sensor FIAT UNO 1983 Service Repair Manual

2
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . “No loss” with radiator and integral expansion tank. Electric cooling
fan, belt-driven coolant pump, thermostat on cylinder head
General
Radiator fan cuts in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 94ºC (194 to 201ºF)
Radiator fan switches off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC (185 to 192ºF)
Thermostat opens:
903 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC (185 to 192ºF)
1116 cc and 1301 cc engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 to 87ºC (181 to 188.6ºF)
Fully open:
903 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100ºC (212ºF)
1116 cc and 1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95ºC (203ºF)
Expansion tank pressure cap rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.78 bar (11 lbf/in2)
Coolant
Capacity:
903 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 litre (8.1 pint)
1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 litre (10.6 pint)
1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 litre (10.9 pint)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ethylene glycol based antifreeze
Torque wrench settingsNm lbf ft
Temperature sender switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Coolant pump mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 25
Alternator adjuster and mountings nuts . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Chapter 2 Cooling and heating systems
For modifications, and information applicable to later models, see Supplement at end of manual
Coolant mixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coolant pump - removal, overhaul and refitting . . . . . . . . . . . . . . . . 9
Cooling system - draining, flushing and refilling . . . . . . . . . . . . . . . . 2
Cooling system sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Description and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Drivebelt - tensioning and renewal . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault finding - cooling and heating . . . . . . . . . . . . See end of ChapterHeater - dismantling, overhaul and reassembly . . . . . . . . . . . . . . . . 13
Heater unit - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Heating and ventilation system - description . . . . . . . . . . . . . . . . . . 11
Radiator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Radiator fan thermostatic switch - removal, checking and refitting . 5
Radiator fan - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . 6
Thermostat - removal, testing and refitting . . . . . . . . . . . . . . . . . . . . 4
2•1
Specifications Contents
1 Description and
maintenance
1
1The cooling system consists of a
front-mounted radiator with built-in expansion
tank, a coolant pump (belt-driven from the
crankshaft pulley) and a thermostatically-
controlled electric cooling fan.
2In order to assist rapid warm-up, athermostat is located in a housing at the
left-hand end of the cylinder head. The hose
connections to the thermostat housing vary
according to model.
3The heater is supplied with coolant from the
engine and incorporates a matrix and blower
with the necessary controls.
4The throttle valve plate block of the
carburettor is coolant-heated as a means of
improving fuel atomisation.
5Maintenance is minimal as in theory no
coolant should ever be lost from theexpansion tank. Regularly check that the
coolant level is between 50.0 and 70.0 mm
(1.97 and 2.8 in) above the MIN mark on the
tank with the engine cold. The need for
regular topping up will indicate a leak
somewhere in the system. If one cannot be
found suspect an internal leak in the engine
although this is usually confirmed by a rise in
the engine oil level and water on the dipstick
(photo). Any topping-up should be done using
an antifreeze mixture (see Section 3), not plain
water.
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

fluid. They are “sealed”. Liquid will get in, but
a thorough clean will be impracticable, and it
will be impossible to get new grease in.
17Check all the parts, get a new gland, two
new grommets, (1116 cc and 1301 cc) and a
new gasket. Scrape all deposits out of the
housing and off the impeller.
18To reassemble, start by inserting the new
grommets (1116 cc and 1301 cc) in the
grooves by each bearing. Fit the circlip to the
shaft, then the shouldered ring, bearings and
spacer. Fit the shaft and bearing assembly
into the cover. Fit the stop screw. Press on
the pulley.
19Fit the new gland (seal), seating it in its
location in the cover. Press the impeller onto
the shaft. The impeller must be put on part
way, and then the housing held in place to see
how far the impeller must go down the shaft
to give the correct clearance, which is 0.8 to
1.3 mm (0.03 to 0.05 in) as shown in Figs. 2.4
and 2.5.
20The impeller clearance can be checked
through the coolant passage in the side of the
pump.
21Refitting is a reversal of the removal
process, but use a new flange gasket and
tension the drivebelt as described in Section 8
(photo).
22Refill the cooling system.
10 Cooling system sensors
1A coolant temperature sender switch is
located in the cylinder head (above No. 1
spark plug) on 903 cc engines and adjacent to
No. 2 spark plug on 1116 cc and 1301 cc
engines.
2The switch operates the coolant
temperature gauge and an excessive
temperature warning lamp.
3On some models, a level sensor is screwed
into the side of the expansion tank. This
sensor consists of a pair of reed switches
within a capsule which are kept closed by the
strong magnetic flux generated by the
hydrostatic force inspired by the action of the
coolant against the float.
4If the coolant level drops then the magneticflux is weakened and the switches open.
5In the event of a fault developing, before
assuming that the cause is the sensor, check
all connecting wiring.
11 Heating and ventilation
system- description
1The heater is centrally mounted under the
facia and is of fresh air type.2Air is drawn in through the grille at the base
of the windscreen. It then passes through the
coolant heated matrix when it can then be
distributed through selective outlets
according to the setting of the control levers.
3A booster fan is provided for use when the
car is stationary or is travelling too slowly to
provide sufficient air ram effect.
4Fresh air outlets are provided at each end
and centrally on the facia panel.
12 Heater unit-
removal and refitting
1
1Drain the cooling system.
2Disconnect the heater hoses at the engine
compartment rear bulkhead.
3Working within the car under the facia
panel, disconnect the leads from the
heater blower by pulling the connecting plug
apart.
4If a radio is fitted, disconnect the
aerial, earth, speaker and power leads from
it.
Cooling and heating systems 2•5
Fig. 2.6 Checking impeller clearance
(Sec 9)9.21 Fitting coolant pump (1116 cc engine)
Fig. 2.7 Heater and ventilation system (Sec 11)
A Fresh air inlet flap
B Air distribution flap
C Coolant valveD Blower
E MatrixF Control levers
G Footwell air duct
2

4
System type
Except ES engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery, coil mechanical breaker distributor
ES engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marelli Digiplex electronic with breakerless distributor
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 - 4 - 2 (No. 1 cylinder at crankshaft pulley end)
Mechanical breaker distributor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marelli or Ducellier
Contact breaker points gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.37 to 0.43 mm (0.015 to 0.017 in)
Condenser capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 to 0.25 µF
Dwell angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 to 58º
Rotor rotational direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Ignition timing (dynamic)
903 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5º BTDC at idle
1116 and 1301 cc engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10º BTDC at idle
Centrifugal advance:
903 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Between 30 and 34º max
1116 and 1301 cc engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Between 22 and 24º max
Vacuum advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Between 10 and 14º max
Ignition coil
Primary winding resistance at 20ºC (68ºF) . . . . . . . . . . . . . . . . . . . . . . . Between 2.6 and 3.3 ohms depending upon make of coil
Secondary winding resistance at 20ºC (68ºF) . . . . . . . . . . . . . . . . . . . . Between 6745 and 12 000 ohms depending upon make of coil
Marelli Digiplex electronic ignition
Rotor arm resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 ohms
Advance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Between 6 to 10º and 47 to 51º
Engine speed sensor
Resistance on flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 to 748 ohms
Sensor to flywheel tooth gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 1.3 mm (0.0099 to 0.0512 in)
TDC sensor
Resistance on pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 to 748 ohms
Sensor to pulley tooth gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 to 1.0 mm (0.016 to 0.039 in)
Ignition coil
Primary winding resistance at 20ºC (68ºF) . . . . . . . . . . . . . . . . . . . . . . . 0.310 to 0.378 ohms
Secondary winding resistance at 20ºC (68ºF) . . . . . . . . . . . . . . . . . . . . 3330 to 4070 ohms
Chapter 4 Ignition system
For modifications and information applicable to later models, see Supplement at end of manual
Condenser (capacitor) - removal, testing and refitting . . . . . . . . . . . 5
Digiplex (electronic) - ignition checks and adjustments . . . . . . . . . . 10
Digiplex (electronic) ignition - location of components and
precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Distributor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Distributor (mechanical breaker type) - overhaul . . . . . . . . . . . . . . . 7
Dwell angle - checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Fault finding - ignition system . . . . . . . . . . . . . . . . See end of Chapter
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Ignition coil - (mechanical breaker ignition) . . . . . . . . . . . . . . . . . . . . 8
Ignition switch - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 12
Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mechanical contact breaker - points servicing . . . . . . . . . . . . . . . . . 2
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4•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

Spark plugs
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RN9YCC or RN9YC
Electrode gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm (0.031 in)
HT leads
903 cc (45) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-07
1116, 1299 and 1301 cc (55, 60 and 70) . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-05
Torque wrench settingNm lbf ft
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
4•2 Ignition system
1 General description
On all models except the 903 ES engine
version, a mechanical contact breaker type
distributor is fitted.
On 45 Super ES models which have the
903 ES engine, an electronic (Digiplex) ignition
system is used which incorporates a
breakerless distributor.
Mechanical contact breaker
system
For the engine to run correctly, it is
necessary for an electrical spark to ignite the
fuel/air mixture in the combustion chamber at
exactly the right moment in relation to engine
speed and load. The ignition system is based
on feeding low tension voltage from the
battery to the coil where it is converted to high
tension voltage. The high tension voltage is
powerful enough to jump the spark plug gap
in the cylinders under high compression
pressures, providing that the system is in
good condition and that all adjustments are
correct.
The ignition system is divided into two
circuits, the low tension (LT) circuit and the
high tension (HT) circuit.
The low tension (sometimes known as the
primary) circuit consists of the battery, the
lead to the ignition switch, the lead from the
ignition switch to the low tension or primary
coil windings, and the lead from the low
tension coil windings to the contact breaker
points and condenser in the distributor.
The high tension circuit consists of the high
tension or secondary coil windings, the heavy
ignition lead from the centre of the coil to the
centre of the distributor cap, the rotor arm,
and the spark plug leads and spark plugs.
The system functions in the following
manner: High tension voltage is generated in
the coil by the interruption of the low tension
circuit. The interruption is effected by the
opening of the contact breaker points in this
low tension circuit. High tension voltage is fed
from the centre of the coil via the carbon
brush in the centre of the distributor cap to
the rotor arm of the distributor.
The rotor arm revolves at half engine speed
inside the distributor cap, and each time it
comes in line with one of the four metal
segments in the cap, which are connected to
the spark plug leads, the opening of thecontact breaker points causes the high
tension voltage to build up, jump the gap from
the rotor arm to the appropriate metal
segment, and so via the spark plug lead to the
spark plug, where it finally jumps the spark
plug gap before going to earth.
The ignition timing is advanced and
retarded automatically, to ensure the sparkoccurs at just the right instant for the
particular load at the prevailing engine speed.
The ignition advance is controlled
mechanically, and by vacuum. The
mechanical governor mechanism consists of
two weights, which move out from the
distributor shaft as the engine speed rises,
due to centrifugal force. As they move
Fig. 4.1 Typical ignition circuit (mechanical contact breaker distributor) (Sec 1)
1 Control unit
2 Multi-plug
3 Ignition coil
4 Distributor cap5 Crankshaft pulley
6 Flywheel
7 Battery
8 Rev counter9 Spark plugs
10 Wiring connector
S1 Engine speed sensor
S2 TDC sensor
Fig. 4.2 Digiplex electronic ignition system (Sec 1)

outwards, they rotate the cam relative to the
distributor shaft, and so advance the spark.
The weights are held in position by two
springs and it is the tension of the springs
which is largely responsible for correct spark
advancement.
The vacuum advance is controlled by a
diaphragm capsule connected to the
carburettor venturi. The vacuum pressure
varies according to the throttle valve plate
opening and so adjusts the ignition advance
in accordance with the engine requirements.
Digiplex ignition system
This electronic system eliminates the
mechanical contact breaker and centrifugal
advance mechanism of conventional
distributors and uses an electronic control
unit to provide advance values according to
engine speed and load. No provision is made
for adjustment of the ignition timing.
Information relayed to the control unit is
provided by two magnetic sensors which
monitor engine speed and TDC directly from
the engine crankshaft.
A vacuum sensor in the control unit
converts intake manifold vacuum into an
electric signal.
The control unit selects the optimum
advance angle required and a closed
magnetic circuit resin coil guarantees a spark
owing to the low primary winding resistance.
Five hundred and twelve advance values
are stored in the control unit memory to suit
any combination of engine operating
conditions.
No maintenance is required to the
distributor used on this system.
Distributor drive
The mechanical breaker type distributor on
903 cc engines and the Digiplex type
distributor on 903 cc ES engines are mounted
on the cylinder head and driven from a gear
on the camshaft through a shaft which also
drives the oil pump.
The distributor on 1116 cc and 1301 cc
engines is mounted on the crankcase and is
driven from a gear on the auxiliary shaft as is
also the oil pump.
2 Mechanical contact breaker
- points servicing
3
1At the intervals specified in “Routine
Maintenance”, prise down the clips on the
distributor cap and place the cap with high
tension leads to one side.
2Pull off the rotor.
3Remove the spark shield. Mechanical wear
of the contact breaker reduces the gap.
Electrical wear builds up a “pip” of burned
metal on one of the contacts. This
|prevents the gap being measured for
re-adjustment, and also spoils the electric
circuit.
Ducellier type distributor
4To remove the contact breaker movable
arm, extract the clip and take off the washer
from the top of the pivot post.
5Extract the screw and remove the fixed
contact arm.
6Clean the points by rubbing the surfaces on
a fine abrasive such as an oil stone. The point
surface should be shaped to a gentle convex
curve. All the “pip” burned onto one contact
must be removed. It is not necessary to go on
until all traces of the crater have been
removed from the other. There is enough
metal on the contacts to allow this to be done
once. At alternate services, fit new points.
Wash debris off cleaned points and
preservatives off new ones.
7Now the distributor should be lubricated.
This lubrication is important for the correct
mechanical function of the distributor, but
excess lubrication will ruin the electrical
circuits, and give difficult starting.
8Whilst the contact breaker is off, squirt
some engine oil into the bottom part of the
distributor, onto the centrifugal advance
mechanism below the plate.
9Wet with oil the felt pad on the top of the
distributor spindle, normally covered by the
rotor arm.
10Put just a drip of oil on the pivot for the
moving contact.11Smear a little general purpose grease
onto the cam, and the heel of the moving
contact breaker.
12Refit the contact points and then set the
gap in the following way.
13Turn the crankshaft by applying a spanner
to the pulley nut or by jacking up a front
wheel, engaging top gear and turning the
roadwheel in the forward direction of
travel. Keep turning until the plastic
heel of the movable contact arm is on the
high point of a cam lobe on the distributor
shaft.
14Set the points gap by moving the fixed
contact arm until the specified feeler blades
are a sliding fit. Tighten the fixed contact arm
screw.
15Check the contact end of the rotor arm.
Remove any slightly burnt deposits using fine
abrasive paper. Severe erosion will
necessitate renewal of the rotor.
16Wipe out the distributor cap and check for
cracks or eroded contacts (photo). Renew if
evident or if the carbon brush is worn.
17Refit the spark shield, rotor and distributor
cap.
18Setting the contact breaker gap with a
feeler blade must be regarded as a means of
ensuring that the engine will start. For
optimum engine performance, the dwell angle
must be checked and adjusted as described
in Section 3.
Marelli type distributor
19Open the points with a finger nail and
inspect their condition. If they are badly
eroded or burned, then they must be
renewed. The contact points can only be
renewed complete with carrier plate as an
assembly.
20Release the low tension leads from the
terminals on the distributor body (photo).
21Extract the screws which hold the vacuum
advance capsule to the distributor body. Tilt
the capsule and release its link rod from the
contact breaker carrier plate (photo).
22Prise out the E-clip from the breaker
carrier and then withdraw the contact
assembly from the top of the distributor shaft.
Ignition system 4•3
2.21 Extracting vacuum diaphragm unit
screw2.20 Marelli distributor2.16 Interior of distributor cap showing
carbon brush
4

Reassembly
14This is a reversal of dismantling. On
Ducellier distributors, make sure that the
advance toothed segment is returned to its
original setting otherwise the advance curves
for your particular engine will be upset.
8 Ignition coil (mechanical
breaker ignition)
1Coils normally last the life of a car. The
most usual reason for a coil to fail is after
being left with the ignition switched on but the
engine not running. There is then constant
current flowing, instead of the intermittent
flow when the contact breaker is opening. The
coil then overheats, and the insulation is
damaged (photo).
2If the coil seems suspect after fault finding,
the measurement of the resistance of the
primary and secondary windings (usually an
ohmmeter) can establish its condition. If an
ohmmeter is not available, it will be necessary
to try a new coil.
9 Digiplex (electronic) ignition
- location of components and
precautions
1The main components of this system are
located within the engine compartment as
shown.
2On cars equipped with this system, it is
4•6 Ignition system
Fig. 4.7 Main components of Digiplex ignition system (Sec 9)8.1 Ignition coil
Fig. 4.6 Exploded view of typical Ducellier distributor (Sec 7)
1 Cap
2 Rotor
3 Movable breaker arm
4 Vacuum advance link
5 Fixed contact breaker arm
6 Contact breaker baseplate
7 Cam assembly8 Centrifugal advance weight
control springs
9 Driveshaft and plate
10 Body
11 LT insulator
12 Condenser
13 Vacuum capsule14 Cap retaining spring
15 Thrust washer
16 Spacer washer
17 Driving dog
18 Retaining pin
19 Felt pad
7.13 Marelli distributor centrifugal weights
and springs
1 Control unit
2 Cut-out control unit
3 Ignition coil
4 Flywheel (engine
speed) sensor
5 Crankshaft pulley
(TDC) sensor
6 Vacuum hose

important that the following precautions are
observed.
3Never start the engine if the battery leads
are loose.
4Do not stop the engine by pulling off a
battery lead.
5Remove the control unit if ambient
temperature (paint drying oven) is above 80ºC
(176ºF).
6Never connect or disconnect the multi-plug
at the control unit unless the ignition is
switched off.
7Disconnect the battery negative lead before
carrying out electric body welding.10 Digiplex (electronic) ignition
- checks and adjustments
3
1Without special equipment, any work on the
system components should be restricted to
the following.
Engine speed sensor
2The gap between the sensor and the teeth
of the flywheel should be between 0.25 and
1.3 mm (0.0099 to 0.0512 in). Any
deviation will be due to mechanical damage to
the sensor, no adjustment being possible.
TDC sensor
3The gap between the sensor and one of the
TDC reference marks on the crankshaft pulley
should be between 0.4 and 1.0 mm (0.016 to
0.039 in).
4Any deviation will be due to the sensor
plate becoming loose. To reposition it will
necessitate setting No. 1 piston at TDC which
can only be carried out accurately by your
dealer using special tools.
Supply circuit and continuity of
coil primary winding
5Connect a test lamp between contacts 11
and 9 of the multi-plug having first pulled it
from the control unit.
6Switch on the ignition, the test lamp should
come on. If it does not, either the connection
at the positive pole of the control unit or the
coil primary winding is open.
Control unit earth
7Connect a test lamp between contacts 8
and 9 of the multi-plug having first pulled it
from the control unit. Switch on the ignition,
the test lamp should come on. If it does not,
improve the earth connection.
11 Spark plugs
1
1The correct functioning of the spark plugs is
vital for the correct running and efficiency of the
engine. It is essential that the plugs fitted are
appropriate for the engine, and the suitable type
is specified at the beginning of this chapter. If
Ignition system 4•7
Fig. 4.9 Digiplex control unit (Sec 9)
1 Vacuum hose connector
2 Multi-plug socket
1 Control unit
2 Distributor
3 Ignition coil4 TDC sensor
5 Wiring connector plug6 Engine speed sensor
7 Wiring connector plug
Fig. 4.8 Location of Digiplex ignition system components (Sec 9)
Fig. 4.13 Test lamp connected between
terminals 8 and 9 of control unit multi-plug
(Sec 10)Fig. 4.12 Test lamp connected between
terminals 11 and 9 of control unit
multi-plug (Sec 10)
Fig. 4.11 TDC sensor gap (Sec 10)
Fig. 4.10 Engine speed sensor gap
(Sec 10)
4

Fault finding - mechanical breaker ignition system
Ignition system 4•9
4
Engine fails to start
m mLoose battery connections
m mDischarged battery
m mOil in contact points
m mDisconnected ignition leads
m mFaulty condenser
Engine overheats, lacks power
m
mSeized distributor weights
m mPerforated vacuum pipe
m mIncorrect ignition timing
Engine starts and runs but misfires
m
mFaulty spark plug
m mCracked distributor cap
m mCracked rotor arm
m mWorn advance mechanism
m mIncorrect spark plug gap
m mIncorrect contact points gap
m mFaulty condenser
m mFaulty coil
m mIncorrect timing
m mPoor engine/transmission earth connections
Fault finding - Digiplex (electronic) ignition system
Engine fails to start
m
mExcessive gap on TDC sensor
m mTDC or engine speed sensor short circuited or earthed
m mDefective ignition control unit
m mControl unit multi-plug contacts corroded
m mDefective coil
Engine lacks power, high fuel consumption
m
mIncorrect ignition advance
m mTDC sensor incorrectly set
m mDistributor vacuum hose blocked

3.4 Removing the caliper unit
1 General description
The braking system is of four wheel
hydraulic type with discs on the front wheels
and drums on the rear.The hydraulic system is of dual-circuit type
and incorporates a pressure regulator valve to
limit pressure to the rear brakes during heavy
braking to prevent rear wheel lock up.
A vacuum servo unit is fitted to some
models.
The handbrake is mechanically operated on
the rear wheels.
2 Maintenance
1
1At the weekly service check, inspect the
fluid level in the master cylinder reservoir.
Topping up should only be required at very
infrequent intervals and should only be
necessary owing to the need for extra fluid in
the hydraulic system caused by wear of the
friction material of the disc pads and shoe
linings.
2The need for frequent or regular topping up
will be due to a leak in the system, probably
from a hydraulic cylinder seal or a flexible
hose. Correct the problem immediately.
3Use only clean new fluid for topping up. lt
must be of the specified type and have been
stored in a closed container and not have
been shaken for at least 24 hours (photo).
4At regular intervals, check the hoses and
pipelines for condition. Adjust the handbrake
if the lever travel becomes excessive. Check
the condition and security of the brake servo
vacuum hose. All these operations are
described later in this Chapter.
3 Disc pads-
inspection and renewal
2
1Jack up the front of the car and remove the
roadwheels.
2Extract the spring clips and slide out the
locking blocks (photos).
3On SX versions, carefully disconnect the
wear sensor lead connecting plug.
4Lift the caliper body from the disc and
inspect the thickness of the friction material
on each pad (photo). If it is 1.5 mm (0.06 in) or
less, renew the pads.
5Withdraw the pads and the anti-rattle
springs.
6Brush away any dust and dirt from the
caliper, taking care not to inhale the dust - this
contains asbestos and is thus potentially
injurious to health.
7As the new pads are thicker than the old
ones, the caliper piston must be depressed
8•2 Braking system
3.8A Disc pad and anti-rattle spring
Fig. 8.1 Components of the braking system (LHD shown) (Sec 1)
1 Caliper
2 Hose
3 Master cylinder
4 Fluid reservoir5 Cap and fluid level sensor
6 Vacuum servo unit
7 Rear wheel cylinder8 Pipeline
9 Hose
10 Pressure regulating valve
3.2B Removing a locking block
3.2A Removing a disc pad locking block
clip2.3 Fluid reservoir cap and float for
warning switch

1 General description
The electrical system is of 12 volt negative
earth type and employs a belt-driven
alternator and a pre-engaged type starter
motor.
The models in the range are all adequately
equipped with electrical accessories, while SX
versions also have power windows and
centralised door locking plus a check control
system (Section 34).
2 Battery- inspection, charging,
removal and refitting
2
1The battery is of maintenance-free type and
under normal circumstances, no topping up
will be required, but regularly check that the
electrolyte level is between the minimum and
maximum lines on the translucent battery
casing.
2If the electrolyte level does drop below theminimum line, suspect a leak in the battery
casing or that the alternator is overcharging. If
the latter is the case, rectify the alternator fault
and then prise out the two rectangular plugs
from the top of the battery and top up with
distilled or purified water.
3Always keep the battery terminals clean
and smear them with petroleum jelly to
prevent corrosion.
4The battery will normally be kept fully
charged by the alternator, but it is possible for
the battery to become discharged if the daily
mileage is very low with much use being
made of the starter and electrical accessories.
5When the battery begins to deteriorate with
age it may also require a boost from a mains
charger.
6Disconnect both battery leads before
connecting the mains charger. 7To remove the battery from the car, first
disconnect the leads from the battery
terminals (earth first) and then unscrew the
securing clamp from the casing projection at
the base of the casing (photo).
8Lift the battery from its mounting platform.
Refitting is a reversal of removal. Reconnect
the earth cable last.
Fuses
Circuit protected Fuse rating (A)
1 Stop lamps, direction indicator lamps, instrument panel warning
lamps, tachometer economy gauge, check control system . . . . . . 10
2 Windscreen wiper and washer, rear screen wiper/washer, check
system panel illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Left front parking, right rear tail lamp, cigar lighter illumination,
heater control and clock, digital clock illumination . . . . . . . . . . . . . 7.5
4 Right front parking lamp and left rear tail lamp, instrument panel
illumination and rear number plate lamp . . . . . . . . . . . . . . . . . . . . . 7.5
5 Left-hand dipped headlamp, rear foglamps . . . . . . . . . . . . . . . . . . 10
6 Right-hand dipped headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Left-hand headlamp (main beam) . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 Right-hand headlamp (main beam) . . . . . . . . . . . . . . . . . . . . . . . . . 10
9 Engine cooling fan and horn (Comfort) . . . . . . . . . . . . . . . . . . . . . . 25
10 Heater booster fan, digital clock map reading lamp . . . . . . . . . . . . 20
11 Heated tailgate glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
12 Courtesy lamps, cigar lighter, radio power feed, disc pad
sensors, economy gauge (ES models) . . . . . . . . . . . . . . . . . . . . . . 10
13 Hazard warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
14 Spare (Comfort), Horn (Super) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BulbsWattage
Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40/45 or Halogen H4 60/55
Front parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Side repeater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rear foglamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Direction indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rear number plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Courtesy lamp (roof) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Courtesy lamp (pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warning and indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wedge base
Torque wrench settingsNm lbf ft
Alternator mounting and adjustment nuts . . . . . . . . . . . . . . . . . . . . . . . 50 87
Starter motor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 35
9•2 Electrical system
2.7 Battery clamp
If battery terminal corrosion
has occurred, it may be
neutralised by applying
sodium bicarbonate or
household ammonia.