1983 FIAT UNO brake light

Safety First!0•5
Working on your car can be dangerous.
This page shows just some of the potential
risks and hazards, with the aim of creating a
safety-conscious attitude.
General hazards
Scalding
• Don’t remove the radiator or expansion
tank cap while the engine is hot.
• Engine oil, automatic transmission fluid or
power steering fluid may also be dangerously
hot if the engine has recently been running.
Burning
• Beware of burns from the exhaust system
and from any part of the engine. Brake discs
and drums can also be extremely hot
immediately after use.
Crushing
• When working under or near
a raised vehicle,
always
supplement the
jack with axle
stands, or use
drive-on
ramps.
Never
venture
under a car which
is only supported by a jack.
• Take care if loosening or tightening high-
torque nuts when the vehicle is on stands.
Initial loosening and final tightening should
be done with the wheels on the ground.
Fire
• Fuel is highly flammable; fuel vapour is
explosive.
• Don’t let fuel spill onto a hot engine.
• Do not smoke or allow naked lights
(including pilot lights) anywhere near a
vehicle being worked on. Also beware of
creating sparks
(electrically or by use of tools).
• Fuel vapour is heavier than air, so don’t
work on the fuel system with the vehicle over
an inspection pit.
• Another cause of fire is an electrical
overload or short-circuit. Take care when
repairing or modifying the vehicle wiring.
• Keep a fire extinguisher handy, of a type
suitable for use on fuel and electrical fires.
Electric shock
• Ignition HT
voltage can be
dangerous,
especially to
people with heart
problems or a
pacemaker. Don’t
work on or near the
ignition system with
the engine running or
the ignition switched on.• Mains voltage is also dangerous. Make
sure that any mains-operated equipment is
correctly earthed. Mains power points should
be protected by a residual current device
(RCD) circuit breaker.
Fume or gas intoxication
• Exhaust fumes are
poisonous; they often
contain carbon
monoxide, which is
rapidly fatal if inhaled.
Never run the
engine in a
confined space
such as a garage
with the doors shut.
• Fuel vapour is also
poisonous, as are the vapours from some
cleaning solvents and paint thinners.
Poisonous or irritant substances
• Avoid skin contact with battery acid and
with any fuel, fluid or lubricant, especially
antifreeze, brake hydraulic fluid and Diesel
fuel. Don’t syphon them by mouth. If such a
substance is swallowed or gets into the eyes,
seek medical advice.
• Prolonged contact with used engine oil can
cause skin cancer. Wear gloves or use a
barrier cream if necessary. Change out of oil-
soaked clothes and do not keep oily rags in
your pocket.
• Air conditioning refrigerant forms a
poisonous gas if exposed to a naked flame
(including a cigarette). It can also cause skin
burns on contact.
Asbestos
• Asbestos dust can cause cancer if inhaled
or swallowed. Asbestos may be found in
gaskets and in brake and clutch linings.
When dealing with such components it is
safest to assume that they contain asbestos.
Special hazards
Hydrofluoric acid
• This extremely corrosive acid is formed
when certain types of synthetic rubber, found
in some O-rings, oil seals, fuel hoses etc, are
exposed to temperatures above 400
0C. The
rubber changes into a charred or sticky
substance containing the acid. Once formed,
the acid remains dangerous for years. If it
gets onto the skin, it may be necessary to
amputate the limb concerned.
• When dealing with a vehicle which has
suffered a fire, or with components salvaged
from such a vehicle, wear protective gloves
and discard them after use.
The battery
• Batteries contain sulphuric acid, which
attacks clothing, eyes and skin. Take care
when topping-up or carrying the battery.
• The hydrogen gas given off by the battery
is highly explosive. Never cause a spark or
allow a naked light nearby. Be careful when
connecting and disconnecting battery
chargers or jump leads.
Air bags
• Air bags can cause injury if they go off
accidentally. Take care when removing the
steering wheel and/or facia. Special storage
instructions may apply.
Diesel injection equipment
• Diesel injection pumps supply fuel at very
high pressure. Take care when working on
the fuel injectors and fuel pipes.
Warning: Never expose the hands,
face or any other part of the body
to injector spray; the fuel can
penetrate the skin with potentially fatal
results.
Remember...
DO
• Do use eye protection when using power
tools, and when working under the vehicle.
• Do wear gloves or use barrier cream to
protect your hands when necessary.
• Do get someone to check periodically
that all is well when working alone on the
vehicle.
• Do keep loose clothing and long hair well
out of the way of moving mechanical parts.
• Do remove rings, wristwatch etc, before
working on the vehicle – especially the
electrical system.
• Do ensure that any lifting or jacking
equipment has a safe working load rating
adequate for the job.
A few tips
DON’T
• Don’t attempt to lift a heavy component
which may be beyond your capability – get
assistance.
• Don’t rush to finish a job, or take
unverified short cuts.
• Don’t use ill-fitting tools which may slip
and cause injury.
• Don’t leave tools or parts lying around
where someone can trip over them. Mop
up oil and fuel spills at once.
• Don’t allow children or pets to play in or
near a vehicle being worked on.

0•8Roadside Repairs
To avoid repetition, the procedure for
raising the vehicle, in order to carry out work
under it, is not included before each relevant
operation described in this Manual.
It is to be preferred, and it is certainly
recommended, that the vehicle is positioned
over an inspection pit or raised on a lift. Where
these facilities are not available, use ramps or
jack up the vehicle strictly in accordance with
the following guide. Once the vehicle is raised,
supplement the jack with axle stands.
Jacking
The jack supplied with the car should only
be used to change a wheel. Do not use this
jack when overhaul or repair work is being
carried out; employ a hydraulic or screw jack
and supplement it with axle stands.
Jacking points are located under the sills
for use with the jack supplied.To raise the front end with a garage jack,
locate the jack under the transmission lower
mounting, just below and slightly to the rear of
the transmission oil drain plug. Protect the
mounting by placing a block of wood between
the jack head and the mounting.
To raise the rear of the car, the jack should
be placed under the spare wheel housing as
far to the rear as possible. Place a wooden
bearer between the jack head and the
housing.
Towing
When being towed, use the left-hand front
towing eye.
When towing another vehicle, use the rear
towing eye adjacent to the exhaust tailpipe.
When being towed, remember that the
brake pedal will require heavier pressure due
to lack of servo assistance. Always turn theignition key to MAR to retain the steering in
the unlocked position.
Wheel changing
With the car on firm level ground, apply the
handbrake fully. Remove the hub cap or
wheel trim, if fitted.
Release, but do not remove, the bolts.
Chock the front and rear of the opposite
roadwheel and then raise the car using the sill
jack supplied with the car if it is being done at
the roadside. Alternatively use a workshop
jack supplemented with axle stands.
Remove the wheel bolts, change the wheel
and screw in the bolts finger tight. It is
recommended that the bolt threads are
smeared with multi-purpose grease. Lower
the car, remove the jack and tighten the wheel
bolts to the specified torque. Refit any wheel
trim that was removed.
Spare wheel and jack stowage
Front tow hook Rear tow hook
Jacking, towing and wheel changing

0•10Routine maintenance
Maintenance is essential for ensuring safety and desirable for the
purpose of getting the best in terms of performance and economy
from the car. Over the years the need for periodic lubrication has been
greatly reduced if not totally eliminated. This has unfortunately tended
to lead some owners to think that because no such action is required
the items either no longer exist or will last forever. This is certainly not
the case; it is essential to carry out regular visual examinations as
comprehensively as possible in order to spot any possible defects at
an early stage before they develop into major and expensive repairs.
For information applicable to later models, see Supplement.
Every 250 miles (400 km), weekly,
or before a long journey
m mCheck engine oil level
m mCheck brake reservoir fluid level
m mCheck tyre pressures
m mCheck operation of all lights and horn
m mTop up washer fluid reservoirs, adding a screen
wash, and check operation of washers and wipers
m mCheck coolant level
m mCheck battery electrolyte level
Every 6000 miles (10 000 km)
or six months, whichever comes first
m mRenew engine oil and filter (Chapter 1, Section 2)
m mCheck drivebelt tension (Chapter 2, Section 8)
m mCheck carburettor idle speed and mixture
adjustments (Chapter 3)
m mCheck contact points and dwell angle (mechanical
breaker distributors) (Chapter 4, Section 3)
m mCheck tyre tread wear (Chapter 7, Section 7)
m mCheck disc pads for wear (Chapter 8, Section 3)
Every 36 000 miles (60 000 km)
or three years, whichever comes first
m mRenew the timing belt - 1116 and 1299/1301 cc
(Chapter 1, Section 28)
m mCheck exhaust system for corrosion (Chapter 3,
Section 19)
m mRenew contact breaker points and adjust dwell
angle (mechanical breaker distributors) (Chapter 4,
Section 3)
m mCheck and adjust ignition timing (Chapter 4,
Section 4)
m mRenew spark plugs (Chapter 4, Section 11)
m mCheck clutch adjustment (Chapter 5, Section 2)
m mCheck transmission oil level (Chapter 6, Section 2)
m mCheck driveshaft and steering rack gaiters for splits
(Chapters 7 and 10)
m mCheck rear brake shoe linings for wear (Chapter 8,
Section 4)
m mCheck handbrake travel (Chapter 8, Section 16)
m mCheck headlamp beam alignment (Chapter 9,
Section 17)
m mCheck balljoints for wear (Chapter 10, Section 2)
m mCheck front wheel alignment (Chapter 10, Section 8)
m mCheck suspension bushes for wear (Chapter 11,
Section 2)
m mCheck seat belts for fraying (Chapter 12, Section 23)
m mLubricate controls, hinges and locks
Every 24 000 miles (40 000 km)
or two years, whichever comes first
m mRenew coolant anti-freeze mixture (Chapter 2,
Section 3)
m mRenew transmission oil (Chapter 6, Section 2)
m mRenew brake hydraulic fluid (Chapter 8, Section 12)
m mCheck for underbody corrosion and clean out door
and sill drain holes (Chapter 12, Section 2)
Every 12 000 miles (20 000 km) or
12 months, whichever comes first
m mCheck and adjust valve clearances (Chapter 1,
Sections 5 and 26)
m mRenew air cleaner element (Chapter 3, Section 2)

Cylinder head and valves
Material (cylinder head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light alloy
Maximum distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in)
Valve guide bore in head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.950 to 12.977 mm (0.5099 to 0.5109 in)
Valve guide outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.010 to 13.030 mm (0.5122 to 0.5130 in)
Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5, 0.10, 0.25 mm (0.002, 0.004, 0.010 in)
Inside diameter of valve guide (reamed) . . . . . . . . . . . . . . . . . . . . . . . . . 7.022 to 7.040 mm (0.2765 to 0.2772 in)
Guide fit in head (interference) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.033 to 0.080 mm (0.0013 to 0.0032 in)
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.982 to 7.000 mm (0.2748 to 0.2756 in)
Maximum clearance (valve stem to guide) . . . . . . . . . . . . . . . . . . . . . . . 0.022 to 0.058 mm (0.0009 to 0.0023 in)
Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44º 55’ to 45º 05’
Valve face angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45º 25’ to 45º 35’
Valve head diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.0 mm (1.1417 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.0 mm (1.0236 in)
Contact band (valve to seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 to 1.5 mm (0.0512 to 0.0591 in)
Valve clearance:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in)
For timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in)
Valve timing:
Inlet valve:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7º BTDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36º ABDC
Exhaust valve:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38º BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5º ATDC
Lubrication system
Oil pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear, driven by shaft from camshaft
Tooth tip to body clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.14 mm (0.0020 to 0.0055 in)
Gear endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.105 mm (0.0008 to 0.0041 in)
Oil pressure at normal operating temperature and average road/
engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.94 to 3.92 bar (42 to 57 lbf/ in
2)
Oil capacity (with filter change) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42 litre (6.0 pint)
Oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multigrade engine oil, viscosity SAE 15W/40
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C101
Torque wrench settingsNm lbf ft
Cylinder head bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 43.5
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 51
Big-end bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 30
Crankshaft pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 72
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 32
Rocker pedestal nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 29
Engine mounting bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Engine mounting centre nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Temperature sender switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Driveshaft to hub nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 200
Hub carrier to strut clamp bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 63
Brake caliper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 39
Tie-rod end balljoint nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 25
Driveshaft inboard boot retainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Engine – general 1•3
1

Auxiliary shaft
Bearing internal diameter (reamed):
No. 1 (timing belt end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.664 to 35.684 mm (1.4052 to 1.4059 in)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.000 to 32.020 mm (1.2608 to 1.2616 in)
Shaft journal diameter:
No. 1 (timing belt end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.593 to 35.618 mm (1.4024 to 1.4033 in)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.940 to 31.960 mm (1.2584 to 1.2592 in)
Cylinder block and crankcase
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast-iron
Bore diameter:
1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.000 to 80.050 mm (3.152 to 3.154 in)
1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.400 to 86.450 mm (3.404 to 3.406 in)
Maximum cylinder bore taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm (0.0006 in)
Maximum cylinder bore ovality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm (0.0006 in)
Torque wrench settingsNm lbf ft
Cylinder head bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn through 90º Turn through 90º
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn through 90º Turn through 90º
Camshaft carrier to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59
Big-end cap nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 38
Flywheel mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 61
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 61
Belt tensioner bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 32
Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 21
Auxiliary shaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 61
Flexible mounting bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 44
Flexible mounting centre nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 24
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 63
Driveshaft/hub nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 200
Tie-rod end balljoint nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 25
Brake caliper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 39
Front strut lower clamp bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 36
Driveshaft inboard boot retainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Crankshaft pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 7
1•6 Engine – general
Part 1: General
1 Description
1The Uno may be powered by one of three
engines depending upon the particular model.
903 cc
2This is of four cylinder overhead valve type
with a light alloy cylinder head and a cast-iron
block and crankcase.
3A three bearing crankshaft is used and the
chain-driven camshaft runs in three steel
backed white metal bearings.
4The light alloy pistons are fitted with two
compression and one oil control ring. The
gudgeon pin is an interference fit in the small
end of the connecting rod.
5Lubrication is provided by an oil pump
within the sump pan and both the pump and
the distributor are driven from a gear on the
camshaft. Pressurised oil passes through acartridge type oil filter. An oil pressure relief
valve is incorporated in the oil pump. The
engine oil is independent of the transmission
lubricant.
1116 cc and 1301 cc
6These engines are of single overhead
camshaft type, the camshaft being driven by a
toothed belt.
7The difference in engine capacity is
achieved by increasing the cylinder bore on
the 1301 cc engine.
8The cylinder head is of light alloy while the
cylinder block and crankcase are of cast-iron
construction.
9A five bearing crankshaft is used and the
camshaft runs in a similar number of bearings,
but as these are in-line bored directly in the
camshaft carrier, no repair is possible.
10The pistons are of light alloy with two
compression and one oil control ring. The
gudgeon pin is an interference fit in the small
end of the connecting rod.
11An auxiliary shaft, driven by the timing belt
is used to drive the distributor, oil pump and
fuel pump.12The oil pump is located within the sump
pan and incorporates a pressure relief valve.
13Pressurised oil passes through a cartridge
type oil filter.
14The crankshaft main bearings are
supplied under pressure from drillings in the
crankcase from the main oil gallery whilst the
connecting rod big-end bearings are
lubricated from the main bearings by oil
forced through the crankshaft oilways. The
camshaft bearings are fed from a drilling from
the main oil gallery. The cams and tappets are
lubricated by oil mist from outlets in the
camshaft bearings.
15The cylinder walls, pistons and gudgeon
pins are lubricated by oil splashed up by the
crankshaft webs. An oil pressure warning light
is fitted to indicate when the pressure is too
low.
All engines
16The engine is mounted transversely with
the transmission at the front of the car.
17The engine oil is independent of the
transmission lubricant.

8Fit the new belt. Start at the crankshaft
drive pulley and, taking care not to kink or
strain the belt, slip it over the camshaft pulley.
The camshaft may have to be turned slightly
to mesh the pulley with the teeth on the belt.
Fit the belt on the tensioner pulley last; if this
is difficult, do not lever or force the belt on,
recheck the belt (photo).
9Release the tensioner nut and rotate the
crankshaft through two complete revolutions.
Retighten the nut. The belt tension may be
checked by twisting it through 90º with the
finger and thumb. It should just turn through
this angle without undue force. 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.
10Refit the timing belt cover (photo). Fit and
tension the alternator drivebelt (Chapter 2,
Section 8).
29 Cylinder head-
removal and refitting
3
1Drain the cooling system (see Chapter 2).
2Disconnect the battery.
3Disconnect and plug the carburettor fuel
hoses.
4Disconnect the throttle and choke linkage
from the carburettor. 5Disconnect the HT leads from the spark
plugs.
6Disconnect the brake servo vacuum hose
from the intake manifold.
7Disconnect the coolant hoses from the
thermostat housing.
8Disconnect the crankcase ventilation
system hoses from the rocker cover and
carburettor.
9Unbolt and remove the timing belt cover.
10Release the timing belt tensioner pulley
bolt, then lever the pulley against the spring
plunger and retighten the bolt to retain the
tensioner pulley in the non-tensioned position.
Slip the belt from the camshaft sprocket.
11Disconnect the coolant hoses from the
carburettor and intake manifold.
12Disconnect the exhaust downpipes from
the manifold.
13If a crowfoot type wrench is available, the
cylinder head nuts and bolts can be removed
and the complete cylinder head camshaft
carrier assembly withdrawn (photo).
14If this type of wrench is not available
however, remove the carrier first as described
in Section 27.
15If a crowfoot is available, unscrew the
cylinder head nuts and bolts evenly and
progressively starting with the centre ones
and working towards both ends.
16Rock the cylinder head by gripping the
manifolds. Note: Do not insert a lever in
the gasket joint to prise the head from the
block.17Pull the head off the studs and remove it
to the bench. Remove and discard the old
cylinder head gasket.
18Unbolt and remove the hot air collecting
shield for the air cleaner from the exhaust
manifold. The exhaust and inlet manifolds can
now be unbolted. The carburettor may remain
on the inlet manifold.
19Overhaul and decarbonising of the
cylinder head is described in Section 39.
20Refitting is a reversal of the removal
process, but make sure the crankshaft and
camshaft timing marks are set as described in
Section 28 to avoid the valve heads digging
into the piston crowns when the head is
refitted.
21Always use new gaskets. The cylinder
1116 cc and 1301 cc engine 1•25
Fig. 1.29 Timing belt arrangement (Sec 28)
1 Camshaft sprocket
2 Tensioner pulley locknut
3 Timing mark on crankshaft front oil seal
retainer
4 Crankshaft sprocket
5 Crankshaft sprocket timing mark
6 Auxiliary shaft sprocket
7 Tensioner bracket bolt
8 Tensioner pulley
9 Timing belt
10 Tensioner bracket
11 Tensioner spring
28.8 Slipping timing belt onto tensioner
pulleyFig. 1.28 TDC marks (1) at front of engine
(Sec 28)
Fig. 1.30 Cylinder head bolt tightening
sequence (Sec 29)28.10 Tightening timing belt cover nut29.13 Using a crowfoot type wrench on a
cylinder head bolt
1

2The big-end bearing shells can be renewed
without having to remove the cylinder head if
the caps are unbolted and the
piston/connecting rod pushed gently about
one inch up the bore (the crankpin being at its
lowest point). If these shells are worn,
however, the main bearing shells will almost
certainly be worn as well. In this case, the
engine should be removed for complete
overhaul including crankshaft removal.
3To remove the piston/connecting rods,
remove the cylinder head as described in
Section 29.
4Grip the oil pick-up pipe and twist or rock it
from its hole in the crankcase. It is an
interference fit in the hole.
5Unscrew the nuts from the big-end caps,
then remove the caps with their bearing
shells. The caps and their connecting rods are
numbered 1, 2, 3 and 4 from the timing cover
end of the engine. The numbers are adjacent
at the big-end cap joint and on the side of the
crankcase furthest from the auxiliary shaft.
6If the bearing shells are to be used again,
tape them to their respective big-end caps.
7Push each connecting rod/piston assembly
up the bore and out of the cylinder block.
There is one reservation; if a wear ridge has
developed at the top of the bores, remove this
by careful scraping before trying to remove
the piston/rod assemblies. The ridge will
otherwise prevent removal or break the piston
rings during the attempt.
8If the connecting rod bearing shells are to
be used again, tape the shells to their
respective rods.
9Dismantling the piston/connecting rod is
described in Section 18.
Refitting
10Fit the new shells into the connecting rod
and caps, ensuring the surfaces on which the
shells seat, are clean and dry.
11Check that the piston ring gaps are evenly
spaced at 120º intervals. Liberally oil the rings
and the cylinder bores.
12Fit a piston ring clamp to compress the
rings.
13Insert the piston/connecting rod into the
cylinder bore, checking that the rod assembly
is correct for that particular bore. The cap and
rod matching numbers must be furthest away
from the auxiliary shaft (Fig. 1.31).14Push the piston into the bore until the
piston ring clamp is against the cylinder block
and then tap the crown of the piston lightly to
push it out of the ring clamp and into the bore
(photo).
15Oil the crankshaft journal and fit the
big-end of the connecting rod to the journal.
Fit the big-end cap and nuts, checking that
the cap is the right way round (photo).
16Tighten the big-end nuts to the specified
torque. The correct torque is important as the
nuts have no locking arrangement. After
tightening each big-end, check the crankshaft
rotates smoothly (photo).
17Refit the oil pick-up pipe, the cylinder
head, oil pump and sump pan, all as
described earlier.
18Refill the engine with oil and coolant.
33 Engine mountings-
renewal
1
1Three engine/transmission flexible
mountings are used.
2To renew a mounting, support the weight of
the engine/transmission on a hoist or jack and
unbolt and remove the mounting.
3In the unlikely event of all three mountings
requiring renewal at the same time, only
disconnect them and renew them one at a
time.
34 Engine- method of removal
1The engine complete with transmission
should be removed by lowering it to the floor
and withdrawing it from under the front of the
car which will have been raised to provide
adequate clearance.
35 Engine/transmission-
removal and separation
3
1Open the bonnet, disconnect the
windscreen washer tube.
2Mark the hinge positions on the undersideof the bonnet and then with the help of an
assistant to support its weight unbolt and
remove the bonnet to a safe place.
3Disconnect the battery negative lead.
4Drain the cooling system and the engine
and transmission oils.
5Remove the air cleaner.
6From the rear of the alternator disconnect
the electrical leads.
7Disconnect the leads from the starter
motor, oil pressure and coolant temperature
switches, also the oil temperature switch.
8Disconnect the LT lead from the distributor
and the HT lead from the ignition coil.
9Disconnect the clutch cable from the
release lever at the transmission. Also
disconnect the speedometer drive cable
(knurled ring).
10Pull the leads from the reversing lamp
switch.
11Disconnect all coolant hoses from the
engine. Also disconnect the brake servo hose
from the intake manifold.
12Disconnect the choke and throttle
controls from the carburettor.
13Disconnect the inlet hose from the fuel
pump and plug the hose.
14Disconnect the fuel return hose from the
carburettor.
15Disconnect the coolant hoses from the
carburettor throttle block.
16Raise the front of the car and remove the
front roadwheels.
17Unscrew and remove the driveshaft to
hub nuts. These are very tight and a long
knuckle bar will be required when unscrewing
them. Have an assistant apply the brake pedal
hard to prevent the hub from turning.
18Working under the car, remove the inner
wing protective shields and then disconnect
the exhaust downpipe from the manifold.
19Disconnect the exhaust pipe sections by
removing the socket clamp just forward of the
rear axle beam. Remove the front section.
20Disconnect the forward ends of the
gearchange rods by prising their sockets from
the ballstuds.
21Unscrew the nuts on the steering tie-rod
end balljoints and then using a suitable
“splitter” tool, separate the balljoints from the
steering arms.
22Unbolt the front brake hose support clips
1116 cc and 1301 cc engine 1•27
32.16 Tightening a big-end cap nut32.15 Fitting a big-end cap32.14 Fitting piston into cylinder bore
1

to the engine. Also reconnect the brake servo
hose to the intake manifold (photos).
22Reconnect the leads to the reversing lamp
switch. Reconnect the transmission earth lead
(photos).
23Reconnect the clutch cable and adjust as
described in Chapter 5.
24Reconnect the speedometer drive cable
to the transmission and tighten the knurled
retaining ring.
25Reconnect the low tension lead to the
distributor and the high tension lead to the
ignition coil.
26Reconnnect the electrical leads to thestarter motor, the oil pressure and
temperature switches and the coolant
temperature switch.
27Connect the leads to the alternator.
28Refit the air cleaner.
29Refill the cooling system. Refill the engine
with oil.
30Reconnect the battery.
31Refit the bonnet and connect the
windscreen washer tube.
32Fit the inner wing protective shields
(photo).
45 Engine- initial start-up after
major overhaul
4
1If new bearings and rings have been fitted,
it is likely that the engine will be stiff to turn so
make sure the battery is well charged.
2Switch on the ignition and check that
appropriate warning lights come on.
3Start up the engine. If it refuses to start,
refer to the “Fault Finding” Section in the
Reference section of this Manual.
4Watch the oil pressure warning light and
alternator charging indicator light. If there is
no charge or if the oil pressure warning light
does not go out after a second or two, havinghad time to fill the new oil filter, switch off and
recheck.
5If the warning lights go out, set the engine
to run on fast idle and check the engine for
leaks.
6Check the coolant level; it will probably go
down as air locks are filled.
7Keep the engine running at a fast idle and
bring it up to normal working temperature. As
the engine warms up, there will be some odd
smells and smoke from parts getting hot and
burning off oil deposits.
8When the engine running temperature has
been reached, adjust the idling speed, as
described in Chapter 3. Check and, if
necessary, adjust the ignition timing using a
stroboscope (see Chapter 4).
9Stop the engine and wait a few minutes;
check to see if there are any coolant or oil
leaks.
10Road test the car to check that the engine
is running with the correct smoothness and
power. If it does not, refer to “Fault finding” in
the Reference section of this Manual. Do not
race the engine. If new bearings and/or
pistons and rings have been fitted, it should
be treated as a new engine and run it at
reduced speed for at east 800 km (500 miles).
11After 800 km (500 miles) change the
engine oil and filter.
1•34 1116 cc and 1301 cc engine
44.32 Inner wing protective shield44.26B Coolant temperature switch44.26A Oil pressure warning switch
44.22B Transmission earth lead
44.22A Reversing lamp switch on
transmission44.21B Brake servo hose at manifold44.21A Heater hose at manifold