engine oil FIAT UNO 1983 Service Workshop Manual
[x] Cancel search | Manufacturer: FIAT, Model Year: 1983, Model line: UNO, Model: FIAT UNO 1983Pages: 303, PDF Size: 10.36 MB
Page 103 of 303
9•14 Electrical system
Fault finding - electrical system
No voltage at starter motor
m mBattery discharged
m mBattery defective internally
m mBattery terminals loose or earth lead not securely attached to body
m mLoose or broken connections in starter motor circuit
m mStarter motor switch or solenoid faulty
Voltage at starter motor - faulty motor
m
mStarter brushes badly worn, sticking, or brush wires loose
m mCommutator dirty, worn or burnt
m mStarter motor armature faulty
m mField coils earthed
Starter motor noisy or rough in engagement
m
mPinion or flywheel gear teeth broken or worn
m mStarter drive main spring broken
m mStarter motor retaining bolts loose
Alternator not charging*
m
mDrivebelt loose and slipping, or broken
m mBrushes worn, sticking, broken or dirty
m mBrush springs weak or broken
* If all appears to be well but the alternator is still not charging, take the
car to an automobile electrician for checking of the alternator
Ignition light fails to go out, battery runs flat in a
few days
m mDrivebelt loose and slipping, or broken
m mAlternator faulty
Battery will not hold charge for more than a few
days
m mBattery defective internally
m mElectrolyte level too low or electrolyte too weak due to leakage
m mPlate separators no longer fully effective
m mBattery plates severely sulphated
m mDrivebelt slipping
m mBattery terminal connections loose or corroded
m mAlternator not charging properly
m mShort in lighting circuit causing continual battery drain
Fuel gauge gives no reading
m
mFuel tank empty!
m mElectric cable between tank sender unit and gauge earthed or loose
m mFuel gauge case not earthed
m mFuel gauge supply cable interrupted
m mFuel gauge unit broken
Fuel gauge registers full all the time
m
mElectric cable between tank unit and gauge broken or disconnected
Horn operates all the time
m
mHorn push either earthed or stuck down
m mHorn cable to horn push earthed
Horn fails to operate
m
mBlown fuse
m mCable or cable connection loose, broken or disconnected
m mHorn has an internal fault
Horn emits intermittent or unsatisfactory noise
m
mCable connections loose
m mHorn incorrectly adjusted
Lights do not come on
m
mIf engine not running, battery discharged
m mLight bulb filament burnt out or bulbs broken
m mWire connections loose, disconnected or broken
m mLight switch shorting or otherwise faulty
Lights come on but fade out
m
mIf engine not running, battery discharged
Lights give very poor illumination
m
mLamp glasses dirty
m mReflector tarnished or dirty
m mLamps badly out of adjustment
m mIncorrect bulb with too low wattage fitted
m mExisting bulbs old and badly discoloured
m mElectrical wiring too thin not allowing full current to pass
Lights work erratically, flashing on and off,
especially over bumps
m mBattery terminals or earth connections loose
m mLights not earthing properly
m mContacts in light switch faulty
Wiper motor fails to work
m
mBlown fuse
m mWire connections loose, disconnected or broken
m mBrushes badly worn
m mArmature worn or faulty
m mField coils faulty
Wiper motor works very slowly and takes
excessive current
m mCommutator dirty, greasy or burnt
m mDrive spindle binding or damaged
m mArmature bearings dry or unaligned
m mArmature badly worn or faulty
Wiper motor works slowly and takes little current
m
mBrushes badly worn
m mCommutator dirty, greasy or burnt
m mArmature badly worn or faulty
Wiper motor works but wiper blade remains static
m
mDrive spindle damaged or worn
m mWiper motor gearbox parts badly worn
Page 111 of 303
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
Page 114 of 303
12
For dimensions, weights etc. refer to the Introductory Section of this Manual.
Chapter 12 Bodywork
For modifications, and information applicable to later models, see Supplement at end of manual
Bonnet - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bonnet - lock and release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Centre console - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 21
Door - dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Door - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Door trim panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 11
Facia panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fixed side window (five-door) - removal and refitting . . . . . . . . . . . . 17
Front bumpers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 9
Front seat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Front wing - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Grab handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maintenance - bodywork and underframe . . . . . . . . . . . . . . . . . . . . 2Maintenance - upholstery and carpets . . . . . . . . . . . . . . . . . . . . . . . 3
Major body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Minor body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Opening side window (three-door) - removal and refitting . . . . . . . . 18
Radiator grille - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 6
Rear bumpers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 26
Rear seat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rear view mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Roof rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Sunroof - operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . 28
Tailgate - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tailgate glass - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 16
Windscreen glass - removal and refitting . . . . . . . . . . . . . . . . . . . . . 15
12•1
Specifications Contents
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
1 General description
The Uno is an all steel, welded Hatchback
of unitary construction available in three- or
five-door versions.
Various levels of trim and equipment are
available depending upon model.
Factory fitted options include a sunroof,
central door locking and electrically-operated
front windows.
2 Maintenance-
bodywork and underframe
1
The general condition of a vehicle’s
bodywork is the one thing that significantly
affects its value. Maintenance is easy, but
needs to be regular. Neglect, particularly after
minor damage, can lead quickly to further
deterioration and costly repair bills. It is
important also to keep watch on those parts
of the vehicle not immediately visible, for
instance the underside, inside all the wheel
arches, and the lower part of the engine
compartment.The basic maintenance routine for the
bodywork is washing - preferably with a lot of
water, from a hose. This will remove all the
loose solids which may have stuck to the
vehicle. It is important to flush these off in
such a way as to prevent grit from scratching
the finish. The wheel arches and underframe
need washing in the same way, to remove any
accumulated mud, which will retain moisture
and tend to encourage rust. Paradoxically
enough, the best time to clean the underframe
and wheel arches is in wet weather, when the
mud is thoroughly wet and soft. In very wet
weather, the underframe is usually cleaned of
large accumulations automatically, and this is
a good time for inspection.
Periodically, except on vehicles with a wax-
based underbody protective coating, it is a
good idea to have the whole of the
underframe of the vehicle steam-cleaned,
engine compartment included, so that a
thorough inspection can be carried out to see
what minor repairs and renovations are
necessary. Steam-cleaning is available at
many garages, and is necessary for the
removal of the accumulation of oily grime,
which sometimes is allowed to become thick
in certain areas. If steam-cleaning facilities are
not available, there are some excellent grease
solvents available which can be brush-applied; the dirt can then be simply hosed off.
Note that these methods should not be used
on vehicles with wax-based underbody
protective coating, or the coating will be
removed. Such vehicles should be inspected
annually, preferably just prior to Winter, when
the underbody should be washed down, and
any damage to the wax coating repaired.
Ideally, a completely fresh coat should be
applied. It would also be worth considering
the use of such wax-based protection for
injection into door panels, sills, box sections,
etc, as an additional safeguard against rust
damage, where such protection is not
provided by the vehicle manufacturer.
After washing paintwork, wipe off with a
chamois leather to give an unspotted clear
finish. A coat of clear protective wax polish
will give added protection against chemical
pollutants in the air. If the paintwork sheen
has dulled or oxidised, use a cleaner/polisher
combination to restore the brilliance of the
shine. This requires a little effort, but such
dulling is usually caused because regular
washing has been neglected. Care needs to
be taken with metallic paintwork, as special
non-abrasive cleaner/polisher is required to
avoid damage to the finish. Always check that
the door and ventilator opening drain holes
and pipes are completely clear, so that water
Page 126 of 303
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
Page 127 of 303
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
Page 130 of 303
Valve timing clearance:
999 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm
1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.70 mm
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm
Valve timing:Inlet Exhaust
999 cc:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1º BTDC 29º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19º ABDC 9º ATDC
1108 cc:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2º BTDC 42º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19º ABDC 2º ATDC
1116 cc:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7º BTDC 37º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35º ABDC 5º ATDC
1299/1301 cc:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9º BTDC 39º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31º ABDC 1º ATDC
1299/1301 cc Turbo ie:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0º TDC 30º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40º ABDC 10º ATDC
1372 cc ie:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7º BTDC 37º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35º ABDC 5º ATDC
1372 cc Turbo ie:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14º BTDC 36º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44º ABDC 6º ATDC
Cam lift:
999 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 mm
1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 mm
1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 mm
1299/1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 mm
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 mm
1372 cc Turbo ie
Inlet valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 mm
Exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 mm
Supplement: Revisions and information on later models 13•5
13
View of engine compartment (air
cleaner removed) on the 999 cc
FIRE engined model
1 Wiper motor cover
2 Suspension strut turret
3 Brake hydraulic fluid reservoir
4 Carburettor
5 Washer fluid reservoir
6 Right-hand engine mounting
7 Fuel pump
8 Ignition distributor
9 Ignition coil
10 Headlamp
11 Oil filler cap
12 Battery
13 Radiator cooling fan
14 Coolant filler/expansion tank
15 Radiator
Page 131 of 303
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
Page 132 of 303
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
Page 133 of 303
Lubrication system
Oil pump type:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear driven from front of crankshaft.
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump operated from front of crankshaft. Oil pressure relief valve in
front cover.
Tooth tip-to-body clearance (999/1108 cc) . . . . . . . . . . . . . . . . . . . . . . 0.080 to 0.186 mm
Gear endfloat:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 to 0.056 mm
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 to 0.106 mm
Oil pressure (at normal operating temperature) . . . . . . . . . . . . . . . . . . . 3.4 to 4.9 bars
Oil filter:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion F107
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C106
Torque wrench settingsNm lbf ft
Auxiliary shaft sprocket bolt (1372 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . 83 62
Big-end cap bolts:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 30
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 38
Camshaft bearing cap bolts:
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 14
M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Camshaft cover screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Camshaft housing to lower cylinder head securing bolt (1372 cc) . . . . . 20 15
Camshaft housing to inlet manifold bracket bolt (1372 cc) . . . . . . . . . . 25 18
Camshaft sprocket bolt
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 50
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 62
Centre mounting to final drive casing bracket (1201/1301 cc) . . . . . . . . 23 17
Coolant temperature switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Crankshaft pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Crankshaft pulley nut (1372 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 145
Crankshaft rear oil seal retainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Crankshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 58
13•8 Supplement: Revisions and information on later models
View of front end from below on
the 1372 cc ie engine model
1 Oil filter
2 Engine oil drain plug
3 Starter motor
4 Horns
5 Transmission front mounting
6 Front fog lamp and adjuster
7 Driveshaft
8 Transmission rear mounting
9 Gearchange linkage
10 Exhaust downpipe and system
joint
11 Anti-roll bar
12 Track control arm
13 Tie-rod balljoint
14 Brake unit
15 Driveshaft damper
16 Underwing shield
Page 134 of 303
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