1983 FIAT UNO wheel torque

Torque wrench settings (continued)Nm lbf ft
Cylinder head bolts:
903 cc (from engine number 581470), 999 and 1108 cc:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
1299/1301 cc (10 main bolts):
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
1299/1301 cc (4 next to spark plug holes) . . . . . . . . . . . . . . . . . . . . . 30 22
1372 cc (M10):
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
1372 cc (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Engine mounting bracket body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Engine mounting bracket-to-body bolt (1299/1301 cc) . . . . . . . . . . . . . 48 35
Engine mounting bracket-to-transmission nut (1299/1301 cc) . . . . . . . 85 63
Engine mounting nuts:
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 42
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Engine mountings to brackets (1299/1301 cc) . . . . . . . . . . . . . . . . . . . . 23 17
Engine mounting to engine and transmission (999/1108 cc) . . . . . . . . . 60 44
Engine mounting-to-engine bracket bolt (1299/1301 cc) . . . . . . . . . . . 85 63
Flywheel bolts:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 32
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 62
Ignition distributor cover (in crankcase) bolt (1372 cc) * . . . . . . . . . . . . 25 18
Main bearing cap bolts:
999/1108 cc:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another 90º
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59
Manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 20
Mounting bracket to final drive casing (1299/1301 cc) . . . . . . . . . . . . . 95 70
Oil pressure sender unit (1372 cc) * . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 28
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 23
Oil pump backplate screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5
Oil pump mounting bolts:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
1372 cc * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Oil pump shaft driven gear bolt (1372 cc ie only) . . . . . . . . . . . . . . . . . . 83 61
Oil temperature sender unit (1372 cc) * . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
Sump pan fixing screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Timing belt tensioner nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 20
Turbine-to-exhaust manifold and head nut * . . . . . . . . . . . . . . . . . . . . . 29 21
Water pump-to-crankcase bolt (1372 cc) * . . . . . . . . . . . . . . . . . . . . . . 25 18
* Turbo models only
Cooling system
General
Thermostat:
Begins to open:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 90ºC
1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 to 82ºC
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 to 84ºC
Fully open:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100ºC
1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95ºC
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96ºC
Expansion tank pressure cap rating:
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.98 bar
Supplement: Revisions and information on later models 13•9
13

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

Fuses (903, 999, 1116, 1299/1301 and 1301 cc Turbo ie) (continued)
Fuse No. Rating Circuit
Supplementary fuses at side of main fuse block:
A 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front fog lamps
B 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling fan (Turbo ie models)
C 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injector cooling fan (Turbo ie models)
D 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric windows
E 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump (Turbo ie models)
Fuses (later 903, 999, 1108, 1372 ie and 1372 cc Turbo ie)
Fuse Rating Circuit
1 7.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH tail, RH front parking, rear number plate lamps and check panel
2 7.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH tail, LH front parking, cigar lighter illumination, clock light, heater
control illumination and map reading light
3 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH headlamp main beam
4 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH headlamp main beam and warning light
5 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator cooling fan (except Turbo ie models) and horn
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
9 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear fog lamp and warning lamp
10 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated rear screen and warning lamp
11 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel, stop-lamps, direction indicators, reversing lamps,
warning module and carburettor cut-off (FIRE models only)
12 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater fan, heater/ventilation control illumination lights and digital
clock light
13 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen wiper, windscreen washer pump and rear wiper/washer
(where fitted)
14 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horns and relay
15 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard warning light and indicator light
Supplementary fuses at side of main fuse block:
A 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric windows
B 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central locking (where fitted)
C 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector cooling fan (where fitted)
D 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlamp washers (where fitted)
E 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foglamp and warning lamp
F - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare
G 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump (fuel injection models)
-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated Lambda sensor
Supplementary fuses on steering column relay bracket:
-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antiskid monitor circuit (where fitted)
-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antiskid supply circuit (where fitted)
Steering and suspension
General
1301 cc Turbo ie
Castor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1º 55’ to 2º 35’ positive
Number of turns of steering wheel, lock-to-lock . . . . . . . . . . . . . . . . . . 3.42
Later models
Steering angles:
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -30’ ± 30’
Castor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2º10’ ± 15’
Toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 2.0 mm
1301/1372 cc Turbo ie
Steering angles of roadwheels:
Inner wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36º 43’
Outer wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31º 27’
Torque wrench settingsNm lbf ft
Anti-roll bar clamp bolts (1301 and 1372 cc Turbo ie) . . . . . . . . . . . . . . 25 18
Anti-roll bar end fixing nuts (1301 and 1372 cc Turbo ie) . . . . . . . . . . . 15 11
13•16 Supplement: Revisions and information on later models

Sump pan -
removal and refitting Á
60Drain the engine oil.
61Unbolt and remove the cover plate from
the lower part of the flywheel housing (photo).
The two lower bolts retain the gearchange rod
support strut.
62Unscrew the sump pan securing screws
and pull the sump pan downwards to remove
it (photo). The joint sealant will require cutting
with a sharp knife to release the pan. Clean
away all old gasket material.
63A bead 3.0 mm in diameter of RTV
silicone instant gasket should be applied to
the sump pan flange and then the pan offered
up. Screw in the fixing screws and tighten to
the specified torque. Note the flange end
fixing screw nuts (photos).64Wait one hour before filling with engine oil.
65Refit the flywheel housing cover plate.Oil pump - removal,
checking and refitting#
66Drain the engine oil and remove the sump
pan as described in the last sub-Section.
Unscrew and remove the oil filter cartridge.
67Remove the timing belt.
68Lock the crankshaft against rotation either
by placing a block of wood between a
crankshaft web and the inside of the
crankcase or by jamming the flywheel starter
ring gear with a suitable tool.
69Unscrew and remove the crankshaft
sprocket bolt and take off the timing belt
sprocket. If it is tight, use two screwdrivers to
lever it off or use a two- or three-legged puller.
70Unbolt and remove the oil pick-up/filter
screen assembly. Note the sealing washer.71Extract the oil pump fixing bolts and
withdraw the pump.
72The oil pump incorporates a pressure
relief valve which can be removed for
examination by depressing the spring plunger
and pulling out the keeper plate (photos).
73If pump wear is suspected, check the
gears in the following way. Extract the fixing
screws and remove the rear cover plate. The
screws are very tight and will probably require
the use of an impact driver to release them
(photo).
74Check the clearance between the outer
gear and the pump housing using feeler
blades, and also the gear endfloat by placing
a straight-edge across the pump body and
checking the gap between the straight-edge
and gear face. If the clearances are outside
the specified tolerance, renew the oil pump
complete (photos).
13•24 Supplement: Revisions and information on later models
5B.74B Checking the oil pump gear
endfloat5B.74A Checking the oil pump gear-to-
housing clearance5B.73 Removing the oil pump rear cover
plate screws
5B.72B Oil pump relief valve components5B.72A Removing the oil pump relief valve
keeper plate5B.63B Sump pan flange end fixing screw
and nut
5B.63A Tightening a sump pan screw5B.62 Removing the sump pan5B.61 Removing the flywheel housing
cover plate

6Fit the main bearing caps in their numbered
sequence and the correct way round (photo).
7Clean the threads of the main bearing cap
bolts, lightly oil them and screw them in
finger-tight. Tighten all bolts progressively to
the specified torque, then check that the
crankshaft turns smoothly and evenly
(photos).
8Now check the crankshaft endfloat. Do this
using a dial gauge or feeler blades inserted
between the machined shoulder of a journal
and the side of the bearing cap (photo). Move
the crankshaft fully in one direction and then
the other to ensure that full movement is
obtained. If the endfloat is outside the
specified tolerance and new bearing shellshave been fitted, then a fault must have
occurred during crankshaft regrinding.
9Fit a new oil seal to the crankshaft rear oil
seal retainer. Apply grease to the seal lips. A
conventional gasket is not used at the oil seal
joint face but a 3.0 mm diameter bead of RTV
silicone instant gasket must be applied
to a clean surface as shown in Fig. 13.9
(photo).
10Bolt the retainer into position. One hour at
least must be allowed for the RTV to cure
before oil contacts it.
11Turn the engine on its side and fit the
piston/connecting rods as described in
sub-Section B.
12Fit a new oil seal to the oil pump, oil theseal lips and bolt on the pump using a new
joint gasket (photos).
13Use a new sealing washer and fit the oil
pick-up/filter screen assembly.
14Fit the engine rear plate and then the
flywheel on its mounting flange. Apply
thread-locking fluid to (clean) bolt threads and
screw in the bolts to the specified torque
(photo). Hold the flywheel against rotation by
locking the starter ring gear with a suitable
tool.
15Fit the sump pan as described in
sub-Section B.
16Fit the crankshaft sprocket so that the
timing mark is visible. Lock the flywheel
starter ring gear teeth, and screw in and
Supplement: Revisions and information on later models 13•31
5D.7B Angle-tightening a main bearing cap
bolt5D.7A Initial tightening of a main bearing
cap bolt5D.6 Fitting a main bearing cap
5D.14 Tightening a flywheel bolt5D.12B Tightening an oil pump bolt5D.12A Oil pump gasket
5D.9 Fitting crankshaft rear oil seal
retainerFig. 13.9 Application area for silicone
gasket on crankshaft rear oil seal retainer
(Sec 5D)5D.8 Checking crankshaft endfloat using a
dial gauge
13

tighten the sprocket bolt to the specified
torque (photos).
17Refit the clutch to the flywheel asdescribed in Chapter 5. Make sure that the
driven plate is centralised.
18Fit the cylinder head.
19Refit the coolant pump. A conventional
gasket is not used at the joint face, but apply
a continuous bead of RTV silicone instant
gasket 3.0 mm in diameter to the pump
mating surface. Allow at least one hour for
curing before permitting coolant to contact it.
20Fit the timing belt rear cover, then the
timing belt tensioner and lock in its retracted
position (photo).
21Fit and tension the timing belt as
described in sub-Section B.
22Bolt on the crankshaft pulley (photo).
23Refit the alternator and drivebelt (photo).
24Refit the engine oil dipstick.
25Using a new gasket, bolt on the inletmanifold, tightening the nuts to the specified
torque (photos).
26Refit the carburettor, or throttle body, as
appropriate.
27Fit the fuel pump, insulator block and
actuating rod, if applicable. Make sure that a
new gasket is placed on each side of the
pump insulator block.
28Using a new gasket, bolt on the
thermostat housing.
29Oil the sealing ring of a new oil filter
cartridge and screw it into position using hand
pressure only (photo).
30Refit the coolant distribution pipe to the
rear of the coolant pump. Use a new seal
(photo).
31Using a new gasket, bolt on the exhaust
manifold (photo).
13•32 Supplement: Revisions and information on later models
5D.31 Exhaust manifold5D.30 Coolant distribution pipe5D.29 Oil filter cartridge and mounting
base
5D.25B Fitting the inlet manifold5D.25A Inlet manifold gasket5D.23 Alternator and drivebelt
5D.22 Crankshaft pulley installation
5D.20 Fitting the timing belt rear cover5D.16B Tightening the crankshaft sprocket
bolt5D.16A Crankshaft sprocket showing
integral key

32Fit the hot air collector plate for the air
cleaner (photo).
33Refer to Section 10 and fit the distributor.
34Bolt on the timing belt cover.
35Fit the camshaft cover, using a new
gasket unless the original one is in perfect
condition.
Engine/transmission -
reconnection and refitting#
36Locate the engine in an upright position
on wooden blocks to allow for the greater
depth of the transmission flywheel housing
when it is joined to the engine.
37Make sure that the clutch driven plate has
been centralised, offer the transmission to the
engine and locate the flywheel housing on the
single stud and dowels.
38Tighten the connecting bolts to specifiedtorque, having located the lifting eye (photo).
39Bolt on the starter motor.
40Refit the cover plate to the flywheel
housing, but do not insert the lower bolts at
this stage as they retain the support bracket
for the gearchange rod.
41The engine and transmission are now
ready for refitting. The operations are a direct
reversal of the operations described earlier,
but observe the following points.
42Have the engine/transmission perfectly
horizontal and suspended on the hoist.
43Lower it into position very slowly until it is
possible to engage the driveshaft inboard
joints with the transmission.
44Continue lowering until the driveshafts
can be fully engaged and the mountings
reconnected. Remove the hoist.
45Tighten all nuts and bolts to the specifiedtorque. Note the method shown for
connecting the gearchange rod ball socket
using pliers (photo).
46Refill the engine with oil and coolant and
replenish the transmission oil.
Initial start-up after major
overhaul
47Refer to Chapter 1, Section 45.
6 Engine-
1301 cc Turbo ie
PART A: GENERAL
Description
1This engine is similar in design to the
1301 cc engine described in Chapter 1, but
the fuel and ignition systems are different, and
a turbocharger, oil cooler and intercooler are
fitted.
2Many dimensions and tolerances have
been altered for this engine, and reference
should be made to the Specifications at the
beginning of this Supplement.
3Operations which differ from those
described in Chapter 1 are given in the
following sub-Sections.
Lubrication system - description
4The lubrication system differs from the
non-Turbo 1301 cc engine in the following
respects.
5An oil cooler is fitted, which comprises a
matrix with inlet and outlet hoses connected
to the oil filter cartridge mounting base.
6A thermostatic control switch is fitted,
which diverts the oil flow through the matrix
only at oil temperatures above 84ºC (183ºF).
Note that a faulty switch will require renewal
of the complete oil filter mounting base.
7Special oil spray nozzles are located in the
crankcase main bearing webs, to cool the
underside of the pistons.
8The ball-type valves in the nozzles open
when the engine oil pressure reaches 1.2 bars
(17.4 lbf/in
2).
9An oil pressure sender unit is screwed into
Supplement: Revisions and information on later models 13•33
5D.45 Connecting ball socket type
gearchange rod5D.38 Lifting eye on flywheel housing
flange5D.32 Air cleaner hot air collector plate
Fig. 13.10 Cutaway view of the 1301 cc Turbo ie engine (Sec 6A)
13

Engine oil cooler -
removal and refittingÁ
23The oil cooler is mounted behind the front
bumper/spoiler (photo).
24Disconnect the oil flow and return hoses,
either from the cooler or the oil filter cartridge
mounting base. Be prepared for some
leakage of oil (photos).
25Unscrew the mounting bolts and remove
the oil cooler heat exchanger (photo).
26When refitting, make sure that the banjo
union sealing washers are in good condition.
PART C: ENGINE REMOVAL,
DISMANTLING, REASSEMBLY
AND REFITTING
Engine/transmission -
removal and separation
#
Warning: Refer to the beginning
of Section 9 before starting any
work.
1Refer to Chapter 1, Section 35, and carry
out the operations described in paragraphs 1
to 11.
2Disconnect the excessive air pressure
switch from the inlet manifold.
3Disconnect the ducts and remove the
airflow meter.
4Disconnect the leads from the spark plugs
and the distributor LT connector, and unbolt
and remove the distributor from the rear end
of the camshaft carrier.
5Disconnect the fuel return hose from the
pressure regulator. 6Disconnect the fuel inlet hose from the
injector rail.
7Disconnect the wiring plugs from the fuel
injectors.
8Disconnect the leads from the oil pressure
sender unit, the low oil pressure switch and
the coolant temperature switch.
9Remove the hose/pipe assemblies from the
intercooler.
10Disconnect the throttle control rod at the
balljoint.
11Disconnect the hoses and ducts from the
turbocharger and the mechanical bypass
valve.
12Disconnect the leads from the engine
speed and anti-knock sensors.
13Raise the front of the car and support it
securely. As the engine/transmission will
eventually be lowered to the floor, make sure
that there is sufficient clearance under the
front end for the assembly to be withdrawn. If
the car is over an inspection pit, then the car
need only be raised enough to lift the
roadwheels from the floor.
14Remove the front roadwheels.
15Disconnect the transmission earth cable.
16Working under the car, remove the engine
shields from under the wheel arches.
17Remove the engine oil cooler, and the
intercooler.
18Unscrew the fixing screws and disconnect
the driveshafts from the flanges at the
transmission final drive. The right-hand
driveshaft will not release until the upper bolt
on the suspension strut-to-hub carrier clamphas been removed, and the hub assembly
tilted downwards.
19Disconnect the exhaust downpipe from
the manifold, and then remove the front
section of the exhaust system.
20Disconnect the coolant return pipe from
the turbocharger.
21Disconnect the gearchange control rods
from the transmission selector rod. Do this by
unscrewing the self-locking nut from the bolt
which connects the clevis fork.
22Attach suitable lifting gear to the engine
lifting eyes, and take the weight of the
engine/transmission.
23Disconnect the left-front, centre-rear and
the right-hand engine/transmission mountings.
Do this by removing the bolts from the
diamond-shaped mounting plates there is no
need to disturb the flexible mounting centre
bolts.
24Lower the engine/transmission to the floor
and withdraw it from under the car.
25Carry out the operations described in
Chapter 1, Section 35, paragraphs 27 to 31.
Engine dismantling and
reassembly
26The operations are essentially as
described for the 1301 cc engine in Chapter 1,
but reference must be made to Sections 9
and 10 of this Chapter for the procedures for
removing and refitting the components of the
fuel injection, turbocharger and ignition
systems.
Engine/transmission -
reconnection and refitting
27The operations are a reversal of those
described in paragraphs 1 to 25, but
otherwise the following (photo).
a) Tighten all nuts and bolts to the specified
torque.
b) Use a new gasket at the exhaust
downpipe-to-manifold flange.
c) Check and adjust the clutch pedal travel.
d) Refill the cooling system.
e) Refill the engine and transmission with oil.
f) Reconnect the battery, negative lead
last.
13•36 Supplement: Revisions and information on later models
6C.27 Filling the engine with oil6B.25 Oil cooler mounting bolts (arrowed)
6B.24B Connections at oil filter cartridge
mounting base6B.24A Oil cooler pipe connection
(arrowed)6B.23 Oil cooler