timing belt FIAT UNO 1983 Service Owner's Manual

13
Chapter 13 Supplement:
Revisions and information on later models
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Routine maintenance - all models from June 1991 . . . . . . . . . . . 3
Engine 903 and 1299/1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sump pan sealing strips (903 cc engine) - modification
1299 cc engine - description
Rocker cover (903 cc engine) - removal
Cylinder head (903 cc engine) - refitting
Engine - 999 and 1108 cc (FIRE) . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Part A: General
Description
Part B: Operations possible with engine in car
Valve clearances - adjustment
Timing belt - renewal
Camshaft - removal and refitting
Cylinder head - removal and refitting
Sump pan - removal and refitting
Oil pump - removal, checking and refitting
Pistons/connecting rods - removal and refitting
Pistons/connecting rods - separation and piston ring renewal
Engine/transmission mountings - renewal
Part C: Engine removal and dismantling
Method of removal - general
Engine/transmission - removal and separation
Dismantling - general
Complete dismantling
Examination and renovation
Part D: Engine reassembly and refitting
Reassembly - general
Complete reassembly
Engine/transmission - reconnection and refitting
Initial start-up after major overhaul
Engine 1301 cc Turbo ie.................................................................. 6
Part A: General
Description
Lubrication system - description
Part B: Operations possible with engine in car
Camshaft and camshaft carrier - removal and refitting
Cylinder head - removal and refitting
Piston rings
Engine mountings - renewal
Timing belt - renewal
Oil pump drivegear cover plate
Engine oil cooler - removal and refittingPart C: Engine removal, dismantling, reassembly and refitting
Engine/transmission - removal and separation
Engine - dismantling and reassembly
Engine/transmission - reconnection and refitting
Initial start-up after major overhaul
Engine 1372 cc ie and 1372 cc Turbo ie......................................... 7
Part A: General
Description
Maintenance
Part B: Operations possible with the engine in car
Valve clearances - checking and adjustment
Timing belt, tensioner and sprockets - removal and refitting
Camshaft front oil seal - renewal
Camshaft, housing and followers - removal and refitting
Camshaft housing, camshaft and cam followers - dismantling,
inspection and reassembly
Cylinder head (1372 cc ie engine) - removal and refitting
Cylinder head (1372 cc Turbo ie engine) - removal and refitting
Cylinder head - inspection and renovation
Crankshaft front oil seal - removal and renewal
Crankshaft rear oil seal - removal and renewal
Flywheel - removal, inspection and refitting
Sump - removal and refitting
Oil pump - removal, checking and refitting
Pistons/connecting rods - removal and refitting
Pistons/connecting rods - examination and renovation
Engine/transmission mountings - renewal
Part C: Engine removal and dismantling
Method of removal - general
1372 cc ie engine/transmission - removal and separation
1372 cc Turbo ie engine/transmission - removal and separation
Engine dismantling - general
Auxiliary shaft - removal, inspection and refitting
Engine - complete dismantling
Crankshaft and main bearings - removal
Engine components - examination and renovation
Part D: Engine reassembly
Reassembly - general
Crankshaft and main bearings - refitting
Pistons and connecting rods - refitting
Oil pump - refitting
Sump - refitting
Flywheel - refitting
Auxiliary shaft - refitting
Cylinder head - refitting
Timing belt and covers - refitting
Engine/transmission - reconnection and refitting
Initial start-up after major overhaul
13•1
Contents

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

2 Specifications
Note: All Specifications are in addition or revisions of those given in the preceding Chapters.
Engine
General
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line overhead camshaft. Transversely mounted with
end-on transmission
Application:
999 cc (FIRE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45, and 45S
1108 cc (FIRE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60S and 1.1 ie
1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 and 60
1299/1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, Turbo and ie
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70S, Sxie. 1.4 ie and Turbo ie
Bore:
999 and 1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70.0 mm
1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.0 mm
1299/1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.4 mm
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.5 mm
Stroke:
999 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.9 mm
1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.0 mm
1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 mm
1299 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 mm
1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 mm
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.4 mm
Compression ratio:
999 cc:
Up to mid 1988 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8:1
From mid 1988* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5:1
1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6:1
1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1:1
1299 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1:1
1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7:1
1372 cc:
Non-Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2:1
Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8:1
Maximum torque (DIN):
999 cc:
Up to mid 1988 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm at 2750 rpm
From mid 1988* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Nm at 2750 rpm
1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Nm at 2900 rpm
1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Nm at 3000 rpm
1299/1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Nm at 3200 rpm
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Nm at 3250 rpm
1372 cc Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Nm at 3500 rpm
Maximum power (DIN):
999 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 kW at 5250 rpm
1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 kW at 5250 rpm
1299/1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 kW at 5750 rpm
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 kW at 6000 rpm
1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 kW at 6000 rpm
Compression pressure (bore wear test):
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ± 0.75 bars
Maximum pressure difference between cylinders:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.96 bars
Firing order:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2 (No 1 at timing belt end)
Cylinder block and crankcase material:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast-iron
Crankshaft endfloat:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.055 to 0.265 mm
Cylinder head material:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light alloy
Valve clearances:Inlet Exhaust
999 and 1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.35 mm 0.35 to 0.45 mm
1299, 1301 cc and 1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 to 0.45 mm 0.45 to 0.55 mm
*95 RON (unleaded fuel) engines
13•4 Supplement: Revisions and information on later models

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

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.

mounted on the front end of the crankshaft
and driven by it.
11The flexible toothed timing belt drives thecamshaft and the coolant pump from a
sprocket on the front end of the crankshaft.
The belt is tensioned by an
eccentrically-mounted pulley.
12The distributor and the fuel pump
(carburettor models) are driven from the
flywheel end of the camshaft. The fuel pump
on fuel injection models is an integral unit
combined with the fuel gauge sender unit and
immersed in the fuel tank.
PART B:
OPERATIONS POSSIBLE
WITH ENGINE IN CAR
Valve clearances - adjustment
1The operations are similar to those
described in Chapter 1, Section 26, but note
that the special tools referred to have differentpart numbers for the FlRE engine -
1860443000 and 1887001000 (photos).
2Remember that the clearance for inlet and
exhaust valves differs see Specifications at
the beginning of this Supplement.
3Counting from the timing cover end of the
engine, the valve sequence is as follows.
Inlet 2-4-5-7
Exhaust 1-3-6-8
Timing belt - renewal #
4Remove the air cleaner.
5Slacken and remove the alternator
drivebelt, then remove the spark plugs.
6Unbolt and remove the timing belt cover.
Note the bolt located at the bottom of the
cover, this can be easily overlooked (photo).
7Unbolt and remove the crankshaft pulley
(photo).
13•20 Supplement: Revisions and information on later models
5B.7 Unscrewing the crankshaft pulley
bolts5B.6 Timing cover lower fixing bolt
removal5B.1B Using a modified C-spanner and
screwdriver to remove a shim
5B.1A Checking a valve clearance
Fig. 13.3 Longitudinal sectional view of the 999 and 1108 cc
engine (Sec 5A)Fig. 13.4 999 and 1008 cc engine lubrication system (Sec 5A)

8Turn the crankshaft sprocket bolt, or
engage top gear and raise and turn a front
roadwheel, until the camshaft sprocket TDC
timing mark is aligned with the mark on the
cylinder head and the crankshaft sprocket
timing mark is aligned with the mark on the oil
pump cover (photos).
9Release the nut on the timing belt
tensioner, move the pulley away from the belt
and retighten the nut to hold the pulley in the
retracted position (photo).
10Slide the drivebelt from the sprockets.
11When refitting the new belt, make sure
that the sprocket timing marks are still in
alignment and fit the belt so that the arrows
on the belt point in the direction of engine
rotation, and the lines of the belt coincide with
the sprocket marks.
12Engage the timing belt with the crankshaft
sprocket first, then place it around the coolant
pump sprocket and the camshaft sprocket
(photo). Finally slip the belt around the
tensioner pulley.
13Release the tensioner nut and push the
pulley against the belt until the belt is quite
taut. Check that the sprocket timing marks
have not moved out of alignment. If they have,
reset them by moving them over the belt
teeth.
14Still applying force to the pulley, tighten its
nut.
15Turn the crankshaft through two complete
turns in the normal direction of rotation and
check that when the centre of the longest runof the belt is gripped between finger and
thumb it can just be twisted through 90º. If
increased tension is required to achieve this,
release the tensioner nut and prise the pulley
against the timing belt. Note: The above
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.
16Refit the timing belt cover, the crankshaft
pulley, alternator drivebelt, spark plugs and
the air cleaner.
Camshaft -
removal and refitting#
Warning: Refer to the beginning
of Section 9 before starting any
work.
17Remove the air cleaner and the fuel pump(carb. models), as described in Section 9 of
this Supplement.
18Remove the distributor (Section 10).
19Remove the timing belt cover.
20Unbolt and remove the camshaft cover,
having first disconnected the HT lead clip
(photos).
21Turn the crankshaft (by engaging top gear
and raising and turning a front roadwheel)
until No. 4 piston is at TDC. The timing mark
on the camshaft sprocket will be in alignment
with the mark on the cylinder head.
22Pass a rod through one of the holes in the
camshaft sprocket to prevent it rotating and
then unscrew the sprocket fixing bolt. Slip the
sprocket from the camshaft and out of the
loop of the belt (photos).
23Mark the camshaft bearing caps as to
position and then unbolt and remove the
Supplement: Revisions and information on later models 13•21
5B.9 Releasing the timing belt tensioner
nut5B.8B Crankshaft sprocket timing mark
and oil pump cover alignment mark
(arrowed)5B.8A Camshaft sprocket timing mark and
cylinder head timing mark in alignment
5B.22B Camshaft sprocket bolt and
washer5B.22A Unscrewing the camshaft sprocket
bolt
5B.20A Camshaft cover HT lead clip5B.12 Fitting the timing belt
5B.20B Removing the camshaft cover
13

lubrication pipe (prise the oil feed stub out
with a screwdriver), unscrew the remaining
bolts and take off the bearing caps (photos).
24Lift the camshaft carefully from the
cylinder head, checking that the valve
clearance shims and cam followers are not
withdrawn by the adhesion of the oil (photo).
25If the shims and cam followers are to be
removed, keep them in their originally fitted
order (photos).
26Refitting is a reversal of removal but use a
new camshaft oil seal and camshaft cover
gasket. Oil the camshaft bearings (photos).
27Make sure that the timing belt is
reconnected and tensioned as described
previously.
28Check the valve clearances.
29Tighten all nuts and bolts to the specified
torque.
Cylinder head -
removal and refitting#
Warning: Refer to the beginning
of Section 9 before starting any
work.
Note: The cylinder head should be removed
cold.
30Drain the cooling system.
31Remove the air cleaner.
32Disconnect the throttle and choke
connections from the carburettor (photo).
33On carburettor models, disconnect the
fuel hoses from the fuel pump and the
carburettor. On fuel injection models,
13•22 Supplement: Revisions and information on later models
5B.26B Camshaft cover gasket5B.26A Camshaft oil seal5B.25B Removing a cam follower (tappet)
with shim
2B.25A Valve clearance shim showing
thickness mark5B.24 Removing the camshaft
5B.23D Camshaft bearing cap showing
short and long positioning dowels for
correct fitting5B.23C Camshaft lubrication pipe
5B.23B Unscrewing the camshaft
bearing/banjo union bolt5B.23A Prising out the camshaft oil feed
pipe stub5B.22C Camshaft sprocket showing
integral key (arrowed)