1983 FIAT UNO belt

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.

3 Alternator-
maintenance and precautions
1
To avoid damage to the alternator, the
following precautions should be observed.
1Disconnect the leads from the battery
before connecting a mains charger to the
battery terminals.
2Never stop the engine by pulling off one of
the battery leads.
3Disconnect the battery if electric welding is
to be carried out on the vehicle.
4If using booster cables from another battery
to start the car, make sure that they are
connected positive to positive and negative to
negative.
5Maintenance consists of keeping the
outside of the alternator clean, the electrical
connections secure and the drivebelt correctly
tensioned, see Chapter 2, Section 8.
4 Alternator-
removal and refitting
1
Note: Depending on the model, access to the
alternator from above may be poor in which
case it will be necessary to work from the
underside of the vehicle, through the
right-hand wheel arch (after removing the
roadwheel and the lower undershield). Refer
to Chapter 13 for details.
1Disconnect the leads from the rear of the
alternator.2Release the mounting and adjuster link nuts
and push the alternator as far as it will go in
towards the engine (photos).
3Slip the drivebelt from the pulley.
4Remove the mounting and adjuster bolts
and lift the alternator from the brackets on the
engine. Remove downwards on 1116 cc and
1301 cc models.
5Refitting is a reversal of removal, tension
the drivebelt as described in Chapter 2,
Section 8.
5 Alternator- overhaul
3
1Overhaul of the alternator should be limited
to renewal of the brushes. If the unit has
covered a high mileage, it will be found moreeconomical to exchange it for a new or
factory-reconditioned one, rather than renew
worn components on the original unit.
Brush renewal
(Marelli alternator)
2Unscrew the nuts and take off the rear cover.
3Unscrew the two small bolts and withdraw
the brush holder (photos).
4Fit the new brush holder which is supplied
complete with brushes, by reversing the
removal operations.
Brush renewal
(Bosch alternator)
5Where applicable, remove the radio
suppression condenser (capacitor) from the
rear end frame (one screw and washer, and a
plug-in connection).
6Undo the two screws which retain the brush
holder to the rear frame of the alternator, then
Electrical system 9•3
5.3A Alternator brush holder bolt4.2B Alternator adjuster bolt4.2A Alternator mounting
Fig. 9.1 Exploded view of typical alternator (Sec 5)
1 Pulley
2 Fan
3 Bolts
4 Washers
5 Drive-end bracket
6 Stator windings
7 Plate screw
8 Diode plate
(rectifier pack)9 Body
10 Brush
11 Spring
12 Brush holder
13 Condenser
14 Screws and
washers
15 Screws and
washers16 Screws and
washers
17 Plug socket
18 Suppressor
19 Shaft nut
20 Spring washer
21 Thrust ring
22 Bearing
23 Retainer plate24 Thrust ring
25 Spring washer
26 Screw and washer
27 Key
28 Rotor
29 Bearing
30 Backing washer
31 Shield (where
applicable)
5.3B Removing alternator brush holder
9

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

12
For dimensions, weights etc. refer to the Introductory Section of this Manual.
Chapter 12 Bodywork
For modifications, and information applicable to later models, see Supplement at end of manual
Bonnet - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bonnet - lock and release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Centre console - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 21
Door - dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Door - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Door trim panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 11
Facia panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fixed side window (five-door) - removal and refitting . . . . . . . . . . . . 17
Front bumpers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 9
Front seat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Front wing - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Grab handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maintenance - bodywork and underframe . . . . . . . . . . . . . . . . . . . . 2Maintenance - upholstery and carpets . . . . . . . . . . . . . . . . . . . . . . . 3
Major body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Minor body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Opening side window (three-door) - removal and refitting . . . . . . . . 18
Radiator grille - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 6
Rear bumpers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 26
Rear seat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rear view mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Roof rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Sunroof - operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . 28
Tailgate - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tailgate glass - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 16
Windscreen glass - removal and refitting . . . . . . . . . . . . . . . . . . . . . 15
12•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
1 General description
The Uno is an all steel, welded Hatchback
of unitary construction available in three- or
five-door versions.
Various levels of trim and equipment are
available depending upon model.
Factory fitted options include a sunroof,
central door locking and electrically-operated
front windows.
2 Maintenance-
bodywork and underframe
1
The general condition of a vehicle’s
bodywork is the one thing that significantly
affects its value. Maintenance is easy, but
needs to be regular. Neglect, particularly after
minor damage, can lead quickly to further
deterioration and costly repair bills. It is
important also to keep watch on those parts
of the vehicle not immediately visible, for
instance the underside, inside all the wheel
arches, and the lower part of the engine
compartment.The basic maintenance routine for the
bodywork is washing - preferably with a lot of
water, from a hose. This will remove all the
loose solids which may have stuck to the
vehicle. It is important to flush these off in
such a way as to prevent grit from scratching
the finish. The wheel arches and underframe
need washing in the same way, to remove any
accumulated mud, which will retain moisture
and tend to encourage rust. Paradoxically
enough, the best time to clean the underframe
and wheel arches is in wet weather, when the
mud is thoroughly wet and soft. In very wet
weather, the underframe is usually cleaned of
large accumulations automatically, and this is
a good time for inspection.
Periodically, except on vehicles with a wax-
based underbody protective coating, it is a
good idea to have the whole of the
underframe of the vehicle steam-cleaned,
engine compartment included, so that a
thorough inspection can be carried out to see
what minor repairs and renovations are
necessary. Steam-cleaning is available at
many garages, and is necessary for the
removal of the accumulation of oily grime,
which sometimes is allowed to become thick
in certain areas. If steam-cleaning facilities are
not available, there are some excellent grease
solvents available which can be brush-applied; the dirt can then be simply hosed off.
Note that these methods should not be used
on vehicles with wax-based underbody
protective coating, or the coating will be
removed. Such vehicles should be inspected
annually, preferably just prior to Winter, when
the underbody should be washed down, and
any damage to the wax coating repaired.
Ideally, a completely fresh coat should be
applied. It would also be worth considering
the use of such wax-based protection for
injection into door panels, sills, box sections,
etc, as an additional safeguard against rust
damage, where such protection is not
provided by the vehicle manufacturer.
After washing paintwork, wipe off with a
chamois leather to give an unspotted clear
finish. A coat of clear protective wax polish
will give added protection against chemical
pollutants in the air. If the paintwork sheen
has dulled or oxidised, use a cleaner/polisher
combination to restore the brilliance of the
shine. This requires a little effort, but such
dulling is usually caused because regular
washing has been neglected. Care needs to
be taken with metallic paintwork, as special
non-abrasive cleaner/polisher is required to
avoid damage to the finish. Always check that
the door and ventilator opening drain holes
and pipes are completely clear, so that water

4Reach up behind the facia panel on the side
opposite to the glove box and unscrew the
remaining console fixing screw.
5Withdraw the console downwards and
disconnect the fibre optics from their source.
6Refitting is a reversal of removal.
22 Facia panel-
removal and refitting
1
1Remove the instrument panel as described
in Chapter 9.
2Remove the steering wheel (Chapter 10). 3Disconnect the choke control lever and
cable from the facia panel as described in
Chapter 3.
4Remove the screws arrowed in Fig. 12.19.
5Remove the facia fixing screws, their
locations on the facia are shown in Fig. 12.20.
Screw (3) is inside the glove box (photos).
6Release the facia from the upper clips and
withdraw it.
7Refitting is a reversal of removal.23 Seat belts
1
1Seat belts are fitted as standard equipment
to both the front and rear seats.
2Regularly inspect the belts for fraying and if
evident, renew the belt.
3The front belt reel may be unbolted if the
seat is pushed fully forward and the reel cover
panel removed (photo).
4The rear belt reels are located at each side
of the luggage area (photo).
5When removing or refitting a belt from its
anchorage point, it is essential to maintain the
original fitted sequence of spacer, washer and
wave washer otherwise the belt anchor plate
will not swivel (photo).
23.4 Rear seat belt reel
23.3 Front seat belt lower
mounting
12•10 Bodywork
23.5 Front seat belt upper
mounting
Fig. 12.20 Rear view of facia panel showing fixing screw locations (Sec 22)
1 and 5 Clips 2, 3 and 4 Screws22.5C Facia panel lower mounting screw
(left-hand side)
22.5B Facia panel lower mounting screw at
centre console22.5A Facia fixing screw inside gloveboxFig. 12.19 Facia panel fixing screws (Sec
22)

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