brake FIAT UNO 1983 Service Repair Manual

REPAIRS & OVERHAUL
Engine and Associated Systems
Engine (also see Chapter 13)Page 1•1
Cooling and heating systems (also see Chapter 13)Page2•1
Fuel system (also see Chapter 13)Page 3•1
Ignition system (also see Chapter 13)Page4•1
Transmission
Clutch (also see Chapter 13)Page5•1
Transmission (also see Chapter 13)Page6•1
Driveshafts, hubs, roadwheels and tyres (also see Chapter 13)Page7•1
Brakes
Braking system(also see Chapter 13)Page 8•1
Electrical
Electrical system(also see Chapter 13)Page 9•1
Steering and suspension
SteeringPage 10•1
Suspension (also see Chapter 13)Page 11•1
Bodywork
Bodywork (also see Chapter 13)Page 12•1
Additional information
Supplement: Revisions and information on later models Page 13•1
Wiring DiagramsPage 14•1
REFERENCE
MOT Test Checks PageREF•1
Tools and Working Facilities Page REF•5
General Repair Procedures Page REF•8
Fault FindingPage REF•9
Buying Spare Parts & Vehicle Identification Numbers PageREF•12
Glossary of Technical Terms PageREF•13
IndexPage REF•17
Contents

Safety First!0•5
Working on your car can be dangerous.
This page shows just some of the potential
risks and hazards, with the aim of creating a
safety-conscious attitude.
General hazards
Scalding
• Don’t remove the radiator or expansion
tank cap while the engine is hot.
• Engine oil, automatic transmission fluid or
power steering fluid may also be dangerously
hot if the engine has recently been running.
Burning
• Beware of burns from the exhaust system
and from any part of the engine. Brake discs
and drums can also be extremely hot
immediately after use.
Crushing
• When working under or near
a raised vehicle,
always
supplement the
jack with axle
stands, or use
drive-on
ramps.
Never
venture
under a car which
is only supported by a jack.
• Take care if loosening or tightening high-
torque nuts when the vehicle is on stands.
Initial loosening and final tightening should
be done with the wheels on the ground.
Fire
• Fuel is highly flammable; fuel vapour is
explosive.
• Don’t let fuel spill onto a hot engine.
• Do not smoke or allow naked lights
(including pilot lights) anywhere near a
vehicle being worked on. Also beware of
creating sparks
(electrically or by use of tools).
• Fuel vapour is heavier than air, so don’t
work on the fuel system with the vehicle over
an inspection pit.
• Another cause of fire is an electrical
overload or short-circuit. Take care when
repairing or modifying the vehicle wiring.
• Keep a fire extinguisher handy, of a type
suitable for use on fuel and electrical fires.
Electric shock
• Ignition HT
voltage can be
dangerous,
especially to
people with heart
problems or a
pacemaker. Don’t
work on or near the
ignition system with
the engine running or
the ignition switched on.• Mains voltage is also dangerous. Make
sure that any mains-operated equipment is
correctly earthed. Mains power points should
be protected by a residual current device
(RCD) circuit breaker.
Fume or gas intoxication
• Exhaust fumes are
poisonous; they often
contain carbon
monoxide, which is
rapidly fatal if inhaled.
Never run the
engine in a
confined space
such as a garage
with the doors shut.
• Fuel vapour is also
poisonous, as are the vapours from some
cleaning solvents and paint thinners.
Poisonous or irritant substances
• Avoid skin contact with battery acid and
with any fuel, fluid or lubricant, especially
antifreeze, brake hydraulic fluid and Diesel
fuel. Don’t syphon them by mouth. If such a
substance is swallowed or gets into the eyes,
seek medical advice.
• Prolonged contact with used engine oil can
cause skin cancer. Wear gloves or use a
barrier cream if necessary. Change out of oil-
soaked clothes and do not keep oily rags in
your pocket.
• Air conditioning refrigerant forms a
poisonous gas if exposed to a naked flame
(including a cigarette). It can also cause skin
burns on contact.
Asbestos
• Asbestos dust can cause cancer if inhaled
or swallowed. Asbestos may be found in
gaskets and in brake and clutch linings.
When dealing with such components it is
safest to assume that they contain asbestos.
Special hazards
Hydrofluoric acid
• This extremely corrosive acid is formed
when certain types of synthetic rubber, found
in some O-rings, oil seals, fuel hoses etc, are
exposed to temperatures above 400
0C. The
rubber changes into a charred or sticky
substance containing the acid. Once formed,
the acid remains dangerous for years. If it
gets onto the skin, it may be necessary to
amputate the limb concerned.
• When dealing with a vehicle which has
suffered a fire, or with components salvaged
from such a vehicle, wear protective gloves
and discard them after use.
The battery
• Batteries contain sulphuric acid, which
attacks clothing, eyes and skin. Take care
when topping-up or carrying the battery.
• The hydrogen gas given off by the battery
is highly explosive. Never cause a spark or
allow a naked light nearby. Be careful when
connecting and disconnecting battery
chargers or jump leads.
Air bags
• Air bags can cause injury if they go off
accidentally. Take care when removing the
steering wheel and/or facia. Special storage
instructions may apply.
Diesel injection equipment
• Diesel injection pumps supply fuel at very
high pressure. Take care when working on
the fuel injectors and fuel pipes.
Warning: Never expose the hands,
face or any other part of the body
to injector spray; the fuel can
penetrate the skin with potentially fatal
results.
Remember...
DO
• Do use eye protection when using power
tools, and when working under the vehicle.
• Do wear gloves or use barrier cream to
protect your hands when necessary.
• Do get someone to check periodically
that all is well when working alone on the
vehicle.
• Do keep loose clothing and long hair well
out of the way of moving mechanical parts.
• Do remove rings, wristwatch etc, before
working on the vehicle – especially the
electrical system.
• Do ensure that any lifting or jacking
equipment has a safe working load rating
adequate for the job.
A few tips
DON’T
• Don’t attempt to lift a heavy component
which may be beyond your capability – get
assistance.
• Don’t rush to finish a job, or take
unverified short cuts.
• Don’t use ill-fitting tools which may slip
and cause injury.
• Don’t leave tools or parts lying around
where someone can trip over them. Mop
up oil and fuel spills at once.
• Don’t allow children or pets to play in or
near a vehicle being worked on.

0•8Roadside Repairs
To avoid repetition, the procedure for
raising the vehicle, in order to carry out work
under it, is not included before each relevant
operation described in this Manual.
It is to be preferred, and it is certainly
recommended, that the vehicle is positioned
over an inspection pit or raised on a lift. Where
these facilities are not available, use ramps or
jack up the vehicle strictly in accordance with
the following guide. Once the vehicle is raised,
supplement the jack with axle stands.
Jacking
The jack supplied with the car should only
be used to change a wheel. Do not use this
jack when overhaul or repair work is being
carried out; employ a hydraulic or screw jack
and supplement it with axle stands.
Jacking points are located under the sills
for use with the jack supplied.To raise the front end with a garage jack,
locate the jack under the transmission lower
mounting, just below and slightly to the rear of
the transmission oil drain plug. Protect the
mounting by placing a block of wood between
the jack head and the mounting.
To raise the rear of the car, the jack should
be placed under the spare wheel housing as
far to the rear as possible. Place a wooden
bearer between the jack head and the
housing.
Towing
When being towed, use the left-hand front
towing eye.
When towing another vehicle, use the rear
towing eye adjacent to the exhaust tailpipe.
When being towed, remember that the
brake pedal will require heavier pressure due
to lack of servo assistance. Always turn theignition key to MAR to retain the steering in
the unlocked position.
Wheel changing
With the car on firm level ground, apply the
handbrake fully. Remove the hub cap or
wheel trim, if fitted.
Release, but do not remove, the bolts.
Chock the front and rear of the opposite
roadwheel and then raise the car using the sill
jack supplied with the car if it is being done at
the roadside. Alternatively use a workshop
jack supplemented with axle stands.
Remove the wheel bolts, change the wheel
and screw in the bolts finger tight. It is
recommended that the bolt threads are
smeared with multi-purpose grease. Lower
the car, remove the jack and tighten the wheel
bolts to the specified torque. Refit any wheel
trim that was removed.
Spare wheel and jack stowage
Front tow hook Rear tow hook
Jacking, towing and wheel changing

Roadside Repairs0•9
Puddles on the garage floor or drive, or
obvious wetness under the bonnet or
underneath the car, suggest a leak that needs
investigating. It can sometimes be difficult to
decide where the leak is coming from,
especially if the engine bay is very dirty
already. Leaking oil or fluid can also be blown
rearwards by the passage of air under the car,
giving a false impression of where the
problem lies.Warning: Most automotive oils
and fluids are poisonous. Wash
them off skin, and change out of
contaminated clothing, without
delay.
Identifying leaks
The smell of a fluid leaking
from the car may provide a
clue to what’s leaking. Some
fluids are distinctively
coloured. It may help to clean the car and
to park it over some clean paper as an
aid to locating the source of the leak.
Remember that some leaks may only
occur while the engine is running.
Sump oil Gearbox oil
Brake fluid
Power steering fluid
Oil from filter
Antifreeze
Engine oil may leak from the drain plug......or from the base of the oil filter.
Leaking antifreeze often leaves a crystalline
deposit like this.Gearbox oil can leak from the seals at the
inboard ends of the driveshafts.
A leak occurring at a wheel is almost
certainly brake fluid.Power steering fluid may leak from the pipe
connectors on the steering rack.

0•10Routine maintenance
Maintenance is essential for ensuring safety and desirable for the
purpose of getting the best in terms of performance and economy
from the car. Over the years the need for periodic lubrication has been
greatly reduced if not totally eliminated. This has unfortunately tended
to lead some owners to think that because no such action is required
the items either no longer exist or will last forever. This is certainly not
the case; it is essential to carry out regular visual examinations as
comprehensively as possible in order to spot any possible defects at
an early stage before they develop into major and expensive repairs.
For information applicable to later models, see Supplement.
Every 250 miles (400 km), weekly,
or before a long journey
m mCheck engine oil level
m mCheck brake reservoir fluid level
m mCheck tyre pressures
m mCheck operation of all lights and horn
m mTop up washer fluid reservoirs, adding a screen
wash, and check operation of washers and wipers
m mCheck coolant level
m mCheck battery electrolyte level
Every 6000 miles (10 000 km)
or six months, whichever comes first
m mRenew engine oil and filter (Chapter 1, Section 2)
m mCheck drivebelt tension (Chapter 2, Section 8)
m mCheck carburettor idle speed and mixture
adjustments (Chapter 3)
m mCheck contact points and dwell angle (mechanical
breaker distributors) (Chapter 4, Section 3)
m mCheck tyre tread wear (Chapter 7, Section 7)
m mCheck disc pads for wear (Chapter 8, Section 3)
Every 36 000 miles (60 000 km)
or three years, whichever comes first
m mRenew the timing belt - 1116 and 1299/1301 cc
(Chapter 1, Section 28)
m mCheck exhaust system for corrosion (Chapter 3,
Section 19)
m mRenew contact breaker points and adjust dwell
angle (mechanical breaker distributors) (Chapter 4,
Section 3)
m mCheck and adjust ignition timing (Chapter 4,
Section 4)
m mRenew spark plugs (Chapter 4, Section 11)
m mCheck clutch adjustment (Chapter 5, Section 2)
m mCheck transmission oil level (Chapter 6, Section 2)
m mCheck driveshaft and steering rack gaiters for splits
(Chapters 7 and 10)
m mCheck rear brake shoe linings for wear (Chapter 8,
Section 4)
m mCheck handbrake travel (Chapter 8, Section 16)
m mCheck headlamp beam alignment (Chapter 9,
Section 17)
m mCheck balljoints for wear (Chapter 10, Section 2)
m mCheck front wheel alignment (Chapter 10, Section 8)
m mCheck suspension bushes for wear (Chapter 11,
Section 2)
m mCheck seat belts for fraying (Chapter 12, Section 23)
m mLubricate controls, hinges and locks
Every 24 000 miles (40 000 km)
or two years, whichever comes first
m mRenew coolant anti-freeze mixture (Chapter 2,
Section 3)
m mRenew transmission oil (Chapter 6, Section 2)
m mRenew brake hydraulic fluid (Chapter 8, Section 12)
m mCheck for underbody corrosion and clean out door
and sill drain holes (Chapter 12, Section 2)
Every 12 000 miles (20 000 km) or
12 months, whichever comes first
m mCheck and adjust valve clearances (Chapter 1,
Sections 5 and 26)
m mRenew air cleaner element (Chapter 3, Section 2)

Routine maintenance0•11
Engine compartment (air cleaner removed for clarity) on 55S model
1 Strut upper mounting
2 Washer fluid reservoir
3 Brake fluid reservoir
4 Ignition coil5 Throttle cable
6 Carburettor
7 Battery
8 Timing belt cover9 Distributor
10 Oil filler cap
11 Radiator electric cooling
fan12 Radiator
13 Coolant expansion tank
14 Front mounting
15 Clutch operating cable

0•12Routine maintenance
View of front end from below on
55S model
1 Tie-rod end
2 Track control arm
3 Lower mounting
4 Gearchange control rods
5 Exhaust pipe
6 Driveshafts
7 Transmission
8 Sump drain plug
9 Disc caliper
10 Front mounting
11 Horns
12 Radiator
13 Oil filter
View of rear end from below
1 Suspension trailing arm
2 Fuel tank filler hose
3 Rear axle beam
4 Rear silencer
5 Spring seat
6 Expansion box
7 Handbrake cable
8 Fuel tank support strap
9 Fuel tank
10 Handbrake cable adjuster

Lubricants and Fluids0•13
Component or system Lubricant type/specification
1 EngineMultigrade engine oil, viscosity SAE 15W/40, meeting API-SG or CCMC
G2/G3 specification (or equivalent multigrade engine oil with viscosity
rating suitable for ambient temperature in which vehicle is operated -
see owner’s handbook)
2 Transmission:
1372 cc Turbo ie model FIAT ZC 80/S gear oil
All other models FIAT ZC 90 gear oil
3 Cooling systemEthylene glycol based antifreeze
4 Brake and clutch hydraulic system(s)Hydraulic fluid to DOT 3 or 4, or SAE J1703C
5 Driveshaft CV joints and steering rackLithium based molybdenum disulphide
General greasingMulti-purpose lithium based grease

Cylinder head and valves
Material (cylinder head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light alloy
Maximum distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in)
Valve guide bore in head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.950 to 12.977 mm (0.5099 to 0.5109 in)
Valve guide outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.010 to 13.030 mm (0.5122 to 0.5130 in)
Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5, 0.10, 0.25 mm (0.002, 0.004, 0.010 in)
Inside diameter of valve guide (reamed) . . . . . . . . . . . . . . . . . . . . . . . . . 7.022 to 7.040 mm (0.2765 to 0.2772 in)
Guide fit in head (interference) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.033 to 0.080 mm (0.0013 to 0.0032 in)
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.982 to 7.000 mm (0.2748 to 0.2756 in)
Maximum clearance (valve stem to guide) . . . . . . . . . . . . . . . . . . . . . . . 0.022 to 0.058 mm (0.0009 to 0.0023 in)
Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44º 55’ to 45º 05’
Valve face angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45º 25’ to 45º 35’
Valve head diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.0 mm (1.1417 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.0 mm (1.0236 in)
Contact band (valve to seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 to 1.5 mm (0.0512 to 0.0591 in)
Valve clearance:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in)
For timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in)
Valve timing:
Inlet valve:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7º BTDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36º ABDC
Exhaust valve:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5º ATDC
Lubrication system
Oil pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear, driven by shaft from camshaft
Tooth tip to body clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.14 mm (0.0020 to 0.0055 in)
Gear endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.105 mm (0.0008 to 0.0041 in)
Oil pressure at normal operating temperature and average road/
engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.94 to 3.92 bar (42 to 57 lbf/ in
2)
Oil capacity (with filter change) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42 litre (6.0 pint)
Oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multigrade engine oil, viscosity SAE 15W/40
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C101
Torque wrench settingsNm lbf ft
Cylinder head bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 43.5
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 51
Big-end bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 30
Crankshaft pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 72
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 32
Rocker pedestal nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 29
Engine mounting bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Engine mounting centre nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Temperature sender switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Driveshaft to hub nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 200
Hub carrier to strut clamp bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 63
Brake caliper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 39
Tie-rod end balljoint nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 25
Driveshaft inboard boot retainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Engine – general 1•3
1

Auxiliary shaft
Bearing internal diameter (reamed):
No. 1 (timing belt end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.664 to 35.684 mm (1.4052 to 1.4059 in)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.000 to 32.020 mm (1.2608 to 1.2616 in)
Shaft journal diameter:
No. 1 (timing belt end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.593 to 35.618 mm (1.4024 to 1.4033 in)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.940 to 31.960 mm (1.2584 to 1.2592 in)
Cylinder block and crankcase
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast-iron
Bore diameter:
1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.000 to 80.050 mm (3.152 to 3.154 in)
1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.400 to 86.450 mm (3.404 to 3.406 in)
Maximum cylinder bore taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm (0.0006 in)
Maximum cylinder bore ovality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm (0.0006 in)
Torque wrench settingsNm lbf ft
Cylinder head bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn through 90º Turn through 90º
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn through 90º Turn through 90º
Camshaft carrier to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59
Big-end cap nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 38
Flywheel mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 61
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 61
Belt tensioner bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 32
Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 21
Auxiliary shaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 61
Flexible mounting bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 44
Flexible mounting centre nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 24
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 63
Driveshaft/hub nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 200
Tie-rod end balljoint nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 25
Brake caliper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 39
Front strut lower clamp bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Driveshaft inboard boot retainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Crankshaft pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 7
1•6 Engine – general
Part 1: General
1 Description
1The Uno may be powered by one of three
engines depending upon the particular model.
903 cc
2This is of four cylinder overhead valve type
with a light alloy cylinder head and a cast-iron
block and crankcase.
3A three bearing crankshaft is used and the
chain-driven camshaft runs in three steel
backed white metal bearings.
4The light alloy pistons are fitted with two
compression and one oil control ring. The
gudgeon pin is an interference fit in the small
end of the connecting rod.
5Lubrication is provided by an oil pump
within the sump pan and both the pump and
the distributor are driven from a gear on the
camshaft. Pressurised oil passes through acartridge type oil filter. An oil pressure relief
valve is incorporated in the oil pump. The
engine oil is independent of the transmission
lubricant.
1116 cc and 1301 cc
6These engines are of single overhead
camshaft type, the camshaft being driven by a
toothed belt.
7The difference in engine capacity is
achieved by increasing the cylinder bore on
the 1301 cc engine.
8The cylinder head is of light alloy while the
cylinder block and crankcase are of cast-iron
construction.
9A five bearing crankshaft is used and the
camshaft runs in a similar number of bearings,
but as these are in-line bored directly in the
camshaft carrier, no repair is possible.
10The pistons are of light alloy with two
compression and one oil control ring. The
gudgeon pin is an interference fit in the small
end of the connecting rod.
11An auxiliary shaft, driven by the timing belt
is used to drive the distributor, oil pump and
fuel pump.12The oil pump is located within the sump
pan and incorporates a pressure relief valve.
13Pressurised oil passes through a cartridge
type oil filter.
14The crankshaft main bearings are
supplied under pressure from drillings in the
crankcase from the main oil gallery whilst the
connecting rod big-end bearings are
lubricated from the main bearings by oil
forced through the crankshaft oilways. The
camshaft bearings are fed from a drilling from
the main oil gallery. The cams and tappets are
lubricated by oil mist from outlets in the
camshaft bearings.
15The cylinder walls, pistons and gudgeon
pins are lubricated by oil splashed up by the
crankshaft webs. An oil pressure warning light
is fitted to indicate when the pressure is too
low.
All engines
16The engine is mounted transversely with
the transmission at the front of the car.
17The engine oil is independent of the
transmission lubricant.