1983 FIAT UNO check engine light

this type is used and the engine is in good
condition, the spark plugs should not need
attention between scheduled replacement
intervals. Spark plug cleaning is rarely
necessary and should not be attempted unless
specialised equipment is available as damage
can easily be caused to the firing ends.
2At the specified intervals, the plugs should
be renewed. The condition of the spark plug
will also tell much about the overall condition
of the engine.
3If the insulator nose of the spark plug is
clean and white, with no deposits, this is
indicative of a weak mixture, or too hot a plug.
(A hot plug transfers heat away from the
electrode slowly - a cold plug transfers it away
quickly.)
4If the tip of the insulator nose is covered
with sooty black deposits, then this is
indicative that the mixture is too rich. Should
the plug be black and oily, then it is likely that
the engine is fairly worn, as well as the mixture
being too rich.
5The spark plug gap is of considerable
importance, as, if it is too large or too small
the size of the spark and its efficiency will be
seriously impaired. The spark plug gap should
be set to the gap shown in the Specifications
for the best results.
6To set it, measure the gap with a feeler
gauge, and then bend open, or close, the
outer plug electrode until the correct gap is
achieved. The centre electrode should never
be bent as this may crack the insulation and
cause plug failure, if nothing worse.
7When fitting new plugs, check that the plug
seats in the cylinder head are quite clean.
Refit the leads from the distributor in the
correct firing order, which is 1-3-4-2; No 1cylinder being the one nearest the flywheel
housing (903 cc) or timing belt (1116 or
1301 cc). The distributor cap is marked with
the HT lead numbers to avoid any confusion.
Simply connect the correctly numbered lead
to its respective spark plug terminal (photo).
12 Ignition switch-
removal and refitting
1
1Access to the steering column lock/ignition
switch is obtained after removing the steering
wheel and column shrouds (Chapter 10) and
the column switch unit (Chapter 9).
2In the interest of safety, disconnect the
battery negative lead and the ignition switch
wiring plug (photo).
3Insert the ignition key and turn to the STOP
position (photo).
4Pull the two leads from the switch.
5Turn the ignition key to MAR.
6Using a screwdriver depress the retaining
tabs (1) (Fig. 4.16) and release the ignition
switch.
7Set the switch cam (2) so that the notches
(3) are in alignment.
8Insert the switch into the steering lock and
engage the retaining tabs.
9Turn the ignition key to STOP and connect
the two leads.
10Reconnect the battery and refit the
steering wheel, switch and shrouds.
11Removal and refitting of the steeringcolumn lock is described in Chapter 10.
Note: The ignition key is removable when set
to the STOP position and all electrical circuits
will be off. If the interlock button is pressed,
the key can be turned to the PARK position in
order that the parking lamps can be left on
and the steering lock engaged, but the key
can be withdrawn.
4•8 Ignition system
Fig. 4.16 Typical ignition switch (Sec 12)
1 Retaining tabs 3 Alignment notches
2 Switch cam 4 Locating projection12.3 Ignition key positions
1 AVV (Start) 3 Stop (Lock)
2 Park (Parking lights on) 4 MAR (Ignition)12.2 Ignition switch and lock
11.7 Distributor cap HT lead markingsFig. 4.15 Spark plug connections on
1116 cc and 1301 cc engines (Sec 11)
Fig. 4.14 Spark plug connections on
903 cc engine (Sec 11)
It’s often difficult to insert spark plugs
into their holes without cross-threading
them. To avoid this possibility, fit a
short piece of rubber hose over the end
of the spark plug. The flexible hose
acts as a universal joint, to help align
the plug with the plug hole. Should the
plug begin to cross-thread, the hose
will slip on the spark plug, preventing
thread damage.

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.

ease the holder out of the alternator. Inspect
the brushes and if worn below the specified
minimum length, they must be renewed.
7Disconnect the brush leads by unsoldering
or carefully cutting them.
8When soldering the new brush leads, do
not allow solder to run down them or their
flexibility will be ruined.
9When inspecting or renewing brushes,
check the surface of the slip rings. Clean them
with solvent or if they are very discoloured,
use very fine glasspaper.
6 Voltage regulator
1This is of integral type and is part of the
brushholder assembly.
2No provision is made for adjustment or
overhaul.
7 Starter motor-
description and testing
2
1The starter motor may be one of two
different makes. Both are of pre-engaged
type.
2This type of starter motor incorporates a
solenoid mounted on top of the starter motor
body. When the ignition switch is operated,
the solenoid moves the starter drive pinion,
through the medium of the shift lever, into
engagement with the flywheel starter ring
gear. As the solenoid reaches the end of its
stroke, and with the pinion by now partially
engaged with the flywheel ring gear, the main
fixed and moving contacts close and engage
the starter motor to rotate the engine.
3This pre-engagement of the starter drive
does much to reduce the wear on the flywheel
ring gear associated with inertia type starter
motors.
4If the starter fails, some fault-finding can be
done with it still on the car. Check the ignition
warning light comes on, and does not go out
when the starter is switched on. If it goes out,
the fault is probably in the battery. If it stays
bright, get an assistant to work the switch,whilst listening to the starter. Listen to find out
if the solenoid clicks into position. If it does
not, pull off the solenoid wire, and check it
with a test bulb. If the wire is live when the key
is turned, but the solenoid does not move,
take off the starter and remove it to the bench
for overhaul.
8 Starter motor-
removal and refitting
1
1Disconnect the battery negative lead.
2Disconnect the lead from the starter motor
(photo).
3Unscrew the fixing bolts and withdraw the
starter motor, downwards on 1116 cc and
1301 cc models (photo).
4Refitting is a reversal of the removal
procedure.
9 Starter motor- overhaul
3
1As with the alternator, the operations
should normally be limited to renewal of the
brushes. If the unit has covered a high
mileage it will usually be more economical to
purchase a new or factory-reconditioned one
rather than renew several components of the
original unit.
2Owing to the possibility that a fault can
develop in the starter motor solenoid or drive
assembly, full dismantling procedures are
given later in this Section.
Brush - renewal
3Slide off the cover band.
4Using a hooked piece of wire, pull up the
springs so that the brushes can be withdrawn
and their lengths checked for wear. If they
have worn below the specified minimum
length, renew them by extracting the brush
lead connecting screws (photo).
Solenoid
5Disconnect the field connecting wire from
the solenoid.
6Unscrew the bolts which hold the solenoid
to the end-frame.
7Unscrew the yoke tie-rod nuts.
9•4 Electrical system
9.4 Starter motor brush partly withdrawn
8.2 Starter motor connections8.3 Removing starter motor
Fig. 9.2 Exploded view of typical starter motor (Sec 9)
1 Armature
2 Drive pinion/clutch3 Drive end bracket
4 Shift lever5 Solenoid
6 Brush endplate7 Brush
8 Field windings
Gripping the brush leads with
a pair of pliers to act as a
heat sink will prevent heat
transfer to the internal
components of the alternator.

3The centralised door locking system can
operate independently of the key.
4To gain access to the lock solenoid and
linkage, remove the front door trim panel as
described in Chapter 12.
5Disconnect the battery negative lead.
6Disconnect the electrical wiring plugs from
the solenoid within the door cavity.
7Disconnect the solenoid from the lock lever
by removing the clip.
8Unscrew the two bolts which secure the
solenoid to the door and remove it.
9Renew the solenoid or switch as necessary.
10Refitting is a reversal of removal.
11Refer to Section 10 for details of system
fuses and relays.
33 Economy gauge
(Econometer)
2
1This device is fitted to ES (energy saving)
models and indicates to the driver the fuel
consumption (in litres per 100 km) coupled
with a needle which moves over coloured
sections of a dial to make the driver aware
that his method of driving is either conducive
to high or low fuel consumption. Refer to
Chapter 3, Section 16.
2The device is essentially a vacuum gauge
which also incorporates a warning lamp to
indicate to the driver when a change of gear is
required.
3A fuel cut-out valve (see Chapter 3, Sec-
tion 11) is used in conjunction with the
economy gauge so that when the accelerator
pedal is released during a pre-determined
engine speed range, fuel supply to the engine
is stopped, but resumes when the engine
speed falls below the specified range.
LED (light emitter diode)
4The gearchange indicator will only light up
at engine speeds in excess of 2000 rev/min
for vacuum pressures up to 600 mm Hg in 1st,
2nd and 3rd speed gears and for vacuum
pressures up to 676 mm Hg in 4th speedgear. The light will not come on if 5th speed
gear is engaged or if the coolant temperature
is below 55ºC.
5There is a two second delay in the light
coming on to prevent it operating during rapid
acceleration in a low gear.
6If the LED light comes on during
deceleration it should be ignored.
Fault finding
7A faulty economy gauge should be checked
in the following way.
8Refer to Section 21 and remove the
instrument panel.
9Disconnect the economy gauge L
connector and then connect a test lamp
between the BN cable contact and earth. If
the lamp comes on then the gauge supply
circuit is not open. If the lamp does not come
on, check all connections in the supply cable
which comes from the interconnecting unit of
the electrical system, also Fuse No 12.
10Now connect a voltmeter between the
white cable and earth. Check the voltage with
the engine not running, but the ignition
switched on. It should be between 0.7 and
0.9 volt. If the reading varies considerably
from that specified, check the connections
between the economy gauge and the fuel
cut-out device control unit. If the fault cannot
be rectified, renew the ignition control unit
(Digiplex system, see Chapter 4).
11Now check the closed throttle valve plate
switch by connecting a voltmeter between the
brown and BN cables of the L connector. With
the valve plate open, there should be no
reading, but with it open, voltage should be
indicated.
12Failure to conform as described will be
due to a faulty earth in the switch or a faulty
fuel cut-out device control unit.
13A further test of the throttle valve plate
switch may be carried out by disconnecting
the multi-plug from the fuel cut-out device
control unit.
14Connect a test lamp to contact 4 (positive
battery terminal). The lamp should come on,
when the engine is idling or the accelerator
released. If it does not, renew the throttle
valve plate switch.15Connect a tachometer to the brown/white
cable contact in the L connector and record
the engine speed with the engine running. If
no reading is obtained, renew the Digiplex
ignition control unit which must be faulty.
34 Check control (warning
module) system
2
1This is fitted into the instrument panel of
certain models to provide a means of
checking the operation of many electrical
circuits and other systems in the interest of
safety. Sensors are used where appropriate.
2The following components are not
monitored by the system, but have separate
warning lamps:
Handbrake “on”
Choke in use
Low engine oil pressure
Battery charge indicator
3The multi-functional electronic device
automatically checks the following functions
whether the engine is running or not:
Coolant level
Disc pad wear
Door closure
Engine oil level
Front parking lamps
Rear foglamps
Stop lamps
4The check information is stored by the
system monitor until the engine is started
when the display panel then indicates the
situation by means of the LEDs (light emitter
diodes) and the general lamp.
5If all functions are in order, the green panel
lamp will come on when the ignition key is
turned and will go out after two to three
seconds.
6If some functions are not in order, then the
red panel lamp will come on also the
appropriate LED.
Sensors - checking
7If a fault signal occurs which is
subsequently found to be incorrect, first
check the wiring connections between the
9•12 Electrical system
Fig. 9.15 Check system control panel (Sec 34)
A Parking lamps
B Coolant levelC Engine oil level
D Door closureE Brake fluid level
F Disc pad wearFig. 9.14 Location of control units (Sec 33)
A Digiplex ignition system control unit
B Fuel cut-out valve control unit

9•14 Electrical system
Fault finding - electrical system
No voltage at starter motor
m mBattery discharged
m mBattery defective internally
m mBattery terminals loose or earth lead not securely attached to body
m mLoose or broken connections in starter motor circuit
m mStarter motor switch or solenoid faulty
Voltage at starter motor - faulty motor
m
mStarter brushes badly worn, sticking, or brush wires loose
m mCommutator dirty, worn or burnt
m mStarter motor armature faulty
m mField coils earthed
Starter motor noisy or rough in engagement
m
mPinion or flywheel gear teeth broken or worn
m mStarter drive main spring broken
m mStarter motor retaining bolts loose
Alternator not charging*
m
mDrivebelt loose and slipping, or broken
m mBrushes worn, sticking, broken or dirty
m mBrush springs weak or broken
* If all appears to be well but the alternator is still not charging, take the
car to an automobile electrician for checking of the alternator
Ignition light fails to go out, battery runs flat in a
few days
m mDrivebelt loose and slipping, or broken
m mAlternator faulty
Battery will not hold charge for more than a few
days
m mBattery defective internally
m mElectrolyte level too low or electrolyte too weak due to leakage
m mPlate separators no longer fully effective
m mBattery plates severely sulphated
m mDrivebelt slipping
m mBattery terminal connections loose or corroded
m mAlternator not charging properly
m mShort in lighting circuit causing continual battery drain
Fuel gauge gives no reading
m
mFuel tank empty!
m mElectric cable between tank sender unit and gauge earthed or loose
m mFuel gauge case not earthed
m mFuel gauge supply cable interrupted
m mFuel gauge unit broken
Fuel gauge registers full all the time
m
mElectric cable between tank unit and gauge broken or disconnected
Horn operates all the time
m
mHorn push either earthed or stuck down
m mHorn cable to horn push earthed
Horn fails to operate
m
mBlown fuse
m mCable or cable connection loose, broken or disconnected
m mHorn has an internal fault
Horn emits intermittent or unsatisfactory noise
m
mCable connections loose
m mHorn incorrectly adjusted
Lights do not come on
m
mIf engine not running, battery discharged
m mLight bulb filament burnt out or bulbs broken
m mWire connections loose, disconnected or broken
m mLight switch shorting or otherwise faulty
Lights come on but fade out
m
mIf engine not running, battery discharged
Lights give very poor illumination
m
mLamp glasses dirty
m mReflector tarnished or dirty
m mLamps badly out of adjustment
m mIncorrect bulb with too low wattage fitted
m mExisting bulbs old and badly discoloured
m mElectrical wiring too thin not allowing full current to pass
Lights work erratically, flashing on and off,
especially over bumps
m mBattery terminals or earth connections loose
m mLights not earthing properly
m mContacts in light switch faulty
Wiper motor fails to work
m
mBlown fuse
m mWire connections loose, disconnected or broken
m mBrushes badly worn
m mArmature worn or faulty
m mField coils faulty
Wiper motor works very slowly and takes
excessive current
m mCommutator dirty, greasy or burnt
m mDrive spindle binding or damaged
m mArmature bearings dry or unaligned
m mArmature badly worn or faulty
Wiper motor works slowly and takes little current
m
mBrushes badly worn
m mCommutator dirty, greasy or burnt
m mArmature badly worn or faulty
Wiper motor works but wiper blade remains static
m
mDrive spindle damaged or worn
m mWiper motor gearbox parts badly worn

Braking system................................................................................. 14
Part A: Braking system general
Front brake pads all later models
Part B: Braking system - Turbo ie models
Description
Front disc pads - renewal
Front disc caliper - removal and refitting
Front disc caliper - overhaul
Front brake disc - inspection, renovation or renewal
Rear disc pads - renewal
Rear disc caliper - removal, overhaul and refitting
Rear brake disc - inspection, renovation and renewal
Pressure regulating valve
Brake pedal - removal and refitting
Vacuum servo unit and master cylinder - general
Antiskid system - description
Electrical system.............................................................................. 15
Alternator (999 cc models) - removal and refitting
Alternator (later models) - removal and refitting
Alternator brushes - renewal
Starter motor (999 cc models) - removal and refitting
Starter motor (1301 cc Turbo ie, 1372 cc ie, 1372 cc Turbo ie)
- removal and refitting
Starter motor brushes (later models) - renewal
Fuses - later models
Relays (Turbo ie models) - general
Headlamps - later models
Headlamp beam adjusters for load compensation - later models
Headlamp unit removal - later models
Headlamp dim-dip system - description
Front fog lamps bulb/unit - removal and refitting and beam
adjustment
Horn - relocation
Steering column combination switches (later models) - removal
and refittingInstrument panel (Turbo ie models) - removal and refitting
Facia-mounted switches (1301 cc Turbo ie model) - removal
and refitting
Instrument panel (later models) - removal and refitting
Auxiliary control panel (later models) - removal and refitting
Heater control panel (later models) - removal and refitting
Trip master
Interior roof mounted spotlamp, switch and/or clock - removal
and refitting
Central door locking system
Cigar lighter (later models) - removal and refitting
Electrically operated window switches - removal and refitting
Windscreen wiper motor (later models) - removal and refitting
Windscreen washer reservoir (Turbo) - removal and refitting
Tailgate wiper motor (later models) - removal and refitting
Radio Check control system sensors - description
Check control system sensors - testing
Suspension....................................................................................... 16
Front anti-roll bar - removal and refitting
Suspension strut later models
Bodywork.......................................................................................... 17
Plastic components
Rear view mirrors
Door armrest
Tailgate (Turbo ie model) - component removal and refitting
Radiator grille (1301 cc Turbo ie model) - removal and
refitting
Radiator grille (1372 cc ie and 1372 cc Turbo ie models) -
removal and refitting
Bumpers (1301 cc Turbo ie, 1372 cc ie and 1372 cc Turbo ie
models) - removal and refitting
Rear hinged windows - removal and refitting
Door trim panel (Turbo ie model) - removal and refitting
Supplement: Revisions and information on later models 13•3
13
1 Introduction
Since its introduction in 1983, the FIAT Uno
has had a number of modifications and
improvements including the fitting of a twin
choke carburettor, low profile tyres, tinted
windows and remotely-controlled central door
locking.
The major mechanical change was the
introduction of the FIRE (Fully Integrated
Robotised Engine) on 45 and 45S models to
be followed by a new 1108 cc “FIRE” engine
on the 60S model from 1989 on.
A 1301 cc Turbo ie engine model wasavailable for a short period. This model had a
Bosch LE2 Jetronic electronic fuel injection
(ie) and a turbocharger to give added
performance. To uprate the braking to suit,
disc brakes were fitted to the rear in place of
the original drum type brakes.
A 1372 cc engine model was introduced in
1989. Two versions were initially available. A
Bosch Mono-Jetronic single-point fuel
injection (SPi) system, as found on the 70 SX
model and Bosch L3.1 or L3.2 Jetronic
multi-point fuel injection (MPi) systems were
fitted to Turbo models. L3.2 MPi system
models were equipped with catalytic
converters, to improve exhaust emission. All
fuel injection engines are fitted with electroni-
cally controlled engine management systems.
A new style instrument panel, switchgearand a revised facia layout was introduced in
1989.
During 1992, SPi fuel systems were fitted to
the 999 cc and 1108 cc engines, along with
catalytic converters for improved exhaust
emissions.
Five speed transmissions were introduced
to 999 cc models in 1993.
It is recommended that this Supplement is
always referred to before the main Chapters
of the Manual.
Project vehicles
The vehicles used in the preparation of this
supplement, and appearing in many of the
photographic sequences were a 1986 Uno
45S FIRE, a 1988 1301 cc Uno Turbo ie and a
1991 1372 cc Uno SXie.
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

Torque wrench settingsNm lbf ft
Driveshaft flange connecting bolts (Turbo ie) . . . . . . . . . . . . . . . . . . . . . 43 32
Final drive output shaft bearing cover bolts (Turbo ie) . . . . . . . . . . . . . . 24 18
Intermediate shaft support to crankcase (Turbo ie) . . . . . . . . . . . . . . . . 48 35
Braking system (903, 999, 1108, 1116 and 1372 cc)
General
Note:The following items differ, or are additional to those specified in Chapter 8:
Master cylinder bore diameter:
903 cc, 999 cc, 1108 cc and 1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . 19.05 mm
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.65 mm
Vacuum servo diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.4 mm
Hydraulic push rod-to-master cylinder support plate clearance . . . . . . 0.825 to 1.025 mm
Braking system (1301 and 1372 cc Turbo ie)
General
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-wheel discs, ventilated front, solid rear. Vacuum servo. Pressure
regulating valve on rear brakes
Master cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.225 mm
Vacuum servo diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177.8 mm
Front disc brakes
Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240.0 mm
Disc thickness - new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9 to 20.1 mm
Disc thickness - minimum (refinishing) . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6 mm
Disc thickness - minimum (wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2 mm
Minimum thickness of pad friction material . . . . . . . . . . . . . . . . . . . . . . 1.5 mm
Caliper cylinder diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.0 mm
Rear disc brakes
Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227.0 mm
Disc thickness - new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 to 10.9 mm
Disc thickness minimum (refinishing):
1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 mm
1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35 mm
Disc thickness - minimum (wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 mm
Minimum thickness of pad friction material . . . . . . . . . . . . . . . . . . . . . . 1.5 mm
Caliper cylinder diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.0 mm
Torque wrench settingsNm lbf ft
Front caliper cylinder housing mounting bolts . . . . . . . . . . . . . . . . . . . . 52 38
Front caliper support bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 38
Front disc fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Rear caliper support bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Rear caliper cylinder housing mounting bolts . . . . . . . . . . . . . . . . . . . . 52 38
Electrical system
Battery
Turbo ie engine models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Ah
Fuses (903, 999, 1116, 1299/1301 and 1301 cc Turbo ie)
Fuse No. Rating Circuit
1 7.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH tail, RH front parking, rear number plate, check panel
2 7.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH tail, LH front parking, cigar lighting, clock light, heater control
illumination, map reading lamp.
3 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH headlamp main beam
4 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH headlamp main beam and warning light
5 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator cooling fan, econometer and horns
6 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cigar lighter, courtesy lamps, digital clock, stop-lamp switch, clock
and radio
7 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH headlamp dipped beam
8 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH headlamp dipped beam, rear fog warning lamp and indicator
9 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated rear screen and warning lamp
10 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel, stop-lamps, direction indicators, reversing lamps
and warning module
11 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater fan, fan control illumination and digital clock
12 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen wiper, washer pump and rear screen wiper
13 - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare
14 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard warning lamps and indicator
Supplement: Revisions and information on later models 13•15
13

13•18 Supplement: Revisions and information on later models
Every 9000 miles (15 000 km) or
12 months (whichever comes first)
m mCheck the tyre pressures and their condition
(including the spare)
m mWhere a pad wear warning light is fitted, check its
operation
m mCheck the front brake disc pads for excessive wear
m mCheck the underbody condition (fuel and brakes
pipes, exhaust system, hoses, bushes and gaiters)
m mCheck the condition and tension of drivebelts
m mCheck the engine idle speed and CO emissions
m mCheck the EGR system (If fitted)
m mCheck fluid levels (coolant, brake fluid and
windscreen washer)
m mRenew spark plugs (1372 cc Turbo models)
m mRenew the engine oil and oil filter (non-Turbo
models)
m mCheck the HT leads and connections
m mCheck the condition of all coolant, fuel and
hydraulic hoses and connections
Every 18 000 miles (30 000 km) or
24 months (whichever comes first)
In addition to the items listed for 9000 mile (15 000 km) or 12 months
service
m mCheck the rear brake disc pads for wear (where
applicable)
m mCheck/adjust the valve clearances
m mCheck and tighten (if necessary), inlet and exhaust
manifolds
m mCheck the clutch adjustment (cable operated
models)
m mRenew the fuel filter (where applicable)
m mRenew the air cleaner element
m mRenew the spark plugs and check the HT leads
and connections (all models)
m mWhere applicable, have the ignition and injection
systems checked (special equipment needed)
m mRenew coolant
m mRenew brake fluid
Every 28 000 miles (45 000 km) or
36 months (whichever comes first)
In addition to the items listed for 9000 mile (15 000 km) or 12 months
service
m mCheck Lambda (oxygen) sensors operation (special
equipment needed)
m mCheck fuel evaporation system (where fitted)
m mCheck the transmission oil level
m mCheck the condition crankcase ventilation system
Every 37 000 miles (60 000 km) or
48 months (whichever comes first)
In addition to the items listed for 18 000 mile (30 000 km) or
24 months service
m mCheck the condition of the rear brake shoe linings
m mCheck the condition of the timing belt
Every 65 000 miles (105 000 km)
m
mRenew the timing belt
Every 74 500 miles (120 000 km)
m
mRenew the manual transmission oil
Every 250 miles (400 km), weekly or
before a long journey
m mProceed as described for the earlier models at the
start of this manual
Every 6000 miles (10 000 km) or
12 months (whichever comes first)
m mRenew the engine oil and oil filter (Turbo models
only)
3 Routine maintenance- all models from June 1991
The maintenance intervals in this manual are provided with the
assumption that you, not the dealer, will be carrying out the work.
These are the minimum maintenance intervals recommended by us, for
vehicles driven daily. If you wish to keep your vehicle in peak condition
at all times, you may wish to perform some of these procedures more
often. We encourage frequent maintenance, since it enhances the
efficiency, performance and resale value of your vehicle.
If the vehicle is driven in dusty areas, used to tow a trailer, or driven
frequently at slow speeds (idling in traffic) or on short journeys, more
frequent maintenance intervals are recommended.
When the vehicle is new, it should be serviced by an authorised
dealer to preserve the factory warranty.