engine coolant FIAT UNO 1983 Service Manual PDF

c) If the engine develops a misfire, do not
drive the car at all (or at least as little as
possible) until the fault is cured - the
misfire will allow unburned fuel to enter
the converter, which will result in its
overheating, as noted above.
d) DO NOT push- or tow-start the car - this
will soak the catalytic converter in
unburned fuel, causing it to overheat
when the engine does start - see b)
above.
e) DO NOT switch off the ignition at high
engine speeds - if the ignition is switched
off at anything above idle speed,
unburned fuel will enter the (very hot)
catalytic converter, with the possible risk
of its igniting on the element and
damaging the converter.
f) DO NOT use fuel or engine oil additives -
these may contain substances harmful to
the catalytic converter.
g) DO NOT continue to use the car if the
engine burns oil to the extent of leaving a
visible trail of blue smoke - the unburned
carbon deposits will clog the converter
passages and reduce its efficiency; in
severe cases the element will overheat.
h) Remember that the catalytic converter
operates at very high temperatures and
the casing will become hot enough to
ignite combustible materials which brush
against it. DO NOT, therefore, park the car
in dry undergrowth, over long grass or
piles of dead leaves.
i) Remember that the catalytic converter is
FRAGILE - do not strike it with tools
during servicing work, take great care
when working on the exhaust system,
ensure that the converter is well clear of
any jacks or other lifting gear used to raise
the car and do not drive the car over
rough ground road humps, etc., in such a
way as to ground the exhaust system.
j) In some cases, particularly when the car is
new and/or is used for stop/start driving, a
sulphurous smell (like that of rotten eggs)
may be noticed from the exhaust. This is
common to many catalytic
converter-equipped cars and seems to be
due to the small amount of sulphur found
in some petrols reacting with hydrogen in
the exhaust to produce hydrogen sulphide
(H
2S) gas; while this gas is toxic, it is not
produced in sufficient amounts to be a
problem. Once the car has covered a few
thousand miles the problem should
disappear - in the meanwhile a change of
driving style or of the brand of petrol used
may effect a solution.
k) The catalytic converter, used on a
well-maintained and well driven car,
should last for at least 50 000 miles
(80 000 km) or five years - from this point
on, careful checks should be made at all
specified service intervals on the CO level
to ensure that the converter is still
operating efficiently - if the converter is no
longer effective it must be renewed.
Fuel evaporation control system
- general
76As mentioned earlier, fuel evaporation is
contained within the system. In high outdoor
temperatures, when the vehicle is parked for a
period of time, the fuel in the tank evaporates,
building up pressure. When the pressure builds
up to a predetermined level a vent valve opens
to allow the vapours to pass on to and absorbed
by a carbon filter. However, if extreme pressure
or vacuum should build up, a two way safety
valve opens to allow external venting.
77If the safety valve needs replacing, note
that it must be fitted correctly. The black end
should be connected to the fuel tank and the
blue to the carbon filter.
78The vapours in the carbon filter are
flushed by warm air passing through the filter
on to a ECU controlled vapour cut-off
solenoid.
79The cut-off solenoid is closed when
starting the engine and opens to allow
vapours to be drawn into the inlet manifold,
through a second solenoid. If the cut-off
solenoid needs replacing ensure that the
black arrow on the casing is pointing towards
the inlet manifold.
80The second solenoid, known as an Elbi
solenoid, is closed when the engine is turned
off, thus preventing engine run-on. The side
facing connection is for the inlet manifold
pipe.
PART E:
BOSCH L3.1/2 JETRONIC
FUEL INJECTION SYSTEMS
Warning: Refer to the beginning
of this Section before starting
any work.
Description
1A Bosch L3.1 (or L3.2, as fitted from 1992)
Jetronic fuel injection system is fitted to the
1372 cc Turbo ie engine. The system circuit
and main component locations are shown in
Figs. 13.48 and 13.49.
2The L3.1/2 Jetronic system is a multi-point
fuel injection (MPi) system. It operates in a
similar manner to that of the LE2-Jetronic
system fitted to the 1301 cc Turbo ie engine
described in Part C of this Section. The L3.1/2
system is more sophisticated and has the
ability to provide reasonably efficient engine
operation when system sensors malfunction.
As with the LE2 system, the fuel and air
supply mixture circuits are regulated in
accordance with the electronic control unit
(ECU), but on the L3.1/2 system the control
unit is attached to the upper part of the
airflow meter.
3The ECU analyses the information passed
to it from the system sensors. These signals
are then processed and the air/fuel mixture is
constantly adjusted as required to provide the
13•78 Supplement: Revisions and information on later models
Fig. 13.48 Bosch L3.1 Jetronic fuel injection system - 1372 cc Turbo ie engine (Sec 9E)
1 ECU
1A Diagnostic socket
2 Injection system relay and
fuel pump relay
3 Ignition switch
4 Battery
5 Fuel tank
6 Fuel pump
6A Primary fuel filter7 Coolant temperature
sensor
8 Intake air cooling radiator
(intercooler)
9 Air cleaner
10 Supplementary air valve
11 Throttle position switch
11A Throttle housing
12 Airflow meter12A Intake air temperature
sensor
13 Fuel pressure regulator
14 Fuel rail (to injectors)
15 Secondary fuel filter
16 Injectors
17 Injector cooling fan
18 Thermostatic switch (to
engage injector cooling fan)

optimum engine operating efficiency. In the
event of a system sensor malfunction, errors
in data passed to the ECU are overcome by
an emergency operation, whereby the ECU
supplies the injectors with one of two set
injection periods independent of the sensors.
One period (2.2 ms) is for idle speed and the
other (2.5 ms) is for speeds above idle
(actuated when the idle speed contact is
opened).
4An injection system relay and a fuel pump
relay are fitted and are located in the engine
compartment, adjacent to the ECU on the left-
hand inner wing panel. In the event of the
engine not being started within two seconds of
the ignition being switched to the “ON”
position, the fuel pump relay is deactivated.
The fuel pump circuit fuse is located in the
main fuse block located under the facia within
the car. Note: To avoid possible damage to the
ECU, it is essential that the ignition is switched
off before disconnecting (or connecting) the
wiring multi-plug from the ECU.A Lambda (or
oxygen) sensor is fitted to L3.2 equipped
models, to measure exhaust gas oxygen
content. In sending signals to the ECU,
optimum catalyst operation is maintained.
Fuel system -
depressurisationÁ
5The fuel system should always be
depressurised whenever any fuel hoses
and/or system components are disconnected
and/or removed. This can easily be achieved
as follows.
6The fuel pump relay is located next to the
ECU and airflow meter in the engine
compartment. Carefully pull free the fuel
pump relay, then start the engine and run it
until it stops. The fuel system is now
depressurised. Turn the ignition off before
removing/dismantling any components.
7Do not refit the fuel pump relay or turn the
ignition on until the system is fully
reconnected. When the engine is ready to be
restarted, refit the relay and its cover, then
restart the engine in the normal manner.
MaintenanceÁ
8Regularly check the condition and security
of the system hoses and connections. Also
check the system wiring connections for
condition and security.9At the specified intervals, renew the air
cleaner element and the fuel filter.
Fuel filter - renewalÁ
10This is located in the engine compartment
on the right-hand side. Disconnect the fuel
inlet and outlet hoses, but be prepared for the
loss of fuel. Loosen off the clamp and remove
the filter.
11Reverse the removal procedure to fit the
new filter, but ensure that the arrow indicating
fuel flow is pointing towards the fuel injector rail.
Air cleaner element -
renewalÁ
12Prise free the four retaining clips, then
remove the cover and the air cleaner element.13Wipe clean the inside surfaces of the air
cleaner housing, then insert the new element,
refit the cover and secure it with the four
retaining clips.
Checks and adjustments°
Engine idle speed and mixture
adjustment
14Before carrying out any adjustments, the
engine must be at its normal operating
temperature, the cooling fan having cut into
Supplement: Revisions and information on later models 13•79
Fig. 13.49 Fuel injection system components layout in engine compartment on the
1372 cc Turbo ie engine (Sec 9E)
1 ECU
1A Diagnostic socket
2 Ignition system relay and
fuel pump relay
7 Coolant temperature
sensor10 Supplementary air valve
11 Throttle position switch
11A Throttle housing
12 Airflow meter
13 Fuel pressure regulator
15 Secondary fuel filter16 Injectors
17 Injector cooling fan
18 Thermostatic switch (to
engage injector cooling
fan)
Fig. 13.52 Idle speed adjustment screw (1)
on the 1372 cc Turbo ie engine (Sec 9E)
Note method of compressing the
supplementary air valve pipe (arrowed)
Fig. 13.51 Air cleaner cover securing clips
(arrowed) on the 1372 cc Turbo ie engine
(Sec 9E)Fig. 13.50 Secondary fuel filter with arrows
indicating direction of flow - 1372 cc Turbo
ie engine (Sec 9E)
13

protective shield to gain access to the pump
which is located forward of the fuel tank.
60Disconnect the fuel hoses and the wiring
connector, release the retaining clamp and
withdraw the pump unit.
Refitting all components
61Refitting of all components is a reversal of
the removal procedure, but note the following
specific points.
62Ensure that all components are clean prior
to refitting and where applicable, use new
seals and gaskets. Ensure that all connectionsare securely and correctly made.
63Do not reconnect the battery until all the
refitting procedures are complete.
64When the engine is restarted, check
around the fuel injection system for any signs
of leakage from the fuel supply and return
components.
Lambda sensor - general
65The sensor is screwed into the exhaust in
front of the catalytic converter.
66A faulty sensor can damage the converter,
therefore it must be checked regularly (see
Maintenance schedule, Section 3) by a dealer
using special equipment.
67Use of leaded fuel will also damage this
sensor, as well the converter.
PART F:
TURBOCHARGER SYSTEM
Description
1A turbocharger is fitted to certain 1301 and
1372 cc ie engines. The accompanying
photographs are all taken from a 1301 cc
engine, but the system is much the same for
both engine types.
2The turbocharger is basically a shaft with an
exhaust gas-driven turbine at one end, and a
compressor located at the other end which
draws in outside air and forces it into the inlet
manifold. By compressing the incoming air, a
larger charge can be let into each cylinder,
and greater power output is achieved than
with normal aspiration.3Lubrication of the turbocharger shaft
bearings is provided by pressurised engine
oil, and the unit is cooled by the coolant from
the engine cooling system.
4A wastegate valve is incorporated in the
turbocharger to divert excessive exhaust gas
pressure from the turbine into the exhaust
pipe at a predetermined pressure level.
5A maximum air pressure switch is located in
the inlet manifold. Its purpose is to cut the
ignition system off when the turbocharger
system pressure continues to increase
beyond 0.86 bars (12.5 lbf/in
2). This would
otherwise damage the engine, due to high
combustion temperatures and pressures
(photo).
6An intercooler (heat exchanger) is located
between the turbocharger and the inlet
manifold. Its function is to cool the inlet
charge, thus increasing its density, to provide
greater power output.
7A mechanical bypass valve is located
between the low-pressure pipe (downstream)
and the high-pressure pipe (upstream), which
reduces the inherent noise from the
turbocharger when the accelerator pedal is
released (photo).
8None of the components of the
turbocharger system can be repaired and
parts are not available. Any fault will therefore
mean that the turbocharger or associated
assemblies will have to be renewed complete.
Precautions
9The following precautions should be
observed when using a turbocharged vehicle.
a) Never operate the engine without the air
cleaner fitted.
b) Never switch off the engine before its
speed has dropped to idling. If the car
has been driven hard, allow it to idle for a
few minutes before switching off. Failure
to observe these recommendations can
cause damage to the turbocharger due to
lack of lubrication.
10Always keep the fuel injection system
well-maintained and tuned. Operating on a
weak mixture can cause overheating of the
turbocharger.
Turbocharger
(1301 cc ie engine) -
removal and refitting
Á
11Disconnect and remove the airflow meter
as described in Section 9C.
12Disconnect the spiral-wound hose from
the fuel injector cooling duct.
13Remove the turbocharger air hoses from
within the left-hand side of the engine
compartment. Note particularly their routing.
14Remove the throttle housing/inlet
manifold as described in Section 9C, also the
fuel rail, injectors and inlet manifold branch
pipe stubs. Remove the alternator heat shield
(photo).
15Remove the exhaust heat shield.
16Unscrew the turbocharger-to-exhaust
pipe flange nuts (photos).
13•82 Supplement: Revisions and information on later models
9F.16A Turbocharger-to-exhaust flange
nut (arrowed)9F.14 Alternator heat shield
9F.7 Bypass valve9F.5 Maximum air pressure switch
(arrowed)
Fig. 13.63 Fuel pump and sender unit
location on the 1372 cc Turbo ie engine
(Sec 9E)
1 Fuel level gauge sender connector
2 Fuel pump connector
3 Fuel return hose
4 Fuel supply hose

17Disconnect the air hoses from the
turbocharger (photo).
18Drain the cooling system, and then
disconnect the coolant hoses from the
turbocharger (photos).
19Disconnect the oil feed pipe, which has a
banjo-type union (photo).
20Disconnect the oil return pipe which runs
to the engine sump pan (photo).
21Working underneath the car, disconnect
the exhaust manifold support bracket (photo).
22Unbolt the exhaust manifold and lift it out
of the engine compartment, complete with
turbocharger.
23The turbocharger may now be unbolted
from the exhaust manifold (photo).
24Refitting is a reversal of removal, but use
new gaskets and seals throughout.Turbocharger
(1372 cc ie engine) -
removal and refitting
Á
25Refer to Part E of this Section for details
and remove the inlet manifold.
26Drain the cooling system as described in
Section 8 of this Chapter.
27Unscrew the union bolt and disconnect
the oil supply pipe from the turbocharger.
28Loosen off the securing clip and detach
the air hose from the turbocharger filter.
29Raise and support the car at the front end
on axle stands.
30Working from underneath the car, unscrew
the downpipe-to-exhaust system joint nuts
then unscrew the retaining nuts and detach
the exhaust downpipe from the turbocharger
outlet flange. Remove the downpipe.
Supplement: Revisions and information on later models 13•83
9F.18A Releasing turbocharger coolant
inlet union (arrowed)9F.17 Releasing turbocharger air hose clip9F.16B Unscrewing turbocharger-to-
exhaust manifold nut
Fig. 13.64 Turbocharger oil supply pipe
connection (arrowed) (Sec 9F)9F.23 Exhaust manifold bolts
9F.21 Exhaust manifold support bracket9F.20 Turbocharger oil return pipe at sump9F.19 Turbocharging oil feed pipe
9F.18B Turbocharger connections
1 Exhaust connecting nut
2 Oil return hose 3 Coolant pipe union
13
Fig. 13.65 Detach the air hose from the
Turbocharger (arrowed) (Sec 9F)

31Unscrew and remove the two
turbocharger mounting bracket bolts.
32Referring to Fig. 13.67, loosen off the
retaining clip and detach the air hose from the
heat exchanger and the oil return pipe from
the turbocharger (to sump).
33Working from above, undo the
turbocharger mounting bracket bolts.
34Unscrew and remove the coolant
pipe-to-pump retaining bolts. The
turbocharger can now be removed from above
by withdrawing it together with the exhaust
manifold from the engine compartment.
35Locate and support the exhaust manifold
in a vice. Fit protector clamps to the jaws of the
vice to avoid possible damage to the manifold.
36Note the orientation and fitted position of
the turbocharger mounting bracket, then
unscrew the retaining nuts and detach the
bracket.
37Undo the retaining nuts, separate andremove the exhaust manifold from the
turbocharger.
38The turbocharger and wastegate valve are
not repairable and must therefore be renewed
as a complete unit. This being the case,
remove the following ancillary items from the
turbocharger unit before renewing it.
a) Loosen off the retaining clip and remove
the air outlet hose from turbocharger.
b) Undo the two retaining bolts and remove
the oil return hose union.
c) Unscrew the union and bolt and coolant
inlet pipe.
d) Undo the retaining nuts and remove the
turbocharger-to-exhaust manifold
connector.
39Where applicable, always use new
gaskets and ensure that the mating faces are
clean before refitting the ancillary components
to the turbocharger.Intercooler -
removal and refitting Á
40The intercooler is mounted behind the
left-hand side of the front bumper/spoiler (photo).
41Disconnect the air ducts from the intercooler.
42Unscrew the mounting bolts and lift the
intercooler from the car.
43Refitting is a reversal of removal (photo).
Injector cooling fan -
removal and refitting Á
44This unit is located on the left-hand side at
the front of the car. It can be accessed for
removal from above, in the engine compartment.
45Detach and remove the air intake duct
from the air cleaner unit to the ECU/airflow
meter.
46Disconnect and remove the air duct from
the air blower unit.
47Undo the air blower retaining nuts, withdraw
the unit and detach its wiring connector.
13•84 Supplement: Revisions and information on later models
9F.43 Intercooler mounting bolt (arrowed)
on 1301 cc engine9F.40 Intercooler location (1301 cc engine)Fig. 13.69 Turbocharger coolant pipe-to-
pump bolt location (arrowed) (Sec 9F)
Fig. 13.68 Turbocharger mounting bracket
bolts removal (Sec 9F)Fig. 13.67 Disconnect the heat exchanger
air hose and the oil return pipe
(turbocharger-to-sump) (Sec 9F)Fig. 13.66 Turbocharger mounting bracket
bolts (arrowed) (Sec 9F)
Fault finding - fuel injection system
Difficult starting from cold
m mFuel pump fault
m mBlocked fuel pipe or filter
m mSupplementary air valve fault
m mCoolant temperature sensor fault
Excessive fuel consumption
m
mIncorrect mixture setting
m mDirty air cleaner element
m mCoolant temperature sensor fault
m mAirflow sensor fault
Difficult to start when hot
m
mChoked air cleaner element
m mFuel pump fault
Uneven idling
m
mIncorrect mixture setting
m mIntake system air leak
m mThrottle position switch out of adjustment
m mLoose ECU connector

14B.54 Master cylinder/vacuum servo
located next to the coolant expansion tank
(1301 cc Turbo ie model)
29Fit the new pads, complete with anti-rattle
springs (photo).
30Refit the caliper using new self-locking
bolts, or if not available, apply thread-locking
fluid to clean threads of the original bolts.
Tighten the bolts to the specified torque.
31Apply the brake pedal several times to
bring the disc pads up against the disc.
32Top up the brake fluid reservoir if
necessary.
33Check the adjustment of the handbrake.
34Refit the roadwheels and lower the car to
the ground.
Rear disc caliper -
removal, overhaul and
refitting
¢
35Carry out the operations described in
paragraphs 25 to 27.36Disconnect the handbrake cable from the
caliper. To do this, grip the cable nipple and
pull it until the cable can be slipped out of its
lever groove (photo). If necessary, slacken the
cable adjustment.
37Using a pair of pliers or similar tool, turn
the piston in an anti-clockwise direction until it
can be removed from the cylinder.
38Having obtained a repair kit, renew the
seal and dust excluder.
39Reassemble the piston to the cylinder,
turning it clockwise as far as it will go.
40Reconnect the handbrake cable.
41Carry out the operations described in
paragraphs 30 to 32.
Rear brake disc -
inspection, renovation
or renewal
ª
42The operations are as described in
Chapter 8, Section 6, but the caliper bracket
fixing bolts are of the socket-headed type and
thread-locking fluid is used, not lockplates
(photo).
Pressure regulating valve
43The valve renewal and adjustment
operations are described in Chapter 8,
Section 10, but the luggage compartment
should be loaded with 45 kg and the load
applied to the bracket eye should be 11 kg.
Brake pedal -
removal and refitting#
44The brake master cylinder and vacuum
servo are mounted on the left-hand side of theengine compartment rear bulkhead. In conse-
quence, the brake pedal on right-hand drive
cars operates through a cross-shaft, which is
located underneath the facia panel inside the
car.
45The cross-shaft is supported in two
brackets, whose mounting nuts can be
reached through cut-outs in the insulation on
the engine compartment rear bulkhead (photo).
46To remove the cross-shaft, working inside
the car, take off the cover from the left-hand
end of the shaft, and then disconnect the
servo pushrod from the crankarm on the
cross-shaft (photo).
47Disconnect the brake pedal from the
right-hand crankarm on the cross-shaft
(photo).
48Disconnect the accelerator pedal by
extracting the split pin which secures its pivot
spindle.
49The cross-shaft may now be removed
after extracting the cotter pin from the
left-hand end of the shaft.
50Push the shaft first to the right, and then
to the left, to release it from its brackets.
51Alternatively, the cross-shaft, complete
with brackets, may be removed as an
assembly if the bulkhead nuts are unscrewed.
52Removal of the brake and clutch pedals is
described in Chapter 5, Section 4, but note
that on hydraulic clutch models, the master
cylinder will also require removal as described
in Section 11 of this Chapter.
53Refitting is a reversal of the removal
procedure.
13•102 Supplement: Revisions and information on later models
14B.47 Right-hand end of brake pedal
cross-shaft14B.46 Left-hand end of brake pedal
cross-shaft
14B.45 Brake pedal cross-shaft fixed nut
(arrowed) on engine compartment rear
bulkhead
14B.42 Unscrewing a rear caliper bracket
bolt14B.36 Disconnecting the handbrake cable
from the caliper lever14B.29 Rear disc pad

As it is lifted, invert it and detach the washer
hose from the washer nozzle (photos).
97Where applicable, detach and remove the
washer reservoir from the recess in the front
of the windscreen to allow access to the wiper
motor.
98Unscrew and remove the two wiper motor
retaining screws. Lower and withdraw the
unit, then detach the cover from the motor.
Disconnect the wiring from the wiper motor
and withdraw it from the car (photos).
99Refit in the reverse order of removal.
Check for satisfactory operation of the wiper
and washer on completion.
Windscreen washer reservoir
(Turbo ie models) -
removal and refitting
Á
100Disconnect the battery negative lead.
101Remove the bonnet as described in
Chapter 12.
102Remove the wiper arm and blade as
described in Chapter 9, then unscrew and
remove the pivot nut.
103Undo the air inlet grille retaining screws
noting that two are not fitted with washers.
Where applicable, remove the washer
reservoir filler cap from the reservoir neck
protruding through the grille. Carefully prise
free and lift the air inlet grille clear of the body.
As it is lifted, invert it and detach the washer
hose from the washer nozzle.
104Syphon any remaining washer fluid from
the reservoir, then disconnect it and partiallywithdraw it from the recess in front of the
windscreen so that the wiring connection and
the washer supply hoses (to the windscreen
washer and the rear screen washer nozzles)
can be detached from the pump unit. Remove
the reservoir from the vehicle.
105Refit in the reverse order of removal. If the
washer pump unit was detached from the
reservoir, use a new seal washer when refitting
it. Top up the reservoir and check the screen
washers for satisfactory operation before
refitting the grille panel and the wiper arm/blade.
Tailgate wiper motor
(later models) -
removal and refitting
Á
106Although the tailgate wiper motor differs
in appearance, its removal and refitting
procedures are much the same as those
described for the earlier models in Section 27
of Chapter 9 (photo).
Radio
107All later models are now equipped with
power supply and speaker leads for radio
installation.
108Installation of the standard FIAT aerial
mounted on the windscreen pillar is shown
(photos).
Check control system sensors -
description
109The locations of the sensors referred to in
Chapter 9, Section 34 are given in the
following paragraphs, and their construction
differs according to their individual function.
Brake fluid level sensor
110This is mounted in the master cylinder
fluid reservoir cap, and comprises a pair of
reed switches in a glass bulb, and a magnet at
the end of a float.
111When the fluid level is correct, the
magnetic flux closes the switches. In the
event of a leak in the system, the magnet
moves away, the switches open and the
warning lamp comes on.
Brake disc pad wear sensor
112This is basically a circuit wire embedded
in the pad friction material. As the pad wears,
the wire is eventually exposed and contacts
the disc, whereupon the warning lamp comes
on to indicate that pad renewal is necessary.
Coolant level sensor
113This is located in the cooling system
expansion tank, and is of the reed switch
type, which operates in a similar way to that
described for the brake fluid sensor.
Engine oil level sensor
114This is located at the end of the dipstick,
and comprises a pair of switches at the end of a
bi-metallic strip, heated by electrical resistance.
115The heat is dissipated by the immersion
of the dipstick in the engine oil, so preventing
the bi-metallic strip from curving so much that
the switches would open.
116If the oil level drops, the heat is no longer
dissipated, the switches open, and the
warning lamp comes on.
13•110 Supplement: Revisions and information on later models
15.108B Pillar lower screw for aerial15.108A Pillar upper screws for aerial15.106 Tailgate wiper motor - later model
15.98C . . . and detach the wiring
connector15.98B . . . separate the wiper motor from
its cover . . .15.98A Remove the wiper motor retaining
screws . . .

Door closure sensor
117The sensor consists of a microswitch
within the lock. The switch actuates the
warning lamp according to whether the lock is
in the open or closed mode.
Check control system sensors -
testing
Brake fluid level sensor
118With the fluid level correct, switch on the
ignition and depress the centre of the
reservoir cap. If the sensor switches are
working correctly, then “FAULT” should be
indicated on the check panel.
Coolant level sensor
119With the coolant level in the expansion
tank correct, switch on the ignition and then
pull the wiring plug from the sensor. “FAULT”
should be indicated on the check panel. If it is
not, then it is the panel which is faulty.
120An ohmmeter should be used to check
for continuity, holding the float in both the full
and low level positions.
Engine oil level sensor
121With the oil level correct, disconnect the
wiring plug from the dipstick, and then bridge
the plug terminals (not dipstick side) with a 12
ohm resistor. Switch on the ignition.
122If the red light on the check panel goes
out, then the fault is due to the sensor.
123If the light stays on, then it is the check
panel module which is faulty.
Door closure sensor
124Any fault in the lock microswitch can best
be detected using an ohmmeter.
16 Suspension
Front anti-roll bar -
removal and refittingª
1A front anti-roll bar is fitted to the 1301 cc,
1372 cc ie and 1372 cc Turbo ie engined
models. Removal of the bar on all models isas follows. Firstly loosen off the front
roadwheel bolts, then raise the front of the
car, securely support it on axle stands and
remove the front roadwheels.
2Disconnect the two gearchange rods from
the transmission.
3Unbolt and disconnect the anti-roll bar
insulating clamps from the floorpan (photo).
4Unbolt the end links from the track control
arms and withdraw the anti-roll bar (photo).
5Refitting is a reversal of removal, but only
tighten the nuts and bolts to the specified
torque with the car parked on level ground,
with four passengers and 40 kg of luggage
inside.
Suspension strut - later models
6The suspension strut upper mounting nuts
on later models also secure the brackets for
the mounting of ancillary components such as
the fuel filter, fuel system relays and fuses,
etc. (depending on model).
7When removing the suspension strut units,
it will therefore be necessary to detach and
support these brackets and their fittings
(photo).
17 Bodywork
Plastic components
1With the use of more and more plastic
body components by the vehicle
manufacturers (e.g. bumpers, spoilers, and in
some cases major body panels), rectification
of more serious damage to such items has
become a matter of either entrusting repair
work to a specialist in this field, or renewing
complete components. Repair of such
damage by the DIY owner is not really
feasible owing to the cost of the equipment
and materials required for effecting such
repairs. The basic technique involves making
a groove along the line of the crack in the
plastic using a rotary burr in a power drill. The
damaged part is then welded back togetherby using a hot air gun to heat up and fuse a
plastic filler rod into the groove. Any excess
plastic is then removed and the area rubbed
down to a smooth finish. It is important that a
filler rod of the correct plastic is used, as
body components can be made of a variety
of different types (e.g. polycarbonate, ABS,
polypropylene). Damage of a less serious
nature (abrasions, minor cracks, etc.) can be
repaired by the DIY owner using a two-part
epoxy filler repair material. Once mixed in
equal proportions, this is used in similar
fashion to the bodywork filler used on metal
panels. The filler is usually cured in twenty to
thirty minutes, ready for sanding and
painting.
2If the owner is renewing a complete
component himself, or if he has repaired it
with epoxy filler, he will be left with the
problem of finding a suitable paint for
finishing which is compatible with the type of
plastic used. At one time the use of a
universal paint was not possible owing to the
complex range of plastics encountered in
body component applications. Standard
paints, generally speaking, will not bond to
plastic or rubber satisfactorily. However, it is
now possible to obtain a plastic body parts
finishing kit which consists of a pre-primer
treatment, a primer and coloured top coat.
Full instructions are normally supplied with a
kit, but basically the method of use is to first
apply the pre-primer to the component
concerned and allow it to dry for up to
30 minutes. Then the primer is applied and
left to dry for about an hour before finally
applying the special coloured top coat. The
result is a correctly coloured component
where the paint will flex with the plastic or
rubber, a property that standard paint does
not normally possess.
Rear view mirrors Á
Interior
3The mirror is of safety type, “breaking” off
its ball fixing upon impact from a front seat
occupant.
4To remove the mirror, grip the head and
Supplement: Revisions and information on later models 13•111
16.7 Suspension strut upper mounting
nuts, showing bracket and cable clip on
the 1372 cc ie model16.4 Anti-roll bar fixing nuts (arrowed)16.3 Anti-roll bar clamp
13

Wiring diagrams 14•1
14
Component key for wiring diagrams 1 to 29
Note: Not all the items listed will be fitted to all models
No Description
00200 Alternator with built-in regulator
00500 Battery
01001 Starter motor
01202 Rear front electric window motor
01203 Left front electric window motor
01206 Windscreen wiper motor
01207 Rear screen wiper motor
01252 Right front door locking motor
01253 Left front door locking motor
01254 Right rear door locking motor
01255 Left rear door locking motor
01400 Windscreen washer pump
01401 Rear screen washer pump
01420 Electric fuel pump
01500 Engine cooling fan
01502 Injector cooling fan
01504 Ventilation fan
02001 Engine cut-out solenoid on injection pump
02010 Fuel injector
02011 Fuel injector
02012 Fuel injector
02013 Fuel injector
02015 Supplementary air valve
02210 Accelerator pump outlet cut-out solenoid on
carburettor
02215 Supplementary air valve
02400 Ignition coil
02405 Ignition coil with electronic control unit
02490 Static advance ignition control unit
02492 Microplex ignition system control unit
03000 Insufficient engine oil pressure switch
03002 Right front door ajar switch
03003 Left front door ajar switch
03004 Right rear door ajar switch
03005 Left rear door ajar switch
03006 Handbrake ‘on’ warning switch
03007 Brake stop-lamp switch
03008 Reversing light switch
03028 Radiator thermostatic switch
03029 Coolant overheating warning light thermostatic switch
03034 Injector cooling fan thermostatic switch
03035 Accelerator pump outlet cut-out solenoid thermostatic
switch
03036 Radiator thermostatic switch with two operating ranges
03053 Map reading light switch
03059 Foglamps switch
03060 Rear foglamp switch
03110 Heated rear screen switch
03114 Ventilation fan switch
03123 Air pressure switch
03142 Choke warning light switch
03144 Reset switch
03145 Display switch
03305 Right front door open light push button
03306 Left front door open light push button No Description
03319 Horn push button
03500 Ignition switch
03505 Butterfly valve cut-off switch
03506 Throttle position switch
03530 Right front electric window switch
03531 Left front electric window switch
03546 Rear screen wash/wipe switch
03550 Hazard warning lights switch
04010 Steering column switch unit, direction indicators
04022 Steering column switch unit, headlamps, main beam
and dipped, side lights
04032 Steering column switch unit, windscreen wash/wipe
04214 Fuel injection system control relay
04215 Antiskid system failure relay
04225 Radiator fan 2nd speed engagement relay feed
04241 Foglamps relay feed
04260 Electric windows motor relay feed
04283 Antiskid system relay
04291 Horn relay feed
04292 Heated rear screen relay feed
04441 Dim-dip cut-out 04600 Ignition distributor
04700 Coolant temperature sender unit
04701 Electronic injection coolant temperature sender unit
04720 Oil pressure sender unit
05008 Right headlamp, main beam and dipped with side light
05009 Left headlamp, main beam and dipped with side light
05013 Abnormal fuel consumption sensor
05015 Right foglamp
05016 Left foglamp
05410 Right front direction indicator
05411 Left front direction indicator
05412 Right front side direction indicator
05413 Left front side direction indicator
05640 Rear number plate lamp
05690 Right rear light cluster, sidelight, direction indicator,
brake light, rear foglamp
05691 Left rear light cluster; side light, direction indicator,
brake light, rear foglamp
06000 Centre courtesy light
06026 Map reading light
06076 Ideogram fibre optic light
06080 Heater controls light
06084 Instrument panel light
06300 Sidelights warning light
06305 Main beam headlamps warning light
06310 Rear foglamps warning light
06311 Foglamps warning light
06315 Hazard warning lights warning light
06320 Direction indicators warning light
06335 Insufficient brake fluid level warning light
06336 Handbrake ‘on’ warning light
06343 Insufficient engine oil pressure warning light
06344 Insufficient brake fluid level warning light
06345 Fuel reserve warning light
06350 Coolant overheating warning light

14•2 Wiring diagrams
No Description
06355 Battery charging warning light
06365 Choke warning light
06368 Antiskid system failure lamp
06385 Heated rear screen warning light
06800 Horn
06801 Right horn
06802 Left horn
07000 Coolant level sensor
07001 Engine oil level sensor
07003 Brake fluid level sensor
07015 Right front brake pad wear sensor
07016 Left front brake pad wear sensor
07020 Engine speed sensor
07021 TDC sensor
07022 Anti-knock sensor
07023 Diagnostic socket
07037 Butterfly valve (cut-off) switch
07050 Fuel gauge
07051 Instant fuel consumption gauge (econometer)
07052 Airflow meter
07060 Idle cut-off device
07107 Roadwheel speed sensors
07109 Vacuum switch
07191 Absolute pressure sensor
07192 Vacuum switch
07400 Fuel gauge
07410 Engine oil temperature gauge
07415 Coolant temperature gauge
07420 Engine oil pressure gauge
07430 Tachometer
07460 Clock
07461 Digital clockNo Description
08051 Ignition coil condenser
09000 Dim-dip transformer
09008 Radiator cooling fan 1st speed resistor
09100 Heated rear screen
10022 Cut-off device electronic control unit
10500 Control (fuse) box
10515 Electronic injection control unit
10571 Central locking control unit
10584 Antiskid system ECU
10586 Pressure modulators
59000 Cigar lighter
60000 Instrument panel
60204 Four place fusebox
70090 General earth
70091 General earth
70092 Earth plate
M Electronic control unit
Wire colour codes
A Light blue
B White
C Orange
G Yellow
H Grey
L Blue
M Brown
N Black
R Red
S Pink
V Green
Z Violet
Example of two-colour wire: BN (White/Black) Component key for wiring diagrams 1 to 29 (continued)
Note: Not all the items listed will be fitted to all models