ECU FIAT UNO 1983 Service Workshop Manual

173Lift the intermediate plate from the oil
pump body.
174The gears can now be removed from the
oil pump body. Inspect them for obvious signs
of wear or damage, and renew if necessary.
175Commence reassembly by lubricating
the gears with clean engine oil, and refitting
them to the casing. Note that the scribed
marks on the top faces of the gears should
face each other with the gears installed
(photo).
176Using a feeler gauge, check that the
clearance between the gears and the pump
body is within the limits given in the Specifica-
tions (photo).
177Using a straight-edge placed across the
top of the pump body and the gears, and a
feeler gauge, check that the gear endfloat is
within the limits given in the Specifications
(photo).
178If either the gear-to-body clearance, or
the gear endfloat is outside the specified
limits, both gears should be renewed.
179Locate the intermediate plate on the
pump body (photo).
180Place the pressure relief valve and spring
over the pressure relief hole in the
intermediate plate, and locate the spring seat
over the boss in the pump cover, then refit the
pump cover, ensuring that the pressure relief
valve components seat correctly (photos).
181Refit and tighten the pump cover
securing bolts.
182Thoroughly clean the mating faces of thepump and crankcase before refitting the
pump. Prime the pump by injecting clean
engine oil into it and turning it by hand.
183Fit the pump using a new gasket, then
insert the securing bolts and tighten them.
184Refit the sump and top up the engine oil
level.
Pistons/connecting rods -
removal and refitting#
185Remove the sump and the cylinder head
as described previously in this Section.
186The big-end caps and connecting rods
normally have identification marks stamped
into their sides, facing the coolant pump side
of the cylinder block. If no marks are present,
use a centre-punch to identify the bearing
caps and the connecting rods for location.187Turn the crankshaft so that No. 1
crankpin is at its lowest point, then unscrew
the nuts and tap off the bearing cap. Keep the
bearing shells in the cap and the connecting
rod if they are to be re-used, taping them in
position if necessary to avoid loss.
188Using the handle of a hammer, push the
piston and connecting rod up the bore and
withdraw it from the top of the cylinder block.
Loosely refit the cap to the connecting rod.
189Repeat the procedure given in
paragraphs 187 and 188 on No. 4 piston and
connecting rod, then turn the crank-
shaft through half a turn and repeat the
procedure on Nos 2 and 3 pistons and
connecting rods.
190The pistons and connecting rods and the
big-end bearings can be examined and if
Supplement: Revisions and information on later models 13•47
7B.176 Check gear-to-body clearance7B.175 Correct alignment of scribed marks
(arrowed) on gears7B.171 Undo the oil pump cover bolts
7B.180C . . . then fit the cover7B.180B Locate spring seat over boss
within pump cover . . .
7B.179 Refitting the intermediate plate7B.177 Checking the gear endfloat
7B.180A Locate pressure relief valve and
spring on the intermediate plate
13

fitting, as during removal. Note that the
compression rings are brittle, and will snap if
expanded too far.
206If new pistons are to be fitted, they must
be selected from the grades available, after
measuring the cylinder bores. Normally, the
appropriate oversize pistons are supplied by
the dealer when the block is rebored.
207Whenever new piston rings are being
installed, the glaze on the original cylinder
bores should be removed using either
abrasive paper or a glaze-removing tool in an
electric drill. If abrasive paper is used, use
strokes at 60º to the bore centre-line, to
create a cross-hatching effect.
Engine/transmission
mountings - renewalÁ
208The engine/gearbox assembly is
suspended in the engine compartment on
three mountings, two of which are attached to
the gearbox, and one to the engine.
Right-hand mounting
209Apply the handbrake, then jack up the
front of the vehicle and support it securely on
axle stands.
210Suitable lifting tackle must now be
attached to the engine in order to support it as
the engine mounting is removed. No lifting
brackets are provided, so care must be taken
when deciding on an engine lifting point. In the
workshop, a right-angled bracket was made up
by bending a suitable piece of steel plate. The
bracket was then bolted to the engine using the
rear right-hand camshaft housing securing bolt
with suitable packing washers.
211Attach the lifting tackle to the bracket on
the engine and just take the weight of the
assembly.
212Working under the vehicle, unbolt the
engine mounting bracket from the cylinder
block, and unbolt the mounting from the
body, then withdraw the bracket/mounting
assembly.
213Unscrew the nut and through-bolt,
counter holding the bolt with a second
spanner or socket, and separate the mounting
from the bracket.
214Fit the new mounting to the bracket, and
tighten the nut to the specified torque, while
counterholding the through-bolt using a
suitable spanner or socket.
215Refit the mounting bracket to the cylinder
block, and tighten the securing bolts to the
specified torque.
216Refit the mounting to the body and
tighten the securing bolts to the specified
torque.
217Disconnect the lifting tackle from the
engine, and remove the engine lifting bracket.
218Lower the vehicle to the ground.
Left-hand mountings
219Apply the handbrake, then jack up the
front of the vehicle and support it securely on
axle stands.
220Suitable lifting tackle must now be
attached to the gearbox lifting bracket inorder to support the weight of the assembly
as the mounting is removed.
221Attach the lifting tackle to the bracket on
the gearbox, and just take the weight of the
assembly.
222Working under the vehicle, unbolt the
mounting bracket from the gearbox, and
unbolt the mounting from the body, then
withdraw the bracket/mounting assembly.
223Proceed as described in paragraphs 213
and 214.
224Refit the mounting bracket to the
gearbox, and tighten the securing bolts to the
specified torque.
225Refit the mounting to the body and
tighten the mounting bolts to the specified
torque.
226Disconnect the lifting tackle from the
engine.
227Lower the vehicle to the ground.
PART C: ENGINE REMOVAL
AND DISMANTLING
Method of removal - general
1The engine (complete with transmission) is
disconnected and lowered downwards
through the engine compartment, then
withdrawn from the front underside of the car.
1372 cc engine/
transmission - removal
and separation
#
Warning: Refer to the beginning
of Section 9 before starting any
work.
2Depressurize the fuel system as described
in Section 9 of this Chapter.
3Disconnect the battery negative lead.
4Mark the position of the hinges on the
underside of the bonnet, then with the aid of
an assistant, unscrew the hinge bolts and lift
the bonnet clear of the car. Store the bonnet
in a safe area.
5Drain the engine coolant.
6Drain the engine and transmission oils.
7Disconnect and remove the air filter.
8Disconnect the coolant hoses from the
engine, including the hose to the inlet
manifold.
9Detach the ignition coil (HT) lead from the
distributor.10Compress the retaining clip and detach
the engine idle speed actuator lead from the
SPi unit (photo).
11Disconnect the brake servo vacuum pipe
from its connector on the inlet manifold.
12Disconnect the throttle cable from the SPi
unit.
13Disconnect the engine speed sensor lead.
14Release and detach the reversing light
lead from the switch on the transmission
(photo).
15Before disconnecting the hydraulic hose
from the clutch slave cylinder, remove the
filler cap from the reservoir and place a piece
of polythene sheet over the filler neck, then
refit the cap; this will help prevent excess fluid
loss. Once disconnected, plug the hose and
its cylinder connection to prevent the ingress
of dirt into the hydraulic system.
16Disconnect the wiring connector from the
alternator.
17Position a clean rag under the fuel supply
and return hose connections to the SPi unit,
then slowly unscrew the hose clips to release
the system pressure; catch fuel leakage in the
rag and dispose of it safely. Detach the hoses
and plug them to prevent ingress of dirt and
any further fuel leakage. Position the hoses
out of the way.
18Detach the wiring connector from the
engine coolant temperature sender unit
(photo).
19Release the retaining clip and detach the
wiring connector from the throttle position
switch. Also detach the associated earth
leads from the cylinder head.
Supplement: Revisions and information on later models 13•49
7C.14 Reversing light switch and lead7C.18 Engine coolant temperature sender
and wiring connector
7C.10 Engine idle speed actuator/SPi unit
lead connection (arrowed)
13

20Release the retaining clip and detach the
wiring connector from the fuel injector
connection (photo).
21Loosen off the front wheel bolts each
side, then raise and support the car at the
front end on axle stands. When raised,
support at a height which will allow the engine
and transmission to be withdrawn from the
underside when fully disconnected. Ensure
that the vehicle is securely supported before
working underneath it.
22Unscrew the wheel bolts and remove the
front roadwheels.
23Release the retaining clips and remove
the underwing shield from the right- and
left-hand front wheel arch.24Relieve the staking, then unscrew and
remove the front hub nut using a socket and
suitable extension. Repeat the procedure on
the opposite front hub.
25Unscrew the retaining nut and disconnect
the tie-rod to steering arm balljoint using a
suitable balljoint separator tool. Repeat the
procedure on the other side.
26Note the direction of fitting, then unscrew
and remove the hub-to-strut retaining bolts
and nuts on each side.
27Unscrew and remove the anti-roll bar-
to-track control arm retaining nuts each side.
28Unscrew and remove the front brake
caliper hydraulic pipe support bracket bolt
each side.29Pull the wheel hub outwards and detach
the driveshaft from it, noting that there may be
a small amount of oil spillage as it is
withdrawn. Repeat the procedure on the
opposite side.
30Disconnect the wiring connector from the
engine oil level sensor lead.
31Unscrew the retaining nuts to detach and
remove the exhaust pipe front section or
alternatively, remove the system complete.
32Unscrew the knurled retaining nut and
detach the speedometer cable from the
transmission (photo).
33Unscrew the retaining nut and detach the
earth strap from the transmission (photo).
34Extract the split pin and detach the gear
selector rod from the transmission pin.
Disconnect the gear engagement and selector
levers from the balljoints.
35The weight of the engine will now need to
be supported from above. Connect a suitable
lift hoist and sling to the engine. When
securely connected, take the weight of the
engine/transmission unit so that the tension is
relieved from the mountings.
36Unscrew and remove the engine and
transmission support mounting bolts at the
points indicated (photos).
37The engine/transmission unit should now
be ready for removal from the vehicle. Check
that all of the associated connections and
13•50 Supplement: Revisions and information on later models
Fig. 13.22 The underwing
shield retaining clips (arrowed)
on the 1372 cc ie and Turbo ie
engines (Sec 7C)Fig. 13.25 Gear engagement
and selector lever balljoints
(arrowed) on the 1372 cc ie and
Turbo ie engines (Sec 7C)Fig. 13.23 Engine oil level
sensor wiring connector
(arrowed) on the 1372 cc ie and
Turbo ie engines (Sec 7C)Fig. 13.24 Disconnect the gear
selector rod at the connection
indicated on the 1372 cc ie and
Turbo ie engines (Sec 7C)
7C.33 Disconnect the transmission earth
strap7C.32 Disconnecting the speedometer
drive cable from the transmission7C.20 Fuel injector wiring connection
7C.36B Transmission rear mounting7C.36A Engine right-hand mounting

fittings are disconnected from the engine and
transmission and positioned out of the way.
Enlist the aid of an assistant to help steady
and guide the power unit down through the
engine compartment as it is removed, If
available, position a suitable engine trolley or
crawler board under the engine/transmission
so that when lowered, the power unit can be
withdrawn from the front end of the vehicle
and moved to the area where it is to be
cleaned and dismantled.
38Carefully lower the engine and
transmission unit, ensuring that no fittings
become snagged. Detach the hoist and
withdraw the power unit from under the
vehicle.
39To separate the engine from the
transmission, unbolt and remove the starter
motor, then unscrew the retaining bolts and
withdraw the transmission from the engine. As
it is withdrawn, do not allow the weight of the
engine or transmission to be taken by the
input shaft.
40To remove the clutch unit, refer to
Chapter 5 for details.
1372 cc Turbo ie
engine/transmission -
removal and separation
#
41The engine and transmission removal and
refitting details for Turbo-engined models are
similar to those described for the non-Turbo
models in the previous sub-Section, but the
following differences should be noted.
42To provide access for the disconnection
of the turbo and related components, first
remove the inlet manifold. Removal of the inlet
manifold and the turbocharger is described in
Section 9 of this Chapter.
43The ignition distributor on the Turbo
engine is driven from the auxiliary shaft and is
mounted at the front of the engine, towards
the timing cover end.
44The right-hand driveshaft has a steady
bearing and this will need to be unbolted and
detached.
Engine dismantling - general
45Refer to Chapter 1, Section 14 for details.
Auxiliary shaft - removal,
inspection and refitting #
46Remove the engine and transmission from
the vehicle as described previously in this
Section part.
47Drain the engine oil and remove the sump
as described in Part B of this Section.
48Remove the oil pump as described in Part
B of this Section.
49Remove the timing belt and the auxiliary
shaft sprocket as described in Part B of this
Section.
50Unscrew the three retaining bolts and
remove the auxiliary shaft cover. Remove the
gasket.
51Withdraw the auxiliary shaft from the
cylinder block.
52Examine the shaft and its bearing bushes
in the cylinder block for signs of excessive
wear and/or damage and renew it if
necessary. Bush renewal is described in
paragraph 79 in this Section.
53The cover gasket and the oil seal should
always be renewed whenever the cover is
removed. To renew the seal, support the
cover on blocks of wood and drive out the old
seal using a suitable drift inserted in the
cut-out in the back of the cover. Clean the
seal location in the housing. Drive the new
seal into place using a suitable metal tube or
socket (photo). The sealing lip must face
towards the cylinder block. Smear the sealing
lips with clean engine oil before installation.
54Commence refitting by lubricating theauxiliary shaft journals with clean engine oil,
then insert the shaft into the cylinder block
(photo).
55Refit the auxiliary shaft cover, using a new
gasket, and tighten the securing bolts
(photos).
56Refit the auxiliary shaft sprocket, timing
belt, cover and crankshaft pulley as described
in Part B of this Section.
57Refit the engine and transmission with
reference to Part D of this Section.
Engine -
complete dismantling#
Warning: Refer to the beginning
of Section 9 before starting any
work.
58Detach and remove the following ancillary
items. Where applicable, refer to the
appropriate Chapter or Section within this
Chapter for more detailed removal instructions.
Engine oil dipstick
Ignition distributor and HT leads
Fuel pump
Alternator
Oil filter
Oil vapour recovery unit
Inlet and exhaust manifolds and associated
fuel injection components (as applicable)
Clutch unit
59Refer to Part B of this Section for details
and remove the timing cover and drivebelt.
60Refer to Part B of this Section for details
and remove the cylinder head unit.
Supplement: Revisions and information on later models 13•51
7C.54 Inserting the auxiliary shaft into the
cylinder block (rear timing belt cover
removed)7C.53 Driving a new oil seal into the
auxiliary shaft cover7C.36C Transmission front mounting
7C.55B . . . and tighten the securing bolts7C.55A Refit the auxiliary shaft cover with
a new gasket . . .
13

61Refer to Part B of this Section for details
and remove the flywheel.
62Refer to the previous sub-Section for
details and remove the auxiliary shaft.
63Refer to Part B of this Section for details
and remove the sump.
64Refer to Part B of this Section for details
and remove the oil pump unit.
65Refer to Part B of this Section for details
and remove the front and rear crankshaft oil
seals.
66Refer to Part B of this Section and remove
the piston/connecting rod assemblies.
67Refer to Part B of this Section for details
and remove the crankshaft and main bearing
assemblies.
Crankshaft and main
bearings - removal#
68Unscrew the securing bolts and remove
the front and rear crankshaft oil seal housings.
Recover the gaskets.
69Check the main bearing caps for identifi-
cation marks and if necessary use a
centre-punch to identify them. Normally the
caps have identifying notches cut into their
top face nearest the timing belt end of the
engine, with the exception of No 5 cap
(flywheel end) which has no marking (photo).
70Before removing the crankshaft, check
that the endfloat is within the specified limits.
Ideally a dial gauge should be used, but
alternatively feeler gauges can be used as
follows. Push the crankshaft as far as possible
towards the timing end of the engine, and
using a feeler gauge, measure the gap
between the rear face of the flywheel
mounting flange on the crankshaft and the
outer face of the thrust washer (photo). Now
push the crankshaft as far as possible in the
opposite direction and take the same
measurement again. The difference between
the two measurements is the crankshaft
endfloat. If the endfloat is outside the
specified limits, new thrustwashers will be
required.
71Unscrew the bolts and tap off the main
bearing caps complete with bearing shells. If
the bearing shells are to be re-used, tape
them to their respective caps.
72Lift the crankshaft from the crankcase.
73Extract the bearing shells from thecrankcase, keeping them identified for
location if they are to be re-used, and recover
the thrust washers from No. 5 main bearing
location.
Engine components -
examination and
renovation
#
74With the engine completely stripped,
clean all the components and examine them
for wear. Each part should be checked and
where necessary renewed or renovated as
described elsewhere in this Section. Renew
main and big-end bearing shells as a matter of
course, unless it is known that they have had
little wear and are in perfect condition.
75If in doubt as to whether to renew a
component which is still just serviceable,
consider the time and effort which will be
incurred should the component fail at an early
date. Obviously the age and expected life of
the vehicle must influence the standards
applied.
76Gaskets, oil seals and O-rings must all be
renewed as a matter of course. FIAT specify
that the main cylinder head bolts should be
renewed after they have been used (ie
tightened) four times - if in any doubt as to the
number of times the bolts have been used,
renew them in any case as a precaution
against possible failure.
77Take the opportunity to renew the engine
core plugs while they are easily accessible.
Knock out the old plugs with a hammer and
chisel or punch. Clean the plug seats, smearthe new plugs with sealant and tap them
squarely into position.
78Clean and examine the cylinder block as
described in paragraphs 2 to 7 of Section 18,
Chapter 1.
79If the auxiliary shaft bushes are
excessively worn or are oval, they must be
renewed. When the new bushes are installed,
they may need to be reamed to suit. The
renewal of the auxiliary shaft bushes is
therefore best entrusted to an engine
reconditioner or FIAT dealer. When the
bushes are renewed, ensure that the oil hole
in each bush is aligned with the oil channel in
the cylinder block.
PART D: ENGINE
REASSEMBLY
Reassembly - general
1Refer to Chapter 1, Section 19.
Crankshaft and main
bearings - refitting#
2Ensure that the crankcase and crankshaft
are thoroughly clean, and that the oilways are
clear. If possible, blow through the oil drillings
with compressed air, and inject clean engine
oil into them.
3Unless they are virtually new, the old main
bearing shells should be renewed. Failure to
do so is a false economy.
4If new bearing shells are being fitted, wipe
away all traces of protective grease.
5Note that there is a tag on the back of each
bearing shell, which engages with a groove in
the relevant seat in the crankcase or bearing
cap.
6Wipe clean the bearing shell locations in the
crankcase with a non-fluffy rag, then lubricate
them and fit the five upper halves of the
bearing shells to their seats. Note that the
centre (No. 3) bearing shell is plain, whereas
all the other shells have oil grooves (photos).
7Fit the thrustwashers to the No. 5 main
bearing shell location, with the grooved side
of each washer facing away from the face of
the cylinder block - ie towards the thrust face
of the crankshaft (photos).
8Wipe the bearing shell locations in the
13•52 Supplement: Revisions and information on later models
7D.6B . . . all others have oil groove7D.6A No. 3 main bearing shell is plain . . .
7C.70 Measuring crankshaft endfloat using
feeler gauge method7C.69 Identification notches on No. 3 main
bearing cap

bearing caps with a soft non-fluffy rag, then fit
the lower halves of the bearing shells to their
seats. Again, note that the centre (No. 3)
bearing shell is plain, whereas all the other
shells have oil grooves (photo).
9Lubricate the crankshaft journals and the
upper and lower main bearing shells with
clean engine oil (photo).
10Carefully lower the crankshaft into the
crankcase (photo). If necessary, seat the
crankshaft using light taps with a
rubber-faced hammer on the crankshaft
balance webs.
11Lubricate the crankshaft main bearing
journals again, the fit the No. 1 bearing cap.
Fit the two securing bolts, and tighten them as
far as possible by hand.
12Fit the No. 5 bearing cap, and as before
tighten the bolts as far as possible by hand.
13Fit the centre and then the intermediate
bearing caps, and again tighten the bolts as
far as possible by hand.
14Check that the markings on the bearing
caps are correctly orientated as noted during
dismantling - ie the identification grooves
should face towards the timing side of the
engine, then working from the centre cap
outwards in a progressive sequence, finally
tighten the bolts to the specified torque
(photo).
15Check that the crankshaft rotates freely.
Some stiffness is to be expected with new
components, but there should be no tight
spots or binding.16Check that crankshaft endfloat is within
the specified limits, as described in paragraph
70 of Part C in this Section.
17Examine the condition of the front and
rear crankshaft oil seals and renew if
necessary with reference to Part B of this
Section. It is advisable to renew the oil seals
as a matter of course unless they are in
perfect condition.
18Lubricate the oil seal lips with clean
engine oil, then carefully fit the front and rear
oil seal housings using new gaskets.
Pistons and connecting rods -
refitting
19Refer to Part B of this Section.
Oil pump - refitting
20Refer to Part B of this Section.
Sump - refitting
21Refer to Part B of this Section.
Flywheel - refitting
22Refer to Part B of this Section. When the
flywheel is bolted in position, refer to Chapter
5 for details and refit the clutch unit.
Auxiliary shaft - refitting
23Refer to Part C of this Section.
Cylinder head - refitting
24Refer to Part B of this Section. Note that
this procedure describes cylinder head
refitting complete with the camshaft housingassembly and manifolds as a complete unit.
Details of refitting the camshaft housing (and
followers) to the cylinder head will be found
separately in Part B.
Timing belt and covers -
refitting
25Refer to Part B of this Section.
Engine/transmission -
reconnection and refitting#
Note: A suitable hoist and lifting tackle will be
required for this operation. New locktabs will
be required for the exhaust
downpipe-to-manifold nuts, and suitable
exhaust assembly paste, will be required when
reconnecting the downpipes to the exhaust
manifold.
26Before attempting to reconnect the
engine to the gearbox, check that the clutch
friction disc is centralised as described in
Chapter 5, Section 8. This is necessary to
ensure that the gearbox input shaft splines
will pass through the splines in the centre of
the friction disc.
27Check that the clutch release arm and
bearing are correctly fitted, and lightly grease
the input shaft splines.
28Mate the engine and gearbox together,
ensuring that the engine adapter plate is
correctly located, and that the gearbox
locates on the dowels in the cylinder block,
then refit the engine-to-gearbox bolts and the
single nut, but do not fully tighten them at this
stage. Ensure that any brackets noted during
Supplement: Revisions and information on later models 13•53
7D.8 Locate the bearing shells into the
main bearing caps . . .7D.7B . . . sliding them into position each
side of the No. 5 main bearing
7DS.14 Tighten the main bearing cap bolts
to the specified torque setting7D.10 Lower the crankshaft into position7D.9 . . . and lubricate the shells
13
7D.7A Locate the thrust washer . . .

removal are in place under the
engine-to-gearbox bolts. Do not allow the
weight of the gearbox to hang on the input
shaft as it is engaged with the clutch friction
disc.
29Refit the starter motor, ensuring that the
wiring harness bracket is in position on the
top bolt.
30Locate the engine/transmission unit at the
front of the car and move it into position under
the engine compartment. Attach the lifting
sling and hoist as during removal.
31Enlist the aid of an assistant to help
steady the combined units as they are raised
into position and to locate the mountings in
the engine compartment.
32Once they are located, tighten the
mountings to the specified torque settings,
then disconnect the lifting hoist and sling.
33The remainder of the refitting and
reconnection procedures are a reversal of the
removal procedure described in Part C. For
further details on reconnecting the
suspension and driveshaft components,
refer to Chapter 7 and Section 13 of this
Chapter.
34Ensure that the exhaust downpipe-to-
manifold connection is clean and renew the
gasket when reconnecting this joint. Use a
smear of exhaust assembly paste on the jointfaces. Use new lockwashers and tighten the
flange nuts securely.
35Ensure that all fuel and coolant
connections are cleanly and securely made.
36Ensure that all wiring connections are
correct and securely made.
37Top up the engine and transmission oil
levels.
38Refill the cooling system.
39Check that all connections are securely
made, then reconnect the battery negative
lead.
Initial start-up after major
overhaul
40Refer to Chapter 1, Section 45.
8 Cooling system
PART A:
999 AND 1108 CC ENGINES
Description
1The operation and function of the cooling
system is essentially as described in Chapter
2 but note the location of the various
components and the routing of the coolant
hoses in Fig. 13.26.
Maintenance
2Topping-up, draining and refilling
procedures are as for 1116 and 1301 cc
engines in Chapter 2, but note that the
coolant capacity is different (see Specifica-
tions).
Thermostat -
removal and refittingÁ
3The thermostat is located on the left-hand
end of the cylinder head, below the
distributor.
4The thermostat cannot be renewed
independently of its housing and if faulty the
complete assembly must be renewed.
5Drain the cooling system.
6Although the thermostat housing can be
removed directly from the cylinder head,
better access is provided if the distributor is
first withdrawn as described in Section 10 of
this Chapter (photo).
7Disconnect the coolant hose from the
thermostat housing and unscrew the housing
flange bolts. Remove the assembly. Note that
it may be necessary to tap it free with a
plastic-faced or wooden mallet if stuck in
place.
8Remove the gasket and clean the mating
surfaces.
9Use a new gasket and bolt the assembly
into position (photo).
10Reconnect the coolant hose, then fill and
bleed the cooling system.
13•54 Supplement: Revisions and information on later models
Fig. 13.26 Cooling system circuit - 999 and 1108 cc engines (Sec 8A)
1 Coolant pump 2 Thermostat 3 Heater matrix
Fig. 13.27 Cooling system thermostat in open and closed positions - 999 and 1108 cc
engines (Sec 8A)8A.9 Fitting the thermostat housing. Note
the new gasket
8A.6 The thermostat housing (shown with
distributor removal) on the 999 cc engine

10Apply suitable sealant to the threads of
the drain plug, then refit and tighten the plug.
11Dispose of the drained coolant safely, or
keep it in a covered container if it is to be
re-used.
12If required, the system can be flushed
through as described in Section 2 of Chap-
ter 2.
13Before attempting to refill the cooling
system, make sure that all hoses have been
reconnected, that the hoses and clips are in
good condition, and that the clips are tight.
Also ensure that the cylinder block drain plug
has been refitted and tightened. Note that an
antifreeze mixture must be used all year round
to prevent corrosion of the engine
components - refer to Section 3, Chapter 2.
14Open the bleed screw in the top of the
expansion tank (photo).
15Remove the expansion tank cap, and fill
the system by slowly pouring the coolant into
the expansion tank to prevent air locks from
forming.
16Top up the coolant until liquid free from air
bubbles emerges from the radiator bleed
screw orifice, then close the bleed screw.
17Continue topping up until the coolant
reaches the Maximum mark on the expansion
tank.
18Start the engine and run it until it reaches
normal operating temperature, then stop the
engine and allow it to cool. Normal operating
temperature is reached when the cooling fancuts into operation. Feel the radiator top hose
to ensure that it is hot. If cool, it indicates an
air lock in the system.
19Check for leaks, particularly around
disturbed components. Check the coolant
level in the expansion tank, and top up if
necessary. Note that the system must be cold
before an accurate level is indicated. There is
a risk of scalding if the expansion tank cap is
removed whilst the system is hot.
Radiator (and cooling fan)
- removal and refitting Á
20Disconnect the battery negative lead.
21Detach the wiring connectors from the
cooling fan and the fan switch located in the
radiator (photos).
22If preferred, the cooling fan unit can be
removed separately from the radiator, by
undoing the attachment bolts and carefully
withdrawing the unit upwards from the
vehicle. Take care not to damage the radiator
core as it is lifted clear (photo).
23Drain the cooling system as described
earlier in this part of the Section, but note that
it will not be necessary to remove the cylinder
block drain plug.
24Undo the retaining screws and remove
the front grille panel.
25Loosen off the retaining clips and detach
the upper coolant hose and the expansion
hose from the radiator.26Note their direction of fitting, then prise
free the radiator retaining clips. Carefully lift
the radiator from the car.
27Refitting is a reversal of the removal
procedure. Ensure that as the radiator is
lowered into position, it engages in the two
rubber location grommets.
28With the radiator (and cooling fan) refitted,
top up the cooling system as described earlier
in this Section (photo).
Thermostat -
removal and refitting Á
Note: A new thermostat cover gasket must be
used on refitting.
29Drain the cooling system as described
earlier in this Section, but note that there is no
need to drain the cylinder block.
30Disconnect the coolant hoses from the
thermostat cover (situated at the gearbox end
of the cylinder head).
31Unscrew the two thermostat cover
securing bolts, noting that the left-hand bolt
may also secure the HT lead bracket, and
remove the thermostat/cover assembly.
Recover the gasket (photo).
32If faulty, the thermostat must be renewed
complete with the housing as an assembly.
33If desired the thermostat can be tested as
described in Chapter 2.
34Refitting is a reversal of removal, bearing
in mind the following points.
Supplement: Revisions and information on later models 13•57
8C.21B Cooling fan switch wiring
connector8C.21A Cooling fan and wiring connector8C.14 Bleed screw location on top of the
expansion tank (arrowed)
8C.31 Thermostat unit removal on the
1372 cc ie engine (distributor removed for
clarity)8C.28 Topping up the radiator coolant level
on the 1372 cc ie engine. Note orientation
of radiator retaining clip (arrowed)8C.22 Cooling fan to radiator securing bolt
13

35Clean the mating faces of the thermostat
cover and cylinder head, and use a new
gasket when refitting the cover.
36Refill the cooling system as described
earlier in this Section.
Coolant pump -
removal and refittingÁ
Note: A new coolant pump gasket must be
used on refitting. If the pump is found to be
worn it must be renewed as a complete unit as
dismantling and repair is not possible.
37Disconnect the battery negative lead.
38Drain the cooling system as described
earlier in this Section.
39Remove the coolant/alternator drivebelt
as described in the next sub-Section.
40Unscrew the four coolant pump securing
bolts, noting that two of the bolts also secure
the alternator adjuster bracket, and withdraw
the pump from the housing (photo). Recover
the gasket.
41Refitting is a reversal of removal, bearing
in mind the following points.
42Use a new gasket between the pump and
the housing.
43Refit and tension the coolant
pump/alternator drivebelt as described in the
next sub-Section.
44On completion, refill the cooling system
as described earlier in this Section.
Coolant pump/alternator
drivebelt - checking,
renewal and tensioning
Á
45At the intervals specified in Section 3 or
“Routine maintenance” at the beginning of
this manual (as applicable), the drivebelt
should be checked and if necessary
re-tensioned.
46Access to the drivebelt is made from the
underside of the car on the right-hand side.
Loosen off the front right-hand roadwheel
retaining bolts, then raise and support the car
on axle stands at the front. Remove the front
roadwheel on the right-hand side.
47Remove the underwing shield from the
right-hand wheel arch by drifting the
compression pins out from the retaining
clips. Prise free the clips and remove the
shield.
48Additional, though somewhat restricted,
access can be obtained from above by
removing the air cleaner unit on the non-Turbo
ie-engine (photo).
49Check the full length of the drivebelt for
cracks and deterioration. It will be necessary
to turn the engine in order to check the
portions of the drivebelt in contact with the
pulleys. If a drivebelt is unserviceable, renew it
as follows (photo).
50Loosen the alternator mounting and
adjuster nuts and bolts and pivot the
alternator towards the cylinder block.51Slip the drivebelt from the alternator,
coolant pump and crankshaft pulleys.
52Fit the new drivebelt around the pulleys,
then lever the alternator away from the
cylinder block until the specified belt tension
is achieved. Lever the alternator using a
wooden or plastic lever at the pulley end to
prevent damage. It is helpful to partially
tighten the adjuster nut before tensioning the
drivebelt (photo).
53When the specified tension has been
achieved, tighten the mounting and adjuster
nuts and bolts (photo).
PART D: HEATER UNIT- LATER
MODELS
Heater unit -
removal and refitting
Á
1The heater unit is removed complete with
the facia/control panel. Commence by
draining the cooling system as described
previously in this Section.
2Disconnect the battery negative lead.
3Refer to Section 15 of this Chapter for
details and remove the ashtray/cigar lighter
and the auxiliary control panel.
4Undo the upper screw retaining the heater
unit to the facia (see Fig. 13.31).
5Remove the radio from the central facia.
6Undo the retaining screw on each side at
the front of the gear lever console. Prise free
13•58 Supplement: Revisions and information on later models
Fig. 13.31 Removing the heater unit-to-
facia upper retaining screw (Sec 8D)8C.53 Tightening the alternator adjuster
nut8C.52 Fitting a new coolant
pump/alternator drivebelt around the
pulleys
8C.49 Alternator/water pump drivebelt and
tensioner viewed from the right-hand
wheel arch8C.48 Top side view of water pump,
alternator and drivebelt8C.40 Coolant pump/alternator bracket
bolt removal

the trim cover, undo the retaining screw at the
rear of the console. Prise free and release the
gear lever gaiter and lift clear the central
console.
7Undo the retaining screws and remove the
steering column upper and lower shroud.
8Detach and remove the lower facia trim on
the side of the central facia.
9Referring to Fig. 13.32, unscrew and
remove the four heater facia to main facia
retaining screws from the points indicated.
10Undo the two retaining nuts securing the
heater to the body on the driver’s side.
11Undo the retaining screws and remove
the pipe shield from the side of the heater
unit, then disconnect the coolant supply and
return hoses from the heater. As the hoses are
detached, be prepared to catch any remainingcoolant as it flows from the hoses and heater
connections.
12Undo the remaining two heater unit
securing nuts and withdraw the heater unit
from the car. As the unit is removed, detach
the wiring and position the hoses with their
ends pointing upwards to avoid further
coolant spillage.
13Refit in the reverse order of removal.
Ensure that the hoses are securely
reconnected. Top up the cooling system on
completion.
Heater unit - dismantling
and reassemblyÁ
14Remove the heater unit as described
previously.
15Pull free the heater/fresh air and blower
control knobs (photo).
16Undo the two retaining screws and
withdraw the control panel from the facia.
Detach the wiring connectors from the panel
illumination lights and remove the panel.17Unscrew the retaining bolts and remove
the centre panel from the heater unit.
18Undo the retaining screws and remove
the control lever mounting.
19Loosen off the grub screws and detach
the cables from the control levers.
20Undo the retaining screws and remove
the control valve.
21Undo the two retaining screws and
withdraw the heater matrix from the heater
housing.
22To separate the casing halves, drill out the
pop rivet securing the mounting bracket,
release the retaining clips and unscrew the
securing bolts.
23Reassemble in the reverse order of
dismantling. Check that the control cables are
correctly adjusted and that the controls
operate in a satisfactory manner before
refitting the heater unit to the car.
Supplement: Revisions and information on later models 13•59
8D.15 Pull free the heater/fresh air and
blower control knobs
Fig. 13.33 Heater pipe shield securing
screw positions on later models (Sec 8D)
Fig. 13.32 Heater unit facia to main facia
retaining screw locations (arrowed)
(Sec 8D)
Fig. 13.34 Heater unit components on later models (Sec 8D)
1 Coolant inlet tap 2 Centre panel 3 Side casings 4 Heater matrix 5 Blower fan
13