chapter 13 FIAT UNO 1983 Service Owner's Manual

pump jet and give ten full strokes of the
throttle lever, pausing between each stroke to
allow fuel to finish dripping.
8The total volume of fuel collected should be
between 2.5 and 4.5 cc. Adjust the nut on the
pump control and if necessary to increase or
decrease the volume of fuel ejected.
Fast idle adjustment
9With the choke valve plate fully closed, the
throttle valve plate should be open to give a
dimension (X) (Fig. 3.18) of between 0.90 and
1.0 mm (0.035 to 0.039 in). Use a twist drill of
suitable diameter to measure the gap. If
necessary, adjust by means of the screw and
locknut.
Anti-flooding device
10Close the choke valve plate by means of
the control lever. At the same time, push the
lean out valve rod towards the valve.
11There should be a gap (X) (Fig. 3.19)
between the edge of the choke valve plateand the carburettor throat of between 4.75
and 5.25 mm (0.187 to 0.207 in). Adjust if
necessary by means of the screw and locknut
on the lean out valve.
11 Carburettors (Weber 32 ICEE/
250 and Solex C32 DISA 14)-
description and adjustment
4
1One of these carburettors is used on
903 cc ES engines. They are very similar to
the Weber 32 ICEV 50/250 and Solex
C32 DISA 11 already described in this
Chapter except that a fuel cut-out solenoid
valve is fitted in association with the Digiplex
ignition system (see Chapters 4 and 9).
2The solenoid valve cuts off the supply of
fuel to the carburettor whenever the
accelerator pedal is released during overrun
conditions.
3A fuel cut-out device control unit receives
information regarding engine speed from the
static ignition control unit.
4A throttle butterfly switch relays informationthat the accelerator pedal is in the released
state.
5At certain minimum idle speeds during
deceleration, the fuel cut-out solenoid valve is
re-energised so that engine idling is
maintained without the tendency to cut out.
6The Solex type control unit varies the fuel
cut-out point according to the deceleration
value.Fault testing
7Should a fault develop, connect a test lamp
between the fuel cut-out solenoid switch and
a good earth.
8Connect a reliable tachometer to the engine
in accordance with the maker’s instructions.
9Start the engine and raise its speed to
between 3000 and 4000 rev/min, then fully
release the accelerator pedal.
10The test lamp should only go out during
the period when the accelerator pedal is
released. Should the test lamp remain on all
the time, or never come on, check the throttle
switch earth and the solenoid switch
connections.
11Disconnect the multi-plug from the control
unit. Switch on the ignition and check that a
test lamp connected between contact 7 of the
multi-plug and earth will illuminate. If it does
not, there is an open circuit from connection
15/54 of the fuel cut-off switch.
12Switch off the ignition and check for
continuity between contact 3 of the multiplug
and earth. An ohmmeter will be required for
this test.
13If there is no continuity (ohmmeter shows
infinity), check all the system earth
connections. Also check that the wiring plug
under the control unit is properly connected.
14Finally, check the engine speed signal. To
do this, a tachometer must be connected to
the single socket under the control unit within
the engine compartment.
15If the tachometer registers correctly then
this confirms that the electronic ignition
Fuel system 3•9
Fig. 3.18 Fast idle adjustment diagram (Solex C32 DISA 11)
(Sec 10)
X = 0.90 to 1.0 mm (0.035 to 0.039 in)Fig. 3.19 Anti-flooding device adjustment diagram
(Solex C32 DISA 11) (Sec 10)
X = 4.75 to 5.25 mm (0.187 to 0.207 in)
Fig. 3.21 Sectional view of fuel cut-off
switch (Solex C32 DISA 14) (Sec 11)
Fig. 3.20 Moving lean out valve rod
(Solex C32 DISA 11) (Sec 10)
X = 4.75 to 5.25 mm (0.187 to 0.207 in)
3

Anti-flooding device (automatic)
10Pull the choke control fully out and hold the
control lever, on the anti-flooding device,
depressed. There should be a gap (Y)
(Fig. 3.27) between the edge of the choke valve
plate and the carburettor wall of between 3.75
and 4.25 mm (0.15 and 0.17 in). If adjustment is
required, turn the adjuster screw provided.
15 Carburettor
(Solex C30-32 (CIC/1)-
servicing and adjustment
4
1The carburettor top cover with float may be
removed without the need to withdraw the
carburettor from the manifold.
2The other adjustments described in this
Section will require removal of the carburettor.
3Extract the top cover fixing screws and lift
away the top cover with float.
4Refer to Section 9 paragraphs 4 and 5 for
details of removal of the fuel inlet needle
valve.
Float adjustment
5Invert the carburettor cover so that theweight of the floats depresses the ball of the
needle valve.
6Measure the distance between the float and
the surface of the cover gasket. This should
be between 6.5 and 7.5 mm (0.26 and 0.30 in).
If adjustment is required, change the
thickness of the needle valve washer or
carefully bend the float arm.
Accelerator pump
7Refer to Section 10, paragraphs 6 and 7.
The total volume of fuel collected should be
between 7.5 and 9.5 cc. If the volume of fuel
is incorrect, release the locknut and turn the
adjuster screw on the pump lever then re-test
the volume ejected.
Fast idle
8Operate the choke control lever to close the
choke valve plate. The gap between the edge
of the primary throttle valve plate and the
venturi wall should be between 0.90 and
1.00 mm (0.035 and 0.039 in). If adjustment is
required, turn the nut on the fast idle rod.
Automatic anti-flooding device
9The vacuum system of the device can be
checked for leaks by applying a vacuum to
the drilling in the carburettor throttle valve
block. If vacuum cannot be maintained, renew
the diaphragm.
Choke valve plate automatic
opening
10Move the choke control lever to fully close
the choke valve plate and then press the lean
out valve rod. There should now be a gap (X)
(Fig. 3.32) between the edge of the choke
valve plate and the wall of the carburettor
throat of between 4.75 and 5.25 mm (0.187
and 0.207 in).
11Where adjustment is required, release the
locknut and turn the screw on the lean out
valve.
16 Economy meter
1This device is fitted to ES (energy saving)
models. It is essentially a vacuum gauge to
advise the driver with regard to economical
throttle opening related to engine and road
speed. The point of change to a higher gear
can also be deduced from this gauge. The
latter facility is provided by an LED (light
emitting diode).
2Fault testing of the system is described in
Chapter 9.
Fuel system 3•11
Fig. 3.29 Adjusting accelerator pump
stroke (Solex C30-32 CIC/1) (Sec 15)Fig. 3.28 Float setting diagram
(Solex C30-32 CIC/1) (Sec 14)
A = 6.7 to 7.5 mm (0.26 to 0.30 in)
Fig. 3.32 Choke valve plate setting
(Solex C30-32 CIC/1) (Sec 15)
X = 4.75 to 5.25 mm (0.187 to 0.207 in)Fig. 3.30 Fast idle screw on
Solex C30-32 CIC/1 (Sec 15)
A Choke control lever C Lean out valve
B Fast idle adjustmentFig. 3.31 Vacuum drilling for automatic
anti-flooding device (Solex C30-32 CIC/1)
(Sec 15)
3
Fig. 3.27 Anti-flooding device (automatic)
adjustment diagram
(Weber 30/32 DMTR 90/250) (Sec 14)
Y = 3.75 to 4.25 mm (0.148 to 0.167 in)

4
System type
Except ES engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery, coil mechanical breaker distributor
ES engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marelli Digiplex electronic with breakerless distributor
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 - 4 - 2 (No. 1 cylinder at crankshaft pulley end)
Mechanical breaker distributor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marelli or Ducellier
Contact breaker points gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.37 to 0.43 mm (0.015 to 0.017 in)
Condenser capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 to 0.25 µF
Dwell angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 to 58º
Rotor rotational direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Ignition timing (dynamic)
903 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5º BTDC at idle
1116 and 1301 cc engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10º BTDC at idle
Centrifugal advance:
903 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Between 30 and 34º max
1116 and 1301 cc engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Between 22 and 24º max
Vacuum advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Between 10 and 14º max
Ignition coil
Primary winding resistance at 20ºC (68ºF) . . . . . . . . . . . . . . . . . . . . . . . Between 2.6 and 3.3 ohms depending upon make of coil
Secondary winding resistance at 20ºC (68ºF) . . . . . . . . . . . . . . . . . . . . Between 6745 and 12 000 ohms depending upon make of coil
Marelli Digiplex electronic ignition
Rotor arm resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 ohms
Advance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Between 6 to 10º and 47 to 51º
Engine speed sensor
Resistance on flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 to 748 ohms
Sensor to flywheel tooth gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 1.3 mm (0.0099 to 0.0512 in)
TDC sensor
Resistance on pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 to 748 ohms
Sensor to pulley tooth gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 to 1.0 mm (0.016 to 0.039 in)
Ignition coil
Primary winding resistance at 20ºC (68ºF) . . . . . . . . . . . . . . . . . . . . . . . 0.310 to 0.378 ohms
Secondary winding resistance at 20ºC (68ºF) . . . . . . . . . . . . . . . . . . . . 3330 to 4070 ohms
Chapter 4 Ignition system
For modifications and information applicable to later models, see Supplement at end of manual
Condenser (capacitor) - removal, testing and refitting . . . . . . . . . . . 5
Digiplex (electronic) - ignition checks and adjustments . . . . . . . . . . 10
Digiplex (electronic) ignition - location of components and
precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Distributor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Distributor (mechanical breaker type) - overhaul . . . . . . . . . . . . . . . 7
Dwell angle - checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Fault finding - ignition system . . . . . . . . . . . . . . . . See end of Chapter
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Ignition coil - (mechanical breaker ignition) . . . . . . . . . . . . . . . . . . . . 8
Ignition switch - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 12
Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mechanical contact breaker - points servicing . . . . . . . . . . . . . . . . . 2
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4•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

Note the washers above and below the
contact assembly (photos).
23Fit the new contact assembly by reversing
the removal operations.
24Although the points gap is normally set in
production, check it using feeler blades when
the plastic heel of the movable arm is on a
high point of the shaft cam. Adjust if
necessary by inserting an Allen key (3.0 mm)
into the socket-headed adjuster screw.
25Carry out the operations described in
paragraphs 14 to 17 in this Section.
3 Dwell angle- checking
3
The dwell angle is the number of degrees
through which the distributor cam turns
between the instants of closure and opening
of the contact breaker points.
1Connect a dwell meter in accordance with
the maker’s instruction. The type of meter that
operates with the engine running is to be
preferred; any variation in contact breaker
gap, caused by wear in the distributor shaft or
bushes, or the height of the distributor cam
peaks, is evened out when using this.
2The correct dwell angle is given in the
Specifications at the beginning of this
Chapter. If the angle is too large, increase the
contact points gap. If the angle is too small,
reduce the points gap. Only very slight
adjustments should be made to the gap
before re-checking.3On Ducellier distributors, adjustment of the
dwell angle can only be carried out by
switching off the ignition, removing the
distributor cap, rotor and spark shield and
adjusting the points gap.
4Re-check once the engine is running.
Adjustment may have to be carried out
several times to obtain the correct dwell
angle.
5On Marelli distributors, adjustment of the
points gap (dwell angle) is carried out with the
engine running by inserting a 3.0 mm Allen
key in the hole provided in the distributor
body.
6Always check and adjust the dwell angle
before timing the ignition as described in
Section 4.
4 Ignition timing
3
1Timing the ignition on engines with
mechanical breaker distributors is carried out
in the following way.
2Disconnect the vacuum hose from the
distributor diaphragm capsule (photo).
3Have the engine at normal operating
temperature and idling with a stroboscope
connected in accordance with the
manufacturer’s instructions.
4Point the stroboscope at the timing marks
on the flywheel and the index on the aperture
on the flywheel housing. The mark on the
flywheel should be opposite to the BTDC
mark on the index specified for your particular
engine. Alternatively, use the notch on the
crankshaft pulley and the marks on the timing
belt cover (photo), but this will necessitate
removal of the wheel arch shield.
5If the marks are not in alignment, release
the distributor clamp plate and turn the
distributor gently until they are (photo).
6Tighten the clamp plate nut, switch off the
ignition, reconnect the vacuum hose and
remove the stroboscope.
7If there is any difficulty in seeing the timing
marks clearly, highlight them by painting with
quick-drying white paint.
4•4 Ignition system
4.4 Ignition timing marks on belt coverFig. 4.5 Flywheel housing timing marks
(Sec 4)4.2 Distributor vacuum hose
Fig. 4.4 Adjusting Marelli type contact
breaker points gap (Sec 2)
Fig. 4.3 Marelli contact breaker (Sec 2)
2.22B Washers above contact breaker2.22A Marelli contact breaker E-clip

important that the following precautions are
observed.
3Never start the engine if the battery leads
are loose.
4Do not stop the engine by pulling off a
battery lead.
5Remove the control unit if ambient
temperature (paint drying oven) is above 80ºC
(176ºF).
6Never connect or disconnect the multi-plug
at the control unit unless the ignition is
switched off.
7Disconnect the battery negative lead before
carrying out electric body welding.10 Digiplex (electronic) ignition
- checks and adjustments
3
1Without special equipment, any work on the
system components should be restricted to
the following.
Engine speed sensor
2The gap between the sensor and the teeth
of the flywheel should be between 0.25 and
1.3 mm (0.0099 to 0.0512 in). Any
deviation will be due to mechanical damage to
the sensor, no adjustment being possible.
TDC sensor
3The gap between the sensor and one of the
TDC reference marks on the crankshaft pulley
should be between 0.4 and 1.0 mm (0.016 to
0.039 in).
4Any deviation will be due to the sensor
plate becoming loose. To reposition it will
necessitate setting No. 1 piston at TDC which
can only be carried out accurately by your
dealer using special tools.
Supply circuit and continuity of
coil primary winding
5Connect a test lamp between contacts 11
and 9 of the multi-plug having first pulled it
from the control unit.
6Switch on the ignition, the test lamp should
come on. If it does not, either the connection
at the positive pole of the control unit or the
coil primary winding is open.
Control unit earth
7Connect a test lamp between contacts 8
and 9 of the multi-plug having first pulled it
from the control unit. Switch on the ignition,
the test lamp should come on. If it does not,
improve the earth connection.
11 Spark plugs
1
1The correct functioning of the spark plugs is
vital for the correct running and efficiency of the
engine. It is essential that the plugs fitted are
appropriate for the engine, and the suitable type
is specified at the beginning of this chapter. If
Ignition system 4•7
Fig. 4.9 Digiplex control unit (Sec 9)
1 Vacuum hose connector
2 Multi-plug socket
1 Control unit
2 Distributor
3 Ignition coil4 TDC sensor
5 Wiring connector plug6 Engine speed sensor
7 Wiring connector plug
Fig. 4.8 Location of Digiplex ignition system components (Sec 9)
Fig. 4.13 Test lamp connected between
terminals 8 and 9 of control unit multi-plug
(Sec 10)Fig. 4.12 Test lamp connected between
terminals 11 and 9 of control unit
multi-plug (Sec 10)
Fig. 4.11 TDC sensor gap (Sec 10)
Fig. 4.10 Engine speed sensor gap
(Sec 10)
4

this type is used and the engine is in good
condition, the spark plugs should not need
attention between scheduled replacement
intervals. Spark plug cleaning is rarely
necessary and should not be attempted unless
specialised equipment is available as damage
can easily be caused to the firing ends.
2At the specified intervals, the plugs should
be renewed. The condition of the spark plug
will also tell much about the overall condition
of the engine.
3If the insulator nose of the spark plug is
clean and white, with no deposits, this is
indicative of a weak mixture, or too hot a plug.
(A hot plug transfers heat away from the
electrode slowly - a cold plug transfers it away
quickly.)
4If the tip of the insulator nose is covered
with sooty black deposits, then this is
indicative that the mixture is too rich. Should
the plug be black and oily, then it is likely that
the engine is fairly worn, as well as the mixture
being too rich.
5The spark plug gap is of considerable
importance, as, if it is too large or too small
the size of the spark and its efficiency will be
seriously impaired. The spark plug gap should
be set to the gap shown in the Specifications
for the best results.
6To set it, measure the gap with a feeler
gauge, and then bend open, or close, the
outer plug electrode until the correct gap is
achieved. The centre electrode should never
be bent as this may crack the insulation and
cause plug failure, if nothing worse.
7When fitting new plugs, check that the plug
seats in the cylinder head are quite clean.
Refit the leads from the distributor in the
correct firing order, which is 1-3-4-2; No 1cylinder being the one nearest the flywheel
housing (903 cc) or timing belt (1116 or
1301 cc). The distributor cap is marked with
the HT lead numbers to avoid any confusion.
Simply connect the correctly numbered lead
to its respective spark plug terminal (photo).
12 Ignition switch-
removal and refitting
1
1Access to the steering column lock/ignition
switch is obtained after removing the steering
wheel and column shrouds (Chapter 10) and
the column switch unit (Chapter 9).
2In the interest of safety, disconnect the
battery negative lead and the ignition switch
wiring plug (photo).
3Insert the ignition key and turn to the STOP
position (photo).
4Pull the two leads from the switch.
5Turn the ignition key to MAR.
6Using a screwdriver depress the retaining
tabs (1) (Fig. 4.16) and release the ignition
switch.
7Set the switch cam (2) so that the notches
(3) are in alignment.
8Insert the switch into the steering lock and
engage the retaining tabs.
9Turn the ignition key to STOP and connect
the two leads.
10Reconnect the battery and refit the
steering wheel, switch and shrouds.
11Removal and refitting of the steeringcolumn lock is described in Chapter 10.
Note: The ignition key is removable when set
to the STOP position and all electrical circuits
will be off. If the interlock button is pressed,
the key can be turned to the PARK position in
order that the parking lamps can be left on
and the steering lock engaged, but the key
can be withdrawn.
4•8 Ignition system
Fig. 4.16 Typical ignition switch (Sec 12)
1 Retaining tabs 3 Alignment notches
2 Switch cam 4 Locating projection12.3 Ignition key positions
1 AVV (Start) 3 Stop (Lock)
2 Park (Parking lights on) 4 MAR (Ignition)12.2 Ignition switch and lock
11.7 Distributor cap HT lead markingsFig. 4.15 Spark plug connections on
1116 cc and 1301 cc engines (Sec 11)
Fig. 4.14 Spark plug connections on
903 cc engine (Sec 11)
It’s often difficult to insert spark plugs
into their holes without cross-threading
them. To avoid this possibility, fit a
short piece of rubber hose over the end
of the spark plug. The flexible hose
acts as a universal joint, to help align
the plug with the plug hole. Should the
plug begin to cross-thread, the hose
will slip on the spark plug, preventing
thread damage.

8
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual-circuit hydraulic with servo unit and pressure regulating valve.
Discs front, drums rear. Handbrake mechanical to rear wheels.
Disc brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single cylinder, sliding caliper
Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227.0 mm (8.94 in)
Disc thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 to 10.9 mm (0.42 to 0.43 in)
Minimum regrind thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 mm (0.35 in)
Minimum wear thickness of pad friction material . . . . . . . . . . . . . . . . . . 1.5 mm (0.06 in)
Caliper cylinder diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.0 mm (1.89 in)
Drum brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single cylinder, with automatic adjusters
Drum internal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185.24 to 185.53 mm (7.30 to 7.31 in)
Maximum regrind diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187.0 mm (7.37 in)
Minimum shoe lining friction material thickness . . . . . . . . . . . . . . . . . . . 1.5 mm (0.06 in)
Cylinder diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.05 mm (0.75 in)
Master cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . 19.05 mm (0.75 in)
Vacuum servo diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158.5 mm (6.0 in)
Hydraulic fluid type/specification . . . . . . . . . . . . . . . . . . . . . Hydraulic fluid to DOT 3 or 4, or SAE J1703C
System capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 litre (0.58 pint)
Torque wrench settingsNm lbf ft
Caliper mounting bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 39
Rear wheel cylinder mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Pressure regulating valve mounting bolts . . . . . . . . . . . . . . . . . . . . . . . 20 15
Master cylinder mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Rear brake backplate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Chapter 8 Braking system
For modifications, and information applicable to later models, see Supplement at end of manual
Brake disc - inspection, renovation or renewal . . . . . . . . . . . . . . . . . 6
Brake drum - inspection, renovation or renewal . . . . . . . . . . . . . . . . 8
Brake pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Caliper - removal, overhaul and refitting . . . . . . . . . . . . . . . . . . . . . . 5
Disc pads - inspection and renewal . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault finding - braking system . . . . . . . . . . . . . . . . See end of Chapter
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handbrake - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Handbrake cable - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic hoses and pipes - inspection and renewal . . . . . . . . . . . . 11Hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Master cylinder - removal, overhaul and refitting . . . . . . . . . . . . . . . 9
Pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear brake shoes - inspection and removal . . . . . . . . . . . . . . . . . . . 4
Rear wheel cylinder - removal, overhaul and refitting . . . . . . . . . . . . 7
Stop lamp switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Vacuum servo unit - description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Vacuum servo unit - removal and refitting . . . . . . . . . . . . . . . . . . . . 15
Vacuum servo unit - servicing and testing . . . . . . . . . . . . . . . . . . . . 14
8•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

3.4 Removing the caliper unit
1 General description
The braking system is of four wheel
hydraulic type with discs on the front wheels
and drums on the rear.The hydraulic system is of dual-circuit type
and incorporates a pressure regulator valve to
limit pressure to the rear brakes during heavy
braking to prevent rear wheel lock up.
A vacuum servo unit is fitted to some
models.
The handbrake is mechanically operated on
the rear wheels.
2 Maintenance
1
1At the weekly service check, inspect the
fluid level in the master cylinder reservoir.
Topping up should only be required at very
infrequent intervals and should only be
necessary owing to the need for extra fluid in
the hydraulic system caused by wear of the
friction material of the disc pads and shoe
linings.
2The need for frequent or regular topping up
will be due to a leak in the system, probably
from a hydraulic cylinder seal or a flexible
hose. Correct the problem immediately.
3Use only clean new fluid for topping up. lt
must be of the specified type and have been
stored in a closed container and not have
been shaken for at least 24 hours (photo).
4At regular intervals, check the hoses and
pipelines for condition. Adjust the handbrake
if the lever travel becomes excessive. Check
the condition and security of the brake servo
vacuum hose. All these operations are
described later in this Chapter.
3 Disc pads-
inspection and renewal
2
1Jack up the front of the car and remove the
roadwheels.
2Extract the spring clips and slide out the
locking blocks (photos).
3On SX versions, carefully disconnect the
wear sensor lead connecting plug.
4Lift the caliper body from the disc and
inspect the thickness of the friction material
on each pad (photo). If it is 1.5 mm (0.06 in) or
less, renew the pads.
5Withdraw the pads and the anti-rattle
springs.
6Brush away any dust and dirt from the
caliper, taking care not to inhale the dust - this
contains asbestos and is thus potentially
injurious to health.
7As the new pads are thicker than the old
ones, the caliper piston must be depressed
8•2 Braking system
3.8A Disc pad and anti-rattle spring
Fig. 8.1 Components of the braking system (LHD shown) (Sec 1)
1 Caliper
2 Hose
3 Master cylinder
4 Fluid reservoir5 Cap and fluid level sensor
6 Vacuum servo unit
7 Rear wheel cylinder8 Pipeline
9 Hose
10 Pressure regulating valve
3.2B Removing a locking block
3.2A Removing a disc pad locking block
clip2.3 Fluid reservoir cap and float for
warning switch

locknut and turn the adjuster nut on the
handbrake primary rod (photo).
3Raise the rear roadwheels and check that
they turn freely when the handbrake lever is
fully released.
17 Handbrake cable-
renewal
1
1There are two cables, either of which may
be renewed independently
2Disconnect the cable, which is to be renewed,
from the shoe lever at the brake backplate.
3Disconnect the longer cable from the
primary link or rod and release the cable from
its retainers. On later models with a plastic
fuel tank, a cable bracket is moulded into the
side of the tank (photo).4Disconnect the shorter cable from the pivot
lever at the pulley on the rear axle (photo).
5Refit the new cables by reversing the
removal operations and then adjust as
described in the preceding Section.
18 Brake pedal-
removal and refitting
1
1The operations are described in
conjunction with the clutch pedal in Chapter
5, Section 4.
2The brake pedal pushrod will slide out of
the servo unit as the pedal is withdrawn.
19 Stop lamp switch
1
1The brake stop lamp switch is of plunger
type acting on the pedal arm.
2Adjust the position of the switch by turning
the locknuts until the stop lamps illuminate
when the pedal arm is depressed through 1.0
mm (0.039 in).
Braking system 8•9
Fig. 8.13 Handbrake components (Sec 17)
17.4 Handbrake cable pulley17.3 Handbrake cable guide on fuel tank
8
Fault finding - braking system
Excessive pedal travel
m mPads or shoes excessively worn
m mIncorrect pedal or servo pushrod adjustment
m mAutomatic adjusters faulty
m mSeized wheel cylinder or caliper piston
m mMaster cylinder seals worn
Pedal feels spongy or soggy
m
mAir in hydraulic system
m mLow fluid level
m mLoose connections
m mFlexible hose perished
m mDefective wheel cylinder or caliper seal
Pedal feels springy
m
mNew pads or linings not bedded-in
m mMaster cylinder mounting loose
Pedal vibrates when brakes applied
m
mDiscs or drums distorted
m mFriction linings excessively worn
m mLoose backplate or caliper mounting bolts
m mWear in steering or suspension components
Excessive effort required to stop car
m
mWorn or contaminated linings or pads
m mIncorrect grade of lining or pad material
m mServo vacuum hose leaking or disconnected
m mFaulty servo or non-return valve (55 or 70 models)
m mSeized caliper or wheel cylinder piston
m mOne circuit defective on dual circuit hydraulic system
Brakes pull to one side
m
mFriction linings contaminated on one side of car
m mSeized hydraulic piston on one side of car
m mDifferent types of linings fitted on different sides of car, or new
linings on one side only
m mSeized automatic adjuster on one side of car
Brakes drag
m
mHandbrake linkage overadjusted or seized
m mSeized caliper or wheel cylinder piston
Brakes squeal
m
mDrums or discs rusty or damp (temporary fault - no action
necessary)
m mDust or grit in brake drums
m mLinings excessively worn

9System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 negative earth, battery alternator and pre-engaged starter
Battery
Except 70S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Ah
70S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Ah
Alternator
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marelli, Valeo or Bosch 45A, 55A or 65A, with integral voltage
regulator
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 V
Minimum brush (wear) length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 mm (0.236 in)
Starter motor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marelli, Bosch or Femsa pre-engaged
Nominal power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 kW or 1.0 kW
Armature shaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 to 0.5 mm (0.0039 to 0.0197 in)
Minimum brush (wear) length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm (0.39 in)
Wiper blades
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion X-4801 (19 in) or X-4503 (18 in)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion X-3303
Chapter 9 Electrical system
For modifications, and information applicable to later models, see Supplement at end of manual
Alternator - maintenance and precautions . . . . . . . . . . . . . . . . . . . . 3
Alternator - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alternator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery - inspection, charging, removal and refitting . . . . . . . . . . . . 2
Central door locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Check control (warning module) system . . . . . . . . . . . . . . . . . . . . . . 34
Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Clocks - setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Courtesy lamp switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Economy gauge (Econometer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Electrically-operated front door windows . . . . . . . . . . . . . . . . . . . . . 31
Exterior lamps - bulb renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fault finding - electrical system . . . . . . . . . . . . . . See end of Chapter
Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Headlamp - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Headlamp beam - alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Headlamp bulb - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Heated tailgate window - precautions and repair . . . . . . . . . . . . . . . 29Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Instrument panel - dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Instrument panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 21
Interior lamps - bulb renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Radio/cassette - fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rocker and push-button switches . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Speedometer drive cable - renewal . . . . . . . . . . . . . . . . . . . . . . . . . 23
Starter motor - description and testing . . . . . . . . . . . . . . . . . . . . . . . 7
Starter motor - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starter motor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering column combination switch . . . . . . . . . . . . . . . . . . . . . . . . 11
Tailgate contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tailgate wiper blade and arm - removal and refitting . . . . . . . . . . . . 26
Tailgate wiper motor - removal and refitting . . . . . . . . . . . . . . . . . . . 27
Voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Windscreen wiper blade and arm - removal and refitting . . . . . . . . . 24
Windscreen wiper motor - removal and refitting . . . . . . . . . . . . . . . . 25
9•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