm (0.0078 to 0.0177 in)
Oversize piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2, 0.4, 0.6 mm (0.008, 0.016, 0.024 in)
Gudgeon pin diameter:
Grade 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.970 to 19.974 mm (0.7862 to 0.7863 in)
Grade 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.974 to 19.978 mm (0.7863 to 0.7865 in)
Grade 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.978 to 19.982 mm (0.7865 to 0.7866 in)
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.008 in)
Crankshaft
Journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.785 to 50.805 mm (1.9994 to 2.0002 in)
Standard main bearing shell thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 1.832 to 1.837 mm (0.0721 to 0.0723 in)
Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254, 0.508, 0.762,1.016 mm (0.010, 0.020. 0.030, 0.040 in)
Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 to 0.26 mm (0.0024 to 0.0102 in)
Crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.985 to 40.005 mm (1.5741 to 1.5750 in)
Standard big-end shell bearing thickness . . . . . . . . . . . . . . . . . . . . . . . 1.807 to 1.813 mm (0.0712 to 0.0714 in)
Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254, 0.508, 0.762, 1.016 mm (0.010, 0.020, 0.030, 0.040 in)
Camshaft
Diameter of camshaft journals:
Timing end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.975 to 38.000 mm (1.4951 to 1.4961 in)
Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.348 to 43.373 mm (1.7079 to 1.7088 in)
Flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.975 to 31.000 mm (1.2194 to 1.2205 in)
Bush reamed diameters:
Timing gear end* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.025 to 38.050 mm (1.4971 to 1.4981 in)
Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.404 to 43.424 mm (1.7088 to 1.7096 in)
Flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.026 to 31.046 mm (1.2215 to 1.2223 in)
*Supplied reamed to size
Cam lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 mm (0.201 in)
Outside diameter of cam follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.982 to 14.000 mm (0.5505 to 0.5512 in)
Oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.010 mm (0.002 to 0.004 in)
Cam follower running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 to 0.046 mm (0.0004 to 0.0018 in)
1•2 Engine – general
Page 17 of 303
Cylinder head and valves
Material (cylinder head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light alloy
Maximum distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in)
Valve guide bore in head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.950 to 12.977 mm (0.5099 to 0.5109 in)
Valve guide outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.010 to 13.030 mm (0.5122 to 0.5130 in)
Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5, 0.10, 0.25 mm (0.002, 0.004, 0.010 in)
Inside diameter of valve guide (reamed) . . . . . . . . . . . . . . . . . . . . . . . . . 7.022 to 7.040 mm (0.2765 to 0.2772 in)
Guide fit in head (interference) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.033 to 0.080 mm (0.0013 to 0.0032 in)
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.982 to 7.000 mm (0.2748 to 0.2756 in)
Maximum clearance (valve stem to guide) . . . . . . . . . . . . . . . . . . . . . . . 0.022 to 0.058 mm (0.0009 to 0.0023 in)
Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44º 55’ to 45º 05’
Valve face angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45º 25’ to 45º 35’
Valve head diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.0 mm (1.1417 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.0 mm (1.0236 in)
Contact band (valve to seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 to 1.5 mm (0.0512 to 0.0591 in)
Valve clearance:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in)
For timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in)
Valve timing:
Inlet valve:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7º BTDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36º ABDC
Exhaust valve:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5º ATDC
Lubrication system
Oil pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear, driven by shaft from camshaft
Tooth tip to body clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.14 mm (0.0020 to 0.0055 in)
Gear endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.105 mm (0.0008 to 0.0041 in)
Oil pressure at normal operating temperature and average road/
engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.94 to 3.92 bar (42 to 57 lbf/ in
2)
Oil capacity (with filter change) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42 litre (6.0 pint)
Oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multigrade engine oil, viscosity SAE 15W/40
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C101
Torque wrench settingsNm lbf ft
Cylinder head bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 43.5
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 51
Big-end bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 30
Crankshaft pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 72
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 32
Rocker pedestal nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 29
Engine mounting bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Engine mounting centre nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Temperature sender switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Driveshaft to hub nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 200
Hub carrier to strut clamp bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 63
Brake caliper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 39
Tie-rod end balljoint nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 25
Driveshaft inboard boot retainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Engine – general 1•3
1
Page 18 of 303
1116 cc and 1301 cc engine
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four cylinder in-line, liquid cooled single overhead camshaft.
Transversely mounted with end-on transmission
General1116 cc 1301 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.0 mm (3.15 in) 86.4 mm (3.40 in)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 mm (2.19 in) 55.5 mm (2.19 in)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116 cc (68.08 cu in) 1301 cc (79.36 cu in)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 : 1 9.1 : 1
Maximum power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.5 kW (55 bhp) at 5600 rev/min50 kW (68 bhp) at 5700 rev/min
Maximum torque (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.3 Nm (64 lbf ft) at 100 Nm (74 lbf ft)
2900 rev/min at 2900 rev/min
Compression pressure (bore wear test) . . . . . . . . . . . . . . . . . . . . . . . . . 10.35 to 11.73 bar (150 to 170 lbf/in
2)
Pressure difference between cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 0.96 bar (14 lbf/ in2)
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 - 4 - 2 (No. 1 at crankshaft pulley end)
Pistons and piston rings
Piston diameter - 1116 cc:
Grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.940 to 79.950 mm (3.1496 to 3.1500 in)
Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.960 to 79.970 mm (3.1504 to 3.1508 in)
Grade E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.980 to 79.990 mm (3.1512 to 3.1516 in)
Piston diameter - 1301 cc:
Grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.320 to 86.330 mm (3.4010 to 3.4014 in)
Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.340 to 86.350 mm (3.4018 to 3.4022 in)
Grade E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.360 to 86.370 mm (3.4025 to 3.4030 in)
Oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2, 0.4, 0.6 mm (0.008, 0.016, 0.023 in)
Piston clearance in cylinder bore:
1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.070 mm (0.0020 to 0.0027 in)
1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.070 to 0.090 mm (0.0027 to 0.0035 in)
Piston ring groove width - 1116 cc:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.535 to 1.555 mm (0.1442 to 0.1461 in)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.015 to 2.035 mm (0.0794 to 0.0802 in)
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.957 to 3.977 mm (0.1559 to 0.1567 in)
Piston ring groove width - 1301 cc:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.535 to 1.555 mm (0.0605 to 0.0613 in)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.030 to 2.050 mm (0.0800 to 0.0808 in)
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.967 to 3.987 mm (0.1563 to 0.1571 in)
Piston ring thickness:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.478 to 1.490 mm (0.0582 to 0.0587 in)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.978 to 1.990 mm (0.0779 to 0.0784 in)
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.925 to 3.937 mm (0.1546 to 0.1551 in)
Oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2, 0.4, 0.6 mm (0.008, 0.016, 0.023 in)
Piston ring groove clearance - 1116 cc:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 to 0.077 mm (0.0018 to 0.0030 in)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 to 0.057 mm (0.0010 to 0.0022 in)
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.052 mm (0.0008 to 0.0020 in)
Piston ring groove clearance - 1301 cc:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 to 0.077 mm (0.0018 to 0.0030 in)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 to 0.072 mm (0.0016 to 0.0028 in)
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 to 0.062 mm (0.0012 to 0.0024 in)
Piston ring end gap - 1116 cc:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.45 mm (0.0012 to 0.0018 in)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 to 0.35 mm (0.008 to 0.014 in)
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 to 0.35 mm (0.008 to 0.014 in)
Piston ring end gap - 1301 cc:
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.45 mm (0.012 to 0.016 in)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.50 mm (0.012 to 0.020 in)
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.40 mm (0.010 to 0.016 in)
Gudgeon pin diameter - 1116 cc:
Grade 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.970 to 21.974 mm (0.8656 to 0.8658 in)
Grade 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.974 to 21.978 mm (0.8658 to 0.8659 in)
Grade 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.978 to 21.982 mm (0.8659 to 0.8661in)
Gudgeon pin diameter - 1301 cc:
Grade 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.991 to 21.994 mm (0.8664 to 0.8666 in)
Grade 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.994 to 21.997 mm (0.8666 to 0.8667 in)
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.008 in)
1•4 Engine – general
Page 19 of 303
Crankshaft
Journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.785 to 50.805 mm (1.9994 to 2.0002 in)
Standard main bearing shell thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 1.825 to 1.831 mm (0.0719 to 0.0721 in)
Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254, 0.508, 0.762, 1.016 mm (0.010. 0.020, 0.030, 0.040 in)
Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 to 0.26 mm (0.0024 to 0.0102 in)
Crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.498 to 45.518 mm (1.7926 to 1.7934 in)
Standard big-end shell bearing thickness . . . . . . . . . . . . . . . . . . . . . . . 1.531 to 1.538 mm (0.0603 to 0.0606 in)
Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254, 0.508, 0.762, 1.016 mm (0.010, 0.020, 0.030, 0.040 in)
Camshaft
Number of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diameter of camshaft journals:
No. 1 (timing end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.944 to 29.960 mm (1.1798 to 1.1804 in)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.935 to 47.950 mm (1.8886 to 1.8892 in)
No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.135 to 48.150 mm (1.8965 to 1.8971 in)
No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.335 to 48.350 mm (1.9044 to 1.9050 in)
No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.535 to 48.550 mm (1.9122 to 1.9129 in)
Cam lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 mm (0.3467 in)
Camshaft bearing diameters in carrier:
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.990 to 30.014 mm (1.1816 to 1.1825 in)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.980 to 48.005 mm (1.8904 to 1.8913 in)
No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.180 to 48.205 mm (1.8982 to 1.8992 in)
No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.380 to 48.405 mm (1.9062 to 1.9072 in)
No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.580 to 48.605 mm (1.9141 to 1.9150 in)
Outside diameter of cam follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.975 to 36.995 mm (1.4568 to 1.4576 in)
Cam follower running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 to 0.050 mm (0.0002 to 0.0020 in)
Lubrication system
Oil pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear driven from auxiliary shaft
Tooth tip to body clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 to 0.180 mm (0.0043 to 0.0071 in)
Gear endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.105 mm (0.0008 to 0.0041 in)
Oil pressure at normal operating temperature and average road/
engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43 to 4.9 bar (50 to 71 lbf/in
2)
Oil capacity (with filter change) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.05 litre (7.1 pint)
Oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multigrade engine oil, viscosity SAE 15W/40
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C106
Cylinder head and valves
Head material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light alloy
Maximum distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in)
Valve guide bore in head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.950 to 13.977 mm (0.5496 to 0.5507 in)
Valve guide outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.040 to 14.058 mm (0.5532 to 0.5539 in)
Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05, 0.10, 0.25 mm (0.002, 0.004, 0.010 in)
Inside diameter of valve guide (reamed) . . . . . . . . . . . . . . . . . . . . . . . . . 8.022 to 8.040 mm (0.3161 to 0.3168 in)
Valve guide fit in cylinder head (interference) . . . . . . . . . . . . . . . . . . . . . 0.063 to 0.108 mm (0.0025 to 0.0043 in)
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.974 to 7.992 mm (0.3142 to 0.3149 in)
Maximum clearance (valve stem to guide) . . . . . . . . . . . . . . . . . . . . . . . 0.030 to 0.066 mm (0.0012 to 0.0026 in)
Valve face angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45º 25’ to 45º 35’
Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44º 55’ to 45º 05’
Valve head diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.850 to 36.150 mm (1.4125 to 1.4243 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.850 to 31.450 mm (1.2155 to 1.2391 in)
Contact band (valve to seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 to 1.5 mm (0.0512 to 0.0591 in)
Valve clearance:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.0158 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.0197 in)
For timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.0315 in)
Valve clearance adjusting shim thicknesses . . . . . . . . . . . . . . . . . . . . . 3.25 to 4.70 mm (0.128 to 0.185 in), in increments of 0.05 mm
(0.002 in)
Valve timing:
Inlet valve:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7º BTDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35º ABDC
Exhaust valve:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5º ATDC
Engine – general 1•5
1
Page 20 of 303
Auxiliary shaft
Bearing internal diameter (reamed):
No. 1 (timing belt end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.664 to 35.684 mm (1.4052 to 1.4059 in)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.000 to 32.020 mm (1.2608 to 1.2616 in)
Shaft journal diameter:
No. 1 (timing belt end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.593 to 35.618 mm (1.4024 to 1.4033 in)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.940 to 31.960 mm (1.2584 to 1.2592 in)
Cylinder block and crankcase
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast-iron
Bore diameter:
1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.000 to 80.050 mm (3.152 to 3.154 in)
1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.400 to 86.450 mm (3.404 to 3.406 in)
Maximum cylinder bore taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm (0.0006 in)
Maximum cylinder bore ovality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm (0.0006 in)
Torque wrench settingsNm lbf ft
Cylinder head bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn through 90º Turn through 90º
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn through 90º Turn through 90º
Camshaft carrier to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59
Big-end cap nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 38
Flywheel mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 61
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 61
Belt tensioner bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 32
Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 21
Auxiliary shaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 61
Flexible mounting bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 44
Flexible mounting centre nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 24
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 63
Driveshaft/hub nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 200
Tie-rod end balljoint nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 25
Brake caliper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 39
Front strut lower clamp bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Driveshaft inboard boot retainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Crankshaft pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 7
1•6 Engine – general
Part 1: General
1 Description
1The Uno may be powered by one of three
engines depending upon the particular model.
903 cc
2This is of four cylinder overhead valve type
with a light alloy cylinder head and a cast-iron
block and crankcase.
3A three bearing crankshaft is used and the
chain-driven camshaft runs in three steel
backed white metal bearings.
4The light alloy pistons are fitted with two
compression and one oil control ring. The
gudgeon pin is an interference fit in the small
end of the connecting rod.
5Lubrication is provided by an oil pump
within the sump pan and both the pump and
the distributor are driven from a gear on the
camshaft. Pressurised oil passes through acartridge type oil filter. An oil pressure relief
valve is incorporated in the oil pump. The
engine oil is independent of the transmission
lubricant.
1116 cc and 1301 cc
6These engines are of single overhead
camshaft type, the camshaft being driven by a
toothed belt.
7The difference in engine capacity is
achieved by increasing the cylinder bore on
the 1301 cc engine.
8The cylinder head is of light alloy while the
cylinder block and crankcase are of cast-iron
construction.
9A five bearing crankshaft is used and the
camshaft runs in a similar number of bearings,
but as these are in-line bored directly in the
camshaft carrier, no repair is possible.
10The pistons are of light alloy with two
compression and one oil control ring. The
gudgeon pin is an interference fit in the small
end of the connecting rod.
11An auxiliary shaft, driven by the timing belt
is used to drive the distributor, oil pump and
fuel pump.12The oil pump is located within the sump
pan and incorporates a pressure relief valve.
13Pressurised oil passes through a cartridge
type oil filter.
14The crankshaft main bearings are
supplied under pressure from drillings in the
crankcase from the main oil gallery whilst the
connecting rod big-end bearings are
lubricated from the main bearings by oil
forced through the crankshaft oilways. The
camshaft bearings are fed from a drilling from
the main oil gallery. The cams and tappets are
lubricated by oil mist from outlets in the
camshaft bearings.
15The cylinder walls, pistons and gudgeon
pins are lubricated by oil splashed up by the
crankshaft webs. An oil pressure warning light
is fitted to indicate when the pressure is too
low.
All engines
16The engine is mounted transversely with
the transmission at the front of the car.
17The engine oil is independent of the
transmission lubricant.