sensor FIAT UNO 1983 Service User Guide

3The centralised door locking system can
operate independently of the key.
4To gain access to the lock solenoid and
linkage, remove the front door trim panel as
described in Chapter 12.
5Disconnect the battery negative lead.
6Disconnect the electrical wiring plugs from
the solenoid within the door cavity.
7Disconnect the solenoid from the lock lever
by removing the clip.
8Unscrew the two bolts which secure the
solenoid to the door and remove it.
9Renew the solenoid or switch as necessary.
10Refitting is a reversal of removal.
11Refer to Section 10 for details of system
fuses and relays.
33 Economy gauge
(Econometer)
2
1This device is fitted to ES (energy saving)
models and indicates to the driver the fuel
consumption (in litres per 100 km) coupled
with a needle which moves over coloured
sections of a dial to make the driver aware
that his method of driving is either conducive
to high or low fuel consumption. Refer to
Chapter 3, Section 16.
2The device is essentially a vacuum gauge
which also incorporates a warning lamp to
indicate to the driver when a change of gear is
required.
3A fuel cut-out valve (see Chapter 3, Sec-
tion 11) is used in conjunction with the
economy gauge so that when the accelerator
pedal is released during a pre-determined
engine speed range, fuel supply to the engine
is stopped, but resumes when the engine
speed falls below the specified range.
LED (light emitter diode)
4The gearchange indicator will only light up
at engine speeds in excess of 2000 rev/min
for vacuum pressures up to 600 mm Hg in 1st,
2nd and 3rd speed gears and for vacuum
pressures up to 676 mm Hg in 4th speedgear. The light will not come on if 5th speed
gear is engaged or if the coolant temperature
is below 55ºC.
5There is a two second delay in the light
coming on to prevent it operating during rapid
acceleration in a low gear.
6If the LED light comes on during
deceleration it should be ignored.
Fault finding
7A faulty economy gauge should be checked
in the following way.
8Refer to Section 21 and remove the
instrument panel.
9Disconnect the economy gauge L
connector and then connect a test lamp
between the BN cable contact and earth. If
the lamp comes on then the gauge supply
circuit is not open. If the lamp does not come
on, check all connections in the supply cable
which comes from the interconnecting unit of
the electrical system, also Fuse No 12.
10Now connect a voltmeter between the
white cable and earth. Check the voltage with
the engine not running, but the ignition
switched on. It should be between 0.7 and
0.9 volt. If the reading varies considerably
from that specified, check the connections
between the economy gauge and the fuel
cut-out device control unit. If the fault cannot
be rectified, renew the ignition control unit
(Digiplex system, see Chapter 4).
11Now check the closed throttle valve plate
switch by connecting a voltmeter between the
brown and BN cables of the L connector. With
the valve plate open, there should be no
reading, but with it open, voltage should be
indicated.
12Failure to conform as described will be
due to a faulty earth in the switch or a faulty
fuel cut-out device control unit.
13A further test of the throttle valve plate
switch may be carried out by disconnecting
the multi-plug from the fuel cut-out device
control unit.
14Connect a test lamp to contact 4 (positive
battery terminal). The lamp should come on,
when the engine is idling or the accelerator
released. If it does not, renew the throttle
valve plate switch.15Connect a tachometer to the brown/white
cable contact in the L connector and record
the engine speed with the engine running. If
no reading is obtained, renew the Digiplex
ignition control unit which must be faulty.
34 Check control (warning
module) system
2
1This is fitted into the instrument panel of
certain models to provide a means of
checking the operation of many electrical
circuits and other systems in the interest of
safety. Sensors are used where appropriate.
2The following components are not
monitored by the system, but have separate
warning lamps:
Handbrake “on”
Choke in use
Low engine oil pressure
Battery charge indicator
3The multi-functional electronic device
automatically checks the following functions
whether the engine is running or not:
Coolant level
Disc pad wear
Door closure
Engine oil level
Front parking lamps
Rear foglamps
Stop lamps
4The check information is stored by the
system monitor until the engine is started
when the display panel then indicates the
situation by means of the LEDs (light emitter
diodes) and the general lamp.
5If all functions are in order, the green panel
lamp will come on when the ignition key is
turned and will go out after two to three
seconds.
6If some functions are not in order, then the
red panel lamp will come on also the
appropriate LED.
Sensors - checking
7If a fault signal occurs which is
subsequently found to be incorrect, first
check the wiring connections between the
9•12 Electrical system
Fig. 9.15 Check system control panel (Sec 34)
A Parking lamps
B Coolant levelC Engine oil level
D Door closureE Brake fluid level
F Disc pad wearFig. 9.14 Location of control units (Sec 33)
A Digiplex ignition system control unit
B Fuel cut-out valve control unit

sensors, lamp circuits and the control unit.
Corrosion at the terminals may also be a
contributory cause.
8Never short circuit a sensor supply wire or
the electronic module will be damaged.
Check control unit and monitor -
removal and refitting
9Remove the instrument panel as described
in Section 21.
10Unbolt the control unit housing from the
instrument panel.
11Access to the monitor can only be
obtained after removing the tachometer andthe red and green general warning lamps.
Unscrew the two monitor fixing bolts.
35 Clocks- setting
1
Quartz type
1To set the hands, depress the knob and
turn it.
Digital type
2To set the clock, depress button A todisplay minutes and seconds and again to
display hours and minutes.
3To correct the hour setting, press button C
then button A and release it at the correct
time. Depress button C three times to display
hours and minutes.
4To correct the minute setting, depress
button C twice. Depress button A and release
it when the correct time is shown. Depress
button C twice to display hours and minutes.
5To correct the second setting, depress
button C three times. Depress button A and
hold it depressed to zero the seconds then
release the button. Depress button C to
display the hours and minutes.
6Switch D, Fig. 9.16 operates the map
reading lamp fitted to SX models in
conjunction with the digital clock.
36 Cigar lighter
1
1This device can be operated without
switching on the ignition.
2Push in the knob and when it springs out it
is ready for use.
3The cigar lighter socket may be used as a
power source provided the rating of the
accessory does not exceed 100 watts.
Electrical system 9•13
Fig. 9.16 Digital clock controls (Sec 35)
A Control button - hour setting C Control button - minute setting
B Control button - display (ignition off) D Map reading lamp switch
9
Fault finding overleaf

Cooling system................................................................................. 8
Part A: 999 cc engine
Description
Maintenance
Thermostat - removal and refitting
Coolant pump - removal and refitting
Part B: 1301 cc Turbo ie engine
Description
Part C: 1372 cc ie and 1372 cc Turbo ie engines
Description
Maintenance
Cooling system - draining, flushing and refilling
Radiator (and cooling fan) - removal and refitting
Thermostat - removal and refitting
Coolant pump - removal and refitting
Coolant pump/alternator drivebelt - checking, renewal and
tensioning
Part D: Heater unit later models
Heater unit - removal and refitting
Heater unit - dismantling and reassembly
Fuel and exhaust systems............................................................... 9
Part A: General
Unleaded fuel
Air cleaner modified types
Fuel pump (999 cc engine) - description, removal and
refitting
Fuel tank (999 cc engine)
Part B: Carburettor models
Carburettor (Weber 32 TLF) - description
Carburettor (Weber 32 TLF) - idle speed and mixture
Carburettor (Weber 32 TLF) - removal and refitting
Carburettor (Weber 32 TLF) - overhaul
Carburettor (Weber 30/32 DMTE) - general
Carburettor (Weber 30/32 DMTE) - overhaul
Carburettor (Weber 32 ICEV 61/250 and DMTE 30/32,
DMTE 30/150) - general
Carburettor (Solex C 30/32-CIC 8) - description
Part C: Bosch LE-2 Jetronic fuel injection system
Description
Maintenance
Fuel filter - renewal
Air cleaner element - renewal
Idle speed and mixture - adjustment
Fuel injection system - electrical tests
Fuel injection system - mechanical tests
Fuel injection system components - removal and
refitting
Throttle control linkage - general
Fuel tank - general
Part D: Bosch Mono-Jetronic fuel injection system
Description
Maintenance
Fuel filter - renewal
Air cleaner element - renewal
Idle speed and mixture adjustment
Accelerator control system - check and adjustment
Fuel system - depressurisation
Fuel pump and supply - system checks
Fuel pump - removal and refitting
Injector unit - removal and refitting
Intake air temperature sensor - removal and refitting
Fuel injector - removal and refitting
Electronic control unit (ECU) - removal and refitting
Inlet manifold - removal and refitting
Exhaust manifold - removal and refitting
Catalytic converter - general information
Fuel evaporation control system - generalPart E: Bosch L3.1/2 Jetronic fuel injection systems
Description
Fuel system - depressurisation
Maintenance
Fuel filter - renewal
Air cleaner element - renewal
Checks and adjustments
Injection system components - removal and refitting
Part G: Turbocharger system
Description
Precautions
Turbocharger (1301 cc ie engine) - removal and refitting
Turbocharger (1372 cc ie engine) - removal and refitting
Intercooler - removal and refitting
Injector cooling fan - removal and refitting
Fault finding - fuel injection system
Fault finding - turbocharger system
Ignition system................................................................................. 10
General
Ignition timing (all later models)
Breakerless ignition system - description
Distributor (breakerless type) - removal and refitting
Distributor (breakerless type) - overhaul
Breakerless ignition system components - testing
Microplex ignition system - description
Distributor (Microplex) - removal and refitting
Microplex ignition system components - testing
Digiplex 2 ignition system - description
Distributor (Digiplex 2) - removal and refitting
Spark plugs and HT leads - general
Fault finding - Microplex ignition system
Clutch................................................................................................ 11
Clutch pedal adjustment (cable clutch)
Hydraulic clutch - description
Maintenance (hydraulic clutch)
Clutch master cylinder - removal, overhaul and
refitting
Clutch operating cylinder - removal, overhaul and
refitting
Clutch hydraulic system - bleeding
Transmission.................................................................................... 12
Part A: 1301 cc Turbo ie engine
Description
Gearchange linkage - removal and refitting
Gearchange linkage (Antiskid models) - general
Final drive output shafts - description and oil seal
renewal
Part B: 1372 cc ie and 1372 cc Turbo ie engines
Description
Maintenance
Oil level - checking
Oil - renewal
Gearlever and linkages - general
Transmission - removal and refitting
Part C: 999 and 1108 cc with C514 type transmission
Description
Maintenance
Driveshafts........................................................................................ 13
Inboard joint boots (non-Turbo models, September 1987 on) -
modification
Intermediate driveshaft (Turbo ie models)
Inboard CV joints (Turbo ie models - overhaul
Right-hand driveshaft damper weight (1108 and 1372 cc
models) - removal and refitting
13•2 Supplement: Revisions and information on later models

Braking system................................................................................. 14
Part A: Braking system general
Front brake pads all later models
Part B: Braking system - Turbo ie models
Description
Front disc pads - renewal
Front disc caliper - removal and refitting
Front disc caliper - overhaul
Front brake disc - inspection, renovation or renewal
Rear disc pads - renewal
Rear disc caliper - removal, overhaul and refitting
Rear brake disc - inspection, renovation and renewal
Pressure regulating valve
Brake pedal - removal and refitting
Vacuum servo unit and master cylinder - general
Antiskid system - description
Electrical system.............................................................................. 15
Alternator (999 cc models) - removal and refitting
Alternator (later models) - removal and refitting
Alternator brushes - renewal
Starter motor (999 cc models) - removal and refitting
Starter motor (1301 cc Turbo ie, 1372 cc ie, 1372 cc Turbo ie)
- removal and refitting
Starter motor brushes (later models) - renewal
Fuses - later models
Relays (Turbo ie models) - general
Headlamps - later models
Headlamp beam adjusters for load compensation - later models
Headlamp unit removal - later models
Headlamp dim-dip system - description
Front fog lamps bulb/unit - removal and refitting and beam
adjustment
Horn - relocation
Steering column combination switches (later models) - removal
and refittingInstrument panel (Turbo ie models) - removal and refitting
Facia-mounted switches (1301 cc Turbo ie model) - removal
and refitting
Instrument panel (later models) - removal and refitting
Auxiliary control panel (later models) - removal and refitting
Heater control panel (later models) - removal and refitting
Trip master
Interior roof mounted spotlamp, switch and/or clock - removal
and refitting
Central door locking system
Cigar lighter (later models) - removal and refitting
Electrically operated window switches - removal and refitting
Windscreen wiper motor (later models) - removal and refitting
Windscreen washer reservoir (Turbo) - removal and refitting
Tailgate wiper motor (later models) - removal and refitting
Radio Check control system sensors - description
Check control system sensors - testing
Suspension....................................................................................... 16
Front anti-roll bar - removal and refitting
Suspension strut later models
Bodywork.......................................................................................... 17
Plastic components
Rear view mirrors
Door armrest
Tailgate (Turbo ie model) - component removal and refitting
Radiator grille (1301 cc Turbo ie model) - removal and
refitting
Radiator grille (1372 cc ie and 1372 cc Turbo ie models) -
removal and refitting
Bumpers (1301 cc Turbo ie, 1372 cc ie and 1372 cc Turbo ie
models) - removal and refitting
Rear hinged windows - removal and refitting
Door trim panel (Turbo ie model) - removal and refitting
Supplement: Revisions and information on later models 13•3
13
1 Introduction
Since its introduction in 1983, the FIAT Uno
has had a number of modifications and
improvements including the fitting of a twin
choke carburettor, low profile tyres, tinted
windows and remotely-controlled central door
locking.
The major mechanical change was the
introduction of the FIRE (Fully Integrated
Robotised Engine) on 45 and 45S models to
be followed by a new 1108 cc “FIRE” engine
on the 60S model from 1989 on.
A 1301 cc Turbo ie engine model wasavailable for a short period. This model had a
Bosch LE2 Jetronic electronic fuel injection
(ie) and a turbocharger to give added
performance. To uprate the braking to suit,
disc brakes were fitted to the rear in place of
the original drum type brakes.
A 1372 cc engine model was introduced in
1989. Two versions were initially available. A
Bosch Mono-Jetronic single-point fuel
injection (SPi) system, as found on the 70 SX
model and Bosch L3.1 or L3.2 Jetronic
multi-point fuel injection (MPi) systems were
fitted to Turbo models. L3.2 MPi system
models were equipped with catalytic
converters, to improve exhaust emission. All
fuel injection engines are fitted with electroni-
cally controlled engine management systems.
A new style instrument panel, switchgearand a revised facia layout was introduced in
1989.
During 1992, SPi fuel systems were fitted to
the 999 cc and 1108 cc engines, along with
catalytic converters for improved exhaust
emissions.
Five speed transmissions were introduced
to 999 cc models in 1993.
It is recommended that this Supplement is
always referred to before the main Chapters
of the Manual.
Project vehicles
The vehicles used in the preparation of this
supplement, and appearing in many of the
photographic sequences were a 1986 Uno
45S FIRE, a 1988 1301 cc Uno Turbo ie and a
1991 1372 cc Uno SXie.
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

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

Fuses (903, 999, 1116, 1299/1301 and 1301 cc Turbo ie) (continued)
Fuse No. Rating Circuit
Supplementary fuses at side of main fuse block:
A 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front fog lamps
B 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling fan (Turbo ie models)
C 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injector cooling fan (Turbo ie models)
D 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric windows
E 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump (Turbo ie models)
Fuses (later 903, 999, 1108, 1372 ie and 1372 cc Turbo ie)
Fuse Rating Circuit
1 7.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH tail, RH front parking, rear number plate lamps and check panel
2 7.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH tail, LH front parking, cigar lighter illumination, clock light, heater
control illumination and map reading light
3 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH headlamp main beam
4 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH headlamp main beam and warning light
5 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator cooling fan (except Turbo ie models) and horn
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
9 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear fog lamp and warning lamp
10 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated rear screen and warning lamp
11 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel, stop-lamps, direction indicators, reversing lamps,
warning module and carburettor cut-off (FIRE models only)
12 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater fan, heater/ventilation control illumination lights and digital
clock light
13 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen wiper, windscreen washer pump and rear wiper/washer
(where fitted)
14 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horns and relay
15 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard warning light and indicator light
Supplementary fuses at side of main fuse block:
A 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric windows
B 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central locking (where fitted)
C 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector cooling fan (where fitted)
D 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlamp washers (where fitted)
E 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foglamp and warning lamp
F - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare
G 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump (fuel injection models)
-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated Lambda sensor
Supplementary fuses on steering column relay bracket:
-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antiskid monitor circuit (where fitted)
-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antiskid supply circuit (where fitted)
Steering and suspension
General
1301 cc Turbo ie
Castor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1º 55’ to 2º 35’ positive
Number of turns of steering wheel, lock-to-lock . . . . . . . . . . . . . . . . . . 3.42
Later models
Steering angles:
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -30’ ± 30’
Castor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2º10’ ± 15’
Toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 2.0 mm
1301/1372 cc Turbo ie
Steering angles of roadwheels:
Inner wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36º 43’
Outer wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31º 27’
Torque wrench settingsNm lbf ft
Anti-roll bar clamp bolts (1301 and 1372 cc Turbo ie) . . . . . . . . . . . . . . 25 18
Anti-roll bar end fixing nuts (1301 and 1372 cc Turbo ie) . . . . . . . . . . . 15 11
13•16 Supplement: Revisions and information on later models

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.

the crankcase to operate the oil pressure
gauge. In addition, a low oil pressure switch
screwed into the camshaft oil gallery actuates
a warning light on the instrument panel in theevent of the pressure dropping dangerously
low (photo).
10Oil supply/return ducts provide the
turbocharger lubrication.
PART B:
OPERATIONS POSSlBLE
WITH ENGINE IN CAR
Camshaft and camshaft
carrier - removal and
refitting
#
Warning: Refer to the beginning
of Section 9 before starting any
work.
1Disconnect the battery, negative lead first.
2Disconnect its leads and unbolt the
distributor from the end of the camshaft, and
place it to one side.
3Disconnect the air intake hose from the
throttle valve housing.
4Disconnect the short throttle control cable
from its sector.
5Remove the throttle cable support bracket.
6Disconnect the earth leads from the
camshaft cover.
7Refer to Section 9, Part C of this
Supplement and remove the following
components.
Supplementary air valve
Inlet manifold with fuel pressure regulator
and excess pressure safety switch
Injector cooling duct
8Disconnect the wiring plug from the
Microplex ignition anti-knock sensor.
9Carry out the operations described in
Chapter 1, Section 27, paragraphs 4 to 12.
10Refitting is a reversal of removal, referring
to Section 28 of Chapter 1 for the timing belt
refitting procedure, and to Chapter 1, Sec-
tion 27, paragraphs 15 to 18.
Cylinder head -
removal and refitting#
11Carry out the operations described in
paragraphs 4 to 9 in the preceding
sub-Section, then refer to Chapter 1, Section
29, but ignore all references to the
carburettor.
12Note the distributor mounting cover.
13Four additional cylinder head bolts are
used on these engines, adjacent to the spark
plugs (photo). Note that their tightening torque
differs from the other cylinder head bolts - see
Specifications. These four bolts are tightened
13•34 Supplement: Revisions and information on later models
1 Oil pick-up strainer
2 Oil pump
3 Oil pressure relief valve
4 Oil filter cartridge
5 Main oil gallery6 Camshaft oil feed
7 Low oil pressure switch
8 Engine oil cooler
9 Filter mounting base
10 Turbocharger oil feed11 Turbocharger oil return
12 Oil pressure sender unit
13 Oil temperature sender
unit
14 Piston oil spray nozzle
Fig. 13.12 Piston oil spray nozzle locations - 1301 cc Turbo ie engine (Sec 6A)
Letters denote cylinder bore grade
Fig. 13.11 1301 cc Turbo ie engine lubrication system (Sec 6A)
6A.9 Oil pressure sender unit

separately, after the ten main bolts (see
Fig. 13.13).
Piston rings
14The piston rings comprise two
compression rings marked TOP, and an oil
control ring.
15Cross-sections and fitting details are
shown in Fig. 13.14.
Engine mountings - renewal
16The operations are essentially as
described in Section 33 of Chapter 1, but note
the design and fixings of the individual
mountings used on the turbocharged engine
(photos).
Timing belt - renewal#
17The operations described in Chapter 1,
Section 28 generally apply, but the following
differences should be noted.18Remove the engine compartment
right-hand shield. This is secured by plastic
clips. To remove a clip, push out its centre
pin.
19The TDC sensor must be unbolted to
provide room to remove and refit the timing
belt, which can be carried out without
having to remove the crankshaft pulley
(photos).
20The belt tensioner on later versions
does not incorporate a spring, but is of
eccentric centre bolt hole type. Have the
pulley bolt released, and tension the belt by
turning the pulley using a pin wrench or
circlip pliers in the two holes provided.
Keep the tension applied while the lockbolt
is tightened. Turn the crankshaft through
two complete turns, and then check the belt
tension. With moderate finger and thumb
pressure, the belt should just twist through90º when gripped at the mid-point of its
longest run (photo). Note: This 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.
Oil pump drivegear cover plate
21Due to the fact that the distributor is
driven from the end of the camshaft, the oil
pump gear does not have an extension to
drive the distributor, which would be the case
if it was mounted on the crankcase.
22The crankcase aperture is therefore
covered by a plate and gasket, together with a
wiring clip (photo).
Supplement: Revisions and information on later models 13•35
6B.13 Two of the four additional cylinder
head bolts (arrowed)
Fig. 13.14 Piston ring arrangement on the
1301 cc Turbo ie engine (Sec 6B)Fig. 13.13 Cylinder head bolt tightening
sequence on the 1301 cc Turbo ie engine
(Sec 6B)
6B.22 Distributor drive hole cover plate
(arrowed)6B.20 Belt tensioner pulley locknut
(arrowed)6B.19B Removing the timing belt
6B.19A Removing the TDC sensor6B.16B Engine/transmission right-hand
mounting6B.16A Engine/transmission centre
mounting
13