1983 FIAT UNO oil filter

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

the crankcase to operate the oil pressure
gauge. In addition, a low oil pressure switch
screwed into the camshaft oil gallery actuates
a warning light on the instrument panel in theevent of the pressure dropping dangerously
low (photo).
10Oil supply/return ducts provide the
turbocharger lubrication.
PART B:
OPERATIONS POSSlBLE
WITH ENGINE IN CAR
Camshaft and camshaft
carrier - removal and
refitting
#
Warning: Refer to the beginning
of Section 9 before starting any
work.
1Disconnect the battery, negative lead first.
2Disconnect its leads and unbolt the
distributor from the end of the camshaft, and
place it to one side.
3Disconnect the air intake hose from the
throttle valve housing.
4Disconnect the short throttle control cable
from its sector.
5Remove the throttle cable support bracket.
6Disconnect the earth leads from the
camshaft cover.
7Refer to Section 9, Part C of this
Supplement and remove the following
components.
Supplementary air valve
Inlet manifold with fuel pressure regulator
and excess pressure safety switch
Injector cooling duct
8Disconnect the wiring plug from the
Microplex ignition anti-knock sensor.
9Carry out the operations described in
Chapter 1, Section 27, paragraphs 4 to 12.
10Refitting is a reversal of removal, referring
to Section 28 of Chapter 1 for the timing belt
refitting procedure, and to Chapter 1, Sec-
tion 27, paragraphs 15 to 18.
Cylinder head -
removal and refitting#
11Carry out the operations described in
paragraphs 4 to 9 in the preceding
sub-Section, then refer to Chapter 1, Section
29, but ignore all references to the
carburettor.
12Note the distributor mounting cover.
13Four additional cylinder head bolts are
used on these engines, adjacent to the spark
plugs (photo). Note that their tightening torque
differs from the other cylinder head bolts - see
Specifications. These four bolts are tightened
13•34 Supplement: Revisions and information on later models
1 Oil pick-up strainer
2 Oil pump
3 Oil pressure relief valve
4 Oil filter cartridge
5 Main oil gallery6 Camshaft oil feed
7 Low oil pressure switch
8 Engine oil cooler
9 Filter mounting base
10 Turbocharger oil feed11 Turbocharger oil return
12 Oil pressure sender unit
13 Oil temperature sender
unit
14 Piston oil spray nozzle
Fig. 13.12 Piston oil spray nozzle locations - 1301 cc Turbo ie engine (Sec 6A)
Letters denote cylinder bore grade
Fig. 13.11 1301 cc Turbo ie engine lubrication system (Sec 6A)
6A.9 Oil pressure sender unit

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

Initial start-up after major
overhaul
28Refer to Chapter 1, Section 45, but note
that an oil pressure gauge is fitted to indicate
oil pressure.
29Check the ignition static timing as
described in Section 10.
30Check the engine idle speed and CO level
as described in Section 9.
7 Engine-
1372 cc ie and 1372 cc
Turbo ie
PART A: GENERAL
Description
1The 1372 cc engine is similar in design to
the OHC engine fitted to the FIAT Tipo
variants. The engine is of four-cylinder, in-line,
overhead camshaft type, mounted
transversely at the front of the vehicle.
2The crankshaft runs in five main bearings.
Thrustwashers are fitted to the rear (flywheel
end) main bearing in order to control
crankshaft endfloat.
3The connecting rods are attached to the
crankshaft by horizontally split shell-type
big-end bearings. The pistons are attached to
the connecting rods by fully-floating gudgeon
pins which are secured by circlips. The
aluminium alloy pistons are fitted with three
piston rings: two compression rings and an oil
control ring.
4The camshaft is driven by a toothed belt
and operates the valves via bucket and shim
type cam followers. The camshaft is located in
a separate housing on top of the cylinder
head.
5The inlet and exhaust valves are each
closed by double valve springs, and operate
in guides pressed into the cylinder head.
6The auxiliary shaft, which is also driven by
the toothed belt, drives the oil pump.
7Lubrication is by means of a gear type
pump which draws oil through a strainer
located in the sump, and forces it through a
full-flow filter into the engine oil galleries fromwhere it is distributed to the crankshaft,
camshaft and auxiliary shaft. The big-end
bearings are supplied with oil via internal
drillings in the crankshaft. The undersides of
the pistons are cooled by oil spray nozzles
located in each main bearing location in the
crankcase.
8A crankcase ventilation system is
employed, whereby piston blow-by gases are
drawn via an oil separator into the air cleaner,
from where they are drawn into the inlet
manifold and re-burnt with fresh air/fuel
mixture.
9The 1372 cc ie engine is fitted with a Bosch
Mono-Jetronic single point fuel injection (SPi)
system. Whilst the higher performance
1372 cc Turbo ie engine is fitted with a Bosch
L3.1 (L3.2 from 1992) Jetronic multi-point
injection (MPi) system and turbocharger with
intercooler and oil cooling. The L3.2 system
models are fitted with catalytic converters.
Maintenanceª
10At the intervals specified in Section 3 or
“Routine maintenance” at the beginning of
this Manual, carry out the following tasks.
11Check the engine oil level as follows. With
the vehicle parked on level ground, and with
the engine having been stopped for a few
minutes, withdraw the oil level dipstick, wipe it
on a clean rag, and re-insert it fully. Withdraw
the dipstick again and read off the oil level
relative to the MAX and MIN marks. The oil
level should be between the marks. If the level
is at or below the MIN mark, top up through
the filler on the camshaft cover without delay
(photo). The quantity of oil required to raise
the level from MIN to MAX on the dipstick is
approximately 1.0 litre (1.8 pints). Do not
overfill.
12Renew the engine oil and filter as
described in Section 2 of Chapter 1 (photos).
13Check and if necessary adjust the valve
clearances as described in Part B of this
Section.
14Inspect the engine for signs of oil, coolant
or fuel leaks and rectify as necessary.
15Inspect the crankcase ventilation hose for
blockage or damage. Clean or renew as
necessary.
16Check the condition and tension of thetiming belt as described in Part B of this
Section.
17Renew the timing belt as described in
Part B of this Section.
PART B:
OPERATIONS POSSlBLE
WITH ENGINE IN CAR
Valve clearances -
checking and adjustment#
1It is important to ensure that the valve
clearances are set correctly, as incorrect
clearances will result in incorrect valve timing
thus affecting engine performance.
2The clearances must be checked and
adjusted with the engine cold.
3On the ie engine, refer to Section 9 in this
Chapter for details and remove the air cleaner
unit.
4On the ie engine disconnect the crankcase
ventilation hose from the injector unit and
position the hose out of the way.
5On Turbo ie engines, loosen off the clips
and remove the air hose to the inlet manifold
(above the camshaft cover).
6On Turbo ie engines, disconnect the
accelerator cable from the throttle housing
and the support bracket on the camshaft
cover.
7Unscrew the securing nuts and washers
and remove the camshaft cover, noting that
on later models two of the nuts also secure
the hose clip assembly. Recover the gasket.
8Numbering from the front (timing belt) end
of the engine, the exhaust valves are 1, 4, 5
and 8, and the inlet valves are 2, 3, 6 and 7.
Supplement: Revisions and information on later models 13•37
7A.12B Engine oil filter removal using a
strap wrench - 1372 cc engine7A.12A Engine sump drain plug - 1372 cc
engine7A.11 Topping up the engine oil level -
1372 cc engine
Fig. 13.15 Engine oil level dipstick location
and level markings on the 1372 cc ie and
Turbo ie engines (Sec 7A)
13

new oil seal, ensuring that it is correctly
orientated, and drive it squarely into position.
149Refit all disturbed components.
Flywheel - removal,
inspection and refitting#
150If not already done, remove the clutch as
described in Chapter 5.
151Prevent the flywheel from turning by
jamming the ring gear teeth, or by bolting a
strap between the flywheel and the cylinder
block.
152Make alignment marks on the flywheel
and the end of the crankshaft, so that the
flywheel can be refitted in its original position.
153Unscrew the securing bolts and remove
the washer plate, then withdraw the flywheel.
Do not drop it, it is very heavy.
154With the flywheel removed, the ring gear
can be examined for wear and damage.
155If the ring gear is badly worn or has
missing teeth it should be renewed. The old
ring gear can be removed from the flywheel by
cutting a notch between two teeth with a
hacksaw and then splitting it with a cold
chisel. Wear eye protection when doing this.
156Fitting of a new ring gear requires heating
the ring to a temperature of 80ºC (176ºF). Do
not overheat, or the hard-wearing properties
will be lost. The gear has a chamfered inner
edge which should fit against the shoulder on
the flywheel. When hot enough, place the gear
in position quickly, tapping it home ifnecessary, and let it cool naturally without
quenching in any way.
157Ensure that the mating faces are clean,
then locate the flywheel on the rear of the
crankshaft, aligning the previously made
marks on the flywheel and crankshaft.
158Fit the washer plate, and insert the
securing bolts, then prevent the flywheel from
turning as described in paragraph 151 whilst
the bolts are tightened progressively to the
specified torque setting in a diagonal
sequence (photos).
159If applicable, refit the clutch as described
in Chapter 5.
Sump -
removal and refittingÁ
160Drain the engine oil from the sump as
described in Chapter 1.
161Disconnect the lead from the engine oil
level sensor in the sump.
162Unscrew and remove the bolts retaining the
gear linkage mounting bracket (where applicable)
and the clutch housing lower cover bolts.
Remove the cover from the clutch housing.
163Unscrew and remove the sump retaining
bolts and nuts and lower the sump from the
crankcase. Recover the gasket.
164Clean all traces of old gasket from the
sump, crankcase and both oil seal housing
mating surfaces.
165Commence reassembly by applying
sealing compound (FIAT No. 5882442 orequivalent) to the joints between the
crankshaft front and rear oil seal housings and
the mating face of the crankcase (photo).
166Locate the new gasket in position on the
crankcase then fit the sump. As it is fitted it
will need to be twisted to avoid fouling the oil
pump unit. Refit the retaining bolts and nuts
and tighten them to the specified torque
(photos).
167Check that the sump drain plug is refitted
and fully tightened. If the engine is in the car,
top up the engine oil level.
Oil pump - removal,
checking and refittingª
168Drain the engine oil and remove the
sump as described in the previous
sub-Section.
169Unscrew the retaining bolts then
withdraw the oil pump and intake pipe/filter
from its location within the crankcase.
Remove the gasket.
170If oil pump wear is suspected, first check
the cost and availability of new parts and the
cost of a new pump. Then examine the pump
as described below and decide whether
renewal or repair is the best course of action.
171Unscrew the three securing bolts and
remove the oil pump cover (photo). Note that
as the cover is removed, the oil pressure relief
valve components will be released.
172Recover the oil pressure relief valve,
spring and spring seat.
13•46 Supplement: Revisions and information on later models
7B.166C . . . and insert the retaining bolts7B.166B . . . refit the sump . . .7B.166A Locate the new gasket . . .
7B.165 Apply sealant to the front oil seal
housing/cylinder block joint7B.158B . . . tighten the bolts to the
specified torque7B.158A Locate the flywheel, washer plate
and bolts . . .

fitting, as during removal. Note that the
compression rings are brittle, and will snap if
expanded too far.
206If new pistons are to be fitted, they must
be selected from the grades available, after
measuring the cylinder bores. Normally, the
appropriate oversize pistons are supplied by
the dealer when the block is rebored.
207Whenever new piston rings are being
installed, the glaze on the original cylinder
bores should be removed using either
abrasive paper or a glaze-removing tool in an
electric drill. If abrasive paper is used, use
strokes at 60º to the bore centre-line, to
create a cross-hatching effect.
Engine/transmission
mountings - renewalÁ
208The engine/gearbox assembly is
suspended in the engine compartment on
three mountings, two of which are attached to
the gearbox, and one to the engine.
Right-hand mounting
209Apply the handbrake, then jack up the
front of the vehicle and support it securely on
axle stands.
210Suitable lifting tackle must now be
attached to the engine in order to support it as
the engine mounting is removed. No lifting
brackets are provided, so care must be taken
when deciding on an engine lifting point. In the
workshop, a right-angled bracket was made up
by bending a suitable piece of steel plate. The
bracket was then bolted to the engine using the
rear right-hand camshaft housing securing bolt
with suitable packing washers.
211Attach the lifting tackle to the bracket on
the engine and just take the weight of the
assembly.
212Working under the vehicle, unbolt the
engine mounting bracket from the cylinder
block, and unbolt the mounting from the
body, then withdraw the bracket/mounting
assembly.
213Unscrew the nut and through-bolt,
counter holding the bolt with a second
spanner or socket, and separate the mounting
from the bracket.
214Fit the new mounting to the bracket, and
tighten the nut to the specified torque, while
counterholding the through-bolt using a
suitable spanner or socket.
215Refit the mounting bracket to the cylinder
block, and tighten the securing bolts to the
specified torque.
216Refit the mounting to the body and
tighten the securing bolts to the specified
torque.
217Disconnect the lifting tackle from the
engine, and remove the engine lifting bracket.
218Lower the vehicle to the ground.
Left-hand mountings
219Apply the handbrake, then jack up the
front of the vehicle and support it securely on
axle stands.
220Suitable lifting tackle must now be
attached to the gearbox lifting bracket inorder to support the weight of the assembly
as the mounting is removed.
221Attach the lifting tackle to the bracket on
the gearbox, and just take the weight of the
assembly.
222Working under the vehicle, unbolt the
mounting bracket from the gearbox, and
unbolt the mounting from the body, then
withdraw the bracket/mounting assembly.
223Proceed as described in paragraphs 213
and 214.
224Refit the mounting bracket to the
gearbox, and tighten the securing bolts to the
specified torque.
225Refit the mounting to the body and
tighten the mounting bolts to the specified
torque.
226Disconnect the lifting tackle from the
engine.
227Lower the vehicle to the ground.
PART C: ENGINE REMOVAL
AND DISMANTLING
Method of removal - general
1The engine (complete with transmission) is
disconnected and lowered downwards
through the engine compartment, then
withdrawn from the front underside of the car.
1372 cc engine/
transmission - removal
and separation
#
Warning: Refer to the beginning
of Section 9 before starting any
work.
2Depressurize the fuel system as described
in Section 9 of this Chapter.
3Disconnect the battery negative lead.
4Mark the position of the hinges on the
underside of the bonnet, then with the aid of
an assistant, unscrew the hinge bolts and lift
the bonnet clear of the car. Store the bonnet
in a safe area.
5Drain the engine coolant.
6Drain the engine and transmission oils.
7Disconnect and remove the air filter.
8Disconnect the coolant hoses from the
engine, including the hose to the inlet
manifold.
9Detach the ignition coil (HT) lead from the
distributor.10Compress the retaining clip and detach
the engine idle speed actuator lead from the
SPi unit (photo).
11Disconnect the brake servo vacuum pipe
from its connector on the inlet manifold.
12Disconnect the throttle cable from the SPi
unit.
13Disconnect the engine speed sensor lead.
14Release and detach the reversing light
lead from the switch on the transmission
(photo).
15Before disconnecting the hydraulic hose
from the clutch slave cylinder, remove the
filler cap from the reservoir and place a piece
of polythene sheet over the filler neck, then
refit the cap; this will help prevent excess fluid
loss. Once disconnected, plug the hose and
its cylinder connection to prevent the ingress
of dirt into the hydraulic system.
16Disconnect the wiring connector from the
alternator.
17Position a clean rag under the fuel supply
and return hose connections to the SPi unit,
then slowly unscrew the hose clips to release
the system pressure; catch fuel leakage in the
rag and dispose of it safely. Detach the hoses
and plug them to prevent ingress of dirt and
any further fuel leakage. Position the hoses
out of the way.
18Detach the wiring connector from the
engine coolant temperature sender unit
(photo).
19Release the retaining clip and detach the
wiring connector from the throttle position
switch. Also detach the associated earth
leads from the cylinder head.
Supplement: Revisions and information on later models 13•49
7C.14 Reversing light switch and lead7C.18 Engine coolant temperature sender
and wiring connector
7C.10 Engine idle speed actuator/SPi unit
lead connection (arrowed)
13