1983 FIAT UNO remove seats

light alloy construction and is easily damaged
use a blunt scraper or rotary wire brush to
clean all traces of carbon deposits from the
combustion spaces and the ports. The valve
head stems and valve guides should also be
freed from any carbon deposits. Wash the
combustion spaces and ports down with
paraffin and scrape the cylinder head surface
free of any foreign matter with the side of a
steel rule, or a similar article.
8If the engine is installed in the car, clean the
pistons and the top of the cylinder bores. If
the pistons are still in the block, then it is
essential that great care is taken to ensure
that no carbon gets into the cylinder bores as
this could scratch the cylinder walls or cause
damage to the piston and rings. To ensure
this does not happen, first turn the crankshaft
so that two of the pistons are at the top of
their bores. Stuff rag into the other two bores
or seal them off with paper and masking tape.
The waterways should also be covered with
small pieces of masking tape to prevent
particles of carbon entering the cooling
system and damaging the coolant pump.
9With a blunt scraper carefully scrape away
the carbon from the piston crown, taking care
not to scratch the aluminium. Also scrape
away the carbon from the surrounding lip of
the cylinder wall. When all carbon has been
removed, scrape away the grease which will
now be contaminated with carbon particles,
taking care not to press any into the bores. To
assist prevention of carbon build-up the
piston crown can be polished with a metal
polish. Remove the rags or masking tape from
the other two cylinders and turn the
crankshaft so that the two pistons which were
at the bottom are now at the top. Place rag in
the cylinders which have been decarbonised,
and proceed as just described.
10Examine the head of the valves for pitting
and burning, especially the heads of the
exhaust valves. The valve seatings should be
examined at the same time. If the pitting on
the valve and seat is very slight, the markscan be removed by grinding the seats and
valves together with coarse, and then fine,
valve grinding paste.
11Where bad pitting has occurred to the
valve seats it will be necessary to recut them
and fit new valves. This latter job should be
entrusted to the local agent or engineering
works. In practice it is very seldom that the
seats are so badly worn. Normally it is the
valve that is too badly worn for refitting, and
the owner can easily purchase a new set of
valves and match them to the seats by valve
grinding.
12Valve grinding is carried out as follows.
Smear a trace of coarse carborundum paste
on the seat face and apply a suction grinder
tool to the valve head. With a semi-rotary
motion, grind the valve head to its seat, lifting
the valve occasionally to redistribute the
grinding paste. When a dull matt even surface
is produced on both the valve seat and the
valve, wipe off the paste and repeat the
process with fine carborundum paste, lifting
and turning the valve to redistribute the paste
as before. A light spring placed under the
valve head will greatly ease this operation.
When a smooth unbroken ring of light grey
matt finish is produced, on both valve and
valve seat faces, the grinding operation is
complete. Carefully clean away every trace of
grinding compound, take great care to leave
none in the ports or in the valve guides. Clean
the valve seats with a paraffin soaked rag,
then with a clean rag, and finally, if an air line
is available, blow the valves, valve guides and
valve ports clean.
13Check that all valve springs are intact. If
any one is broken, all should be renewed.
Check the free height of the springs against
new ones. If some springs are not within
specifications, replace them all. Springs suffer
from fatigue and it is a good idea to renew
them even if they look serviceable.
14Check that the oil supply holes in the
rocker arms are clear.
15The cylinder head can be checked for
warping either by placing it on a piece of plate
glass or using a straight-edge and feeler
blades. If there is any doubt or if its block face
is corroded, have it re-faced by your dealer or
motor engineering works.
16Test the valves in their guides for side toside rock. If this is any more than almost
imperceptible, new guides must be fitted.
Again this is a job for your dealer as a special
tool is required to ensure the correct
installation depth and the cylinder head must
be warmed to 80ºC (176ºF) before fitting the
guides.
17Commence reassembly by oiling the stem
of the first valve and pushing it into its guide
which should have been fitted with a new oil
seal (photos).
18Fit the spring seat. Fit the valve spring so
that the closer coils are towards the cylinder
head and then fit the spring retaining cap.
19Compress the valve spring and locate the
split cotters in the valve stem cut-out (photo).
20Gently release the compressor, checking
to see that the collets are not displaced.
21Fit the remaining valves in the same way.
22Tap the end of each valve stem with a
plastic or copper-faced hammer to settle the
components.
23The cylinder head is now ready for
refitting as described in Section 7.
18 Examination and renovation
4
1With the engine stripped down and all parts
thoroughly clean, it is now time to examine
everything for wear. The following items
should be checked and where necessary
renewed or renovated as described in the
following Sections.
Cylinder block and crankcase
2Examine the casting carefully for cracks
especially around the bolt holes and between
cylinders.
3The cylinder bores must be checked for
taper, ovality, scoring and scratching. Start by
examining the top of the cylinder bores. If they
are at all worn, a ridge will be felt on the thrust
side. This ridge marks the limit of piston ring
travel. The owner will have a good indication
of bore wear prior to dismantling by the
quantity of oil consumed and the emission of
blue smoke from the exhaust especially when
the engine is cold.
4An internal micrometer or dial gauge can be
903 cc engine 1•17
17.19 Fitting split collets17.17B Inserting a valve into its guide17.17A Valve stem oil seal
1
Press a little grease into the
gap between the cylinder
walls and the two pistons
which are to be worked on.

6Remove the spring seat (photo).
7Discard the valve stem oil seal and fit a new
one (photo).
8Remove the remaining valves in a similar
way and keep the components in their
originally fitted sequence.
9Reassembly is a reversal of removal. Refit
the components to their original positions, but
renew the valve springs if their free length is
less than that of a new spring or if the
springs have been in operation for more than
80 000 km (50 000 miles).
10The original valve clearance adjusting
shims will no longer provide the correct
clearances if the valves have been ground in
or the seats recut. Only where dismantling of
a valve was carried out to renew a spring is
there any purpose in returning the shims to
their original locations. Try to obtain the loan
of eight thin shims from your dealer and insert
them into the tappets (cam followers) before
assembling the cam followers to the carrier,
where they should be retained with thick
grease (photo).
11Fit the camshaft carrier, complete with
cam followers and shims to the cylinder head.
12Adjust the valve clearances as described
in Section 26.
40 Examination and renovation
4
1The procedures are similar to those
described in Section 18 covering the
following:
Cylinder block and crankcase
Crankshaft and bearings
Pistons and piston rings
Flywheel
2The following additional items must also be
examined.
Oil pump
3Carefully, clamp the pump housing in a
vice, shaft downwards.
4Take off the pump cover, with the suction
pipe. This will release the oil pressure relief
valve inside. Also inside is a filter.
5Remove the internal cover plate.6Take out the driveshaft and the gears.
7Clean and examine all the parts. Measure
the clearances against the Specifications. The
end clearance is measured by putting a
straight-edge across the cover face.
8The oil pump should only need
replacements after very long mileage, when
the rest of the engine is showing great signs
of wear.
9The length of a new gear can be measured
against the old gear to see if a new gear will
restore the end clearance to the Specifica-
tions. Otherwise the housing must be
changed.
10The driven gear shaft is mounted in the
housing with an interference fit. If there is any
slackness, a new housing (which will come
with shaft fitted) must be used.
11The oil pump shares its drive with the
distributor.
Camshaft, cam followers and
shims
12The camshaft journals and cams should
be smooth, without grooves or scores.
13Wear in the camshaft carrier bearings can
only be rectified by renewal of the carrier.
14Cam follower wear is usually very small
and when they show slackness in their bores,
it is probably the light alloy of the camshaft
carrier which has worn.
15Always measure the thickness of the valve
clearance shims using a metric micrometer.
Any grooving or wear marks in the shims
should be rectified by renewal with ones of
similar thickness.
Auxiliary shaft
16The shaft journals, the fuel pump
eccentric, and the drivegear for the distributor
and oil pump should be smooth and shiny. If
not, the shaft will have to be renewed.
17The bushes should still be tight in the
cylinder block, their oil holes lined up with
those in the block.
18Measure the bearing clearance. If
excessive, the bushes will have to be
renewed. They are a press fit, and require
reaming with a special reamer after fitting.
This is a job best done by a Fiat agent with the
special tools.
19Ensure the new bushes are fitted with the
oil holes lined up.
20Also check the driven gear and its bush.
21It is recommended a new oil seal is fitted
in the endplate. Hold the shaft in a vice, and
remove the pulley. Fit the new oil seal in the
endplate, lips inwards.
Timing belt tensioner
22Check the bearing revolves smoothly and
freely, and has no play. Do not immerse it in
cleaning fluid, as it is partially sealed. Wipe
the outside, and then smear in some new
general purpose grease.
23The action of the spring will have been felt
when the belt was taken off. It should be
cleaned, and oiled, to prevent seizure through
dirt and rust.
24Note the circlip on the engine right-hand
mounting bracket. This retains the timing belt
tensioner plunger.
1116 cc and 1301 cc engine 1•29
39.6 Valve spring seat39.5 Removing a valve39.4B Double valve springs
39.10 Cam followers fitted to camshaft
carrier39.7 Valve stem oil seal
1

can be drained out (photos). Brightwork
should be treated in the same way as
paintwork. Windscreens and windows can be
kept clear of the smeary film which often
appears, by the use of proprietary glass
cleaner. Never use any form of wax or other
body or chromium polish on glass.
3 Maintenance-
upholstery and carpets
1
Mats and carpets should be brushed or
vacuum-cleaned regularly, to keep them free
of grit. If they are badly stained, remove them
from the vehicle for scrubbing or sponging,
and make quite sure they are dry before
refitting. Seats and interior trim panels can be
kept clean by wiping with a damp cloth. If they
do become stained (which can be more
apparent on light-coloured upholstery), use a
little liquid detergent and a soft nail brush to
scour the grime out of the grain of the
material. Do not forget to keep the headlining
clean in the same way as the upholstery.
When using liquid cleaners inside the vehicle,
do not over-wet the surfaces being cleaned.
Excessive damp could get into the seams and
padded interior, causing stains, offensive
odours or even rot.
4 Minor body damage-
repair
3
Note:For more detailed information about
bodywork repair, Haynes Publishing produce
a book by Lindsay Porter called “The Car
Bodywork Repair Manual”. This incorporates
information on such aspects as rust treatment,
painting and glass-fibre repairs, as well asdetails on more ambitious repairs involving
welding and panel beating.
Repairs of minor scratches in
bodywork
If the scratch is very superficial, and does
not penetrate to the metal of the bodywork,
repair is very simple. Lightly rub the area of
the scratch with a paintwork renovator, or a
very fine cutting paste, to remove loose paint
from the scratch, and to clear the surrounding
bodywork of wax polish. Rinse the area with
clean water.
Apply touch-up paint to the scratch using a
fine paint brush; continue to apply fine layers
of paint until the surface of the paint in the
scratch is level with the surrounding
paintwork. Allow the new paint at least two
weeks to harden, then blend it into the
surrounding paintwork by rubbing the scratch
area with a paintwork renovator or a very fine
cutting paste. Finally, apply wax polish.
Where the scratch has penetrated right
through to the metal of the bodywork, causing
the metal to rust, a different repair technique
is required. Remove any loose rust from the
bottom of the scratch with a penknife, then
apply rust-inhibiting paint to prevent the
formation of rust in the future. Using a rubber
or nylon applicator, fill the scratch with
bodystopper paste. If required, this paste can
be mixed with cellulose thinners to provide a
very thin paste which is ideal for filling narrow
scratches. Before the stopper-paste in the
scratch hardens, wrap a piece of smooth
cotton rag around the top of a finger. Dip the
finger in cellulose thinners, and quickly sweep
it across the surface of the stopper-paste in
the scratch; this will ensure that the surface of
the stopper-paste is slightly hollowed. The
scratch can now be painted over as described
earlier in this Section.
Repairs of dents in bodywork
When deep denting of the vehicle’s
bodywork has taken place, the first task is to
pull the dent out, until the affected bodywork
almost attains its original shape. There is little
point in trying to restore the original shape
completely, as the metal in the damaged area
will have stretched on impact, and cannot be
reshaped fully to its original contour. It isbetter to bring the level of the dent up to a
point which is about 3 mm below the level of
the surrounding bodywork. In cases where the
dent is very shallow anyway, it is not worth
trying to pull it out at all. If the underside of the
dent is accessible, it can be hammered out
gently from behind, using a mallet with a
wooden or plastic head. Whilst doing this,
hold a suitable block of wood firmly against
the outside of the panel, to absorb the impact
from the hammer blows and thus prevent a
large area of the bodywork from being
“belled-out”.
Should the dent be in a section of the
bodywork which has a double skin, or some
other factor making it inaccessible from
behind, a different technique is called for. Drill
several small holes through the metal inside
the area - particularly in the deeper section.
Then screw long self-tapping screws into the
holes, just sufficiently for them to gain a good
purchase in the metal. Now the dent can be
pulled out by pulling on the protruding heads
of the screws with a pair of pliers.
The next stage of the repair is the removal
of the paint from the damaged area, and from
an inch or so of the surrounding “sound”
bodywork. This is accomplished most easily
by using a wire brush or abrasive pad on a
power drill, although it can be done just as
effectively by hand, using sheets of abrasive
paper. To complete the preparation for filling,
score the surface of the bare metal with a
screwdriver or the tang of a file, or
alternatively, drill small holes in the affected
area. This will provide a really good “key” for
the filler paste.
To complete the repair, see the Section on
filling and respraying.
Repairs of rust holes or gashes
in bodywork
Remove all paint from the affected area,
and from an inch or so of the surrounding
“sound” bodywork, using an abrasive pad or a
wire brush on a power drill. If these are not
available, a few sheets of abrasive paper will
do the job most effectively. With the paint
removed, you will be able to judge the severity
of the corrosion, and therefore decide
whether to renew the whole panel (if this is
possible) or to repair the affected area. New
body panels are not as expensive as most
people think, and it is often quicker and more
satisfactory to fit a new panel than to attempt
to repair large areas of corrosion.
Remove all fittings from the affected area,
except those which will act as a guide to the
original shape of the damaged bodywork (eg
headlight shells etc). Then, using tin snips or a
hacksaw blade, remove all loose metal and
any other metal badly affected by corrosion.
Hammer the edges of the hole inwards, in
order to create a slight depression for the filler
paste.
Wire-brush the affected area to remove the
powdery rust from the
surface of the remaining metal. Paint the
12•2 Bodywork
2.4B Sill drain with non-return valve2.4A Door drain hole
If the inside of the vehicle
gets wet accidentally, it is
worthwhile taking some
trouble to dry it out properly,
particularly where carpets are involved.
Do not leave oil or electric heaters
inside the vehicle for this purpose.

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

crankcase. If the shells are to be used again,
keep them with their respective bearing caps.
70The thrust washers which control
crankshaft endfloat are located in the
crankcase, and retained by the turned-over
edges of the centre main bearing shell.
71The engine is now fully stripped.
Examination and renovation
72The procedures for the following items are
essentially as described in Chapter 1, Sec-
tion 18.
Cylinder block and crankcase
Crankshaft and bearings
Flywheel
Oil seals and gaskets
Cylinder head
73Using a straight-edge, check the cylinder
head gasket surface for distortion. If it
exceeds the specified tolerance, it must be
surface ground by your dealer.74Refer to Chapter 1, Section 39, for
dismantling and renovation operations. Note
that single valve springs are fitted.
Oil pump
75Checking operations are described in
sub-Section B.
Pistons and connecting rods
76Refer to sub-Section B.
77If one or more connecting rods are
changed, it is important that its weight is
identical to that of the original. Use an
accurate balance to weigh them and remove
metal if necessary from the new rod in the
areas indicated in Fig. 13.7.
Camshaft and cam followers
78If the camshaft journals or bearings show
any sign of wear or scoring, then the
camshaft, or cylinder head, or both must be
renewed.
79The cam followers should be checked for
ovality using a micrometer. Unless unworn
they should be renewed.
Timing belt tensioner and timing belt
80The tensioner is a lubricant-sealed pulley,
and it should be tested for smooth and quiet
operation by turning it with the fingers. Any
evidence of roughness or rattle will indicate
the need for a new assembly (photo).81The timing belt should be inspected at
regular intervals for correct adjustment and
condition (see Section 3 or “Routine
maintenance” at the beginning of the Manual).
If there is evidence of worn teeth, cracking or
fraying, or oil contamination, renew the belt.
The vehicle manufacturers recommend that
the belt is renewed whenever it is removed,
and it should certainly be renewed at the
intervals specified in Section 3 or the main
“Routine maintenance” section at the
beginning of this Manual as a precautionary
measure against belt breakage and
consequent expensive engine damage.
PART D:
ENGINE REASSEMBLY AND
REFITTING
Reassembly - general
1Refer to Chapter 1, Section 19.
Complete reassembly#
2With the cylinder block/crankcase standing
on the work surface, fit the bearing half shells
into their crankcase seats (photo). Make sure
that the seats are perfectly clean as dirt or grit
trapped under the shell will cause binding
when the crankshaft is turned.
3The centre bearing crankcase web
incorporates the thrust washers held by the
lips of the bearing shell (photo).
4Oil the shells and lower the crankshaft into
the crankcase (photo).
5Fit the bearing shells into the main bearing
caps, again making sure that the shell seats
are perfectly clean (photo).
13•30 Supplement: Revisions and information on later models
5D.5 Main bearing cap and shell5D.4 Fitting the crankshaft5D.3 Crankshaft thrust washer at centre
bearing
5D.2 Main bearing shell in crankcase
Fig. 13.8 Checking a cam follower for
ovality - 999 and 1108 cc engine (Sec 5C)
Fig. 13.7 Metal removing areas (arrowed)
on connecting rod - 999 and 1108 cc
engine (Sec 5C)
5C.80 Timing belt tensioner

tightened, refit the five smaller (M8 x 1.25)
bolts adjacent to the line of the spark plug
holes and tighten them to their specified
torque wrench setting (photo).
123Reconnect the associated fittings to the
cylinder head in the reverse order of removal.
Ensure that the mating faces of the exhaust
manifold-to-downpipe are clean and fit a new
gasket when reconnecting.
124Ensure that all wiring connections are
cleanly and securely made.
125Top up the engine oil and coolant levels
as required on completion.
Cylinder head
(1372 cc Turbo ie engine)
- removal and refitting
#
126Proceed as described in paragraphs 102
to 125 above for the non-Turbo model, but
note the following differences.127The cylinder head cannot be removed
and refitted with the manifolds and
turbocharger fitted. It is therefore first
necessary to detach and remove the inlet
manifold, then the turbocharger and the
exhaust manifold as described in Section 9.
128The ignition distributor is mounted on the
side of the engine, not the rear end of the
cylinder head as on the “ie” engine. It is
therefore only necessary to disconnect the HT
leads from the spark plugs.
Cylinder head - inspection
and renovation¢
Note: Refer to a dealer for advice before
attempting to carry out valve grinding or seat
recutting operations. These operations may
not be possible for the DIY mechanic due to
the fitment of hardened valve seats for use
with unleaded petrol.129Use a straight-edge to check the cylinder
head gasket surface for distortion. If it
exceeds the specified tolerance, it must be
resurfaced by a FIAT dealer or automotive
engineer.
130Refer to Section 39 in Chapter 1 for the
general details on dismantling and renovating
operations on the cylinder head but note that
there is a spring seat and a flat washer fitted
between the cylinder head and the valve
springs (photos).
Crankshaft front oil seal -
removal and renewal#
131Remove the timing belt as described
earlier in this Section. Note that as mentioned
previously, the timing belt will need to be
renewed during reassembly.
132Referring to Fig. 13.18, loosen off the bolt
indicated from the timing belt rear cover.
13•44 Supplement: Revisions and information on later models
7B.130H . . . the outer spring . . .7B.130G . . . the inner spring . . .7B130F . . . locate the spring seat . . .
7B.130E Refit the flat washer . . .7B.130D . . . and drive it into position7B.130C . . . locate stem oil seal . . .
7B.130B Valve assembly - 1372 cc engine;
insert valve into guide . . .7B.130A Inlet (A) and exhaust (B) valves
and associate components - 1372 cc
engine7B.122 Tighten the smaller cylinder head
bolts to their specified torque setting

61Refer to Part B of this Section for details
and remove the flywheel.
62Refer to the previous sub-Section for
details and remove the auxiliary shaft.
63Refer to Part B of this Section for details
and remove the sump.
64Refer to Part B of this Section for details
and remove the oil pump unit.
65Refer to Part B of this Section for details
and remove the front and rear crankshaft oil
seals.
66Refer to Part B of this Section and remove
the piston/connecting rod assemblies.
67Refer to Part B of this Section for details
and remove the crankshaft and main bearing
assemblies.
Crankshaft and main
bearings - removal#
68Unscrew the securing bolts and remove
the front and rear crankshaft oil seal housings.
Recover the gaskets.
69Check the main bearing caps for identifi-
cation marks and if necessary use a
centre-punch to identify them. Normally the
caps have identifying notches cut into their
top face nearest the timing belt end of the
engine, with the exception of No 5 cap
(flywheel end) which has no marking (photo).
70Before removing the crankshaft, check
that the endfloat is within the specified limits.
Ideally a dial gauge should be used, but
alternatively feeler gauges can be used as
follows. Push the crankshaft as far as possible
towards the timing end of the engine, and
using a feeler gauge, measure the gap
between the rear face of the flywheel
mounting flange on the crankshaft and the
outer face of the thrust washer (photo). Now
push the crankshaft as far as possible in the
opposite direction and take the same
measurement again. The difference between
the two measurements is the crankshaft
endfloat. If the endfloat is outside the
specified limits, new thrustwashers will be
required.
71Unscrew the bolts and tap off the main
bearing caps complete with bearing shells. If
the bearing shells are to be re-used, tape
them to their respective caps.
72Lift the crankshaft from the crankcase.
73Extract the bearing shells from thecrankcase, keeping them identified for
location if they are to be re-used, and recover
the thrust washers from No. 5 main bearing
location.
Engine components -
examination and
renovation
#
74With the engine completely stripped,
clean all the components and examine them
for wear. Each part should be checked and
where necessary renewed or renovated as
described elsewhere in this Section. Renew
main and big-end bearing shells as a matter of
course, unless it is known that they have had
little wear and are in perfect condition.
75If in doubt as to whether to renew a
component which is still just serviceable,
consider the time and effort which will be
incurred should the component fail at an early
date. Obviously the age and expected life of
the vehicle must influence the standards
applied.
76Gaskets, oil seals and O-rings must all be
renewed as a matter of course. FIAT specify
that the main cylinder head bolts should be
renewed after they have been used (ie
tightened) four times - if in any doubt as to the
number of times the bolts have been used,
renew them in any case as a precaution
against possible failure.
77Take the opportunity to renew the engine
core plugs while they are easily accessible.
Knock out the old plugs with a hammer and
chisel or punch. Clean the plug seats, smearthe new plugs with sealant and tap them
squarely into position.
78Clean and examine the cylinder block as
described in paragraphs 2 to 7 of Section 18,
Chapter 1.
79If the auxiliary shaft bushes are
excessively worn or are oval, they must be
renewed. When the new bushes are installed,
they may need to be reamed to suit. The
renewal of the auxiliary shaft bushes is
therefore best entrusted to an engine
reconditioner or FIAT dealer. When the
bushes are renewed, ensure that the oil hole
in each bush is aligned with the oil channel in
the cylinder block.
PART D: ENGINE
REASSEMBLY
Reassembly - general
1Refer to Chapter 1, Section 19.
Crankshaft and main
bearings - refitting#
2Ensure that the crankcase and crankshaft
are thoroughly clean, and that the oilways are
clear. If possible, blow through the oil drillings
with compressed air, and inject clean engine
oil into them.
3Unless they are virtually new, the old main
bearing shells should be renewed. Failure to
do so is a false economy.
4If new bearing shells are being fitted, wipe
away all traces of protective grease.
5Note that there is a tag on the back of each
bearing shell, which engages with a groove in
the relevant seat in the crankcase or bearing
cap.
6Wipe clean the bearing shell locations in the
crankcase with a non-fluffy rag, then lubricate
them and fit the five upper halves of the
bearing shells to their seats. Note that the
centre (No. 3) bearing shell is plain, whereas
all the other shells have oil grooves (photos).
7Fit the thrustwashers to the No. 5 main
bearing shell location, with the grooved side
of each washer facing away from the face of
the cylinder block - ie towards the thrust face
of the crankshaft (photos).
8Wipe the bearing shell locations in the
13•52 Supplement: Revisions and information on later models
7D.6B . . . all others have oil groove7D.6A No. 3 main bearing shell is plain . . .
7C.70 Measuring crankshaft endfloat using
feeler gauge method7C.69 Identification notches on No. 3 main
bearing cap

26Loosen off the knurled retaining nut and
remove the cover from the fuel pump relay.
This is located on the left-hand suspension
turret in the engine compartment (photo).
27Carefully pull free the fuel pump relay,
then start the engine and run it until it stops
(photo). The fuel system is now
depressurised. Turn the ignition off before
removing/dismantling any components.
28Do not refit the fuel pump relay or turn the
ignition on until the system is fully
reconnected. When the engine is ready to be
restarted, refit the relay and its cover, then
restart the engine in the normal manner.
Fuel pump and supply
system checks°
29Specialised equipment is required to
undertake accurate tests in the fuel supply
system and such checks must therefore be
entrusted to a FIAT dealer or a fuel injection
specialist. If the fuel pump is suspected of
malfunction, a basic check can be made by
removing the fuel filler cap then listening
through the filler pipe, get an assistant to turn
on the ignition whilst you listen to hear if the
pump is heard to operate in the tank. If the
pump fails to operate, check that the pump
fuse is sound and that its connection (and
also that of the relay) are clean and secure.
30The pump can be further checked by first
depressurising the fuel system as described in
the previous sub-Section, then disconnect the
fuel supply pipe at the injector unit and locateit in a suitable container. With the fuel pump
relay removed, connect up a suitable test lead
with a 7.5 amp (10 amp on models with
catalyst) fuse, in series, to the relay terminals
30 and 87, and check that fuel flows into the
container from the supply pipe (photo). If a
suitable pressure gauge is available for
connecting into the fuel line between the
engine compartment fuel filter and the
injection unit, check that the fuel pressure is
as specified at the beginning of this Chapter.
31If the pump fails to operate, check that the
battery is in good condition and that the pump
wiring connections are clean and secure
before condemning the pump. To remove the
pump unit from the fuel tank, proceed as
described in the following sub-Section.
Fuel pump -
removal and refittingÁ
32Release the pressure from the fuel system
as described previously.
33Move the front seats forward, then tilt the
rear seat cushions forward. Peel back the
luggage area floor cover from the right-hand
side towards the centre to expose the access
cover above the pump/sender unit in the floor.
Remove the access cover.
34Detach the wiring connectors from the
pump unit and the fuel level sender unit.
35Loosen off the hose retaining clips and
detach the fuel supply and return hoses from
the pump unit connections. Mark the hosesfor identity to avoid incorrect attachment
during refitting.
36Unscrew the retaining nuts then carefully
lift out and withdraw the fuel pump/level
sender unit from the fuel tank.
37Refitting is a reversal of the removal
procedure. A new seal gasket must be used
and it is important to ensure that all
connections are securely and correctly made.
Injector unit -
removal and refittingÁ
38Depressurise the fuel system as
described previously, then disconnect the
battery negative lead.
39Remove the air cleaner unit and the
rubber seal (photo).
40Disconnect the engine idle speed check
actuator lead and the throttle position switch
lead from the side faces of the injector unit.
41Undo the retaining clips and detach the
fuel supply and return hose from the injector
unit. If crimped type retaining clips are fitted,
they will have to be carefully cut free and new
screw type clips obtained to replace them.
Take care not to cut into the hoses when
releasing the crimped type clips.
42Detach the crankcase ventilation hose
from the fuel injector unit.
43Disconnect the accelerator linkage at the
throttle lever on the injector unit.
44Undo the four retaining screws and lift the
injector unit from the inlet manifold. Remove
the gasket (photo).
45Clean the injector unit and the inlet
manifold mating faces.
46Refit in the reverse order of removal.
Intake air temperature
sensor - removal and
refitting
Á
47The air temperature sensor is located in
the top of the injector unit. It is basically a
resistor which varies its value in accordance
with the air temperature entering the induction
circuit from the air filter. The sensor can then
transmit the registered air temperature at this
point to the ECU temperature sensor (2).
48Remove the air cleaner unit and its
mounting bracket in the injector.
49Disconnect the wiring connector from the
13•76 Supplement: Revisions and information on later models
9D.44 Injector unit retaining screws
(arrowed)9D.39 Removing the filter seal from the
injector unit
9D.30 Test lead connected to relay
terminals 30 and 879D.27 Fuel pump relay removal9D.26 Fuel pump relay (1), injection control
relay (2), Lambda sensor fuse (3) and pump
fuse (4) with cover (5) removed