1983 FIAT UNO transmission oil

Fault finding - all engines
Note: When investigating starting and uneven running faults, do not be tempted into snap diagnosis. Start from the beginning of the check
procedure and follow it through. It will take less time in the long run. Poor performance from an engine in terms of power and economy is not
normally diagnosed quickly. In any event, the ignition and fuel systems must be checked first before assuming any further investigation needs to
be made.
All engines 1•35
1
Engine fails to turn when starter operated
m mBattery discharged
m mBattery terminals loose or corroded
m mBattery earth to body defective
m mEngine/transmission earth strap broken or loose
m mDisconnected or broken wire in starter circuit
m mIgnition/starter switch defective
m mStarter motor or solenoid defective (see Chapter 9)
m mMajor mechanical failure (seizure) or long disuse (piston rings rusted
to bores)
Engine turns and fails to start
m mBattery discharged
m mBattery terminals loose or corroded
m mBattery or engine earth strap loose
m mStarter motor connections loose
m mOil in engine/transmission too thick
m mStarter motor defective
m mVapour lock in fuel line (in hot conditions or at high altitude)
m mBlocked float chamber needle valve
m mFuel pump filter blocked
m mChoked or blocked carburettor jets
m mFaulty fuel pump
m mFuel tank empty
m mOther fuel system fault (see Chapter 3)
m mShorted or disconnected low tension leads
m mDirty, incorrectly set, or pitted contact breaker points
m mContact breaker point spring earthed or broken
m mFaulty condenser
m mDefective ignition switch
m mFaulty coil
m mDamp or dirty HT leads, distributor cap or plug bodies
m mBroken, loose or disconnected LT leads
m mIgnition leads connected wrong way round
m mOther ignition fault (see Chapter 4)
m mValve timing incorrect (after rebuild)
Engine fires but will not run
m
mInsufficient choke (cold engine)
m mFuel starvation or tank empty
m mIgnition fault (see Chapter 4)
m mOther fuel system fault (see Chapter 3)
Engine stalls and will not restart
m
mToo much choke allowing too rich a mixture to wet plugs
m mFloat damaged or leaking or needle not seating
m mFloat lever incorrectly adjusted
m mIgnition failure - sudden
m mIgnition failure - misfiring precedes total stoppage
m mIgnition failure - in severe rain or after traversing water splash
m mNo petrol in petrol tank
m mPetrol tank breather choked
m mSudden obstruction in carburettor
m mWater in fuel system
Engine slow to warm up
m
mChoke linkage maladjusted
m mAir cleaner temperature control unit defective
m mThermostat stuck open (see Chapter 2)
m mOther fuel system fault (see Chapter 3)
Difficult starting when cold
m
mInsufficient choke
m mFouled or incorrectly gapped spark plugs
m mDamp or dirty HT leads, distributor cap or spark plug bodies
m mDirty or maladjusted contact breaker points
m mOther ignition fault or timing maladjustment (see Chapter 4)
m mFuel system or emission control fault (see Chapter 3)
m mPoor compression (may be due to incorrect valve clearances, burnt
or sticking valves, blown head gasket, worn or damaged pistons,
rings or bores)
m mIncorrect valve timing (after rebuild)
Difficult starting when hot
m
mIncorrect use of manual choke
m mFuel line vapour lock (especially in hot weather or at high altitudes)
m mIncorrect ignition timing
m mOther fuel system or emission control fault (see Chapter 3)
m mPoor compression (see above)
Engine lacks power
m
mIgnition timing incorrect
m mContact breaker points incorrectly gapped
m mIncorrectly set spark plugs
m mDirty contact breaker points
m mDistributor automatic advance and retard mechanisms not
functioning correctly
m mOther ignition system fault (see Chapter 4)
m mAir cleaner choked
m mCarburation too rich or too weak
m mFuel filter blocked
m mAir filter blocked
m mFaulty fuel pump giving top and fuel starvation
m mOther fuel system fault (see Chapter 3)
m mPoor compression
m mValve clearances incorrect
m mCarbon build-up in cylinder head
m mSticking or leaking valves
m mWeak or broken valve springs
m mWorn valve guides or stems
m mWorn pistons and piston rings
m mBurnt out valves
m mBlown cylinder head gasket (accompanied by increase in noise)
m mWorn pistons and piston rings
m mWorn or scored cylinder bore
m mBrakes binding
Engine misfires throughout speed range
m
mDefective or fouled spark plug
m mLoose, cracked or defective HT lead
m mMaladjusted, sticking or burnt valves
m mIgnition timing incorrect
m mBlown head gasket
m mFuel contaminated
m mOther ignition fault (see Chapter 4)
m mOther fuel system fault (see Chapter 3)
Poor engine braking
m
mHigh idle speed
m mOther fuel system fault (see Chapter 3)
m mLow compression

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

balljoint from the hub carrier using a suitable
“splitter” tool. If such a tool is not available,
support the base of the brake disc and drive
the balljoint taper pin downwards, but screw
on the nut to protect the threads.
4Remove the hub carrier.
5Refitting is a reversal of removal, use a new
driveshaft nut and tighten all nuts and bolts to
the specified torque. Stake the driveshaft nut
after tightening.
6 Track control arm-
removal and refitting
3
1Raise the front of the car and support it
securely.
2Unless a special tool is available to press
the track control arm balljoint from the hub
carrier, the driveshaft will have to be
disconnected as described in Chapter 7,
Section 2, paragraphs 1 to 8 to provide more
space to enable the balljoint taper pin to be
driven from the hub carrier. This should now
be done as described in the preceding
Section (photo).
3Unbolt the inboard end of the track control
arm. This is retained by a pivot bolt and a
clamp (photo).
4As previously explained, a worn balljoint or
flexible pivot bushes will necessitate renewal
of the track control arm complete. Note that itmay, however, be possible to obtain a
replacement balljoint through a motor factor.
5Refitting is a reversal of removal. Tighten all
nuts and bolts to the specified torque. Use a
new driveshaft nut and stake it into the
driveshaft groove after tightening.
7 Front crossmember-
removal and refitting
3
1Raise the front of the car, support securely
with axle stands placed under the
side-members or sill jacking points.
2Remove the front roadwheels.
3Unscrew the nuts from the tie-rod end
balljoint taper pins and then using a balljoint
“splitter” tool disconnect the balljoints from
the steering arms on the hub carrier.
4Unscrew the bolts which hold the inboard
track control arms to the body members, and
also withdraw the pivot bolt from the body
bracket.
5Support the weight of the engine/
transmission using a hoist or support bar
across the top of the engine compartment as
described in Chapter 6.
6Disconnect the lower (central) engine/
transmission flexible mounting from the floor
pan.
7Unscrew the steering rack mounting boltsand remove them. Leave the steering rack
hanging loose.
8Remove the front crossmember mounting
bolts and manoeuvre it from the car.
9Refitting is a reversal of removal. Tighten all
nuts and bolts to the specified torque wrench
settings and on completion, check the front
wheel alignment as described in Chapter 10.
8 Rear shock absorber-
removal and refitting
3
1Open the tailgate and remove the cover
from the shock absorber top mounting which
is located within the luggage area (photo).
2Hold the flats on the spindle with an
open-ended spanner and then unscrew the
self-locking nut.
3Working under the car, disconnect the
shock absorber lower mounting.
4Withdraw the unit from under the wing.
5The shock absorber can be tested as
described in Section 2.
6Refitting is a reversal of removal. Tighten
mounting nuts and bolts to the specified
torque.
9 Rear coil spring-
removal and refitting
3
1Raise the rear of the car and support it
securely on axle stands placed under the
side-members or sill jacking points.
2Remove the roadwheel.
3Place a jack under the brake drum and
support the suspension trailing arm.
4Disconnect the shock absorber lower
mounting and then lower the trailing arm jack
until the coil spring can be withdrawn.
5Refitting is a reversal of removal. If the
spring is being changed, make sure that it is
of the same colour code as the original and
that its lower coil is correctly located up
against its stop in the spring pan.
6Tighten the shock absorber lower mounting
bolt to the specified torque.
11•4 Suspension
8.1 Rear shock absorber upper mounting
coverFig. 11.7 Front crossmember bolts (Sec 7)Fig. 11.6 Steering rack mounting bolts
(Sec 7)
6.3 Track control arm inboard fixing6.2 Separating track control arm balljoint
from hub carrier

13
Chapter 13 Supplement:
Revisions and information on later models
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Routine maintenance - all models from June 1991 . . . . . . . . . . . 3
Engine 903 and 1299/1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sump pan sealing strips (903 cc engine) - modification
1299 cc engine - description
Rocker cover (903 cc engine) - removal
Cylinder head (903 cc engine) - refitting
Engine - 999 and 1108 cc (FIRE) . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Part A: General
Description
Part B: Operations possible with engine in car
Valve clearances - adjustment
Timing belt - renewal
Camshaft - removal and refitting
Cylinder head - removal and refitting
Sump pan - removal and refitting
Oil pump - removal, checking and refitting
Pistons/connecting rods - removal and refitting
Pistons/connecting rods - separation and piston ring renewal
Engine/transmission mountings - renewal
Part C: Engine removal and dismantling
Method of removal - general
Engine/transmission - removal and separation
Dismantling - general
Complete dismantling
Examination and renovation
Part D: Engine reassembly and refitting
Reassembly - general
Complete reassembly
Engine/transmission - reconnection and refitting
Initial start-up after major overhaul
Engine 1301 cc Turbo ie.................................................................. 6
Part A: General
Description
Lubrication system - description
Part B: Operations possible with engine in car
Camshaft and camshaft carrier - removal and refitting
Cylinder head - removal and refitting
Piston rings
Engine mountings - renewal
Timing belt - renewal
Oil pump drivegear cover plate
Engine oil cooler - removal and refittingPart C: Engine removal, dismantling, reassembly and refitting
Engine/transmission - removal and separation
Engine - dismantling and reassembly
Engine/transmission - reconnection and refitting
Initial start-up after major overhaul
Engine 1372 cc ie and 1372 cc Turbo ie......................................... 7
Part A: General
Description
Maintenance
Part B: Operations possible with the engine in car
Valve clearances - checking and adjustment
Timing belt, tensioner and sprockets - removal and refitting
Camshaft front oil seal - renewal
Camshaft, housing and followers - removal and refitting
Camshaft housing, camshaft and cam followers - dismantling,
inspection and reassembly
Cylinder head (1372 cc ie engine) - removal and refitting
Cylinder head (1372 cc Turbo ie engine) - removal and refitting
Cylinder head - inspection and renovation
Crankshaft front oil seal - removal and renewal
Crankshaft rear oil seal - removal and renewal
Flywheel - removal, inspection and refitting
Sump - removal and refitting
Oil pump - removal, checking and refitting
Pistons/connecting rods - removal and refitting
Pistons/connecting rods - examination and renovation
Engine/transmission mountings - renewal
Part C: Engine removal and dismantling
Method of removal - general
1372 cc ie engine/transmission - removal and separation
1372 cc Turbo ie engine/transmission - removal and separation
Engine dismantling - general
Auxiliary shaft - removal, inspection and refitting
Engine - complete dismantling
Crankshaft and main bearings - removal
Engine components - examination and renovation
Part D: Engine reassembly
Reassembly - general
Crankshaft and main bearings - refitting
Pistons and connecting rods - refitting
Oil pump - refitting
Sump - refitting
Flywheel - refitting
Auxiliary shaft - refitting
Cylinder head - refitting
Timing belt and covers - refitting
Engine/transmission - reconnection and refitting
Initial start-up after major overhaul
13•1
Contents

Cooling system................................................................................. 8
Part A: 999 cc engine
Description
Maintenance
Thermostat - removal and refitting
Coolant pump - removal and refitting
Part B: 1301 cc Turbo ie engine
Description
Part C: 1372 cc ie and 1372 cc Turbo ie engines
Description
Maintenance
Cooling system - draining, flushing and refilling
Radiator (and cooling fan) - removal and refitting
Thermostat - removal and refitting
Coolant pump - removal and refitting
Coolant pump/alternator drivebelt - checking, renewal and
tensioning
Part D: Heater unit later models
Heater unit - removal and refitting
Heater unit - dismantling and reassembly
Fuel and exhaust systems............................................................... 9
Part A: General
Unleaded fuel
Air cleaner modified types
Fuel pump (999 cc engine) - description, removal and
refitting
Fuel tank (999 cc engine)
Part B: Carburettor models
Carburettor (Weber 32 TLF) - description
Carburettor (Weber 32 TLF) - idle speed and mixture
Carburettor (Weber 32 TLF) - removal and refitting
Carburettor (Weber 32 TLF) - overhaul
Carburettor (Weber 30/32 DMTE) - general
Carburettor (Weber 30/32 DMTE) - overhaul
Carburettor (Weber 32 ICEV 61/250 and DMTE 30/32,
DMTE 30/150) - general
Carburettor (Solex C 30/32-CIC 8) - description
Part C: Bosch LE-2 Jetronic fuel injection system
Description
Maintenance
Fuel filter - renewal
Air cleaner element - renewal
Idle speed and mixture - adjustment
Fuel injection system - electrical tests
Fuel injection system - mechanical tests
Fuel injection system components - removal and
refitting
Throttle control linkage - general
Fuel tank - general
Part D: Bosch Mono-Jetronic fuel injection system
Description
Maintenance
Fuel filter - renewal
Air cleaner element - renewal
Idle speed and mixture adjustment
Accelerator control system - check and adjustment
Fuel system - depressurisation
Fuel pump and supply - system checks
Fuel pump - removal and refitting
Injector unit - removal and refitting
Intake air temperature sensor - removal and refitting
Fuel injector - removal and refitting
Electronic control unit (ECU) - removal and refitting
Inlet manifold - removal and refitting
Exhaust manifold - removal and refitting
Catalytic converter - general information
Fuel evaporation control system - generalPart E: Bosch L3.1/2 Jetronic fuel injection systems
Description
Fuel system - depressurisation
Maintenance
Fuel filter - renewal
Air cleaner element - renewal
Checks and adjustments
Injection system components - removal and refitting
Part G: Turbocharger system
Description
Precautions
Turbocharger (1301 cc ie engine) - removal and refitting
Turbocharger (1372 cc ie engine) - removal and refitting
Intercooler - removal and refitting
Injector cooling fan - removal and refitting
Fault finding - fuel injection system
Fault finding - turbocharger system
Ignition system................................................................................. 10
General
Ignition timing (all later models)
Breakerless ignition system - description
Distributor (breakerless type) - removal and refitting
Distributor (breakerless type) - overhaul
Breakerless ignition system components - testing
Microplex ignition system - description
Distributor (Microplex) - removal and refitting
Microplex ignition system components - testing
Digiplex 2 ignition system - description
Distributor (Digiplex 2) - removal and refitting
Spark plugs and HT leads - general
Fault finding - Microplex ignition system
Clutch................................................................................................ 11
Clutch pedal adjustment (cable clutch)
Hydraulic clutch - description
Maintenance (hydraulic clutch)
Clutch master cylinder - removal, overhaul and
refitting
Clutch operating cylinder - removal, overhaul and
refitting
Clutch hydraulic system - bleeding
Transmission.................................................................................... 12
Part A: 1301 cc Turbo ie engine
Description
Gearchange linkage - removal and refitting
Gearchange linkage (Antiskid models) - general
Final drive output shafts - description and oil seal
renewal
Part B: 1372 cc ie and 1372 cc Turbo ie engines
Description
Maintenance
Oil level - checking
Oil - renewal
Gearlever and linkages - general
Transmission - removal and refitting
Part C: 999 and 1108 cc with C514 type transmission
Description
Maintenance
Driveshafts........................................................................................ 13
Inboard joint boots (non-Turbo models, September 1987 on) -
modification
Intermediate driveshaft (Turbo ie models)
Inboard CV joints (Turbo ie models - overhaul
Right-hand driveshaft damper weight (1108 and 1372 cc
models) - removal and refitting
13•2 Supplement: Revisions and information on later models

View of front end from below on
the 999 cc FIRE engined model
1 Left hand front engine mounting
2 Transmission
3 Track control arm
4 Driveshaft
5 Left hand rear (lower) engine
mounting
6 Gearchange rods
7 Exhaust pipe
8 Oil filter cartridge
9 Brake caliper
10 Sump pan drain plug
View of engine compartment on
the 1301 cc Turbo ie engined
model
1 Alternator air cooling intake
2 Washer fluid reservoir cap
3 Suspension strut turret
4 Secondary fuel filter
5 Fuel supply hose
6 Coolant expansion tank
7 Brake fluid reservoir cap
8 Ignition system ECU
9 Inlet manifold
10 Excessive pressure switch
11 Air cleaner
12 Timing belt cover
13 Fuel pressure regulator
14 Airflow meter
15 Throttle position switch
16 Air intake duct
17 Air intake to throttle valve
housing
18 Engine oil filler cap
19 Radiator cooling fan
20 Headlamp dim-dip transformer
21 Intercooler air duct
22 Ignition distributor
23 Headlamp
24 Main idle speed adjusting screw
25 Base setting idle speed screw
13•6 Supplement: Revisions and information on later models

Supplement: Revisions and information on later models 13•7
View of engine compartment (air
cleaner removed) on the
1372 cc ie engined model
1 Engine oil level dipstick
2 Timing belt cover
3 Engine mounting (right-hand)
4 Clutch master cylinder fluid
reservoir
5 Fuel supply and return hoses
6 Injection unit
7 Inlet manifold
8 Washer reservoir
9 Brake master cylinder and fluid
reservoir
10 Injection system fuse/relay block
11 Suspension strut turret
12 Ignition coil
13 Ignition system ECU
14 Battery
15 Coolant filter expansion tank
16 Ignition distributor
17 Radiator cooling fan
18 Engine oil filler cap
19 Starter motor
20 Oil filter
View of front end from below on
the 1031 cc Turbo ie engined
model
1 Anti-roll bar
2 Exhaust pipe
3 Track control arm
4 Engine centre mounting
5 Gearchange rods
6 Brake caliper
7 Left-hand driveshaft
8 Intermediate driveshaft
9 Right-hand driveshaft
10 Transmission
11 Engine oil drain plug
12 Auxiliary lamp
13 Horn
14 Intercooler
15 Starter motor
16 Oil filter cartridge
17 Oil pressure sender unit
18 Engine oil cooler
19 Right-hand underwing shield
20 Left-hand underwing shield
13

Lubrication system
Oil pump type:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear driven from front of crankshaft.
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump operated from front of crankshaft. Oil pressure relief valve in
front cover.
Tooth tip-to-body clearance (999/1108 cc) . . . . . . . . . . . . . . . . . . . . . . 0.080 to 0.186 mm
Gear endfloat:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 to 0.056 mm
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 to 0.106 mm
Oil pressure (at normal operating temperature) . . . . . . . . . . . . . . . . . . . 3.4 to 4.9 bars
Oil filter:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion F107
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C106
Torque wrench settingsNm lbf ft
Auxiliary shaft sprocket bolt (1372 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . 83 62
Big-end cap bolts:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 30
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 38
Camshaft bearing cap bolts:
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 14
M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Camshaft cover screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Camshaft housing to lower cylinder head securing bolt (1372 cc) . . . . . 20 15
Camshaft housing to inlet manifold bracket bolt (1372 cc) . . . . . . . . . . 25 18
Camshaft sprocket bolt
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 50
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 62
Centre mounting to final drive casing bracket (1201/1301 cc) . . . . . . . . 23 17
Coolant temperature switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Crankshaft pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Crankshaft pulley nut (1372 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 145
Crankshaft rear oil seal retainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Crankshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 58
13•8 Supplement: Revisions and information on later models
View of front end from below on
the 1372 cc ie engine model
1 Oil filter
2 Engine oil drain plug
3 Starter motor
4 Horns
5 Transmission front mounting
6 Front fog lamp and adjuster
7 Driveshaft
8 Transmission rear mounting
9 Gearchange linkage
10 Exhaust downpipe and system
joint
11 Anti-roll bar
12 Track control arm
13 Tie-rod balljoint
14 Brake unit
15 Driveshaft damper
16 Underwing shield