Fiat 45 manual

Fiat Uno Service and Repair Manual Peter G Strasman Models covered Fiat Uno 45, 55, 60, 70, 1.1 and 1.4, including Turbo ie and special/limited editions 903 cc, 999 cc, 1108 cc, 1116 cc, 1299 cc, 1301 cc and 1372 cc petrol engines with manual transmissions Does not Selecta, Fiorino type vans or Diesel engine (923-320-3Y7) © Haynes Publishing 1996 [...]

Contents LIVING WITH YOUR FIA T UNO Introduction Page 0•4 Safety First! Page 0•5 General dimensions, weights and capacities Page 0•6 Roadside Repairs Jump starting Page 0•7 Jacking, towing and wheel changing Page 0•8 Identifying leaks Page 0•9 Routine Maintenance and Servicing Maintenance schedule (also see Chapter 13) Page 0•10 Recom[...]

REP AIRS & OVERHAUL Engine and Associated Systems Engine (also see Chapter 13) Page 1•1 Cooling and heating systems (also see Chapter 13) Page 2•1 Fuel system (also see Chapter 13) Page 3•1 Ignition system (also see Chapter 13) Page 4•1 T ransmission Clutch (also see Chapter 13) Page 5•1 Transmission (also see Chapter 13) Page 6•1 D[...]

The Fiat Uno is a well designed and constructed car having an excellent power-to-weight ratio. The car is very economical, but still offers good performance with excellent body interior space. Attractive features include the options available for four- or five-speeds or three- or five-door bodywork. All essential accessories, except a radio, are fi[...]

Safety First! 0•5 W orking on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of cr eating a safety-conscious attitude. General hazar ds Scalding • Don’t r emove the radiator or expansion tank cap while the engine is hot. • Engine oil, automatic transmission fluid or power steering fluid[...]

0•6 General dimensions, weights and capacities Dimensions Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3644 mm (143.6 in) Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1555 mm (61.3 in) Height . . . . . . . . . . . . . . . . . .[...]

Roadside Repairs 0•7 Connect one end of the red jump lead to the positive (+) terminal of the flat battery Connect the other end of the red lead to the positive (+) terminal of the booster battery. Connect one end of the black jump lead to the negative (-) terminal of the booster battery Connect the other end of the black jump lead to a bolt or b[...]

0•8 Roadside 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[...]

Roadside Repairs 0•9 Puddles on the garage floor or drive, or obvious wetness under the bonnet or underneath the car , suggest a leak that needs investigating. It can sometimes be difficult to decide where the leak is coming fr om, especially if the engine bay is very dirty already . Leaking oil or fluid can also be blown rearwar ds by the passag[...]

0•10 Routine 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 su[...]

Routine maintenance 0•11 Engine compartment (air cleaner removed for clarity) on 55S model 1 Strut upper mounting 2 Washer fluid reservoir 3 Brake fluid reservoir 4 Ignition coil 5 Throttle cable 6 Carburettor 7 Battery 8 Timing belt cover 9 Distributor 10 Oil filler cap 11 Radiator electric cooling fan 12 Radiator 13 Coolant expansion tank 14 Fr[...]

0•12 Routine maintenance View of front end from below on 55S model 1 Tie-rod end 2 Track control arm 3 Lower mounting 4 Gearchange control rods 5 Exhaust pipe 6 Driveshafts 7 Transmission 8 Sump drain plug 9 Disc caliper 10 Front mounting 11 Horns 12 Radiator 13 Oil filter View of rear end from below 1 Suspension trailing arm 2 Fuel tank filler h[...]

Lubricants and Fluids 0•13 Component or system Lubricant type/specification 1 Engine Multigrade engine oil, viscosity SAE 15W/40, meeting API-SG or CCMC G2/G3 specification (or equivalent multigrade engine oil with viscosity rating suitable for ambient temperature in which vehicle is operated - see owner’s handbook) 2 Transmission: 1372 cc Turb[...]

0•14 Conversion Factors Length (distance) Inches (in) x 25.4 = Millimetres (mm) x 0.0394 = Inches (in) Feet (ft) x 0.305 = Metres (m) x 3.281 = Feet (ft) Miles x 1.609 = Kilometres (km) x 0.621 = Miles V olume (capacity) Cubic inches (cu in; in 3 ) x 16.387 = Cubic centimetres (cc; cm 3 ) x 0.061 = Cubic inches (cu in; in 3 ) Imperial pints (Imp [...]

1 903 cc engine Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four cylinder in-line, liquid cooled, overhead valve. Transversely mounted with end-on transmission General Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.0 mm (2[...]

Cylinder block and crankcase Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast-iron Bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.000 to 65.050 mm (2.5591 to 2.5610 in) Diameter of camshaft bearing bores in crankcase timing g[...]

Cylinder head and valves Material (cylinder head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light alloy Maximum distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in) Valve guide bore in head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

1116 cc and 1301 cc engine Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four cylinder in-line, liquid cooled single overhead camshaft. Transversely mounted with end-on transmission General 1116 cc 1301 cc Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Crankshaft Journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.785 to 50.805 mm (1.9994 to 2.0002 in) Standard main bearing shell thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 1.825 to 1.831 mm (0.0719 to 0.0721 in) Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

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 jour[...]

Engine – general 1•7 Fig. 1.1 Longitudinal section of 903 cc engine (Sec 1) Fig. 1.3 Longitudinal section of 1116 cc and 1301 cc engines (Sec 1) Fig. 1.2 Cross-section of 903 cc engine (Sec 1) Fig. 1.4 Cross-section of 1116 cc and 1301 cc engines (Sec 1) 1[...]

2 Engine oil and filter 1 1 The engine oil level should be checked at the weekly service (see “ Routine Maintenance” ). Preferably check the level cold, first thing in the morning or if the engine has been running, allow at least ten minutes to elapse after switching off to permit the oil to drain. 2 Withdraw the dipstick, wipe it clean on non-[...]

Cylinder head - removal and refitting Sump pan - removal and refitting Pistons/connecting rods - removal and refitting Oil pump - removal and refitting Engine mountings - renewal 1116 cc and 1301 cc engines Valve clearances - checking and adjusting Camshaft and camshaft carrier - removal and refitting Timing belt - removal and refitting Cylinder he[...]

13 Engage the timing chain with the teeth of the crankshaft sprocket. Then locate the camshaft sprocket within the upper loop of the chain in such a way that when the sprocket is pushed onto the camshaft, the timing marks will be in alignment. Make sure that the self-tensioning links are on the inside of the chain against the cylinder block (photos[...]

19 Never smear grease on the gasket as, when the engine heats up, the grease will melt and may allow compression leaks to develop. 20 The cylinder head gasket cannot be fitted incorrectly due to its asymmetrical shape, but the word ALTO should be uppermost in any event (photo). 21 The locating dowels should be refitted to the front right and left-h[...]

9 Pistons/connecting rods - removal and refitting 3 1 Remove the cylinder head as described in Section 7. 2 Remove the sump pan as described in Section 8. 3 Undo and remove the big-end cap retaining bolts and keep them in their respective order for correct refitting. 4 Check that the connecting rod and big-end bearing cap assemblies are correctly m[...]

24 Screw in the big-end bolts and tighten to the specified torque (photo). 25 Refit the sump pan (Sec 8) and the cylinder head (Sec 7). 26 Refill the engine with oil and coolant. 10 Oil pump - removal and refitting 1 1 Remove the sump pan as described in Section 8. 2 Unscrew the two bolts which hold the oil pump housing to the underside of the cran[...]

Fig. 1.20 Flywheel housing cover plate removed (Sec 13) Fig. 1.19 Left-hand flexible mounting (Sec 13) 10 Disconnect the leads from the reversing lamp switch. 11 Disconnect the coolant hoses from the cylinder head and coolant pump. 12 Disconnect the fuel inlet hose from the fuel pump. Plug the hose. 13 Disconnect the throttle and choke controls fro[...]

31 Support the weight of the transmission and withdraw it in a straight line from the engine. 14 Engine - dismantling (general) 1 Stand the engine on a strong bench at a suitable working height. Failing this, it can be dismantled on the floor, but at least stand it on a sheet of hardboard. 2 During the dismantling process, the greatest care should [...]

16 Engine - complete dismantling 3 1 Unbolt and remove the rocker cover. 2 Unscrew the rocker pedestal securing nuts and lift away the rocker assembly. 3 Remove the pushrods, keeping them in their original fitted order. 4 Remove the cylinder head as described in Section 7. Remove the dipstick and guide tube. 5 Turn the engine on its side and unbolt[...]

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 fre[...]

used to check bore wear and taper against the Specifications, but this is a pointless operation if the engine is obviously in need of reboring due to excessive oil consumption. 5 Your engine reconditioner will be able to re-bore the block for you and supply the correct oversize pistons to give the correct running clearance. 6 If the engine has reac[...]

clearance and end gap. Both clearances should be checked with a feeler gauge. Check the end gap when the ring has been pushed squarely down the cylinder bore for two or three inches (photos). 25 If new rings are being used and the cylinder bores have not been rebored, always make sure that the top compression ring has been stepped to prevent it con[...]

Oil seals and gaskets 49 It is recommended that all gaskets and oil seals are renewed at major engine overhaul. Sockets are useful for removing or refitting oil seals. An arrow is moulded onto some seals to indicate the rotational direction of the component which it serves. Make sure that the seal is fitted the correct way round to comply with the [...]

micrometer to trace the cause of the trouble. It is very seldom that any trouble of this nature will be experienced when fitting the crankshaft. 9 Tighten the main bearing bolts to the specified torque wrench settings (photo). 10 Using a dial gauge or feeler blades inserted between a thrust washer and the crankshaft, check the crankshaft endfloat. [...]

17 Screw in the camshaft front bearing lockscrew (photo). Oil pump 18 Refit the oil pump as described in Sec- tion 10. Timing chain and sprockets 19 Fit the timing chain and sprockets as described in Section 6. Fit the Woodruff key to the crankshaft nose. 20 Using a new gasket, fit the timing chain cover, but leave the bolts finger tight (photo). 2[...]

removed and the weight of the car is again on its roadwheels. 4 Fill the cooling system. 5 Fill the engine with oil. 6 Replenish lost transmission oil. 7 Reconnect the battery. 8 Adjust the clutch pedal as described in Chapter 5. 24 Engine - initial start-up after overhaul or major repair 4 1 Make sure that the battery is fully charged and that all[...]

5 In practice, if several shims have to be changed, they can often be interchanged, so avoiding the necessity of having to buy more new shims than is necessary. 6 If more than two or three valve clearances are found to be incorrect, it will be more convenient to remove the camshaft carrier for easier removal of the shims. 7 Where no clearance can b[...]

8 Fit 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 (p[...]

head gasket must be fitted (ALTO visible) so that the oil pressure hole in the block is central in the copper ringed cut-out in the gasket (photos). Make sure that the gasket surfaces on head and block are perfectly clean and free from oil, otherwise the heat sealing (polymerisation) process of the gasket cannot take place. 22 Tighten the cylinder [...]

2 The 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 sh[...]

from the suspension struts and then remove the bolts which secure the hub carriers to the U-clamps at the base of the suspension struts. 23 Pull the tops of the hub carriers down and then outwards and push the driveshafts from them. 24 Unbolt the driveshaft inboard boot retainers and then remove the driveshafts from the transmission. 25 Support the[...]

6 Remove the spring seat (photo). 7 Discard the valve stem oil seal and fit a new one (photo). 8 Remove the remaining valves in a similar way and keep the components in their originally fitted sequence. 9 Reassembly is a reversal of removal. Refit the components to their original positions, but renew the valve springs if their free length is less t[...]

42.9 Fitting the auxiliary shaft 41 Engine - reassembly (general) Refer to Section 19, Part 2. 42 Engine - complete reassembly 4 Crankshaft and main bearings 1 Fit the bearing shells to their crankcase seats and to their caps. The seatings and backs of the shells must be spotlessly clean, otherwise tight spots will occur when the crankshaft is fitt[...]

plate to the crankcase, using a new gasket (photos). 11 Fit the belt sprocket and partially tighten its bolt. Then, using an oil filter strap wrench or similar device to hold the sprocket against rotation, tighten the bolt to the specified torque. Take care not to damage the teeth of the sprocket, which is of fibre construction (photo). Oil sump, s[...]

prevent the flywheel turning. Fit the engine endplate (photo). 20 Fit the timing belt sprocket to the front end of the crankshaft (photo). 21 Fit the crankshaft pulley and the nut; tighten it to the specified torque, again jamming the starter ring gear to prevent the crankshaft from rotating (photo). Cylinder head 22 Refitting is described in Secti[...]

2 Draw the engine and transmission together by screwing in the connecting bolts. Refit lifting lugs and hose and wiring clips (photo). 3 Bolt the lower cover plate to the face of the flywheel housing. 4 Bolt the starter motor into position. 5 Bolt the mounting brackets into place. 6 Place the engine/transmission on the floor ready for raising by ho[...]

to the engine. Also reconnect the brake servo hose to the intake manifold (photos). 22 Reconnect the leads to the reversing lamp switch. Reconnect the transmission earth lead (photos). 23 Reconnect the clutch cable and adjust as described in Chapter 5. 24 Reconnect the speedometer drive cable to the transmission and tighten the knurled retaining ri[...]

Fault finding - all engines Note: When investigating starting and uneven running faults, do not be tempted into snap diagnosis. Start from the beginning of the check procedure and follow it through. It will take less time in the long run. Poor performance from an engine in terms of power and economy is not normally diagnosed quickly. In any event, [...]

Engine idles roughly m m Mixture too weak m m Air leak in carburettor m m Air leak at inlet manifold to cylinder head, or inlet manifold to carburettor m m Carburettor incorrectly adjusted m m Other fuel system fault (see Chapter 3) m m Low tension leads on coil loose m m Low tension lead to distributor loose m m Dirty, incorrectly set, or pitted c[...]

2 System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . “No loss” with radiator and integral expansion tank. Electric cooling fan, belt-driven coolant pump, thermostat on cylinder head General Radiator fan cuts in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to [...]

6 Avoid unscrewing the expansion tank cap when the engine is hot, but if this must be done, cover the cap with a cloth to avoid scalding by escaping steam. 7 Periodically, check the condition of all coolant hoses and tighten the clips. 2 Cooling system - draining, flushing and refilling 1 1 Set the heater temperature lever to maximum. 2 Unscrew the[...]

inhibitor should be used. Again, a reputable make giving full protection must be chosen and renewed every two years. Inhibitors with dyes are useful for finding leaks, and on some makes the dye shows when the inhibiting ability is finished. 4 Thermostat - removal, testing and refitting 1 1 The thermostat assembly is mounted on the flywheel end of t[...]

towards the engine. Slip the belt off the pulleys. If this is difficult, turn the crankshaft pulley using a spanner on its retaining nut while pressing the belt over the edge of the pulley rim. Use this method to fit the new belt after first having engaged it with the coolant pump and alternator pulley grooves. 5 Tension the belt as previously desc[...]

fluid. They are “sealed”. Liquid will get in, but a thorough clean will be impracticable, and it will be impossible to get new grease in. 17 Check all the parts, get a new gland, two new grommets, (1116 cc and 1301 cc) and a new gasket. Scrape all deposits out of the housing and off the impeller. 18 To reassemble, start by inserting the new gro[...]

5 Pull off the knobs from the control levers (photo). 6 Extract the screws and take off the control indicator plate (photos). Disconnect the leads from the cigar lighter and carefully detach the fibre optic which provides the panel illumination. 7 Unscrew and remove the screws which hold the console to the heater unit and withdraw the console. 8 Th[...]

2 The control lever mounting platform can be removed after extracting its fixing screws. 3 The coolant control valve can be removed after extracting its fixing nuts. 4 Unscrew the screws which hold the heater matrix in the casing and then slide the matrix from its location. 5 If the matrix is leaking, do not attempt a repair, but obtain a new one. [...]

Fault finding - cooling and heating systems 2•8 Cooling and heating systems Overheating m m Insufficient coolant in system m m Pump ineffective due to slack drivebelt m m Radiator blocked either internally or externally m m Kinked or collapsed hose causing coolant flow restriction m m Thermostat not working properly m m Engine out of tune m m Ign[...]

3 System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear mounted fuel tank, mechanically-operated fuel pump, downdraught carburettor Air cleaner element 903 cc (45) and 1116 cc (55) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W121 1116 cc (60) and 1299/1301 cc (70) engines [...]

Solex C32 DISA 11 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903 cc engine Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Auxiliary venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Weber 32 ICEV 51/250 (continued) Fuel inlet needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 Anti-syphon device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 Idle mixture adjustment hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 Float s[...]

Engine idle speed At normal operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 to 850 rev/min CO percentage at idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 maximum Torque wrench settings Nm lbf ft Exhaust manifold nuts (903 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

12 The air cleaner on the 1301 cc engine is mounted on the four flange studs of the carburettors, their nuts being accessible after the air cleaner lid has been removed and the filter element extracted. 13 Refitting of all types of air cleaner is a reversal of removal. 3 Fuel pump - removal and refitting 2 1 On 903 cc engines, the fuel pump is moun[...]

6 Carburettors - general 1 The need to completely overhaul a carburettor is rare. A carburettor can normally be kept in good working order if the top cover is removed and the fuel mopped out of the fuel bowl. Individual jets can be removed and blown through. Never probe them with wire or their calibration will be ruined. 2 Take the opportunity to c[...]

7 Carburettor idle speed and mixture - adjustment 4 1 All carburettors have their mixture adjustment set in production. The screw is fitted with a tamperproof cap. 2 Under normal circumstances, only the idle speed screw need be adjusted to set the engine idle speed to the specified level. 3 Before attempting to adjust the idle speed or mixture, it [...]

plate should be open (dimension A) (Fig. 3.1 2) between 0.75 and 0.80 mm (0.030 and 0.032 in). Adjust if necessary by means of the screw and locknut. Anti-flooding device 11 This consists of a diaphragm capsule and link rod. 12 The condition of the diaphragm can be checked by applying a vacuum source to the hole in the throttle valve plate block. T[...]

pump jet and give ten full strokes of the throttle lever, pausing between each stroke to allow fuel to finish dripping. 8 The total volume of fuel collected should be between 2.5 and 4.5 cc. Adjust the nut on the pump control and if necessary to increase or decrease the volume of fuel ejected. Fast idle adjustment 9 With the choke valve plate fully[...]

control unit is functioning, if the tachometer does not register, renew the ignition control unit. 16 If a replacement carburettor is to be fitted, only fit the Solex assembly including the control module, even if a Weber was originally fitted. 12 Carburettor (Weber 32 ICEV 51/250) - servicing and adjustment 4 1 This carburettor, fitted to 1116 cc [...]

Anti-flooding device (automatic) 10 Pull the choke control fully out and hold the control lever, on the anti-flooding device, depressed. There should be a gap (Y) (Fig. 3.27) between the edge of the choke valve plate and the carburettor wall of between 3.75 and 4.25 mm (0.15 and 0.17 in). If adjustment is required, turn the adjuster screw provided.[...]

19.7A Exhaust pipe support rings 17 Accelerator cable - adjustment and renewal 2 1 The socket type cable end fitting is detached from the carburettor throttle lever simply by prising it off the ball stud. 2 Adjustment can be carried out by releasing the locknut and turning the end fitting. With the accelerator pedal fully depressed, check that full[...]

6 On 1116 cc and 1301 cc models, the exhaust system is of dual downpipe, two silencer, two section type. 7 The exhaust system is flexibly mounted (photo). 8 Do not attempt to separate the sections of the exhaust system, while in position in the car. Unbolt the pipe from the manifold and, using a screwdriver, prise off the flexible suspension rings.[...]

4 System type Except ES engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery, coil mechanical breaker distributor ES engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marelli Digiplex electronic with breakerless distributor Firing order . . . . . . . . [...]

Spark plugs Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RN9YCC or RN9YC Electrode gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm (0.031 in) HT leads 903 cc (45) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

outwards, they rotate the cam relative to the distributor shaft, and so advance the spark. The weights are held in position by two springs and it is the tension of the springs which is largely responsible for correct spark advancement. The vacuum advance is controlled by a diaphragm capsule connected to the carburettor venturi. The vacuum pressure [...]

Note the washers above and below the contact assembly (photos). 23 Fit the new contact assembly by reversing the removal operations. 24 Although the points gap is normally set in production, check it using feeler blades when the plastic heel of the movable arm is on a high point of the shaft cam. Adjust if necessary by inserting an Allen key (3.0 m[...]

5 Condenser (capacitor) - removal, testing and refitting 1 The purpose of the condenser (sometimes known as the capacitor) is to ensure that when the contact breaker points open there is no sparking across them which would weaken the spark and cause rapid deterioration of the points. The condenser is fitted in parallel with the contact breaker poin[...]

Reassembly 14 This is a reversal of dismantling. On Ducellier distributors, make sure that the advance toothed segment is returned to its original setting otherwise the advance curves for your particular engine will be upset. 8 Ignition coil (mechanical breaker ignition) 1 Coils normally last the life of a car. The most usual reason for a coil to f[...]

important that the following precautions are observed. 3 Never start the engine if the battery leads are loose. 4 Do not stop the engine by pulling off a battery lead. 5 Remove the control unit if ambient temperature (paint drying oven) is above 80ºC (176ºF). 6 Never connect or disconnect the multi-plug at the control unit unless the ignition is [...]

this type is used and the engine is in good condition, the spark plugs should not need attention between scheduled replacement intervals. Spark plug cleaning is rarely necessary and should not be attempted unless specialised equipment is available as damage can easily be caused to the firing ends. 2 At the specified intervals, the plugs should be r[...]

Fault finding - mechanical br eaker ignition system Ignition system 4•9 4 Engine fails to start m m Loose battery connections m m Discharged battery m m Oil in contact points m m Disconnected ignition leads m m Faulty condenser Engine overheats, lacks power m m Seized distributor weights m m Perforated vacuum pipe m m Incorrect ignition timing En[...]

8 System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual-circuit hydraulic with servo unit and pressure regulating valve. Discs front, drums rear. Handbrake mechanical to rear wheels. Disc brakes Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

3.4 Removing the caliper unit 1 General description The braking system is of four wheel hydraulic type with discs on the front wheels and drums on the rear. The hydraulic system is of dual-circuit type and incorporates a pressure regulator valve to limit pressure to the rear brakes during heavy braking to prevent rear wheel lock up. A vacuum servo [...]

into its cylinder to accommodate them. This will cause the fluid level to rise in the reservoir. Anticipate this by syphoning some out beforehand, but take care not to let it drip onto the paintwork - it acts as an effective paint stripperl 8 Refit the anti-rattle springs, the pads (friction lining-to-disc), the cylinder body, the locking blocks an[...]

assembly and the flexible pipe, particularly the fixing bracket and union at the car end of the flexible pipe. 3 Have ready a container suitable to catch the brake fluid, and sheets of clean newspaper on which to put parts. 4 Take out the spring clips and locking blocks, and take the caliper off the support bracket. 5 Disconnect the hydraulic flexi[...]

9 Master cylinder - removal, overhaul and refitting 4 Note: Purchase a repair kit in advance of overhaul. 1 The master cylinder is mounted on the front face of the brake vacuum servo unit (55 and 70 models) or directly to the bulkhead (45 models). 2 Cover the front wings with polythene sheeting or similar material, in case hydraulic fluid spills on[...]

their originally fitted sequence and note in which direction the seal lips are located. 11 Inspect the surfaces of the piston and cylinder bore. If scoring, corrosion or metal-to-metal rubbing areas are evident, renew the master cylinder complete. 12 If the components are in good condition, discard the oil seals and manipulate the new ones into pos[...]

The hose ends can then be unclipped from the brackets. The mounting brackets, particularly on the body frame, are not very heavy gauge and care must be taken not to wrench them off (photo). 4 With the flexible hose removed, examine the internal bore. If it is blown through first, it should be possible to see through it. Any specks of rubber which c[...]

20 By connecting a pressurised container to the master cylinder fluid reservoir, bleeding is then carried out by simply opening each bleed screw in turn and allowing the fluid to run out, rather like turning on a tap, until no air is visible in the expelled fluid. 21 By using this method, the large reserve of hydraulic fluid provides a safeguard ag[...]

locknut and turn the adjuster nut on the handbrake primary rod (photo). 3 Raise the rear roadwheels and check that they turn freely when the handbrake lever is fully released. 17 Handbrake cable - renewal 1 1 There are two cables, either of which may be renewed independently 2 Disconnect the cable, which is to be renewed, from the shoe lever at the[...]

9 System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 negative earth, battery alternator and pre-engaged starter Battery Except 70S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Ah 70S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

1 General description The electrical system is of 12 volt negative earth type and employs a belt-driven alternator and a pre-engaged type starter motor. The models in the range are all adequately equipped with electrical accessories, while SX versions also have power windows and centralised door locking plus a check control system (Section 34). 2 B[...]

3 Alternator - maintenance and precautions 1 To avoid damage to the alternator, the following precautions should be observed. 1 Disconnect the leads from the battery before connecting a mains charger to the battery terminals. 2 Never stop the engine by pulling off one of the battery leads. 3 Disconnect the battery if electric welding is to be carri[...]

ease the holder out of the alternator. Inspect the brushes and if worn below the specified minimum length, they must be renewed. 7 Disconnect the brush leads by unsoldering or carefully cutting them. 8 When soldering the new brush leads, do not allow solder to run down them or their flexibility will be ruined. 9 When inspecting or renewing brushes,[...]

8 Withdraw the solenoid and yoke off the armature and from the drive end bracket. Note the steel and fibre washers and the shims on the armature shaft (photo). 9 Extract the split pin and tap out the engagement lever pivot pin. 10 Pull the rubber packing piece from the drive end bracket. 11 Withdraw the armature with solenoid plunger, coil spring a[...]

them. Carefully release the fibre optic filaments (photos). 6 A push-button switch can be removed by compressing its retaining tabs and pushing it from the panel. 7 A rocker switch can be removed if its knob is pulled off and the switch sections withdrawn from the panel. 8 Reassembly and refitting of both types of switches are reversals of removal [...]

the tyres correctly inflated and square to a wall, at a distance of 10.0 m (32.8 ft) from it. 4 Mark the wall to correspond with the centres of the headlamps. 5 Switch to dipped beams when the brightest parts of the light pattern should be below the marks on the wall by an amount equal to one tenth of the distance between the floor and the mark on [...]

20 Interior lamps - bulb renewal 1 Courtesy lamp 1 The lamp lenses, whether roof or pillar mounted, are removed by prising off using a screwdriver inserted under one end (photo). 2 The festoon type bulb is pulled from its spring contacts. Instrument panel lamps 3 Remove the instrument panel hood cover as described in the next Section. The panel lig[...]

3 Working at the transmission, disconnect the speedometer cable by unscrewing the knurled retaining ring (photo). 4 Withdraw the cable through the bulkhead grommet. 5 Refit the new cable assembly by reversing the removal operations. 24 Windscreen wiper blade and arm - removal and refitting 1 1 The wiper blade can be removed once the arm has been pu[...]

27 Tailgate wiper motor - removal and refitting 1 1 Remove the blade and arm as previously described. Unscrew the drive spindle bezel nut. 2 Open the tailgate fully. 3 Unclip and remove the wiper motor cover. 4 Unscrew the mounting screws, withdraw the motor and disconnect the wiring plug (photo). 5 Refitting is a reversal of removal. 28 Washer sys[...]

paintwork should the drill slip. Three methods of making the hole are in use: a) Use a hole saw in the electric drill. This is, in effect, a circular hacksaw blade wrapped round a former with a centre pilot drill. b) Use a tank cutter which also has cutting teeth, but is made to shear the metal by tightening with an Allen key. c) The hard way of dr[...]

3 The centralised door locking system can operate independently of the key. 4 To gain access to the lock solenoid and linkage, remove the front door trim panel as described in Chapter 12. 5 Disconnect the battery negative lead. 6 Disconnect the electrical wiring plugs from the solenoid within the door cavity. 7 Disconnect the solenoid from the lock[...]

sensors, lamp circuits and the control unit. Corrosion at the terminals may also be a contributory cause. 8 Never short circuit a sensor supply wire or the electronic module will be damaged. Check control unit and monitor - removal and refitting 9 Remove the instrument panel as described in Section 21. 10 Unbolt the control unit housing from the in[...]

9•14 Electrical system Fault finding - electrical system No voltage at starter motor m m Battery discharged m m Battery defective internally m m Battery terminals loose or earth lead not securely attached to body m m Loose or broken connections in starter motor circuit m m Starter motor switch or solenoid faulty Voltage at starter motor - faulty [...]

10 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack and pinion with safety column Steering wheel diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381.0 mm (15.0 in) Number of turns, lock-to-lock . . . . . . . . . . . . . . . . . . . . . . . . 4 Turning circle . . . .[...]

2 Tie-rod end balljoint - renewal 4 1 Jack up the front of the car and remove the roadwheel from the side on which the balljoint is to be renewed. 2 Unscrew the tie-rod balljoint taper pin nut and, using a suitable extractor, separate the tie-rod balljoint from the eye of the steering arm (photo). 3 Release the locknut on the tie-rod, unscrewing it[...]

13 Stake the lower end of the tube to retain the bush. 14 Reassembly is a reversal of removal, noting that the universal joint coupling pinch-bolts should pass smoothly through the grooves in the steering shaft. 15 Fit the steering wheel when the roadwheels are in the straight-ahead position. 16 Tighten all nuts and bolts to the specified torque. R[...]

Note: Before diagnosing steering faults, be sure that trouble is not due to incorrect or uneven tyre pressures, inappropriate tyre combinations, or braking system or suspension defects. Car pulls to one side m m Incorrect steering geometry m m Collision damage Vibration at steering wheel m m Roadwheels out of balance or loose m m Tyre damage m m Lo[...]

11 Front suspension Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent with MacPherson struts and coil springs Coil springs Free height: 903 cc models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 mm (13.16 in) 1116 and 1301 cc models . .[...]

1 General description The front suspension is of independent MacPherson strut type. The rear suspension consists of a beam axle with trailing arms, coil springs and double acting gas-filled telescopic shock absorbers. Operations covering the hubs, roadwheels and tyres are described in Chapter 7. 2 Maintenance 4 1 Periodically check the tightness of[...]

release its top coil from the strut upper mounting, hold the flats on the strut spindle and unscrew the spindle nut. 8 Take off the upper mounting components and the clamped coil spring. The clamps need not be removed if the spring is to be fitted to a new strut. 9 Commence reassembly by fitting the coil spring onto the strut. Make sure that the sm[...]

balljoint from the hub carrier using a suitable “splitter” tool. If such a tool is not available, support the base of the brake disc and drive the balljoint taper pin downwards, but screw on the nut to protect the threads. 4 Remove the hub carrier. 5 Refitting is a reversal of removal, use a new driveshaft nut and tighten all nuts and bolts to [...]

10 Trailing arm rubber bush - renewal 3 1 A worn trailing arm rubber bush may be renewed in the following way. 2 Raise the rear of the car and support securely on axle stands placed under the body side-members or sill jacking points. 3 Remove the roadwheels. 4 Unscrew and remove both pivot bolts which hold the forward ends of the trailing arms to t[...]

Car pulls to one side m m Worn or weak shock absorbers or struts on one side Excessive roll on corners m m Weak shock absorbers or struts m m Coil spring weak or cracked Car wanders or skips on rough surfaces m m Defective shock absorbers or struts Vibration and wheel wobble m m Loose or defective shock absorbers or struts Excessive or uneven tyre [...]

12 For dimensions, weights etc. refer to the Introductory Section of this Manual. Chapter 12 Bodywork For modifications, and information applicable to later models, see Supplement at end of manual Bonnet - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bonnet - lock and release . . . . . . . . . . . . . . . . . . [...]

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 br[...]

affected area with rust-inhibiting paint, if the back of the rusted area is accessible, treat this also. Before filling can take place, it will be necessary to block the hole in some way. This can be achieved by the use of aluminium or plastic mesh, or aluminium tape. Aluminium or plastic mesh, or glass-fibre matting, is probably the best material [...]

9.1A Front bumper upper fixing screw of the bonnet or stick strips of masking tape around them as a guide to refitting (photo). 3 With the help of an assistant, support the weight of the bonnet, unbolt the hinges and lift the bonnet from the car. 4 Refitting is a reversal of removal, but do not fully tighten the hinge bolts until the bonnet has bee[...]

10 Front wing - removal and refitting 1 1 Remove the headlamp and front parking lamp as described in Chapter 9. 2 Withdraw the side repeater lamp and disconnect the leads. 3 Remove the front roadwheel. 4 Working under the wing, remove the fixing screw and withdraw the plastic protective shield (photos). 5 Unscrew the wing lower fixing screws at the[...]

rag between the handle and the door trim panel at its lower gap (photo). 5 Insert the fingers or a broad blade between the trim panel and the door and release the panel. 6 Remove the trim panel and the waterproof sheet (photo). 7 Refitting is a reversal of removal, but when refitting the window regulator handle locate its retaining spring clip full[...]

6 Turn the glass very carefully and withdraw it from the door. A new glass is supplied complete with lower mounting. Window regulator 7 Extract the fixing screws (arrowed) (Fig. 12.9) and withdraw the regulator from the door through one of the larger lower apertures (photo). Door lock (three-door) 8 Extract the screw and remove the handle from the [...]

speakers, central door locking or power operated windows, the electrical leads must be disconnected and withdrawn through the flexible duct before the door hinges are unbolted. Disconnection will require removal of the door trim panel as described in Section 11. 5 It is recommended that the door is unbolted from the hinge, leaving the hinge attache[...]

body so that the bottom edge of the rubber seal engages over the metal flange. 7 With an assistant pressing on the outside of the glass, go inside and pull the cords evenly. This will draw the lip of the weatherseal over the body flange and seat the glass. 8 Tap the glass with the palm of the hand to settle it. 9 If the weatherseal is in good condi[...]

4 Reach up behind the facia panel on the side opposite to the glove box and unscrew the remaining console fixing screw. 5 Withdraw the console downwards and disconnect the fibre optics from their source. 6 Refitting is a reversal of removal. 22 Facia panel - removal and refitting 1 1 Remove the instrument panel as described in Chapter 9. 2 Remove t[...]

24 Rear view mirrors 1 Interior 1 The mirror may be removed after extracting the fixing screws. The mirror is designed to break off if struck. Exterior 2 The mirror is remotely controlled. To remove the mirror, peel back the rubber cover from the control knob (photo). 3 Unscrew the ring nut using a C-spanner or similar (photo). 4 Withdraw the mirro[...]

28 Sunroof - operation and maintenance 1 1 To unlock the sunroof, bring the control lever down and turn it anti-clockwise. The glass sunroof will partially rise and then slide rearwards. 2 A sliding louvre is provided to decrease noise and airflow. 3 On cars fitted with a sunroof, the interior lamps are of pillar-mounted type. 4 If the sunroof must[...]

13 Chapter 13 Supplement: Revisions and information on later models Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Routine maintenance - all models from June 1991 . . . . . . . . . . . 3 Engine 903[...]

Cooling system ................................................................................. 8 Part A: 999 cc engine Description Maintenance Thermostat - removal and refitting Coolant pump - removal and refitting Part B: 1301 cc Turbo ie engine Description Part C: 1372 cc ie and 1372 cc Turbo ie engines Description Maintenance Cooling system - [...]

Braking system ................................................................................. 14 Part A: Braking system general Front brake pads all later models Part B: Braking system - Turbo ie models Description Front disc pads - renewal Front disc caliper - removal and refitting Front disc caliper - overhaul Front brake disc - inspection, re[...]

2 Specifications Note: All Specifications are in addition or revisions of those given in the preceding Chapters. Engine General Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line overhead camshaft. Transversely mounted with end-on transmission Application: 999 cc (FIRE[...]

Valve timing clearance: 999 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm 1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.70 mm 1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

View of front end from below on the 999 cc FIRE engined model 1 Left hand front engine mounting 2 Transmission 3 Track control arm 4 Driveshaft 5 Left hand rear (lower) engine mounting 6 Gearchange rods 7 Exhaust pipe 8 Oil filter cartridge 9 Brake caliper 10 Sump pan drain plug View of engine compartment on the 1301 cc Turbo ie engined model 1 Alt[...]

Supplement: Revisions and information on later models 13•7 View of engine compartment (air cleaner removed) on the 1372 cc ie engined model 1 Engine oil level dipstick 2 Timing belt cover 3 Engine mounting (right-hand) 4 Clutch master cylinder fluid reservoir 5 Fuel supply and return hoses 6 Injection unit 7 Inlet manifold 8 Washer reservoir 9 Br[...]

Lubrication system Oil pump type: 999/1108 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear driven from front of crankshaft. 1372 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump operated from front of crankshaft. Oil pressure relief valve in front[...]

Torque wrench settings (continued) Nm lbf ft Cylinder head bolts: 903 cc (from engine number 581470), 999 and 1108 cc: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22 Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by another [...]

Cooling system (continued) Radiator fan cut-in temperature: 1301 cc Turbo ie: 1st speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 to 90ºC 2nd speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 94ºC 1372 cc . . . . . . . . . . . . . . . . . . . . . . [...]

Weber 32 (continued) TLF 4/252 (and 251) TLF 27/251 Exhaust gas CO at idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 2.0% 0.5 to 1.5% Fast idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.65 to 0.75 mm - Float level (with gasket) . . . . . . . . . . . .[...]

Weber 30/32 DMTE 12/150 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1299/1301 cc All calibration as for the Weber 30/32 DMTE 10/150 except for the following: Primary Secondary Accelerator pump jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 45 Air cor[...]

Ignition timing (in relation to distributor type) At idle with vacuum hose disconnected and plugged: Marelli SE101A and Ducellier 525473A . . . . . . . . . . . . . . . . . . . . . . . 2º BTDC Marelli SE100EX, SE100CX and SE100NX . . . . . . . . . . . . . . . . . . . . . 10º BTDC Marelli SE101G . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Ignition timing At idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8º to 12º BTDC Maximum advance (at 4000 to 6000 rpm with 0.377 bars/5.5 lbf/in 2 vacuum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32º to 36º BTDC Component testing values Ignition coil: Primary resistance [...]

Torque wrench settings Nm lbf ft Driveshaft flange connecting bolts (Turbo ie) . . . . . . . . . . . . . . . . . . . . . 43 32 Final drive output shaft bearing cover bolts (Turbo ie) . . . . . . . . . . . . . . 24 18 Intermediate shaft support to crankcase (Turbo ie) . . . . . . . . . . . . . . . . 48 35 Braking system (903, 999, 1108, 1116 and 137[...]

Fuses (903, 999, 1116, 1299/1301 and 1301 cc Turbo ie) (continued) Fuse No. Rating Circuit Supplementary fuses at side of main fuse block: A 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front fog lamps B 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooli[...]

General dimensions, weights and capacities Dimensions Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3689 mm Overall width: Base and Super models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1558 mm SX and Turbo models . . . . . . . . . . . . . . . . . . . . . . . . [...]

13•18 Supplement: Revisions and information on later models Every 9000 miles (15 000 km) or 12 months (whichever comes first) m m Check the tyre pressures and their condition (including the spare) m m Where a pad wear warning light is fitted, check its operation m m Check the front brake disc pads for excessive wear m m Check the underbody condit[...]

4 Engine - 903 and 1299/1301 cc Sump pan sealing strips (903 cc engine) - modification 1 The design of the sealing strips which go between the sump pan and the main bearing caps has been changed. Make sure that the narrower side of the strip fits into the channel in the sump pan. 1299 cc engine - description 2 In April 1984, a 1299 cc engine was in[...]

mounted on the front end of the crankshaft and driven by it. 11 The flexible toothed timing belt drives the camshaft and the coolant pump from a sprocket on the front end of the crankshaft. The belt is tensioned by an eccentrically-mounted pulley. 12 The distributor and the fuel pump (carburettor models) are driven from the flywheel end of the cams[...]

8 Turn the crankshaft sprocket bolt, or engage top gear and raise and turn a front roadwheel, until the camshaft sprocket TDC timing mark is aligned with the mark on the cylinder head and the crankshaft sprocket timing mark is aligned with the mark on the oil pump cover (photos). 9 Release the nut on the timing belt tensioner, move the pulley away [...]

lubrication pipe (prise the oil feed stub out with a screwdriver), unscrew the remaining bolts and take off the bearing caps (photos). 24 Lift the camshaft carefully from the cylinder head, checking that the valve clearance shims and cam followers are not withdrawn by the adhesion of the oil (photo). 25 If the shims and cam followers are to be remo[...]

depressurize the fuel system, before disconnecting the fuel pipes and removing the throttle body, as described in Section 9D. 34 Disconnect the coolant and vacuum hoses from the cylinder head and inlet manifold (photo). 35 Disconnect the electrical lead from the coolant temperature switch, the LT leads from the distributor and the idle cut-off sole[...]

Sump pan - removal and refitting ¡ 60 Drain the engine oil. 61 Unbolt and remove the cover plate from the lower part of the flywheel housing (photo). The two lower bolts retain the gearchange rod support strut. 62 Unscrew the sump pan securing screws and pull the sump pan downwards to remove it (photo). The joint sealant will require cutting with [...]

75 If the pump is unworn, refit the rear cover plate and tighten the screws fully. 76 Apply air pressure from a tyre pump to the oil pump oil ducts to clear any sludge or other material and then prime the pump by pouring clean engine oil into its intake duct at the same time turning the oil pump inner gear with the fingers. 77 Lever out the oil sea[...]

99 Tighten the big-end bolts to the specified torque (photo). The correct torque is important as the bolts have no locking arrangement. After tightening each big-end, check that the crankshaft rotates smoothly. 100 Repeat the operations on the remaining piston/rod assemblies. 101 Refit the oil pump pick-up assembly using a new sealing ring. 102 Ref[...]

8 Disconnect the heater hose from the inlet manifold. 9 On fuel injection models, depressurize the fuel system (refer to Section 9D). Disconnect the fuel inlet and return hoses from the fuel pump (photo) or throttle body, as applicable. 10 Disconnect the brake servo vacuum hose from the inlet manifold. 11 Disconnect the throttle cable from the carb[...]

snap-on ball socket. Unbolt the gearchange rod support bracket from the cover plate on the flywheel housing (photos). 25 Remove the screws from the driveshaft inboard gaiter retaining plates (photos). Expect slight oil loss. 26 Disconnect the rear left-hand transmission mounting. Do this by unscrewing the two outer bolts not the centre one. The eng[...]

can be lowered to rest on the exhaust and bodymember. 34 Continue to raise the engine and the transmission until it can be removed from the engine compartment and placed on the work surface (photo). 35 Clean the exterior of the engine and transmission by steam cleaning or using a water soluble solvent. 36 Unbolt and remove the starter motor. 37 Uns[...]

crankcase. If the shells are to be used again, keep them with their respective bearing caps. 70 The thrust washers which control crankshaft endfloat are located in the crankcase, and retained by the turned-over edges of the centre main bearing shell. 71 The engine is now fully stripped. Examination and renovation 72 The procedures for the following[...]

6 Fit the main bearing caps in their numbered sequence and the correct way round (photo). 7 Clean 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). 8 Now check the crankshaft endfloat.[...]

tighten the sprocket bolt to the specified torque (photos). 17 Refit the clutch to the flywheel as described in Chapter 5. Make sure that the driven plate is centralised. 18 Fit the cylinder head. 19 Refit 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 diam[...]

32 Fit the hot air collector plate for the air cleaner (photo). 33 Refer to Section 10 and fit the distributor. 34 Bolt on the timing belt cover. 35 Fit the camshaft cover, using a new gasket unless the original one is in perfect condition. Engine/transmission - reconnection and refitting # 36 Locate the engine in an upright position on wooden bloc[...]

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 the event of the pressure dropping dangerously low (photo). 10 Oil supply/return ducts provide the turbocharger lubrication. P ART B: OPERA TIONS POSSlBLE WITH ENGINE IN CA[...]

separately, after the ten main bolts (see Fig. 13.13). Piston rings 14 The piston rings comprise two compression rings marked TOP, and an oil control ring. 15 Cross-sections and fitting details are shown in Fig. 13.14. Engine mountings - renewal 16 The operations are essentially as described in Section 33 of Chapter 1, but note the design and fixin[...]

Engine oil cooler - removal and refitting ¡ 23 The oil cooler is mounted behind the front bumper/spoiler (photo). 24 Disconnect 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). 25 Unscrew the mounting bolts and remove the oil cooler heat exchanger (photo)[...]

Initial start-up after major overhaul 28 Refer to Chapter 1, Section 45, but note that an oil pressure gauge is fitted to indicate oil pressure. 29 Check the ignition static timing as described in Section 10. 30 Check the engine idle speed and CO level as described in Section 9. 7 Engine - 1372 cc ie and 1372 cc Turbo ie P ART A: GENERAL Descriptio[...]

9 Turn the engine clockwise using a suitable socket on the crankshaft pulley bolt, until the exhaust valve of No 1 cylinder (valve No 1) is fully closed; ie the cam lobe is pointing directly upwards. Alternatively, the engine can be turned by jacking up one front corner of the vehicle and supporting it securely on an axle stand (apply the handbrake[...]

28 Loosen off the retaining clips and detach the air intake pipe from the air filter. 29 Slide back the inspection cover from the upper end of the timing cover (photo). 30 Turn the engine over by hand to bring the TDC timing marks of the flywheel- to-bellhousing and the camshaft sprocket -to-rear cover projection into alignment. The crankshaft pull[...]

crankshaft after the pulley securing nut has been removed. Recover the Woodruff key from the end of the crankshaft if it is loose (photo). 44 To remove the auxiliary shaft sprocket, a suitable tool must be used to hold the sprocket stationary as the securing bolt is loosened (the bolt is extremely tight). In the workshop, a “scissors” style too[...]

thumb and forefinger at the centre of the run between the auxiliary shaft sprocket and the camshaft sprocket. Using this method it should just be possible to twist the belt through 90º using moderate pressure. 55 To adjust the tension, loosen off the tensioner pulley nut then insert two rods (or screwdrivers) into position in the pulley holes and [...]

79 Recover the gasket. 80 Removal of the camshaft from the housing, and inspection of the components is described in the following sub-Section. 81 Commence refitting by cleaning the gasket mating surfaces of the camshaft housing and cylinder head. 82 Locate a new gasket on the cylinder head, making sure that it is correctly positioned over the dowe[...]

98 Commence reassembly by liberally oiling the bearings in the housing, and the oil seal lip. 99 Carefully insert the camshaft into the housing from the blanking plate/distributor end, taking care to avoid damage to the bearings. 100 Refit the blanking plate using a new gasket. 101 Refit the camshaft housing as described previously in this Section.[...]

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). 123 Reconnect 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 gaske[...]

133 Drain the engine oil from the sump into a suitable container. Disconnect the lead from the engine oil level sensor in the sump. 134 Where applicable, unscrew and remove the bolts retaining the gear linkage mounting bracket and the clutch housing lower cover bolts. Remove the cover from the clutch housing. 135 Unscrew the sump retaining nuts and[...]

new oil seal, ensuring that it is correctly orientated, and drive it squarely into position. 149 Refit all disturbed components. Flywheel - removal, inspection and refitting # 150 If not already done, remove the clutch as described in Chapter 5. 151 Prevent the flywheel from turning by jamming the ring gear teeth, or by bolting a strap between the [...]

173 Lift the intermediate plate from the oil pump body. 174 The gears can now be removed from the oil pump body. Inspect them for obvious signs of wear or damage, and renew if necessary. 175 Commence reassembly by lubricating the gears with clean engine oil, and refitting them to the casing. Note that the scribed marks on the top faces of the gears[...]

necessary renovated as described later in this Section. 191 Commence refitting as follows. 192 Clean the backs of the bearing shells and the recesses in the connecting rods and big-end caps. 193 Lubricate the cylinder bores with engine oil. 194 Fit a ring compressor to No. 1 piston, then insert the piston and connecting rod into No. 1 cylinder. Wit[...]

fitting, as during removal. Note that the compression rings are brittle, and will snap if expanded too far. 206 If 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. 207 Whenever new piston[...]

20 Release the retaining clip and detach the wiring connector from the fuel injector connection (photo). 21 Loosen off the front wheel bolts each side, then raise and support the car at the front end on axle stands. When raised, support at a height which will allow the engine and transmission to be withdrawn from the underside when fully disconnect[...]

fittings are disconnected from the engine and transmission and positioned out of the way. Enlist the aid of an assistant to help steady and guide the power unit down through the engine compartment as it is removed, If available, position a suitable engine trolley or crawler board under the engine/transmission so that when lowered, the power unit ca[...]

61 Refer to Part B of this Section for details and remove the flywheel. 62 Refer to the previous sub-Section for details and remove the auxiliary shaft. 63 Refer to Part B of this Section for details and remove the sump. 64 Refer to Part B of this Section for details and remove the oil pump unit. 65 Refer to Part B of this Section for details and r[...]

bearing caps with a soft non-fluffy rag, then fit the lower halves of the bearing shells to their seats. Again, note that the centre (No. 3) bearing shell is plain, whereas all the other shells have oil grooves (photo). 9 Lubricate the crankshaft journals and the upper and lower main bearing shells with clean engine oil (photo). 10 Carefully lower [...]

removal are in place under the engine-to-gearbox bolts. Do not allow the weight of the gearbox to hang on the input shaft as it is engaged with the clutch friction disc. 29 Refit the starter motor, ensuring that the wiring harness bracket is in position on the top bolt. 30 Locate the engine/transmission unit at the front of the car and move it into[...]

Coolant pump - removal and refitting # 11 The coolant pump is located on the crankshaft pulley end of the engine and is driven by the timing belt. 12 The pump cannot be repaired and must be regarded as disposable. 13 Drain the cooling system. 14 Remove the timing belt cover and then set No. 1 piston to TDC. To achieve this, turn the crankshaft pull[...]

1 Electric fan 2 Radiator 3 Thermostat 4 Coolant supply hose (inlet manifold to heater matrix) 5 Heater matrix 6 Coolant return hose (heater matrix to the manifold pipe) 7 Coolant pump 8 Coolant manifold pipe 9 Coolant supply hose (cylinder block/crankcase to the turbocharger) 10 Coolant return hose (turbocharger to the expansion tank) 11 Coolant s[...]

10 Apply suitable sealant to the threads of the drain plug, then refit and tighten the plug. 11 Dispose of the drained coolant safely, or keep it in a covered container if it is to be re-used. 12 If required, the system can be flushed through as described in Section 2 of Chap- ter 2. 13 Before attempting to refill the cooling system, make sure that[...]

35 Clean the mating faces of the thermostat cover and cylinder head, and use a new gasket when refitting the cover. 36 Refill the cooling system as described earlier in this Section. Coolant pump - removal and refitting ¡ Note: A new coolant pump gasket must be used on refitting. If the pump is found to be worn it must be renewed as a complete uni[...]

the trim cover, undo the retaining screw at the rear of the console. Prise free and release the gear lever gaiter and lift clear the central console. 7 Undo the retaining screws and remove the steering column upper and lower shroud. 8 Detach and remove the lower facia trim on the side of the central facia. 9 Referring to Fig. 13.32, unscrew and rem[...]

9 Fuel and exhaust systems Warning: Many of the procedures in this Section require the removal of fuel lines and connections that may result in some fuel spillage. Before carrying out any operation on the fuel system refer to the precautions given in ‘Safety first!’ at the beginning of this Manual and follow them implicitly. Petrol is a highly [...]

8 The air cleaner on the 1116 cc and 1299/1301 cc engine is of circular type. Access to the element is obtained by extracting the three cover nuts and lifting off the lid (photos). 9 The air cleaner casing can be removed after unscrewing the four nuts which hold it to the carburettor and the single nut on the camshaft cover bracket. As the casing i[...]

P ART B: CARBURETTOR MODELS Carburettor (Weber 32 TLF) - description Warning: Refer to the beginning of this Section before starting any work. 1 This carburettor is used on the 999 cc engine and is of the single venturi downdraught type, with a manually-operated choke (cold start). 2 The unit incorporates an automatic anti-flooding device, a full p[...]

15 Release the clamp screw and pinch-bolt, and disconnect the choke cable. 16 Slacken the throttle cable by releasing the locknut and turning the adjuster sleeve, then slip the cable nipple out of the notch in the throttle spindle quadrant. 17 Disconnect the lead from the idle cut-off solenoid valve. 18 Unscrew the two long mounting bolts and lift [...]

Float level - checking and adjustment 28 With the carburettor top cover held vertically so that the float arm just touches the fuel inlet needle valve ball, measure between the float and the surface of the flange gasket as shown in Fig. 13.36. If the dimension is not within the specified tolerance, bend the float tab which bears on the needle valve[...]

Idle speed and mixture adjustment 36 Refer to Chapter 3, Section 7 (photos). Removal and refitting 37 The operations are similar to those described for the Weber 32 TLF earlier in this Supplement, but note that the carburettor is secured by four nuts and additional electrical leads must be disconnected (photos). Carburettor (Weber 30/32 DMTE) - ove[...]

adjustments described in this sub-Section, however, will require removal of the carburettor. 39 Disconnect the short, curved diaphragm hose from the top cover. 40 Extract the top cover screws, lift the cover from the carburettor body, and rotate it in order to release the cranked choke control rod from its key hole (photo). Mop out the fuel and cle[...]

solenoid-operated type, actuated from the ECU. 7 Fuel pressure is regulated according to inlet manifold vacuum pressure by a fuel pressure regulator. Excess unpressurised fuel is returned to the fuel tank. Airflow meter 8 This component measures the quantity of air drawn into the engine, and converts this into an electric signal which is transmitte[...]

Idle speed and mixture adjustment ¢ 29 Before carrying out any adjustments, the engine must be at operating temperature, the fan having cut in at second speed and then switched off. 30 Release the locknut and turn the main idle speed screw in the throttle valve housing until the engine idles at the specified speed. This should be all that is neces[...]

39 Now use the ohmmeter to check the resistance of the following components. Supplementary air valve 40 Resistance between the terminals should be between 40 and 60 ohms at 20ºC (68ºF). Airflow meter 41 Resistance between terminals 5 and 8 of the potentiometer should be between 330 and 360 ohms at 20ºC (68ºF). 42 Resistance between terminals 8 [...]

Fuel pressure regulator 60 Disconnect the vacuum hose from the regulator (photo). 61 Anticipate some loss of pressurised fuel, and then disconnect the fuel hose from the regulator. Unbolt and remove the unit. Excessive air pressure switch 62 This is screwed into the end of the inlet manifold. Disconnect the electrical leads and unscrew the switch. [...]

80 The injector retaining plate socket-headed screws may now be removed using an Allen key. Withdraw the fuel injectors and insulators (photos). 81 New injectors, complete with the fuel rail, must be purchased as an assembly. Always use new seals when refitting the injectors and the insulators (photos). Electronic control unit (ECU) 82 The ECU is l[...]

Throttle position switch (potentiometer) 90 This is located on the left side of the throttle valve housing (photo). 91 Disconnect the wiring plug, unscrew the two fixing screws and withdraw the switch. Fuel filter 92 Unscrew the fuel line banjo unions from the filter, which is located in the right-hand rear corner of the engine compartment. Be prep[...]

P ART D: BOSCH MONO-JETRONIC FUEL INJECTION SYSTEM Warning: Refer to the beginning of this Section before starting any work. Description 1 The Bosch Mono-Jetronic fuel injection system fitted to the 1372 cc ie engine and later 999/1108 ‘FIRE’ models is an electroni- cally-controlled single point injection (SPi) system. The SPi system is a compr[...]

necessary processing (photo). A conventional paper type air filter element is used and this must be renewed at the specified intervals. 9 The ECU is specific to the model type, its function being to control the fuel system under all operating conditions, including starting from cold - it richens the fuel mixture as required but at the same time pre[...]

15 Undo the retaining strap bolt and withdraw the filter from its location bracket. Disconnect the inlet and supply hose from the filter. If crimp connectors are fitted they will have to be cut free and new screw type clips fitted (photo). 16 Connect the hoses to the new filter ensuring that the filter is correctly orientated (the arrow mark on the[...]

26 Loosen 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). 27 Carefully 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/[...]

air temperature sensor. Undo the retaining screw and remove the sensor from the injector unit (photo). 50 Refit in the reverse order of removal. Fuel injector - removal and refitting ¡ 51 Depressurise the fuel system as described previously, then disconnect the battery negative lead. 52 Remove the air cleaner unit. 53 Release the injector feed wir[...]

c) If the engine develops a misfire, do not drive the car at all (or at least as little as possible) until the fault is cured - the misfire will allow unburned fuel to enter the converter, which will result in its overheating, as noted above. d) DO NOT push- or tow-start the car - this will soak the catalytic converter in unburned fuel, causing it [...]

optimum engine operating efficiency. In the event of a system sensor malfunction, errors in data passed to the ECU are overcome by an emergency operation, whereby the ECU supplies the injectors with one of two set injection periods independent of the sensors. One period (2.2 ms) is for idle speed and the other (2.5 ms) is for speeds above idle (act[...]

operation twice. Also prior to making adjustments ensure that the supplementary air valve pipe is in good condition, with no leaks. Compress the air valve pipe using a pair of grips to prevent incorrect adjustment caused by a defective supplementary air valve. 15 The air cleaner must be connected when checking and/or adjusting the engine idle speed[...]

33 Detach the vacuum pick-up pipes from the points indicated in Fig. 13.57. 34 Detach the wiring connector from the throttle position switch. 35 Unscrew and remove the inlet manifold mounting bracket-to-cylinder head retaining bolt shown in Fig. 13.58. 36 Unscrew and remove the injector cable shield retaining screws. Detach the cables from the inje[...]

protective shield to gain access to the pump which is located forward of the fuel tank. 60 Disconnect the fuel hoses and the wiring connector, release the retaining clamp and withdraw the pump unit. Refitting all components 61 Refitting of all components is a reversal of the removal procedure, but note the following specific points. 62 Ensure that [...]

17 Disconnect the air hoses from the turbocharger (photo). 18 Drain the cooling system, and then disconnect the coolant hoses from the turbocharger (photos). 19 Disconnect the oil feed pipe, which has a banjo-type union (photo). 20 Disconnect the oil return pipe which runs to the engine sump pan (photo). 21 Working underneath the car, disconnect th[...]

31 Unscrew and remove the two turbocharger mounting bracket bolts. 32 Referring to Fig. 13.67, loosen off the retaining clip and detach the air hose from the heat exchanger and the oil return pipe from the turbocharger (to sump). 33 Working from above, undo the turbocharger mounting bracket bolts. 34 Unscrew and remove the coolant pipe-to-pump reta[...]

Fault finding - turbocharger system Supplement: Revisions and information on later models 13•85 13 Noise or vibration m m Worn shaft bearings m m Lack of lubrication m m Inlet or exhaust manifold leaking m m Out-of-balance impeller shaft Engine “pinking” m m High boost pressure, caused by faulty wastegate valve m m Fuel octane rating too low [...]

6 On 999, 1108 and 1372 cc engines, the distributor is driven from the rear end of the camshaft. 7 On the 1116 and 1299/1301 cc engines, the distributor is driven from an extension of the oil pump driveshaft which is geared to the auxiliary shaft. 8 The distributor contains a reluctor mounted on its shaft, and a magnet and stator fixed to the basep[...]

Supplement: Revisions and information on later models 13•87 13 10.35 Ignition ECU on rear bulkhead (1301 cc Turbo ie engine) Fig. 13.76 Microplex ignition system components on the 1372 cc Turbo ie engine (Sec 10) Fig. 13.75 Microplex ignition system components on the 1301 cc Turbo ie engine (Sec 10) 1 ECU 2 Safety pressure switch 3 Ignition unit [...]

13•88 Supplement: Revisions and information on later models Fig. 13.73 Wiring diagram of the Microplex ignition system on the 1301 cc Turbo ie engine (Sec 10) Fig. 13.74 Wiring diagram of the Microplex ignition system on the 1372 cc Turbo ie engine (Sec 10) 1 ECU 2 Safety pressure switch 3 Ignition unit with coil 4 Distributor 5 Anti-knock sensor[...]

Ignition unit 36 This comprises four elements (photo). a) Power module - receives the ignition advance command and controls the conduction angle of the primary current and energy stored in the coil. b) Dissipater plate - eliminates the heat which is generated by the high volume of current. c) Ignition coil with low primary resistance. d) Distributo[...]

TDC sensor 48 Insert the probes of the ohmmeter between terminals 1 and 2 of the multipin connector; 618 to 748 ohms (1301 cc) or 578 to 782 ohms (1372 cc) should be indicated. 49 If necessary, carry out a check of the gap between the sensor and the crankshaft pulley, as described in Chapter 4, Section 10. ECU supply 50 Switch on the ignition, and [...]

advance points than the earlier system. Comparison of Fig. 13.82 with Fig. 4.2 illustrates the difference in layout. Note that the distributor is mounted on the rear end of the cylinder head and is driven by the camshaft. 63 When working on the Digiplex 2 ignition system or associated components, the precautionary notes outlined in Section 9 of Cha[...]

11 Clutch Clutch pedal - adjustment (cable clutch) ¡ 1 The method of adjusting the clutch has been revised. 2 Fully depress the clutch pedal two or three times. 3 Using a suitable measuring stick placed in contact with the floor panel (carpet peeled back), measure dimension “X” in Fig. 13.87. This dimension must be taken between the centre of [...]

mounted in-line with and just forward of the clutch pedal. The operating cylinder is mounted within a housing on top of the transmission. The fluid reservoir is located in the engine compartment and is mounted on the left-hand side near the bulkhead. No settings or specific procedures are given by the manufacturer at the time of writing. Maintenanc[...]

25 Unscrew the union nut and detach the hydraulic fluid line from the operating cylinder (photo). 26 Undo the cylinder/mounting bracket retaining bolts and lift clear the cylinder together with the bracket (photo). Release the retaining clip and separate the cylinder from the bracket. 27 To dismantle the cylinder, prise free and pull back the dust [...]

final drive unit. The inboard end of each driveshaft locates in the differential. All helical gear clusters are in constant mesh, with the fifth gear assembly located on an intermediate plate mounted on the rear end of the gearbox. Gear engagement is made by sliding synchromesh hubs. Gearchanges are made via a central floor-mounted gear lever. Main[...]

require maintenance other than general inspection for wear in the linkage joints. If excessive wear is found in any of the joints, they can be individually detached and renewed. 13 Access to the control rods is eased by detaching and lowering the exhaust system from the exhaust manifold. 14 If a new adjustable control rod is to be fitted, remove th[...]

27 The engine must now be supported at its left-hand end. If the engine/transmission lift bracket is unbolted it can be attached at another suitable position on the engine and the lift sling/tool attached to it, but take care not to attach it to a weak fixing point. 28 The engine will need to be supported using an engine lift beam/support bar of th[...]

P ART C: 999 CC AND 1108 CC WITH C514 TYPE TRANSMISSIONS Description 1 A new 5-speed transmission was introduced to selected models during 1992. Identified by the way reverse gear is engaged. The gear knob needs to pressed downwards whilst pushing the lever to the extreme right. 2 The new design includes control cables as well as rods for gear sele[...]

3 The boot retaining band must be crimped using suitable pinchers at the highest point on the boot. Intermediate driveshaft (Turbo ie models) # Description 4 On these models, an intermediate driveshaft is fitted between the final drive of the transmission and the flange of the right-hand driveshaft. 5 A support bearing assembly for the intermediate[...]

20 When reassembling, pack the joint with special FIAT Tutela MRM2 lubricant; if this is not available, use molybdenum disulphide grease. 21 The reference groove on the outer track must be assembled so that it is towards the final drive when refitted (photo). 22 Pack the joint and the inside of the boot liberally with the specified grease. 23 If a [...]

4 Using a ring spanner and an open-ended spanner, unscrew and remove the caliper cylinder housing lower guide bolt (photo). Release the upper bolt, but do not remove it. 5 Swivel the cylinder housing upwards and tie it up out of the way. There is no need to disconnect the hydraulic hose. The sensor wiring plug will have to be disconnected (where fi[...]

14B.54 Master cylinder/vacuum servo located next to the coolant expansion tank (1301 cc Turbo ie model) 29 Fit the new pads, complete with anti-rattle springs (photo). 30 Refit the caliper using new self-locking bolts, or if not available, apply thread-locking fluid to clean threads of the original bolts. Tighten the bolts to the specified torque. [...]

Vacuum servo unit and master cylinder - general 54 Access to the vacuum servo unit and the master cylinder can only be obtained after the cooling system expansion tank has been released and moved aside (photo). Antiskid system - description 55 This system is available as an option on the Turbo ie models only. 56 The purpose of the system is to prev[...]

15.23A Starter motor removal from the 1301 cc Turbo ie engine 15.20 Starter motor removal from the 999 cc engine 12 Disconnect the air cooling hose from the rear cover of the alternator, and then unscrew the fixing nuts and take off the rear cover with hose spout. Mark the position of the cover on the alternator before removing it, so that the spou[...]

Starter motor brushes (later models) - renewal # 25 When renewing the starter motor brushes on later models, the old brushes will need to be crushed (in a vice or with a hammer) and their leads then soldered to the new brushes. Fuses - later models 26 The fuse arrangement is slightly different on later models, but the circuits protected are still i[...]

adjustment procedures are the same as those outlined for the previous model units in Chapter 9, but ensure that the load compensation lever is turned to the “O” (normal load setting) position before making any adjustments. Headlamp unit removal - later models 32 The removal and refitting procedures described in Chapter 9 also apply to the later[...]

47 Loosen off the switch-to-column clamp screw, disconnect the wiring connectors to the switch and withdraw the switch from the column (photos). 48 Refit in the reverse order of removal, but ensure that the lug of the switch aligns with the slot in the column as it is fitted into position. Check for satisfactory operation of the switches on complet[...]

Auxiliary control panel (later models) - removal and refitting ¡ 61 Disconnect the battery negative lead. 62 Insert the flat of a screwdriver under the trim piece at the end of the auxiliary panel as shown and prise it free. Repeat the procedure and remove the trim piece at the other end of the panel (photo). 63 Undo the retaining screws, withdraw[...]

83 Refitting is a reversal of the removal procedure. Reset the clock on completion. Central door locking system 84 Certain later models, equipped with a central door locking system, have an infra-red remote control for opening the door locks. 85 It is important that the battery used in the hand control is renewed when necessary with one of identica[...]

As it is lifted, invert it and detach the washer hose from the washer nozzle (photos). 97 Where applicable, detach and remove the washer reservoir from the recess in the front of the windscreen to allow access to the wiper motor. 98 Unscrew and remove the two wiper motor retaining screws. Lower and withdraw the unit, then detach the cover from the [...]

Door closure sensor 117 The sensor consists of a microswitch within the lock. The switch actuates the warning lamp according to whether the lock is in the open or closed mode. Check control system sensors - testing Brake fluid level sensor 118 With the fluid level correct, switch on the ignition and depress the centre of the reservoir cap. If the s[...]

push it towards the windscreen; the ball socket will release (photo). 5 Extract the screws from the mounting plate (photo). 6 When refitting the mirror, engage the front of the socket on the ball and then twist the mirror rearwards and upwards. Exterior 7 On models without remotely-controlled type exterior mirrors, the ball-jointed mirror is held i[...]

18 Refitting of all components is a reversal of removal. Radiator grille (1301 cc Turbo ie model) - removal and refitting ¡ 19 The grille is secured by a central screw and two upper clips. Use a screwdriver to prise the tabs on the upper clips downwards (photos). 20 Lift the grille upwards and forwards to disengage its lower mountings (photo). 21 [...]

the ring nut which secures the handle to the glass. 33 When refitting the screws or ring nut to the glass, make sure that the insulating washers are in good condition to prevent metal-to-glass contact. Door trim panel (Turbo ie model) - removal and refitting ¡ 34 The operations are similar to those described in Chapter 12, Section 11, except that [...]

Wiring diagrams 14•1 14 Component key for wiring diagrams 1 to 29 Note: Not all the items listed will be fitted to all models No Description 00200 Alternator with built-in regulator 00500 Battery 01001 Starter motor 01202 Rear front electric window motor 01203 Left front electric window motor 01206 Windscreen wiper motor 01207 Rear screen wiper m[...]

14•2 Wiring diagrams No Description 06355 Battery charging warning light 06365 Choke warning light 06368 Antiskid system failure lamp 06385 Heated rear screen warning light 06800 Horn 06801 Right horn 06802 Left horn 07000 Coolant level sensor 07001 Engine oil level sensor 07003 Brake fluid level sensor 07015 Right front brake pad wear sensor 070[...]

Wiring diagrams 14•3 14 Wiring diagram 1 - starting, ignition, charging, oil pressure, low brake fluid, choke warning light and handbrake “on” (S and SX models) Wiring diagram 2 - starting, charging, oil pressure and low brake fluid (Comfort and ES models)[...]

14•4 Wiring diagrams Wiring diagram 3 - direction indicators, hazard warning lamps, brake stop- lamps and horn (S and SX models) Wiring diagram 4 - direction indicators, hazard warning lamps, brake stop- lamps and horn (Comfort and ES)[...]

Wiring diagrams 14•5 14 Wiring diagram 5 - front parking lamps, rear number plate lamp and fuel gauge (Comfort, ES, S and SX models) Wiring diagram 6 - electronic ignition, fuel cut-off device and economy gauge (ES models)[...]

14•6 Wiring diagrams Wiring diagram 7 - headlamps, reversing lamps and front and rear foglamps (SX model) Wiring diagram 8 - headlamps, reversing lamps and rear foglamps (Comfort, ES and S models)[...]

Wiring diagrams 14•7 14 Wiring diagram 9 - windscreen wash/wipe, radiator fan, coolant temperature sensor, heated rear screen and instrument panel illumination Wiring diagram 10 - windscreen wash/wipe, radiator fan and coolant temperature sensor (Comfort and ES models)[...]

14•8 Wiring diagrams Wiring diagram 11 - courtesy lamps, heater fan, heater illumination, cigar lighter, digital clock and radio (S and SX models) Wiring diagram 12 - courtesy lamps, heater fan and heater illumination (Comfort and ES models)[...]

Wiring diagrams 14•9 14 Wiring diagram 13 - heated rear screen and rear wash/wipe (S and SX models) Wiring diagram 14 - tachometer, digital clock, map reading lamp and vacuum gauge (Comfort, ES, S and SX models)[...]

Wiring diagram 15 - central door locking and electric windows (S and SX models) Wiring diagram 16 - headlamp dim-dip system (1987-on models) 14•10 Wiring diagrams[...]

Wiring diagrams 14•11 14 Wiring diagram 17 - check panel (S and SX models)[...]

14•12 Wiring diagrams Wiring diagram 18 - check panel with trip master (SL model)[...]

Wiring diagrams 14•13 14 Wiring diagram 20 - ignition cut-off device, tachometer and accelerator pump cut-out (60 and 70 models) Wiring diagram 19 - ignition and idle cut-out (later 45 models)[...]

14•14 Wiring diagrams Wiring diagram 21 - starting, charging, Microplex ignition, LE-2 Jetronic fuel injection, fuel pump and fuel injector cooling fan (1301 cc Turbo ie model)[...]

Wiring diagrams 14•15 14 Wiring diagram 22 - direction indicators, hazard warning lamps, brake stop- lamps, horn and low brake fluid sensor (1301 cc Turbo ie model) Wiring diagram 23 - courtesy lamps, heater fan, heater illumination, cigar lighter, digital clock, radio, low oil pressure lamp, oil pressure switch, oil temperature gauge and tachome[...]

14•16 Wiring diagrams Wiring diagram 24 - dipped headamps, headlamp main beam, foglamps (front and rear) and reversing lamps (1301 cc Turbo ie model) Wiring diagram 25 - front parking lamps, rear number plate lamp, fuel gauge and low level warning lamp, and instrument panel illumination (1301 cc Turbo ie model)[...]

Wiring diagrams 14•17 14 Wiring diagram 26 - windscreen wash/wipe, radiator fan, heated rear screen, instrument panel fibre optic, coolant temperature gauge and rear screen wash/wipe (1301 cc Turbo ie model) Wiring diagram 27 - electric windows (1301 cc Turbo ie model)[...]

14•18 Wiring diagrams Wiring diagram 28 - check panel (1301 cc Turbo ie model)[...]

Wiring diagrams 14•19 14 Wiring diagram 29 - Antiskid braking system (1301 cc Turbo ie model - where fitted)[...]

14•20 Wiring diagrams Component key for wiring diagrams 30 to 52 Note: Not all the items listed will be fitted to all models No Description 1 Injector cooling fan 2 Left front light cluster 3 Left foglamp 4 Left front engine compartment earth 5 Radiator cooling fan 6 Double contact thermostatic switch on engine radiator 6A Thermostatic switch on [...]

Wiring diagrams 14•21 14 Component key for wiring diagrams 30 to 52 (continued) Note: Not all the items listed will be fitted to all models No Description 111 Push button on left front pillar for centre courtesy light 112 Front electric windows switch panel, driver’s side 113 Join between dashboard cable and adjustable map reading light cables [...]

14•22 Wiring diagrams Wiring diagram 30 - starting, charging, ignition, low oil pressure and choke warning lamps (1990-on 45, and 55 models) * To the rev counter (only for the 999 SX – 1108 SX) ** Non-existent for the 903[...]

Wiring diagrams 14•23 14 Wiring diagram 31 - starting, charging, Digiplex 2 ignition, SPi fuel injection, fuel pump and low oil pressure (1990-on 70 SX and 1.4 models) * To the rev counter[...]

14•24 Wiring diagrams Wiring diagram 32 - starting, charging, Microplex ignition, MPi fuel injection, fuel pump and low oil pressure (1372 cc Turbo ie model) * To the rev counter ** Only for the 1372 Turbo with A.B.S. (AP)[...]

Wiring diagrams 14•25 14 Wiring diagram 33 - parking lamps, main/dipped headlamps, headlamp flasher and rear number plate lamp (1990-on 45, 55, 70 and 1.4 models) * Only for 1372 S ie – 1372 SX ie[...]

14•26 Wiring diagrams Wiring diagram 34 - parking lamps, main/dipped headlamps, headlamp flasher and rear number plate lamp (1372 cc Turbo ie models) * Only for 1116 S (CTX) and 1372 (CTX) versions ** Only for 1116 S (CTX) and 1372 Turbo ie versions[...]

Wiring diagrams 14•27 14 Wiring diagram 35 - direction indicators, hazard warning lamps, reversing lamps and brake stop-lamps (1990-on 45, 55, 70 and 1.4 models)[...]

14•28 Wiring diagrams Wiring diagram 36 - direction indicators, hazard warning lamps, reversing lamps and brake stop-lamps (1372 cc Turbo ie model)[...]

Wiring diagrams 14•29 14 Wiring diagram 37 - rear foglamps (1990-on 45 and 55 models)[...]

14•30 Wiring diagrams Wiring diagram 38 - front and rear foglamps (1990-on 70 SX and 1.4 models)[...]

Wiring diagrams 14•31 14 Wiring diagram 39 - front and rear foglamps (1372 cc Turbo ie model)[...]

14•32 Wiring diagrams Wiring diagram 40 - courtesy lamps and instrument panel lamps (1990-on 45, 55, 70 and 1.4 models)[...]

Wiring diagrams 14•33 14 Wiring diagram 41 - courtesy lamps and instrument panel lamps (1372 cc Turbo ie model)[...]

14•34 Wiring diagrams Wiring diagram 42 - horns, heated rear screen and windscreen/rear screen wash/wipe (1990-on 45 and 55 models)[...]

Wiring diagrams 14•35 14 Wiring diagram 43 - horns, heated rear screen and windscreen/rear screen wash/wipe (1990-on 70 SX and 1.4 models)[...]

14•36 Wiring diagrams Wiring diagram 44 - horns, heated rear screen, windscreen/rear screen wash/wipe and headlamp wash/wipe (1372 cc Turbo ie model)[...]

Wiring diagrams 14•37 14 Wiring diagram 45 - radiator cooling fan, heater, radio and cigar lighter (1990-on 45, 55, 70 and 1.4 models)[...]

14•38 Wiring diagrams Wiring diagram 46 - radiator cooling fan, heater, radio and cigar lighter (1372 cc Turbo ie model)[...]

Wiring diagrams 14•39 14 Wiring diagram 47 - fuel gauge, tachometer, digital clock, brake fluid and handbrake warning lamp (1990-on 45, 55, 70 and 1.4 models) *Only for 1372 S ie – 1372 SX ie – 1697 D ** Only for D versions s Only for SX versions[...]

14•40 Wiring diagrams Wiring diagram 48 - fuel gauge, tachometer, digital clock, brake fluid level sensor, handbrake-on switch, brake pad wear sensor, door ajar switch and oil pressure/temperature sender units (1372 cc Turbo ie model)[...]

Wiring diagrams 14•41 14 Wiring diagram 49 - electric windows and central locking (1990-on 3-door models)[...]

14•42 Wiring diagrams Wiring diagram 50 - electric windows and central locking (1990-on 5-door models)[...]

Wiring diagrams 14•43 14 Wiring diagram 51 - Antiskid braking system (1372 cc Turbo ie model - where fitted)[...]

14•44 Wiring diagrams Wiring diagram 52 - check panel (1990-on 5-door models (3-door similar)[...]

MOT T est Checks REF•1 This is a guide to getting your vehicle through the MOT test. Obviously it will not be possible to examine the vehicle to the same standard as the pr ofessional MOT tester . However , working thr ough the following checks will enable you to identify any problem areas before submitting the vehicle for the test. Where a testa[...]

REF•2 MOT T est Checks Seat belts and seats Note: The following checks are applicable to all seat belts, front and rear . M Examine the webbing of all the belts (including rear belts if fitted) for cuts, serious fraying or deterioration. Fasten and unfasten each belt to check the buckles. If applicable, check the retracting mechanism. Check the s[...]

MOT T est Checks REF•3 REF Exhaust system M Start the engine. With your assistant holding a rag over the tailpipe, check the entire system for leaks. Repair or renew leaking sections. Jack up the front and rear of the vehicle, and securely support it on axle stands. Position the stands clear of the suspension assemblies. Ensure that the wheels ar[...]

REF•4 MOT T est Checks M Examine the handbrake mechanism, checking for frayed or broken cables, excessive corrosion, or wear or insecurity of the linkage. Check that the mechanism works on each relevant wheel, and r eleases fully , without binding. M It is not possible to test brake efficiency without special equipment, but a road test can be car[...]

Introduction A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a considerable expense, offsetting some of the savings made by doing-it-yourself. However, provided that the tools purchased meet the relevant n[...]

REF•6 T ools and W orking Facilities Valve spring compressor Piston ring compressor Compression testing gauge Clutch plate alignment set Brake shoe steady spring cup removal tool Piston ring removal/installation tool Cylinder bore hone Three-legged hub and bearing puller Micrometer set Vernier calipers Dial test indicator and magnetic stand Socke[...]

T ools and W orking Facilities REF•7 REF M Impact screwdriver M Micrometer and/or vernier calipers (see illustrations) M Dial gauge (see illustration) M Universal electrical multi-meter M Cylinder compression gauge (see illustration) M Clutch plate alignment set (see illustration) M Brake shoe steady spring cup removal tool (see illustration) M B[...]

REF•8 General Repair Pr ocedur es Whenever servicing, repair or overhaul work is carried out on the car or its components, observe the following procedur es and instructions. This will assist in carrying out the operation efficiently and to a pr ofessional standard of workmanship. Joint mating faces and gaskets When separating components at their[...]

Fault Finding REF•9 REF Introduction The vehicle owner who does his or her own maintenance according to the recommended schedules should not have to use this section of the manual very often. Modern component reliability is such that, provided those items subject to wear or deterioration are inspected or renewed at the specified intervals, sudden[...]

Engine fails to turn when starter operated m m Flat battery (recharge use jump leads or push start) m m Battery terminals loose or corroded m m Battery earth to body defective m m Engine earth strap loose or broken m m Starter motor (or solenoid) wiring loose or broken m m Ignition/starter switch faulty m m Major mechanical failure (seizure) m m St[...]

Engine cuts out suddenly – ignition fault m m Loose or disconnected LT wires m m Wet HT leads or distributor cap (after traversing water splash) m m Coil failure (check for spark) m m Other ignition fault (see Chapter 4) Engine misfires before cutting out – fuel fault m m Fuel tank empty m m Fuel pump defective or filter blocked (check for deli[...]

Buying spar e parts Spare parts are available from many sources, for example, FIAT garages, other garages and accessory shops, and motor factors. Our advice regarding spare parts is as follows: Officially appointed FIAT garages - This is the best source of parts which are peculiar to your car and otherwise not generally available (eg complete cylin[...]

Glossary of T echnical T erms REF•13 REF A ABS (Anti-lock brake system) A system, usually electronically contr olled, that senses incipient wheel lockup during braking and relieves hydraulic pr essure at wheels that are about to skid. Air bag An inflatable bag hidden in the steering wheel (driver’ s side) or the dash or glovebox (passenger side[...]

REF•14 Glossary of T echnical T erms Catalytic converter A silencer -like device in the exhaust system which converts certain pollutants in the exhaust gases into less harmful substances. Circlip A ring-shaped clip used to pr event endwise movement of cylindrical parts and shafts. An internal circlip is installed in a groove in a housing; an exte[...]

Glossary of T echnical T erms REF•15 REF G Gap The distance the spark must travel in jumping from the centr e electrode to the side electrode in a spark plug. Also r efers to the spacing between the points in a contact breaker assembly in a conventional points- type ignition, or to the distance between the reluctor or r otor and the pickup coil i[...]

REF•16 Glossary of T echnical T erms Rotor In a distributor , the rotating device inside the cap that connects the centre electrode and the outer terminals as it turns, distributing the high voltage from the coil secondary winding to the proper spark plug. Also, that part of an alternator which rotates inside the stator . Also, the rotating assem[...]

A Accelerator cable - 3 • 12, 13•80 Accelerator control system - 13•75 Accelerator pump - 3•7, 3•8, 3•11, 13•66 Acknowledgements - 0•4 Aerial - 9•10 Air bags - 0•5 Air cleaner - 3•4, 13•60, 13•69, 13•67, 13•75, 13•79 Air pressure switch - 13•70 Air temperature sensor - 13•76 Airflow meter - 13•67, 13•69, 13?[...]

F Facia - 12•10, 13•107 Fan - 2•3, 13•57, 13•71, 13•84 Fast idle adjustment - 3•7, 3•9, 3•10, 3•11, 13•64 Fault finding - REF `• 9 et seq Fault finding - braking system - 8•9 Fault finding - clutch - 5•3 Fault finding - cooling and heating systems - 2•8 Fault finding - driveshafts and hubs - 7•6 Fault finding - Econo[...]

S Safety first - 0•5 Safety pressure switch - 13•90 Scalding - 0•5 Scratches in bodywork - 12•2 Screw threads and fastenings - REF • 8 Seat belts - 12•10, REF • 2 Seats - 12•9, REF • 2 Servo unit - 8•8, 13•103 Shock absorbers - 11•4, REF • 2, REF • 3 Shoes - 8•3 Side light - 9•7 Side repeater lamp - 9•7 Spares - RE[...]

REF•20 Almost ever y car you’ve ever loved, loathed or desired is gathered under one roof at the Haynes Motor Museum. Over 300 immaculately presented cars and motorbikes represent ever y aspect of our motoring heritage, from elegant reminders of bygone days, such as the superb Model J Duesenberg to curiosities like the bug-eyed BMW Isetta. Ther[...]