transmission FIAT UNO 1983 Service Owner's Manual

2Draw the engine and transmission together
by screwing in the connecting bolts.
Refit lifting lugs and hose and wiring clips
(photo).
3Bolt the lower cover plate to the face of the
flywheel housing.
4Bolt the starter motor into position.
5Bolt the mounting brackets into place.
6Place the engine/transmission on the floor
ready for raising by hoist or jack into the
engine compartment.
7Raise the car and position it over the
engine/transmission.
8Hoist or jack the power unit upwards until
the left and right-hand mountings can be
connected (photos).9Remove the lifting mechanism and connect
the bottom mounting (photos).
10Connect the inboard ends of the
driveshafts with the transmission and the
outboard ends with the hub carriers.
11Reconnect the hub carriers with the
clamps at the base of the suspension struts.
Tighten the fixing bolts to the specified torque.
12Bolt the brake flexible hose support clips
to the suspension struts.
13Reconnect the tie-rod end balljoints
tightening the nuts to the specified torque.
14Reconnect the gearchange rods. The
easiest way to do this is to force the sockets
onto the ball studs using a pair of self-locking
grips (photo).15Refit the exhaust system and
reconnect the downpipe to the manifold
(photo).
16Screw on the driveshaft nuts and tighten
them to the specified torque. Have an
assistant apply the brake pedal hard to
prevent the driveshaft from turning.
17Refit the front roadwheels and lower the
car to the floor.
18Reconnect the carburettor fuel and
coolant hoses.
19Unplug the fuel hose and connect it to the
pump.
20Reconnect the choke and throttle controls
to the carburettor.
21Reconnect the coolant and heater hoses
1116 cc and 1301 cc engine 1•33
44.8B Left-hand engine mounting44.8A Raising engine/transmission into
engine compartment44.2 Lifting lug at bellhousing bolt
44.15 Exhaust downpipe flange nuts44.14 Connecting a gearchange rod ball
cup44.9B Lower mounting attachment bolts
44.9A Engine/transmission lower mounting44.8D Right-hand mounting bolted up44.8C Right-hand engine mounting
brackets
1

to the engine. Also reconnect the brake servo
hose to the intake manifold (photos).
22Reconnect the leads to the reversing lamp
switch. Reconnect the transmission earth lead
(photos).
23Reconnect the clutch cable and adjust as
described in Chapter 5.
24Reconnect the speedometer drive cable
to the transmission and tighten the knurled
retaining ring.
25Reconnect the low tension lead to the
distributor and the high tension lead to the
ignition coil.
26Reconnnect the electrical leads to thestarter motor, the oil pressure and
temperature switches and the coolant
temperature switch.
27Connect the leads to the alternator.
28Refit the air cleaner.
29Refill the cooling system. Refill the engine
with oil.
30Reconnect the battery.
31Refit the bonnet and connect the
windscreen washer tube.
32Fit the inner wing protective shields
(photo).
45 Engine- initial start-up after
major overhaul
4
1If new bearings and rings have been fitted,
it is likely that the engine will be stiff to turn so
make sure the battery is well charged.
2Switch on the ignition and check that
appropriate warning lights come on.
3Start up the engine. If it refuses to start,
refer to the “Fault Finding” Section in the
Reference section of this Manual.
4Watch the oil pressure warning light and
alternator charging indicator light. If there is
no charge or if the oil pressure warning light
does not go out after a second or two, havinghad time to fill the new oil filter, switch off and
recheck.
5If the warning lights go out, set the engine
to run on fast idle and check the engine for
leaks.
6Check the coolant level; it will probably go
down as air locks are filled.
7Keep the engine running at a fast idle and
bring it up to normal working temperature. As
the engine warms up, there will be some odd
smells and smoke from parts getting hot and
burning off oil deposits.
8When the engine running temperature has
been reached, adjust the idling speed, as
described in Chapter 3. Check and, if
necessary, adjust the ignition timing using a
stroboscope (see Chapter 4).
9Stop the engine and wait a few minutes;
check to see if there are any coolant or oil
leaks.
10Road test the car to check that the engine
is running with the correct smoothness and
power. If it does not, refer to “Fault finding” in
the Reference section of this Manual. Do not
race the engine. If new bearings and/or
pistons and rings have been fitted, it should
be treated as a new engine and run it at
reduced speed for at east 800 km (500 miles).
11After 800 km (500 miles) change the
engine oil and filter.
1•34 1116 cc and 1301 cc engine
44.32 Inner wing protective shield44.26B Coolant temperature switch44.26A Oil pressure warning switch
44.22B Transmission earth lead
44.22A Reversing lamp switch on
transmission44.21B Brake servo hose at manifold44.21A Heater hose at manifold

Fault finding - all engines
Note: When investigating starting and uneven running faults, do not be tempted into snap diagnosis. Start from the beginning of the check
procedure and follow it through. It will take less time in the long run. Poor performance from an engine in terms of power and economy is not
normally diagnosed quickly. In any event, the ignition and fuel systems must be checked first before assuming any further investigation needs to
be made.
All engines 1•35
1
Engine fails to turn when starter operated
m mBattery discharged
m mBattery terminals loose or corroded
m mBattery earth to body defective
m mEngine/transmission earth strap broken or loose
m mDisconnected or broken wire in starter circuit
m mIgnition/starter switch defective
m mStarter motor or solenoid defective (see Chapter 9)
m mMajor mechanical failure (seizure) or long disuse (piston rings rusted
to bores)
Engine turns and fails to start
m mBattery discharged
m mBattery terminals loose or corroded
m mBattery or engine earth strap loose
m mStarter motor connections loose
m mOil in engine/transmission too thick
m mStarter motor defective
m mVapour lock in fuel line (in hot conditions or at high altitude)
m mBlocked float chamber needle valve
m mFuel pump filter blocked
m mChoked or blocked carburettor jets
m mFaulty fuel pump
m mFuel tank empty
m mOther fuel system fault (see Chapter 3)
m mShorted or disconnected low tension leads
m mDirty, incorrectly set, or pitted contact breaker points
m mContact breaker point spring earthed or broken
m mFaulty condenser
m mDefective ignition switch
m mFaulty coil
m mDamp or dirty HT leads, distributor cap or plug bodies
m mBroken, loose or disconnected LT leads
m mIgnition leads connected wrong way round
m mOther ignition fault (see Chapter 4)
m mValve timing incorrect (after rebuild)
Engine fires but will not run
m
mInsufficient choke (cold engine)
m mFuel starvation or tank empty
m mIgnition fault (see Chapter 4)
m mOther fuel system fault (see Chapter 3)
Engine stalls and will not restart
m
mToo much choke allowing too rich a mixture to wet plugs
m mFloat damaged or leaking or needle not seating
m mFloat lever incorrectly adjusted
m mIgnition failure - sudden
m mIgnition failure - misfiring precedes total stoppage
m mIgnition failure - in severe rain or after traversing water splash
m mNo petrol in petrol tank
m mPetrol tank breather choked
m mSudden obstruction in carburettor
m mWater in fuel system
Engine slow to warm up
m
mChoke linkage maladjusted
m mAir cleaner temperature control unit defective
m mThermostat stuck open (see Chapter 2)
m mOther fuel system fault (see Chapter 3)
Difficult starting when cold
m
mInsufficient choke
m mFouled or incorrectly gapped spark plugs
m mDamp or dirty HT leads, distributor cap or spark plug bodies
m mDirty or maladjusted contact breaker points
m mOther ignition fault or timing maladjustment (see Chapter 4)
m mFuel system or emission control fault (see Chapter 3)
m mPoor compression (may be due to incorrect valve clearances, burnt
or sticking valves, blown head gasket, worn or damaged pistons,
rings or bores)
m mIncorrect valve timing (after rebuild)
Difficult starting when hot
m
mIncorrect use of manual choke
m mFuel line vapour lock (especially in hot weather or at high altitudes)
m mIncorrect ignition timing
m mOther fuel system or emission control fault (see Chapter 3)
m mPoor compression (see above)
Engine lacks power
m
mIgnition timing incorrect
m mContact breaker points incorrectly gapped
m mIncorrectly set spark plugs
m mDirty contact breaker points
m mDistributor automatic advance and retard mechanisms not
functioning correctly
m mOther ignition system fault (see Chapter 4)
m mAir cleaner choked
m mCarburation too rich or too weak
m mFuel filter blocked
m mAir filter blocked
m mFaulty fuel pump giving top and fuel starvation
m mOther fuel system fault (see Chapter 3)
m mPoor compression
m mValve clearances incorrect
m mCarbon build-up in cylinder head
m mSticking or leaking valves
m mWeak or broken valve springs
m mWorn valve guides or stems
m mWorn pistons and piston rings
m mBurnt out valves
m mBlown cylinder head gasket (accompanied by increase in noise)
m mWorn pistons and piston rings
m mWorn or scored cylinder bore
m mBrakes binding
Engine misfires throughout speed range
m
mDefective or fouled spark plug
m mLoose, cracked or defective HT lead
m mMaladjusted, sticking or burnt valves
m mIgnition timing incorrect
m mBlown head gasket
m mFuel contaminated
m mOther ignition fault (see Chapter 4)
m mOther fuel system fault (see Chapter 3)
Poor engine braking
m
mHigh idle speed
m mOther fuel system fault (see Chapter 3)
m mLow compression

Fault finding - mechanical breaker ignition system
Ignition system 4•9
4
Engine fails to start
m mLoose battery connections
m mDischarged battery
m mOil in contact points
m mDisconnected ignition leads
m mFaulty condenser
Engine overheats, lacks power
m
mSeized distributor weights
m mPerforated vacuum pipe
m mIncorrect ignition timing
Engine starts and runs but misfires
m
mFaulty spark plug
m mCracked distributor cap
m mCracked rotor arm
m mWorn advance mechanism
m mIncorrect spark plug gap
m mIncorrect contact points gap
m mFaulty condenser
m mFaulty coil
m mIncorrect timing
m mPoor engine/transmission earth connections
Fault finding - Digiplex (electronic) ignition system
Engine fails to start
m
mExcessive gap on TDC sensor
m mTDC or engine speed sensor short circuited or earthed
m mDefective ignition control unit
m mControl unit multi-plug contacts corroded
m mDefective coil
Engine lacks power, high fuel consumption
m
mIncorrect ignition advance
m mTDC sensor incorrectly set
m mDistributor vacuum hose blocked

them. Carefully release the fibre optic
filaments (photos).
6A push-button switch can be removed by
compressing its retaining tabs and pushing it
from the panel.
7A rocker switch can be removed if its knob
is pulled off and the switch sections
withdrawn from the panel.
8Reassembly and refitting of both types of
switches are reversals of removal and
dismantling.
14 Tailgate contacts
1
1Contact blocks are used to transmit power
to the heated tailgate window and to the wiper
motor.
2The block on the tailgate or the body may
be released by prising their ends with a
screwdriver (photos).
15 Horns
1
1These are mounted close to the
engine/transmission left-hand mounting
below the radiator.
2Apart from keeping the connecting leads
secure, no maintenance or adjustment is
required.
16 Headlamp bulb- renewal
1
1Open the bonnet and pull off the plug and
the rubber cover from the rear of the
headlamp (photo).
2Prise back the spring bulbholder clips and
withdraw the combined bulb and holder
(photos).
3Refit the new bulb. Avoid fingering it if it is
of halogen type. Should the fingers touch the
bulb, wipe it with a rag soaked in methylated
spirit to remove any residual grease.
4Turn the bulbholder until the pip on its
flange engages in the cut-out in the rim of the
reflector.
5Snap back the spring retaining clips, refit
the rubber cover and reconnect the plug.
17 Headlamp beam- alignment
2
1It is recommended that the headlamp
beams are aligned by your dealer or a service
station having optical setting equipment.
2Where an owner wishes to do the job
himself, proceed in the following way.
3Have the car standing on a level floor with
9•6 Electrical system
Fig. 9.3 Headlamp beam adjustment
screws (Sec 17)
A Vertical B Horizontal
16.2B Headlamp halogen type bulb16.2A Headlamp bulbholder spring
clips
14.2B Body contact block
16.1 Headlamp plug and rubber
cover
14.2A Tailgate contact block13.5B Switch panel fibre optic13.5A Withdrawing switch panel

3Working at the transmission, disconnect
the speedometer cable by unscrewing the
knurled retaining ring (photo).
4Withdraw the cable through the bulkhead
grommet.
5Refit the new cable assembly by reversing
the removal operations.
24 Windscreen wiper blade and
arm- removal and refitting
1
1The wiper blade can be removed once the
arm has been pulled away from the glass and
locked in position.
2Depress the small tab (A) and push the
U-shaped carrier out of the hook (B) of thewiper arm. The blade can then be withdrawn,
passing the wiper arm hook through the
slot (C) in the blade stretcher (Fig. 9.5).
3Before removing the wiper arm, it is
worthwhile sticking a strip of masking tape on
the screen to indicate the setting of the arm
and blade as a guide to refitting.
4Flip up the plastic cover and unscrew the
arm retaining nut. Pull off the arm from the
splined drive spindle (photo).
5Refitting is a reversal of removal.25 Windscreen wiper motor-
removal and refitting
2
1Open the bonnet and disconnect the
battery negative lead.
2Remove the wiper arm and blade as
previously described.
3Prise off the sealing cover from around the
drive spindle and then unscrew the drive
spindle bezel nut.
4Pull back the weathersealing strip from
above the wiper motor location and remove
the two screws which are exposed (photo).
5Withdraw the motor/gearbox with
protective cover from under the lip of the
upper bulkhead. Disconnect the wiring plug
(photos).
6Refitting is a reversal of removal.
26 Tailgate wiper blade and arm
- removal and refitting
1
1Pull the wiper arm from the glass until it
locks.
2With the thumb nail pull down the tab to
release the peg (B) from the hole (A) (Fig. 9.7).
Pull the blade from the arm.
3To remove the arm, flip up the plastic cover
and remove the nut exposed. Pull the arm
from the drive spindle.
4Refitting is a reversal of removal.
Electrical system 9•9
Fig. 9.5 Windscreen wiper blade fixing
(Sec 24)
A Tab B Wiper arm C Blade slot
24.4 Windscreen wiper arm nut23.3 Speedometer cable connector at
transmission
Fig. 9.7 Tailgate wiper blade fixing (Sec 26)
A Hole B Peg25.5B Removing windscreen wiper motor25.5A Windscreen wiper motor cover
25.4 Removing windscreen wiper motor
mounting screws
Fig. 9.6 Windscreen wiper motor
components (Sec 25)
1 Gears 4 Intermittent
2 Crank arm control unit
3 Shaft gear 5 Motor yoke
9

balljoint from the hub carrier using a suitable
“splitter” tool. If such a tool is not available,
support the base of the brake disc and drive
the balljoint taper pin downwards, but screw
on the nut to protect the threads.
4Remove the hub carrier.
5Refitting is a reversal of removal, use a new
driveshaft nut and tighten all nuts and bolts to
the specified torque. Stake the driveshaft nut
after tightening.
6 Track control arm-
removal and refitting
3
1Raise the front of the car and support it
securely.
2Unless a special tool is available to press
the track control arm balljoint from the hub
carrier, the driveshaft will have to be
disconnected as described in Chapter 7,
Section 2, paragraphs 1 to 8 to provide more
space to enable the balljoint taper pin to be
driven from the hub carrier. This should now
be done as described in the preceding
Section (photo).
3Unbolt the inboard end of the track control
arm. This is retained by a pivot bolt and a
clamp (photo).
4As previously explained, a worn balljoint or
flexible pivot bushes will necessitate renewal
of the track control arm complete. Note that itmay, however, be possible to obtain a
replacement balljoint through a motor factor.
5Refitting is a reversal of removal. Tighten all
nuts and bolts to the specified torque. Use a
new driveshaft nut and stake it into the
driveshaft groove after tightening.
7 Front crossmember-
removal and refitting
3
1Raise the front of the car, support securely
with axle stands placed under the
side-members or sill jacking points.
2Remove the front roadwheels.
3Unscrew the nuts from the tie-rod end
balljoint taper pins and then using a balljoint
“splitter” tool disconnect the balljoints from
the steering arms on the hub carrier.
4Unscrew the bolts which hold the inboard
track control arms to the body members, and
also withdraw the pivot bolt from the body
bracket.
5Support the weight of the engine/
transmission using a hoist or support bar
across the top of the engine compartment as
described in Chapter 6.
6Disconnect the lower (central) engine/
transmission flexible mounting from the floor
pan.
7Unscrew the steering rack mounting boltsand remove them. Leave the steering rack
hanging loose.
8Remove the front crossmember mounting
bolts and manoeuvre it from the car.
9Refitting is a reversal of removal. Tighten all
nuts and bolts to the specified torque wrench
settings and on completion, check the front
wheel alignment as described in Chapter 10.
8 Rear shock absorber-
removal and refitting
3
1Open the tailgate and remove the cover
from the shock absorber top mounting which
is located within the luggage area (photo).
2Hold the flats on the spindle with an
open-ended spanner and then unscrew the
self-locking nut.
3Working under the car, disconnect the
shock absorber lower mounting.
4Withdraw the unit from under the wing.
5The shock absorber can be tested as
described in Section 2.
6Refitting is a reversal of removal. Tighten
mounting nuts and bolts to the specified
torque.
9 Rear coil spring-
removal and refitting
3
1Raise the rear of the car and support it
securely on axle stands placed under the
side-members or sill jacking points.
2Remove the roadwheel.
3Place a jack under the brake drum and
support the suspension trailing arm.
4Disconnect the shock absorber lower
mounting and then lower the trailing arm jack
until the coil spring can be withdrawn.
5Refitting is a reversal of removal. If the
spring is being changed, make sure that it is
of the same colour code as the original and
that its lower coil is correctly located up
against its stop in the spring pan.
6Tighten the shock absorber lower mounting
bolt to the specified torque.
11•4 Suspension
8.1 Rear shock absorber upper mounting
coverFig. 11.7 Front crossmember bolts (Sec 7)Fig. 11.6 Steering rack mounting bolts
(Sec 7)
6.3 Track control arm inboard fixing6.2 Separating track control arm balljoint
from hub carrier

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

Braking system................................................................................. 14
Part A: Braking system general
Front brake pads all later models
Part B: Braking system - Turbo ie models
Description
Front disc pads - renewal
Front disc caliper - removal and refitting
Front disc caliper - overhaul
Front brake disc - inspection, renovation or renewal
Rear disc pads - renewal
Rear disc caliper - removal, overhaul and refitting
Rear brake disc - inspection, renovation and renewal
Pressure regulating valve
Brake pedal - removal and refitting
Vacuum servo unit and master cylinder - general
Antiskid system - description
Electrical system.............................................................................. 15
Alternator (999 cc models) - removal and refitting
Alternator (later models) - removal and refitting
Alternator brushes - renewal
Starter motor (999 cc models) - removal and refitting
Starter motor (1301 cc Turbo ie, 1372 cc ie, 1372 cc Turbo ie)
- removal and refitting
Starter motor brushes (later models) - renewal
Fuses - later models
Relays (Turbo ie models) - general
Headlamps - later models
Headlamp beam adjusters for load compensation - later models
Headlamp unit removal - later models
Headlamp dim-dip system - description
Front fog lamps bulb/unit - removal and refitting and beam
adjustment
Horn - relocation
Steering column combination switches (later models) - removal
and refittingInstrument panel (Turbo ie models) - removal and refitting
Facia-mounted switches (1301 cc Turbo ie model) - removal
and refitting
Instrument panel (later models) - removal and refitting
Auxiliary control panel (later models) - removal and refitting
Heater control panel (later models) - removal and refitting
Trip master
Interior roof mounted spotlamp, switch and/or clock - removal
and refitting
Central door locking system
Cigar lighter (later models) - removal and refitting
Electrically operated window switches - removal and refitting
Windscreen wiper motor (later models) - removal and refitting
Windscreen washer reservoir (Turbo) - removal and refitting
Tailgate wiper motor (later models) - removal and refitting
Radio Check control system sensors - description
Check control system sensors - testing
Suspension....................................................................................... 16
Front anti-roll bar - removal and refitting
Suspension strut later models
Bodywork.......................................................................................... 17
Plastic components
Rear view mirrors
Door armrest
Tailgate (Turbo ie model) - component removal and refitting
Radiator grille (1301 cc Turbo ie model) - removal and
refitting
Radiator grille (1372 cc ie and 1372 cc Turbo ie models) -
removal and refitting
Bumpers (1301 cc Turbo ie, 1372 cc ie and 1372 cc Turbo ie
models) - removal and refitting
Rear hinged windows - removal and refitting
Door trim panel (Turbo ie model) - removal and refitting
Supplement: Revisions and information on later models 13•3
13
1 Introduction
Since its introduction in 1983, the FIAT Uno
has had a number of modifications and
improvements including the fitting of a twin
choke carburettor, low profile tyres, tinted
windows and remotely-controlled central door
locking.
The major mechanical change was the
introduction of the FIRE (Fully Integrated
Robotised Engine) on 45 and 45S models to
be followed by a new 1108 cc “FIRE” engine
on the 60S model from 1989 on.
A 1301 cc Turbo ie engine model wasavailable for a short period. This model had a
Bosch LE2 Jetronic electronic fuel injection
(ie) and a turbocharger to give added
performance. To uprate the braking to suit,
disc brakes were fitted to the rear in place of
the original drum type brakes.
A 1372 cc engine model was introduced in
1989. Two versions were initially available. A
Bosch Mono-Jetronic single-point fuel
injection (SPi) system, as found on the 70 SX
model and Bosch L3.1 or L3.2 Jetronic
multi-point fuel injection (MPi) systems were
fitted to Turbo models. L3.2 MPi system
models were equipped with catalytic
converters, to improve exhaust emission. All
fuel injection engines are fitted with electroni-
cally controlled engine management systems.
A new style instrument panel, switchgearand a revised facia layout was introduced in
1989.
During 1992, SPi fuel systems were fitted to
the 999 cc and 1108 cc engines, along with
catalytic converters for improved exhaust
emissions.
Five speed transmissions were introduced
to 999 cc models in 1993.
It is recommended that this Supplement is
always referred to before the main Chapters
of the Manual.
Project vehicles
The vehicles used in the preparation of this
supplement, and appearing in many of the
photographic sequences were a 1986 Uno
45S FIRE, a 1988 1301 cc Uno Turbo ie and a
1991 1372 cc Uno SXie.
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321