1983 FIAT UNO coolant

Cooling system (continued)
Radiator fan cut-in temperature:
1301 cc Turbo ie:
1st speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 to 90ºC
2nd speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 94ºC
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 94ºC
Radiator fan switch-off temperature:
1301 cc Turbo ie:
1st speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 to 85ºC
2nd speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC
Coolant pump/alternator drivebelt tension:
1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 10 mm deflection midway between crankshaft and
alternator pulleys under firm thumb pressure
Torque wrench settingsNm lbf ft
Coolant pump mounting bolts (999/1108 cc) . . . . . . . . . . . . . . . . . . . . . 8 6
Coolant pump to crankcase (1372 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Coolant temperature gauge sender unit (1372 cc ie) . . . . . . . . . . . . . . . 30 22
Coolant temperature sender unit (1372 cc) . . . . . . . . . . . . . . . . . . . . . . 27 20
Fan thermostatic switch (1372 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Thermal valve on inlet manifold (1372 cc):
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Water pump cover (1372 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
Fuel system
General
Air cleaner element
999 cc and 1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U520
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U533
1301/1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U522
Fuel filter:
999 cc and 1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L101
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L201
1301/1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L203
Carburettor calibration
Weber 32 ICEV 61/250 TLF 4/250
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903 cc 999 cc
Accelerator pump capacity (for 10 strokes) . . . . . . . . . . . . . . . . . . . . . . 3.8 to 6.3 cc -
Air bleed jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 mm 50/90
Air compensating jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 165
Air idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.60 mm -
Anti-flooding device (choke valve plate gap) . . . . . . . . . . . . . . . . . . . . . - 4.0 to 5.0 mm
Auxiliary venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 mm -
Fast idle (throttle valve plate gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 0.65 to 0.75 mm
Float level (with gasket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.75 mm 26.75 to 27.25 mm
Full power jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm 50
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F74 F70
Exhaust gas CO at idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 2.0% 1.0 to 2.0%
Idle air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 50/90
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.47 mm 47
Idle mixture adjustment port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm -
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 800 rpm 750 to 800 rpm
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 mm 105
Needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm 1.5 mm
Pump jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm 35
Pump outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm -
Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 mm 22 mm
Weber 32 TLF 4/252 (and 251) TLF 27/251
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 999 cc 1108 cc
Accelerator pump capacity (for 10 strokes) . . . . . . . . . . . . . . . . . . . . . . 8 to 12 cc 8 to 12 cc
Air bleed jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.65 mm 1.65 mm
Air idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm 0.50 mm
Auxiliary venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 mm 4.5 mm
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F70 F70
13•10 Supplement: Revisions and information on later models

Weber 30/32 DMTE 12/150
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1299/1301 cc
All calibration as for the Weber 30/32 DMTE 10/150 except for the following:
Primary Secondary
Accelerator pump jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 45
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 1.75
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 70
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.90 0.97
Fuel injection systems
System type:
999/1108 cc ie (from 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch Mono-Jetronic SPi with catalyst
1301 Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch LE2 Jetronic MPi
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch Mono-Jetronic SPi
1372 cc Turbo ie (up to 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch L3.1 Jetronic MPi
1372 cc Turbo ie (from 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch L3.2 Jetronic MPi with catalyst
Fuel pump:
All fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric
Fuel pressure:
999/1108/1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 to 1.10 bars
1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 bars
1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 bars maximum
Fuel octane rating:
Without catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 RON minimum (unleaded or leaded)
With catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RON minimum (unleaded only)
Idle speed:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 ± 50 rpm
1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 ± 50 rpm
1372 cc ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 ± 50 rpm
1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825 ± 25 rpm
Exhaust gas CO at idle:
999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 0.35%
1301 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5%
1372 cc Turbo ie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 to 1.8%
Torque wrench settingsNm lbf ft
Coolant pipe bolt to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Coolant pipe union nut to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . 38 28
Exhaust bracket nuts and bolts (999/1108 cc) . . . . . . . . . . . . . . . . . . . . 23 17
Exhaust manifold flange nut (1372 cc models) . . . . . . . . . . . . . . . . . . . . 18 13
Exhaust manifold to crankcase bracket (1372 cc) . . . . . . . . . . . . . . . . . 25 18
Exhaust manifold to cylinder head (1372 cc) . . . . . . . . . . . . . . . . . . . . . 25 18
Exhaust pipe flange-to-manifold nuts (999/1108 cc) . . . . . . . . . . . . . . . 18 13
Fuel pump mounting bolts (999/1108 cc) . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Fuel pump unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
Fuel pressure regulator nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 35
Inlet and exhaust manifold to cylinder head nuts (999/1108 cc) . . . . . . 27 20
Rear exhaust pipe/silencer mounting bracket nut . . . . . . . . . . . . . . . . . 24 18
Turbocharger-to-exhaust manifold-and-cylinder head nut . . . . . . . . . . 28 21
Ignition system
“Breakerless” (999, 1108, 1116, 1299/1301 cc)
General
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic impulse generator electronic
Spark plug type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC9YCC or RC9YC
Spark plug electrode gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm
HT lead type (999 and 1108 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-20
Component testing values
Magnetic impulse generator resistance:
Models with Marelli distributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758 to 872 ohms
Models with the Ducellier distributor . . . . . . . . . . . . . . . . . . . . . . . . . 171 to 209 ohms
Ignition coil resistance at 20ºC (68ºF):
Models with BA506A coil:
Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.756 to 0.924 ohms
Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3330 to 4070 ohms
Models with BA506D coil:
Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.666 to 0.814 ohms
Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2970 to 3630 ohms
13•12 Supplement: Revisions and information on later models

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.

4 Engine-
903 and 1299/1301 cc
Sump pan sealing strips (903 cc
engine) - modification
1The design of the sealing strips which go
between the sump pan and the main bearing
caps has been changed. Make sure that the
narrower side of the strip fits into the channel
in the sump pan.
1299 cc engine - description
2In April 1984, a 1299 cc engine was
introduced, progressively replacing the
1301 cc units used previously. The new
engine is identical to the 1301 cc engine
described in Chapter 1, with the exception of
having a slightly shorter stroke.
3However, as of approximately September
1987, the 1299 cc unit was phased out, being
progressively replaced by the 1301 cc engine
used initially.
4As mentioned above, the two engines are
all but identical, so identification of the unit
fitted should not be necessary in practice.
Consult a FIAT dealer if in doubt.
Rocker cover (903 cc engine) -
removal
5Before removing the rocker cover, it will be
necessary to remove the distributor, first.
Refer to Chapter 4 for more details.
Cylinder head (903 cc engine) -
refitting
6Modified cylinder head bolts are fitted to
903 cc models, from engine number 8581470.
When refitting the cylinder head, tighten each
head bolt, as described in Chapter 1, by the
torques and angles shown the Specifications
in this Chapter.
5 Engine-
999 and 1108 cc (FIRE)
Note:Later models are fitted with SPi fuel
injection. Where a procedure refers to a
carburettor, if applicable, replace with throttle
body.
PART A: GENERAL
Description
1Both of these engine types are designated
FIRE (Fully Integrated Robotised Engine),
being largely manufactured and assembled by
computer-controlled mechanical robots.
2The engine is of oversquare design, having
four cylinders and a belt-driven overhead
camshaft.
3The high torque of this engine enableshigher gear ratios to be used with the result
that fuel economy is exceptionally good.
4The cylinder head is of light alloy, while the
cylinder block is cast-iron.
5The camshaft is supported in three
bearings which have detachable caps.
6Valve clearances are maintained by shims
located in the cam followers (tappets).
7The cylinder head is of crossflow type
having the intake manifold (coolant-heated)
and exhaust manifold on opposite sides.
8The pistons have two compression rings
and one oil control ring and are connected to
the connecting rods by means of a gudgeon
pin which is an interference fit in the rod
small-end.
9The crankshaft is supported in five main
bearings. The upper section of the centre
bearing shell retains semi-circular thrust
washers to control crankshaft endfloat.
10The oil pump, which is of gear type, is
Supplement: Revisions and information on later models 13•19
Fig. 13.2 Cross-section view of the 999 and 1108 cc engine (Sec 5A)
Fig. 13.1 Correct method of fitting sump
pan sealing strip (Sec 4)
13

mounted on the front end of the crankshaft
and driven by it.
11The flexible toothed timing belt drives thecamshaft and the coolant pump from a
sprocket on the front end of the crankshaft.
The belt is tensioned by an
eccentrically-mounted pulley.
12The distributor and the fuel pump
(carburettor models) are driven from the
flywheel end of the camshaft. The fuel pump
on fuel injection models is an integral unit
combined with the fuel gauge sender unit and
immersed in the fuel tank.
PART B:
OPERATIONS POSSIBLE
WITH ENGINE IN CAR
Valve clearances - adjustment
1The operations are similar to those
described in Chapter 1, Section 26, but note
that the special tools referred to have differentpart numbers for the FlRE engine -
1860443000 and 1887001000 (photos).
2Remember that the clearance for inlet and
exhaust valves differs see Specifications at
the beginning of this Supplement.
3Counting from the timing cover end of the
engine, the valve sequence is as follows.
Inlet 2-4-5-7
Exhaust 1-3-6-8
Timing belt - renewal #
4Remove the air cleaner.
5Slacken and remove the alternator
drivebelt, then remove the spark plugs.
6Unbolt and remove the timing belt cover.
Note the bolt located at the bottom of the
cover, this can be easily overlooked (photo).
7Unbolt and remove the crankshaft pulley
(photo).
13•20 Supplement: Revisions and information on later models
5B.7 Unscrewing the crankshaft pulley
bolts5B.6 Timing cover lower fixing bolt
removal5B.1B Using a modified C-spanner and
screwdriver to remove a shim
5B.1A Checking a valve clearance
Fig. 13.3 Longitudinal sectional view of the 999 and 1108 cc
engine (Sec 5A)Fig. 13.4 999 and 1008 cc engine lubrication system (Sec 5A)

8Turn the crankshaft sprocket bolt, or
engage top gear and raise and turn a front
roadwheel, until the camshaft sprocket TDC
timing mark is aligned with the mark on the
cylinder head and the crankshaft sprocket
timing mark is aligned with the mark on the oil
pump cover (photos).
9Release the nut on the timing belt
tensioner, move the pulley away from the belt
and retighten the nut to hold the pulley in the
retracted position (photo).
10Slide the drivebelt from the sprockets.
11When refitting the new belt, make sure
that the sprocket timing marks are still in
alignment and fit the belt so that the arrows
on the belt point in the direction of engine
rotation, and the lines of the belt coincide with
the sprocket marks.
12Engage the timing belt with the crankshaft
sprocket first, then place it around the coolant
pump sprocket and the camshaft sprocket
(photo). Finally slip the belt around the
tensioner pulley.
13Release the tensioner nut and push the
pulley against the belt until the belt is quite
taut. Check that the sprocket timing marks
have not moved out of alignment. If they have,
reset them by moving them over the belt
teeth.
14Still applying force to the pulley, tighten its
nut.
15Turn the crankshaft through two complete
turns in the normal direction of rotation and
check that when the centre of the longest runof the belt is gripped between finger and
thumb it can just be twisted through 90º. If
increased tension is required to achieve this,
release the tensioner nut and prise the pulley
against the timing belt. Note: The above
procedure serves only as a rough guide to
setting the belt tension having it checked by a
FIAT dealer at the earliest opportunity is
recommended.
16Refit the timing belt cover, the crankshaft
pulley, alternator drivebelt, spark plugs and
the air cleaner.
Camshaft -
removal and refitting#
Warning: Refer to the beginning
of Section 9 before starting any
work.
17Remove the air cleaner and the fuel pump(carb. models), as described in Section 9 of
this Supplement.
18Remove the distributor (Section 10).
19Remove the timing belt cover.
20Unbolt and remove the camshaft cover,
having first disconnected the HT lead clip
(photos).
21Turn the crankshaft (by engaging top gear
and raising and turning a front roadwheel)
until No. 4 piston is at TDC. The timing mark
on the camshaft sprocket will be in alignment
with the mark on the cylinder head.
22Pass a rod through one of the holes in the
camshaft sprocket to prevent it rotating and
then unscrew the sprocket fixing bolt. Slip the
sprocket from the camshaft and out of the
loop of the belt (photos).
23Mark the camshaft bearing caps as to
position and then unbolt and remove the
Supplement: Revisions and information on later models 13•21
5B.9 Releasing the timing belt tensioner
nut5B.8B Crankshaft sprocket timing mark
and oil pump cover alignment mark
(arrowed)5B.8A Camshaft sprocket timing mark and
cylinder head timing mark in alignment
5B.22B Camshaft sprocket bolt and
washer5B.22A Unscrewing the camshaft sprocket
bolt
5B.20A Camshaft cover HT lead clip5B.12 Fitting the timing belt
5B.20B Removing the camshaft cover
13

depressurize the fuel system, before
disconnecting the fuel pipes and removing the
throttle body, as described in Section 9D.
34Disconnect the coolant and vacuum
hoses from the cylinder head and inlet
manifold (photo).
35Disconnect the electrical lead from the
coolant temperature switch, the LT leads from
the distributor and the idle cut-off solenoid
lead.
36Remove the distributor cap, disconnect
the plug leads and place the cap and leads to
one side of the engine compartment.
37Unbolt and remove the timing belt cover.
38Set No. 4 piston to TDC and then release
the timing belt tensioner and slip the belt from
the camshaft and coolant pump sprockets.
39Unbolt and remove the inlet manifold,
complete with carburettor, or throttle body as
applicable.
40Unbolt the exhaust manifold from the
cylinder head and tie it to one side of the
engine compartment; the downpipe bracket
will have to be disconnected.
41Unscrew the cylinder head bolts, a half
turn at a time in the reverse order to that
shown in Fig. 1.30 of Chapter 1. When the
bolts are free, remove them with their
washers.
42Lift the cylinder head from the block. If it is
stuck tight, insert pieces of wood into the
exhaust or inlet ports and use them as levers
to “rock” the head off the block. On no
account drive levers into the gasket joint orattempt to tap the head sideways as it is
located on positioning dowels.
43Remove and discard the cylinder head
gasket and both manifold gaskets.
44The cylinder head can be dismantled after
removing the camshaft and cam followers as
described in the preceding sub-Section.
45Further dismantling and decarbonising are
described in Chapter 1, Section 39. Note that
single valve springs are used.
46If the valves have been ground in, the
valve clearances will require adjusting, as
described previously. This should be done
before the cylinder head is refitted to the
engine.
47Before refitting the assembled cylinder
head, make sure that the head and block
mating surfaces are perfectly clean, and that
the block bolt holes have been cleared of any
oil.
48The camshaft sprocket timing mark must
be aligned with the one on the cylinder head.
49The new gasket should not be removed
from its nylon cover until required for use. Fit
the gasket dry to perfectly clean surfaces.
50Place the gasket on the cylinder block so
that the word ALTO can be read from above
(photos).
51Lower the cylinder head onto the block so
that it locates on the positioning dowels
(photo).
52The cylinder head bolts must have clean
threads, dipped in engine oil and allowed to
drain for thirty minutes. Screw the bolts infinger-tight and then tighten them in the
sequence shown in Fig. 1.30 of Chapter 1,
and in the stages specified (see Specification)
(photos).
53Refit the inlet manifold and carburettor
using a new gasket.
54Reconnect the exhaust manifold using a
new gasket. Tighten all nuts to the specified
torque. Reconnect the exhaust downpipe
bracket.
55Reconnect the timing belt and tension it
as described earlier.
56Refit the timing belt cover and the
distributor cap and camshaft cover.
57Reconnect all hoses, electrical leads and
controls.
58Fit the air cleaner.
59Fill and bleed the cooling system.
Supplement: Revisions and information on later models 13•23
5B.50A Cylinder head gasket5B.34 Inlet manifold coolant hose (A) and
brake servo vacuum hose (B)5B.32 Disconnecting the throttle cable
5B.52B Typical disc for angular tightening
of cylinder head bolts
5B.50B Cylinder head gasket top surface
marking
5B.52A Inserting a cylinder head bolt5B.51 Fitting the cylinder head
13

99Tighten the big-end bolts to the specified
torque (photo). The correct torque is
important as the bolts have no locking
arrangement. After tightening each big-end,
check that the crankshaft rotates smoothly.
100Repeat the operations on the remaining
piston/rod assemblies.
101Refit the oil pump pick-up assembly
using a new sealing ring.
102Refit the sump pan and the cylinder head
as described in earlier sub-Sections.
103Fill the engine with oil and coolant.
Pistons/connecting rods -
separation and piston
ring renewal
ª
104If the piston/connecting rods have been
removed in order to renew the piston rings,
refer to Chapter 1, Section 18, but note thatthe piston rings should be fitted so that the
word TOP is uppermost.
105If new pistons are to be fitted, it is
recommended that the gudgeon pins are
removed and refitted by a FIAT dealer as the
connecting rods must be carefully heated in
order to be able to push the gudgeon pin out
of the rod small-end, change the piston and
push the pin back into position. Locating the
gudgeon pin will require a special tool. The
gudgeon pin is a sliding fit in the piston but an
interference fit in the connecting rod.
106Refer to Fig. 13.6 for the correct
assembly of the piston and connecting rod.
Engine/transmission mountings
- renewal
107Refer to Chapter 1, Section 33. Three
mountings are used (photos).
PART C: ENGINE REMOVAL
AND DISMANTLING
Method of removal - general
1The engine, complete with transmission,
should be removed upwards out of the engine
compartment.
Engine/transmission -
removal and separation #
Warning: Refer to the beginning
of Section 9 before starting any
work.
2Mark the position of the hinges on the
underside of the bonnet and then, with the
help of an assistant, unscrew the hinge bolts
and lift the bonnet to a safe storage area.
3Drain the coolant; a cylinder block drain
plug is not fitted.
4Drain the engine and transmission oils.
5Disconnect the battery, negative lead first.
6Remove the air filter.
7Disconnect the radiator hoses from the
engine (photos).
13•26 Supplement: Revisions and information on later models
5C.7B Radiator hose at thermostat
housing5C.7A Radiator hose connection to coolant
distribution tube5B.107C Right-hand engine mounting
5B.107B Left-hand rear
engine/transmission mounting5B.107A Left-hand front
engine/transmission mounting
Fig. 13.6 Piston/connecting rod correctly
assembled - 999 and 1108 cc engine
(Sec 5B)
1 Piston grade (A) and directional arrow on
piston crown (towards timing belt)
2 Rod/cap matching numbers
3 Gudgeon pin offset in piston (0.9 to 1.1 mm)
Arrow indicates crankshaft rotation direction
Fig. 13.5 Piston ring arrangement on the
999 cc engine (Sec 5B)5B.99 Tightening a big-end cap bolt