oil filter FIAT UNO 1983 Service Repair Manual

0•6General dimensions, weights and capacities
Dimensions
Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3644 mm (143.6 in)
Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1555 mm (61.3 in)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1432 mm (56.4 in)
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2362 mm (93.1 in)
Front track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1340 mm (52.8 in)
Rear track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 mm (51.2 in)
Weights (kerb)
Uno 45:
Three-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 kg (1543 lb)
Five-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 kg (1566 lb)
Uno 55:
Three-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730 kg (1610 lb)
Five-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740 kg (1632 lb)
Uno 70:
Three-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740 kg (1632 lb)
Five-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 kg (1654 lb)
Uno SX:
Three-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 770 kg (1698 lb)
Five-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 780 kg (1720 lb)
Capacities
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.0 litre (9.25 gal)
Engine oil (with filter change):
903 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42 litre (6.0 pint)
1116 and 1301 cc engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 Iitre (7.2 pint)
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40 litre (4.2 pint)
Steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140.0 cc
Driveshaft CV joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125.0 cc
Cooling system:
903 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 litre (8.1 pint)
1116 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 litre (10.6 pint)
1301 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 litre (10.9 pint)
For information applicable to later models, see Supplement at end of manual

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)

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

1
903 cc engine
Type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four cylinder in-line, liquid cooled, overhead valve. Transversely
mounted with end-on transmission
General
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.0 mm (2.56 in)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.0 mm (2.68 in)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903 cc (55 cu in)
Compression ratio:
900 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 : 1
900 ES models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 : 1
Maximum power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 kW at 5600 rev/min (45 bhp)
Maximum torque (DIN):
900 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Nm at 3000 rev/min (49 lbf ft)
900 ES models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Nm at 3000 rev/min (51 lbf ft)
Compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 to 10.35 bar (135 to 150 lbf/in2)
Maximum pressure difference between cylinders . . . . . . . . . . . . . . . . . 0.69 bar (10 lbf/in2)
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 - 4 - 2 (No. 1 at crankshaft pulley end)
Chapter 1 Engine
For modifications, and information applicable to later models, see Supplement at end of manual
Part 1: General
Crankcase ventilation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Major operations possible without removing the engine
from the car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Part 2: 903 cc engine
Cylinder head - dismantling and decarbonising . . . . . . . . . . . . . . . . 17
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine - complete dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine - complete reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine - dismantling (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine - initial start-up after overhaul or major repair . . . . . . . . . . . . 24
Engine - method of removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine - reassembly (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine - refitting ancillary components . . . . . . . . . . . . . . . . . . . . . . . 21
Engine - removing ancillary components . . . . . . . . . . . . . . . . . . . . . 15
Engine mountings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine/transmission - reconnection . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine/transmission - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine/transmission - removal and separation . . . . . . . . . . . . . . . . . 13
Examination and renovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fault finding - all engines . . . . . . . . . . . . . . . . . . . . See end of Chapter
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pistons/connecting rods - removal and refitting . . . . . . . . . . . . . . . . 9Sump pan - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Timing chain and sprockets - removal and refitting . . . . . . . . . . . . . 6
Valve clearances - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Part 3: 1116 cc and 1301 cc engines Camshaft and camshaft carrier - removal and refitting . . . . . . . . . . 27
Cylinder head - dismantling and decarbonising . . . . . . . . . . . . . . . . 39
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine - complete dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Engine - complete reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Engine - dismantling (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Engine - initial start-up after major overhaul . . . . . . . . . . . . . . . . . . . 45
Engine - method of removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Engine - reassembly (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Engine ancillary components - refitting . . . . . . . . . . . . . . . . . . . . . . . 43
Engine ancillary components - removal . . . . . . . . . . . . . . . . . . . . . . 37
Engine mountings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Engine/transmission - reconnection and refitting . . . . . . . . . . . . . . . 44
Engine/transmission - removal and separation . . . . . . . . . . . . . . . . . 35
Examination and renovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fault finding - all engines . . . . . . . . . . . . . . . . . . . . See end of Chapter
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Pistons/connecting rods - removal and refitting . . . . . . . . . . . . . . . . 32
Sump pan - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Timing belt - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Valve clearances - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Valve clearances - checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1•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

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

Crankshaft
Journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.785 to 50.805 mm (1.9994 to 2.0002 in)
Standard main bearing shell thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 1.825 to 1.831 mm (0.0719 to 0.0721 in)
Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254, 0.508, 0.762, 1.016 mm (0.010. 0.020, 0.030, 0.040 in)
Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 to 0.26 mm (0.0024 to 0.0102 in)
Crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.498 to 45.518 mm (1.7926 to 1.7934 in)
Standard big-end shell bearing thickness . . . . . . . . . . . . . . . . . . . . . . . 1.531 to 1.538 mm (0.0603 to 0.0606 in)
Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254, 0.508, 0.762, 1.016 mm (0.010, 0.020, 0.030, 0.040 in)
Camshaft
Number of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diameter of camshaft journals:
No. 1 (timing end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.944 to 29.960 mm (1.1798 to 1.1804 in)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.935 to 47.950 mm (1.8886 to 1.8892 in)
No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.135 to 48.150 mm (1.8965 to 1.8971 in)
No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.335 to 48.350 mm (1.9044 to 1.9050 in)
No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.535 to 48.550 mm (1.9122 to 1.9129 in)
Cam lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 mm (0.3467 in)
Camshaft bearing diameters in carrier:
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.990 to 30.014 mm (1.1816 to 1.1825 in)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.980 to 48.005 mm (1.8904 to 1.8913 in)
No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.180 to 48.205 mm (1.8982 to 1.8992 in)
No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.380 to 48.405 mm (1.9062 to 1.9072 in)
No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.580 to 48.605 mm (1.9141 to 1.9150 in)
Outside diameter of cam follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.975 to 36.995 mm (1.4568 to 1.4576 in)
Cam follower running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 to 0.050 mm (0.0002 to 0.0020 in)
Lubrication system
Oil pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear driven from auxiliary shaft
Tooth tip to body clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 to 0.180 mm (0.0043 to 0.0071 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43 to 4.9 bar (50 to 71 lbf/in
2)
Oil capacity (with filter change) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.05 litre (7.1 pint)
Oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multigrade engine oil, viscosity SAE 15W/40
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C106
Cylinder head and valves
Head material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light alloy
Maximum distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in)
Valve guide bore in head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.950 to 13.977 mm (0.5496 to 0.5507 in)
Valve guide outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.040 to 14.058 mm (0.5532 to 0.5539 in)
Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05, 0.10, 0.25 mm (0.002, 0.004, 0.010 in)
Inside diameter of valve guide (reamed) . . . . . . . . . . . . . . . . . . . . . . . . . 8.022 to 8.040 mm (0.3161 to 0.3168 in)
Valve guide fit in cylinder head (interference) . . . . . . . . . . . . . . . . . . . . . 0.063 to 0.108 mm (0.0025 to 0.0043 in)
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.974 to 7.992 mm (0.3142 to 0.3149 in)
Maximum clearance (valve stem to guide) . . . . . . . . . . . . . . . . . . . . . . . 0.030 to 0.066 mm (0.0012 to 0.0026 in)
Valve face angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45º 25’ to 45º 35’
Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44º 55’ to 45º 05’
Valve head diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.850 to 36.150 mm (1.4125 to 1.4243 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.850 to 31.450 mm (1.2155 to 1.2391 in)
Contact band (valve to seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 to 1.5 mm (0.0512 to 0.0591 in)
Valve clearance:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.0158 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.0197 in)
For timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.0315 in)
Valve clearance adjusting shim thicknesses . . . . . . . . . . . . . . . . . . . . . 3.25 to 4.70 mm (0.128 to 0.185 in), in increments of 0.05 mm
(0.002 in)
Valve timing:
Inlet valve:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7º BTDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35º ABDC
Exhaust valve:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5º ATDC
Engine – general 1•5
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.

2 Engine oil and filter
1
1The engine oil level should be checked at
the weekly service (see “Routine
Maintenance”). Preferably check the level
cold, first thing in the morning or if the engine
has been running, allow at least ten minutes
to elapse after switching off to permit the oil to
drain.
2Withdraw the dipstick, wipe it clean on
non-fluffy material, re-insert it and then
withdraw it for the second time (photo).
3The oil level should be between the MIN
and MAX marks. If not, top up with specified
oil to the MAX mark. Pour the oil slowlythrough the filler orifice on the rocker cover.
To raise the oil level from MIN to MAX will
require approximately 1.1 litre (2.0 pints)
(photos).
4At the intervals specified in “Routine
Maintenance” the oil and filter should be
renewed.
5Have the engine at normal operating
temperature, remove the oil filler cap.
6Place a suitable container under the sump
pan. Unscrew and remove the oil drain plug
and allow the oil to drain (photo).
7While the oil is draining, unscrew and
discard the oil filter. To unscrew the filter, a
filter or chain wrench will normally be
required. If such a tool is not available, drive a
long screwdriver through the oil tester casing
and use it as a lever to unscrew the filter
cartridge.
8Smear the rubber sealing ring of the new oil
filter with oil and screw into position using
hand pressure only (photo).
9Refit the drain plug and refill the engine with
the correct quantity and grade of oil.
10Start the engine. It will take two or three
seconds for the oil warning lamp to go out.
This is normal and is due to the time taken for
the new filter to fill with oil.
11Switch off, check for leaks and check the
oil level, topping up if necessary.
3 Crankcase ventilation
system
1
1This system is designed to draw oil fumes
and blow-by gas (which has passed the piston
rings) from the crankcase and draw it into the
intake manifold when it will then be burned
during the normal combustion process.
2Regularly check the security of the system
hoses which run from the rocker cover or
crankcase breather unit (photo).
3Periodically, detach the hoses and clean
them out with paraffin and a brush or rag pull
through.
4Evidence of sludge or emulsified oil within
the hoses or inside the oil filler cap will
indicate that the engine is running too cool
particularly if the car is used mainly for short
journeys where the engine never reaches full
working temperature.
4 Major operations possible
without removing engine
from car
1The following work can be carried out without
the need to remove the engine from the car.
903 cc engine
Valve clearances - checking and adjusting
Timing chain and sprockets - removal and
refitting
1•8 Engine – general
3.2 Crankcase vent hose (1116 cc)Fig. 1.5 Sectional view of oil filter. Bypass
valve arrowed (Sec 2)2.8 Screwing on the oil filter (903 cc)
2.6 Engine sump drain plug
2.3B Topping up engine oil (1116 cc)2.3A Typical dipstick markings2.2 Withdrawing engine oil dipstick
(1116 cc)

31Support the weight of the transmission
and withdraw it in a straight line from the
engine.
14 Engine- dismantling (general)
1Stand the engine on a strong bench at a
suitable working height. Failing this, it can be
dismantled on the floor, but at least stand it
on a sheet of hardboard.
2During the dismantling process, the
greatest care should be taken to keep the
exposed parts free from dirt. As the engine is
stripped, clean each part in a bath of paraffin.
3Never immerse parts with oilways in
paraffin, e.g. the crankshaft, but to clean,
wipe down carefully with a paraffin dampened
rag. Oilways can be cleaned out with a piece
of wire. If an air line is available, all parts can
be blown dry and the oilways blown through
as an added precaution.
4Re-use of old gaskets is false economy and
can give rise to oil and water leaks, if nothing
worse. To avoid the possibility of trouble after
the engine has been reassembled always use
new gaskets throughout.
5To strip the engine, it is best to work from
the top downwards. The engine oil sump
provides a firm base on which the engine can
be supported in an upright position. When the
stage is reached where the pistons are to be
removed, turn the engine on its side. Turn the
block upside down to remove the crankshaft.
6Wherever possible, replace nuts, bolts and
washers finger-tight from wherever they were
removed. This helps avoid later loss and
muddle. If they cannot be replaced then lay
them out in such a fashion that it is clear from
where they came.
15 Engine- removing ancillary
components
1Before dismantling the engine, remove the
engine ancillary components.
Carburettor (Chapter 3)
Thermostat housing (Chapter 2)
Alternator (Chapter 9)
Coolant pump (Chapter 2)
Distributor (Chapter 4)
Exhaust manifold (Chapter 3)
Fuel pump (Chapter 3)
Oil filter cartridge (Section 2 this Chapter)
Clutch (Chapter 5)
903 cc engine 1•15
Fig. 1.21 Camshaft and rocker gear components (Sec 16)
Fig. 1.22 Cylinder head, block and crankcase (Sec 16)
1 Camshaft bush
lockbolt
2 Washer
3 Camshaft front
bearing
4 Exhaust valve
5 Spring cap
6 Valve guide
7 Adjuster screw8 Rocker arm
9 Thrust washer
10 Circlip
11 Locknut
12 Washer
13 Locknut
14 Pedestal
15 Rocker arm
16 Plug17 Rocker shaft
18 Coil spring
19 Stud
20 Split collets
21 Spring cap
22 Valve guide
23 Outer valve spring
24 Inner valve spring
25 Spring seat26 Inlet valve
27 Camshaft bearing
28 Camshaft bearing
29 Camshaft
30 Locating dowel
31 Cam follower
32 Pushrod
33 Washer
1 Washer
2 Cylinder head bolt
3 Gasket
4 Rocker cover
gasket
5 Rocker cover6 Washer
7 Plate
8 Nut
9 Stud
10 Plug
11 Cylinder head12 Plug
13 Cylinder head bolt
14 Washer
15 Dowel
16 Plug
17 Plug18 Dowel
19 Block/crankcase
20 Plug
21 Plug
22 Bolt
23 Plug
1
Do not throw the old
gaskets away as it
sometimes happens that an
immediate replacement
cannot be found and the old gasket is
then very useful as a template. Hang
up the gaskets on a suitable nail or
hook as they are removed.