cooling FIAT UNO 1983 Service Owner's Manual

2The control lever mounting platform can be
removed after extracting its fixing screws.
3The coolant control valve can be removed
after extracting its fixing nuts.
4Unscrew the screws which hold the heater
matrix in the casing and then slide the matrix
from its location. 5If the matrix is leaking, do not attempt a
repair, but obtain a new one. These are
usually obtainable on an exchange basis from
radiator repairers.
6The heater casing can be separated after
prising off the clips and removing the bolts.
The blower motor/fan can then be lifted out. 7Reassembly is a reversal of dismantling, but
set the cables to give complete range of travel
between open and closed positions of the flap
valve or coolant valve concerned.
Cooling and heating systems 2•7
Fig. 2.11 Exploded view of heater (Sec 13)
Fig. 2.12 Heater control components (Sec 13)
2

Fault finding - cooling and heating systems
2•8 Cooling and heating systems
Overheating
m mInsufficient coolant in system
m mPump ineffective due to slack drivebelt
m mRadiator blocked either internally or externally
m mKinked or collapsed hose causing coolant flow restriction
m mThermostat not working properly
m mEngine out of tune
m mIgnition timing retarded or auto advance malfunction
m mCylinder head gasket blown
m mEngine not yet run-in
m mExhaust system partially blocked
m mEngine oil level too low
m mBrakes binding
Engine running too cool
m
mFaulty, incorrect or missing thermostat
Loss of coolant
m
mLoose hose clips
m mHoses perished or leaking
m mRadiator leaking
m mFiller/pressure cap defective
m mBlown cylinder head gasket
m mCracked cylinder block or head
Heater gives insufficient output
m
mEngine overcooled (see above)
m mHeater matrix blocked
m mHeater controls maladjusted or broken
m mHeater control valve jammed or otherwise
defective

7 Carburettor idle speed and
mixture- adjustment
4
1All carburettors have their mixture
adjustment set in production. The screw is
fitted with a tamperproof cap.
2Under normal circumstances, only the idle
speed screw need be adjusted to set the
engine idle speed to the specified level.
3Before attempting to adjust the idle speed
or mixture, it is important to have the ignition
and valve clearances correctly set and the
engine at normal operating temperature with
the air cleaner fitted.
4Where the mixture must be adjusted, prise
out the tamperproof plug and turn the mixture
screw in to weaken or out to enrich the
mixture until the engine runs smoothly without
any tendency to “hunt”.
5Ideally an exhaust gas analyser should be
used to make sure that the CO level is within
the specified range.
6Once the mixture has been correctly set,
re-adjust the idle speed screw.
8 Carburettor-
removal and refitting
2
1Remove the air cleaner.
2Disconnect the flow and return fuel hoses
from the carburettor and plug them.3Disconnect the coolant hoses from the
carburettor throttle valve plate block.
Provided the cooling system is cold and not
under pressure there should be almost no loss
of coolant. Tie the hoses up as high as
possible with a piece of wire.
4Disconnect the vacuum and vent hoses
from the carburettor.
5Disconnect the throttle and choke controls
from the carburettor.
6Unscrew the mounting flange nuts and lift
the carburettor from the intake manifold
(photo).
7Refitting is a reversal of removal. Use a new
flange gasket and make sure that the fuel
return hose is routed above the air cleaner
intake.
9 Carburettor
(Weber 32 ICEV 50/250/1)-
servicing and adjustment
4
1The carburettor top cover with float may be
removed without the need to withdraw the
carburettor from the manifold. The other
adjustments described will require removal of
the carburettor.
2Unscrew the filter plug from the top cover,
clean the filter screen and refit it.
3Extract the top cover fixing screws, lift the
cover and tilt it to unhook it from the
diaphragm capsule link rod.
4Access to the fuel inlet needle valve isobtained by carefully tapping out the float arm
pivot pin. Take care, the pivot pin pillars are
very brittle.
5Check that the needle valve body is tight
otherwise fuel can bypass the needle valve
and cause flooding.
Float adjustment
6Reassemble and check the float setting. Do
this by holding the top cover vertically so that
the float hangs down under its own weight.
Measure dimension (A) (Fig. 3.10) which
should be between 1 0.50 and 11.10 mm
(0.41 to 0.44 in) with the gasket in position. If
necessary, bend the float arm tab to adjust.
7Now check the float travel which should be
45.0 mm (1.77 in). If adjustment is required,
bend the end of the float arm.
Accelerator pump stroke
8Using a twist drill as a gauge, open the
throttle valve plate through 3.5 mm (0.138 in).
9Turn the nut on the accelerator pump rod
until it just makes contact with the pump
control lever.
Fast idle adjustment
10With the choke valve plate fully closed by
means of the control lever, the throttle valve
Fuel system 3•7
Fig. 3.9 Fuel return hose correctly located
(Sec 8)
8.6 Carburettor mounting flange nut8.2 Fuel hose at carburettor
Fig. 3.10 Float setting diagram (Weber 32 ICEV 50/250) (Sec 9)
A = 10.5 to 11.0 mm (0.41 to 0.44 in) B = 45.0 mm (1.77 in)Fig. 3.11 Accelerator pump setting diagram
(Weber 32 ICEV 50/250) (Sec 9)
X = 3.5 mm (0.138 in)
3

1 General description
The electrical system is of 12 volt negative
earth type and employs a belt-driven
alternator and a pre-engaged type starter
motor.
The models in the range are all adequately
equipped with electrical accessories, while SX
versions also have power windows and
centralised door locking plus a check control
system (Section 34).
2 Battery- inspection, charging,
removal and refitting
2
1The battery is of maintenance-free type and
under normal circumstances, no topping up
will be required, but regularly check that the
electrolyte level is between the minimum and
maximum lines on the translucent battery
casing.
2If the electrolyte level does drop below theminimum line, suspect a leak in the battery
casing or that the alternator is overcharging. If
the latter is the case, rectify the alternator fault
and then prise out the two rectangular plugs
from the top of the battery and top up with
distilled or purified water.
3Always keep the battery terminals clean
and smear them with petroleum jelly to
prevent corrosion.
4The battery will normally be kept fully
charged by the alternator, but it is possible for
the battery to become discharged if the daily
mileage is very low with much use being
made of the starter and electrical accessories.
5When the battery begins to deteriorate with
age it may also require a boost from a mains
charger.
6Disconnect both battery leads before
connecting the mains charger. 7To remove the battery from the car, first
disconnect the leads from the battery
terminals (earth first) and then unscrew the
securing clamp from the casing projection at
the base of the casing (photo).
8Lift the battery from its mounting platform.
Refitting is a reversal of removal. Reconnect
the earth cable last.
Fuses
Circuit protected Fuse rating (A)
1 Stop lamps, direction indicator lamps, instrument panel warning
lamps, tachometer economy gauge, check control system . . . . . . 10
2 Windscreen wiper and washer, rear screen wiper/washer, check
system panel illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Left front parking, right rear tail lamp, cigar lighter illumination,
heater control and clock, digital clock illumination . . . . . . . . . . . . . 7.5
4 Right front parking lamp and left rear tail lamp, instrument panel
illumination and rear number plate lamp . . . . . . . . . . . . . . . . . . . . . 7.5
5 Left-hand dipped headlamp, rear foglamps . . . . . . . . . . . . . . . . . . 10
6 Right-hand dipped headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Left-hand headlamp (main beam) . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 Right-hand headlamp (main beam) . . . . . . . . . . . . . . . . . . . . . . . . . 10
9 Engine cooling fan and horn (Comfort) . . . . . . . . . . . . . . . . . . . . . . 25
10 Heater booster fan, digital clock map reading lamp . . . . . . . . . . . . 20
11 Heated tailgate glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
12 Courtesy lamps, cigar lighter, radio power feed, disc pad
sensors, economy gauge (ES models) . . . . . . . . . . . . . . . . . . . . . . 10
13 Hazard warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
14 Spare (Comfort), Horn (Super) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BulbsWattage
Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40/45 or Halogen H4 60/55
Front parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Side repeater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rear foglamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Direction indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rear number plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Courtesy lamp (roof) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Courtesy lamp (pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warning and indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wedge base
Torque wrench settingsNm lbf ft
Alternator mounting and adjustment nuts . . . . . . . . . . . . . . . . . . . . . . . 50 87
Starter motor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 35
9•2 Electrical system
2.7 Battery clamp
If battery terminal corrosion
has occurred, it may be
neutralised by applying
sodium bicarbonate or
household ammonia.

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

Valve timing clearance:
999 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm
1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.70 mm
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm
Valve timing:Inlet Exhaust
999 cc:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1º BTDC 29º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19º ABDC 9º ATDC
1108 cc:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2º BTDC 42º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19º ABDC 2º ATDC
1116 cc:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7º BTDC 37º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35º ABDC 5º ATDC
1299/1301 cc:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9º BTDC 39º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31º ABDC 1º ATDC
1299/1301 cc Turbo ie:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0º TDC 30º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40º ABDC 10º ATDC
1372 cc ie:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7º BTDC 37º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35º ABDC 5º ATDC
1372 cc Turbo ie:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14º BTDC 36º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44º ABDC 6º ATDC
Cam lift:
999 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 mm
1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 mm
1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 mm
1299/1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 mm
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 mm
1372 cc Turbo ie
Inlet valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 mm
Exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 mm
Supplement: Revisions and information on later models 13•5
13
View of engine compartment (air
cleaner removed) on the 999 cc
FIRE engined model
1 Wiper motor cover
2 Suspension strut turret
3 Brake hydraulic fluid reservoir
4 Carburettor
5 Washer fluid reservoir
6 Right-hand engine mounting
7 Fuel pump
8 Ignition distributor
9 Ignition coil
10 Headlamp
11 Oil filler cap
12 Battery
13 Radiator cooling fan
14 Coolant filler/expansion tank
15 Radiator

View of front end from below on
the 999 cc FIRE engined model
1 Left hand front engine mounting
2 Transmission
3 Track control arm
4 Driveshaft
5 Left hand rear (lower) engine
mounting
6 Gearchange rods
7 Exhaust pipe
8 Oil filter cartridge
9 Brake caliper
10 Sump pan drain plug
View of engine compartment on
the 1301 cc Turbo ie engined
model
1 Alternator air cooling intake
2 Washer fluid reservoir cap
3 Suspension strut turret
4 Secondary fuel filter
5 Fuel supply hose
6 Coolant expansion tank
7 Brake fluid reservoir cap
8 Ignition system ECU
9 Inlet manifold
10 Excessive pressure switch
11 Air cleaner
12 Timing belt cover
13 Fuel pressure regulator
14 Airflow meter
15 Throttle position switch
16 Air intake duct
17 Air intake to throttle valve
housing
18 Engine oil filler cap
19 Radiator cooling fan
20 Headlamp dim-dip transformer
21 Intercooler air duct
22 Ignition distributor
23 Headlamp
24 Main idle speed adjusting screw
25 Base setting idle speed screw
13•6 Supplement: Revisions and information on later models

Supplement: Revisions and information on later models 13•7
View of engine compartment (air
cleaner removed) on the
1372 cc ie engined model
1 Engine oil level dipstick
2 Timing belt cover
3 Engine mounting (right-hand)
4 Clutch master cylinder fluid
reservoir
5 Fuel supply and return hoses
6 Injection unit
7 Inlet manifold
8 Washer reservoir
9 Brake master cylinder and fluid
reservoir
10 Injection system fuse/relay block
11 Suspension strut turret
12 Ignition coil
13 Ignition system ECU
14 Battery
15 Coolant filter expansion tank
16 Ignition distributor
17 Radiator cooling fan
18 Engine oil filler cap
19 Starter motor
20 Oil filter
View of front end from below on
the 1031 cc Turbo ie engined
model
1 Anti-roll bar
2 Exhaust pipe
3 Track control arm
4 Engine centre mounting
5 Gearchange rods
6 Brake caliper
7 Left-hand driveshaft
8 Intermediate driveshaft
9 Right-hand driveshaft
10 Transmission
11 Engine oil drain plug
12 Auxiliary lamp
13 Horn
14 Intercooler
15 Starter motor
16 Oil filter cartridge
17 Oil pressure sender unit
18 Engine oil cooler
19 Right-hand underwing shield
20 Left-hand underwing shield
13

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

Cooling system (continued)
Radiator fan cut-in temperature:
1301 cc Turbo ie:
1st speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 to 90ºC
2nd speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 94ºC
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 94ºC
Radiator fan switch-off temperature:
1301 cc Turbo ie:
1st speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 to 85ºC
2nd speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC
Coolant pump/alternator drivebelt tension:
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 10 mm deflection midway between crankshaft and
alternator pulleys under firm thumb pressure
Torque wrench settingsNm lbf ft
Coolant pump mounting bolts (999/1108 cc) . . . . . . . . . . . . . . . . . . . . . 8 6
Coolant pump to crankcase (1372 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Coolant temperature gauge sender unit (1372 cc ie) . . . . . . . . . . . . . . . 30 22
Coolant temperature sender unit (1372 cc) . . . . . . . . . . . . . . . . . . . . . . 27 20
Fan thermostatic switch (1372 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Thermal valve on inlet manifold (1372 cc):
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Water pump cover (1372 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
Fuel system
General
Air cleaner element
999 cc and 1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U520
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U533
1301/1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U522
Fuel filter:
999 cc and 1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L101
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L201
1301/1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L203
Carburettor calibration
Weber 32 ICEV 61/250 TLF 4/250
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903 cc 999 cc
Accelerator pump capacity (for 10 strokes) . . . . . . . . . . . . . . . . . . . . . . 3.8 to 6.3 cc -
Air bleed jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 mm 50/90
Air compensating jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 165
Air idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.60 mm -
Anti-flooding device (choke valve plate gap) . . . . . . . . . . . . . . . . . . . . . - 4.0 to 5.0 mm
Auxiliary venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 mm -
Fast idle (throttle valve plate gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 0.65 to 0.75 mm
Float level (with gasket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.75 mm 26.75 to 27.25 mm
Full power jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm 50
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F74 F70
Exhaust gas CO at idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 2.0% 1.0 to 2.0%
Idle air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 50/90
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.47 mm 47
Idle mixture adjustment port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm -
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 800 rpm 750 to 800 rpm
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 mm 105
Needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm 1.5 mm
Pump jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm 35
Pump outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm -
Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 mm 22 mm
Weber 32 TLF 4/252 (and 251) TLF 27/251
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 999 cc 1108 cc
Accelerator pump capacity (for 10 strokes) . . . . . . . . . . . . . . . . . . . . . . 8 to 12 cc 8 to 12 cc
Air bleed jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.65 mm 1.65 mm
Air idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm 0.50 mm
Auxiliary venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 mm 4.5 mm
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F70 F70
13•10 Supplement: Revisions and information on later models