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Fiat Uno Service and Repair Manual
Peter G Strasman
Models covered
Does not Selecta, Fiorino type vans or Diesel engine
(923-320-3Y7)
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
© Haynes Publishing 1996 A book in the Haynes Service and Repair Manual Series
ABCDE FGHIJ KLMNO PQRST 123
Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil, Somerset BA22 7JJ Haynes Publishing Sparkford, Nr Yeovil, Somerset BA22 7JJ, England Haynes North America, Inc 861 Lawrence Drive, Newbury Park, California 91320, USA Editions Haynes S.A. 147/149, rue Saint Honoré, 75001 Paris, France Haynes Publishing Nordiska AB Fyrisborgsgatan 5, 754 50 Uppsala, Sverige
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. ISBN 1 85960 089 1 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library.
Contents
LIVING WITH YOUR FIAT UNO
Introduction Safety First! General dimensions, weights and capacities Page Page Page 0·4 0·5 0·6
Roadside Repairs
Jump starting Jacking, towing and wheel changing Identifying leaks Page Page Page 0·7 0·8 0·9
Routine Maintenance and Servicing
Maintenance schedule (also see Chapter 13) Recommended Lubricants and Fluids Conversion factors Page Page Page 0·10 0·13 0·14
Contents
REPAIRS & OVERHAUL
Engine and Associated Systems
Engine (also see Chapter 13) Cooling and heating systems (also see Chapter 13) Fuel system (also see Chapter 13) Ignition system (also see Chapter 13) Page Page Page Page 1·1 2·1 3·1 4·1
Transmission
Clutch (also see Chapter 13) Transmission (also see Chapter 13) Driveshafts, hubs, roadwheels and tyres (also see Chapter 13) Page Page Page 5·1 6·1 7·1
Brakes
Braking system (also see Chapter 13) Page 8·1
Electrical
Electrical system (also see Chapter 13) Page 9·1
Steering and suspension
Steering Suspension (also see Chapter 13) Page Page 10·1 11·1
Bodywork
Bodywork (also see Chapter 13) Page 12·1
Additional information
Supplement: Revisions and information on later models Page Page 13·1 14·1
Wiring Diagrams
REFERENCE
MOT Test Checks Tools and Working Facilities General Repair Procedures Fault Finding Buying Spare Parts & Vehicle Identification Numbers Glossary of Technical Terms Page Page Page Page REF·1 REF·5 REF·8 REF·9
Page REF·12 Page REF·13 Page REF·17
Index
0·4
Introduction
Introduction to the Fiat Uno
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 fitted as standard and a sunroof is optionally available. From the home mechanic's point of view all repair and servicing operations are straightforward without the need for special tools. Spare parts are immediately available at moderate cost.
Acknowledgements
Thanks are due to Champion Spark Plug who supplied the illustrations showing spark plug conditions. Certain other illustrations are the copyright of the Fiat Motor Company (UK) Limited and are used with their permission. Thanks are also due to Sykes-Pickavant Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual. We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us, No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.
Fiat Uno 1301 cc Turbo ie
Fiat Uno 1372 cc 70 SX ie
Safety First!
Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude. · Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker.
0·5
Special hazards
Hydrofluoric acid
· This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses etc, are exposed to temperatures above 4000C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. · When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use.
General hazards
Scalding
· Don't remove the radiator or expansion tank cap while the engine is hot. · Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running.
Fume or gas intoxication
· Exhaust fumes are poisonous; they often contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine in a confined space such as a garage with the doors shut. · Fuel vapour is also poisonous, as are the vapours from some cleaning solvents and paint thinners.
Burning
· Beware of burns from the exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use.
The battery
· Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. · The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads.
Crushing
· When working under or near a raised vehicle, always supplement the jack with axle stands, or use drive-on ramps. Never venture under a car which is only supported by a jack. · Take care if loosening or tightening hightorque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground.
Poisonous or irritant substances
· Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don't syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice. · Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream if necessary. Change out of oilsoaked clothes and do not keep oily rags in your pocket. · Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame (including a cigarette). It can also cause skin burns on contact.
Air bags
· Air bags can cause injury if they go off accidentally. Take care when removing the steering wheel and/or facia. Special storage instructions may apply.
Diesel injection equipment
· Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes. Warning: Never expose the hands, face or any other part of the body to injector spray; the fuel can penetrate the skin with potentially fatal results.
Fire
· Fuel is highly flammable; fuel vapour is explosive. · Don't let fuel spill onto a hot engine. · Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of tools). · Fuel vapour is heavier than air, so don't work on the fuel system with the vehicle over an inspection pit. · Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring. · Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires.
Asbestos
· Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it is safest to assume that they contain asbestos.
Remember...
DO
· Do use eye protection when using power tools, and when working under the vehicle. · Do wear gloves or use barrier cream to protect your hands when necessary. · Do get someone to check periodically that all is well when working alone on the vehicle. · Do keep loose clothing and long hair well out of the way of moving mechanical parts. · Do remove rings, wristwatch etc, before working on the vehicle especially the electrical system. · Do ensure that any lifting or jacking equipment has a safe working load rating adequate for the job.
A few tips
DON'T
· Don't attempt to lift a heavy component which may be beyond your capability get assistance. · Don't rush to finish a job, or take unverified short cuts. · Don't use ill-fitting tools which may slip and cause injury. · Don't leave tools or parts lying around where someone can trip over them. Mop up oil and fuel spills at once. · Don't allow children or pets to play in or near a vehicle being worked on.
Electric shock
· Ignition HT voltage can be dangerous, especially to people with heart problems or a pacemaker. Don't work on or near the ignition system with the engine running or the ignition switched on.
0·6
General dimensions, weights and capacities
Dimensions
Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3644 mm (143.6 in) 1555 mm (61.3 in) 1432 mm (56.4 in) 2362 mm (93.1 in) 1340 mm (52.8 in) 1300 mm (51.2 in)
Weights (kerb)
Uno 45: Three-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Five-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uno 55: Three-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Five-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uno 70: Three-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Five-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uno SX: Three-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Five-door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 kg (1543 lb) 710 kg (1566 lb) 730 kg (1610 lb) 740 kg (1632 lb) 740 kg (1632 lb) 750 kg (1654 lb) 770 kg (1698 lb) 780 kg (1720 lb)
Capacities
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.0 litre (9.25 gal) Engine oil (with filter change): 903 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42 litre (6.0 pint) 1116 and 1301 cc engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 Iitre (7.2 pint) Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40 litre (4.2 pint) Steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140.0 cc Driveshaft CV joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125.0 cc Cooling system: 903 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 litre (8.1 pint) 1116 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 litre (10.6 pint) 1301 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 litre (10.9 pint) For information applicable to later models, see Supplement at end of manual
Roadside Repairs
Jump starting will get you out of trouble, but you must correct whatever made the battery go flat in the first place. There are three possibilities: The battery has been drained by repeated attempts to start, or by leaving the lights on. The charging system is not working properly (alternator drivebelt slack or broken, alternator wiring fault or alternator itself faulty). The battery itself is at fault (electrolyte low, or battery worn out).
0·7
Jump Booster battery (jump) starting starting
When jump-starting a car using a booster battery, observe the following precautions: 4 Before connecting the booster battery, make sure that the ignition is switched off. 4 Ensure that all electrical equipment (lights, heater, wipers, etc) is switched off. 4 Make sure that the booster battery is the same voltage as the discharged one in the vehicle. 4 If the battery is being jump-started from the battery in another vehicle, the two vehcles MUST NOT TOUCH each other. 4 Make sure that the transmission is in neutral (or PARK, in the case of automatic transmission).
1
2 3
1
Connect one end of the red jump lead to the positive (+) terminal of the flat battery
2
Connect the other end of the red lead to the positive (+) terminal of the booster battery.
3
Connect one end of the black jump lead to the negative (-) terminal of the booster battery
4
Connect the other end of the black jump lead to a bolt or bracket on the engine block, well away from the battery, on the vehicle to be started. Make sure that the jump leads will not come into contact with the fan, drivebelts or other moving parts of the engine.
+
5 6
Start the engine using the booster battery, then with the engine running at idle speed, disconnect the jump leads in the reverse order of connection.
+
0·8
Roadside Repairs
Jacking, towing and wheel changing
To avoid repetition, the procedure for raising the vehicle, in order to carry out work under it, is not included before each relevant operation described in this Manual. It is to be preferred, and it is certainly recommended, that the vehicle is positioned over an inspection pit or raised on a lift. Where these facilities are not available, use ramps or jack up the vehicle strictly in accordance with the following guide. Once the vehicle is raised, supplement the jack with axle stands. To raise the front end with a garage jack, locate the jack under the transmission lower mounting, just below and slightly to the rear of the transmission oil drain plug. Protect the mounting by placing a block of wood between the jack head and the mounting. To raise the rear of the car, the jack should be placed under the spare wheel housing as far to the rear as possible. Place a wooden bearer between the jack head and the housing. ignition key to MAR to retain the steering in the unlocked position.
Wheel changing
With the car on firm level ground, apply the handbrake fully. Remove the hub cap or wheel trim, if fitted. Release, but do not remove, the bolts. Chock the front and rear of the opposite roadwheel and then raise the car using the sill jack supplied with the car if it is being done at the roadside. Alternatively use a workshop jack supplemented with axle stands. Remove the wheel bolts, change the wheel and screw in the bolts finger tight. It is recommended that the bolt threads are smeared with multi-purpose grease. Lower the car, remove the jack and tighten the wheel bolts to the specified torque. Refit any wheel trim that was removed.
Jacking
The jack supplied with the car should only be used to change a wheel. Do not use this jack when overhaul or repair work is being carried out; employ a hydraulic or screw jack and supplement it with axle stands. Jacking points are located under the sills for use with the jack supplied.
Towing
When being towed, use the left-hand front towing eye. When towing another vehicle, use the rear towing eye adjacent to the exhaust tailpipe. When being towed, remember that the brake pedal will require heavier pressure due to lack of servo assistance. Always turn the
Spare wheel and jack stowage
Front tow hook
Rear tow hook
Roadside Repairs
0·9
Identifying leaks
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 from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the problem lies. Warning: Most automotive oils and fluids are poisonous. Wash them off skin, and change out of contaminated clothing, without delay. The smell of a fluid leaking from the car may provide a clue to what's leaking. Some fluids are distinctively coloured. It may help to clean the car and to park it over some clean paper as an aid to locating the source of the leak. Remember that some leaks may only occur while the engine is running.
Sump oil
Oil from filter
Gearbox oil
Engine oil may leak from the drain plug...
...or from the base of the oil filter.
Gearbox oil can leak from the seals at the inboard ends of the driveshafts.
Antifreeze
Brake fluid
Power steering fluid
Leaking antifreeze often leaves a crystalline deposit like this.
A leak occurring at a wheel is almost certainly brake fluid.
Power steering fluid may leak from the pipe connectors on the steering rack.
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 such action is required the items either no longer exist or will last forever. This is certainly not the case; it is essential to carry out regular visual examinations as comprehensively as possible in order to spot any possible defects at an early stage before they develop into major and expensive repairs. For information applicable to later models, see Supplement.
Every 250 miles (400 km), weekly, or before a long journey
Check engine oil level Check brake reservoir fluid level Check tyre pressures Check operation of all lights and horn Top up washer fluid reservoirs, adding a screen wash, and check operation of washers and wipers Check coolant level Check battery electrolyte level
Check exhaust system for corrosion (Chapter 3, Section 19) Renew contact breaker points and adjust dwell angle (mechanical breaker distributors) (Chapter 4, Section 3) Check and adjust ignition timing (Chapter 4, Section 4) Renew spark plugs (Chapter 4, Section 11) Check clutch adjustment (Chapter 5, Section 2) Check transmission oil level (Chapter 6, Section 2) Check driveshaft and steering rack gaiters for splits (Chapters 7 and 10) Check rear brake shoe linings for wear (Chapter 8, Section 4) Check handbrake travel (Chapter 8, Section 16) Check headlamp beam alignment (Chapter 9, Section 17) Check balljoints for wear (Chapter 10, Section 2) Check front wheel alignment (Chapter 10, Section 8) Check suspension bushes for wear (Chapter 11, Section 2) Check seat belts for fraying (Chapter 12, Section 23) Lubricate controls, hinges and locks
Every 6000 miles (10 000 km) or six months, whichever comes first
Renew engine oil and filter (Chapter 1, Section 2) Check drivebelt tension (Chapter 2, Section 8) Check carburettor idle speed and mixture adjustments (Chapter 3) Check contact points and dwell angle (mechanical breaker distributors) (Chapter 4, Section 3) Check tyre tread wear (Chapter 7, Section 7) Check disc pads for wear (Chapter 8, Section 3)
Every 24 000 miles (40 000 km) or two years, whichever comes first
Renew coolant anti-freeze mixture (Chapter 2, Section 3) Renew transmission oil (Chapter 6, Section 2) Renew brake hydraulic fluid (Chapter 8, Section 12) Check for underbody corrosion and clean out door and sill drain holes (Chapter 12, Section 2)
Every 12 000 miles (20 000 km) or 12 months, whichever comes first
Check and adjust valve clearances (Chapter 1, Sections 5 and 26) Renew air cleaner element (Chapter 3, Section 2)
Every 36 000 miles (60 000 km) or three years, whichever comes first
Renew the timing belt - 1116 and 1299/1301 cc (Chapter 1, Section 28)
Routine maintenance
0·11
Engine compartment (air cleaner removed for clarity) on 55S model 1 2 3 4 Strut upper mounting Washer fluid reservoir Brake fluid reservoir Ignition coil 5 6 7 8 Throttle cable Carburettor Battery Timing belt cover 9 Distributor 10 Oil filler cap 11 Radiator electric cooling fan 12 13 14 15 Radiator Coolant expansion tank Front mounting Clutch operating cable
0·12
Routine maintenance
View of front end from below on 55S model 1 2 3 4 5 6 7 8 9 10 11 12 13 Tie-rod end Track control arm Lower mounting Gearchange control rods Exhaust pipe Driveshafts Transmission Sump drain plug Disc caliper Front mounting Horns Radiator Oil filter
View of rear end from below 1 2 3 4 5 6 7 8 9 10 Suspension trailing arm Fuel tank filler hose Rear axle beam Rear silencer Spring seat Expansion box Handbrake cable Fuel tank support strap Fuel tank Handbrake cable adjuster
Lubricants and Fluids
0·13
Component or system 1 Engine
Lubricant type/specification 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 Turbo ie model All other models 3 Cooling system 4 Brake and clutch hydraulic system(s) 5 Driveshaft CV joints and steering rack General greasing
FIAT ZC 80/S gear oil FIAT ZC 90 gear oil Ethylene glycol based antifreeze Hydraulic fluid to DOT 3 or 4, or SAE J1703C Lithium based molybdenum disulphide Multi-purpose lithium based grease
0·14
Conversion Factors
x 25.4 x 0.305 x 1.609 x x x x x x x x = Millimetres (mm) = Metres (m) = Kilometres (km) Cubic centimetres (cc; cm3) Litres (l) Litres (l) US quarts (US qt) Litres (l) Litres (l) US gallons (US gal) Litres (l) x 0.0394 = Inches (in) x 3.281 = Feet (ft) x 0.621 = Miles x x x x x x x x 0.061 1.76 0.88 0.833 1.057 0.22 0.833 0.264 = = = = = = = = Cubic inches (cu in; in3) Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal)
Length (distance)
Inches (in) Feet (ft) Miles
Volume (capacity)
Cubic inches (cu in; in3) Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal) 16.387 = 0.568 = 1.137 = 1.201 = 0.946 = 4.546 = 1.201 = 3.785 =
Mass (weight)
Ounces (oz) Pounds (lb) x 28.35 = Grams (g) x 0.454 = Kilograms (kg) x 0.278 = Newtons (N) x 4.448 = Newtons (N) x 0.1 = Kilograms-force (kgf; kg) x 0.070 = Kilograms-force per square centimetre (kgf/cm2; kg/cm2) x 0.068 = Atmospheres (atm) x 0.069 = Bars x 6.895 = Kilopascals (kPa) x 0.01 x x x x x x = Kilograms-force per square centimetre (kgf/cm2; kg/cm2) 100 = Pascals (Pa) 0.0145 = Pounds-force per square inch (psi; lbf/in2; lb/in2) 0.75 = Millimetres of mercury (mmHg) 0.401 = Inches of water (inH2O) 0.535 = Inches of water (inH2O) 0.036 = Pounds-force per square inch (psi; lbf/in2; lb/in2) x 0.035 = Ounces (oz) x 2.205 = Pounds (lb) x 3.6 = Ounces-force (ozf; oz) x 0.225 = Pounds-force (lbf; lb) x 9.81 = Newtons (N) x 14.223 = Pounds-force per square inch (psi; lbf/in2; lb/in2) x 14.696 = Pounds-force per square inch (psi; lbf/in2; lb/in2) x 14.5 = Pounds-force per square inch (psi; lbf/in2; lb/in2) x 0.145 = Pounds-force per square inch (psi; lbf/in2; lb/in2) x 98.1 = Kilopascals (kPa) x 0.01 = Millibar (mbar) x 68.947 = Millibar (mbar) x x x x 1.333 2.491 1.868 27.68 = = = = Millibar (mbar) Millibar (mbar) Millimetres of mercury (mmHg) Inches of water (inH2O)
Force
Ounces-force (ozf; oz) Pounds-force (lbf; lb) Newtons (N)
Pressure
Pounds-force per square inch (psi; lbf/in2; lb/in2) Pounds-force per square inch (psi; lbf/in2; lb/in2) Pounds-force per square inch (psi; lbf/in2; lb/in2) Pounds-force per square inch (psi; lbf/in2; lb/in2) Kilopascals (kPa) Millibar (mbar) Millibar (mbar) Millibar (mbar) Millibar (mbar) Millimetres of mercury (mmHg) Inches of water (inH2O)
Torque (moment of force)
Pounds-force inches (lbf in; lb in) Pounds-force inches (lbf in; lb in) Pounds-force inches (lbf in; lb in) Pounds-force feet (lbf ft; lb ft) Pounds-force feet (lbf ft; lb ft) Newton metres (Nm) x 1.152 = Kilograms-force centimetre (kgf cm; kg cm) x 0.113 = Newton metres (Nm) x 0.083 = Pounds-force feet (lbf ft; lb ft) x 0.138 = Kilograms-force metres (kgf m; kg m) x 1.356 = Newton metres (Nm) x 0.102 = Kilograms-force metres (kgf m; kg m) x 745.7 = Watts (W) x 0.868 = Pounds-force inches (lbf in; lb in) x 8.85 = Pounds-force inches (lbf in; lb in) x 12 = Pounds-force inches (lbf in; lb in) x 7.233 = Pounds-force feet (lbf ft; lb ft) x 0.738 = Pounds-force feet (lbf ft; lb ft) x 9.804 = Newton metres (Nm)
Power
Horsepower (hp) x 0.0013 = Horsepower (hp)
Velocity (speed)
Miles per hour (miles/hr; mph) x 1.609 = Kilometres per hour (km/hr; kph) x 0.621 = Miles per hour (miles/hr; mph) x 0.354 = Kilometres per litre (km/l) x 2.825 = Miles per gallon (mpg)
Fuel consumption*
Miles per gallon (mpg)
Temperature
Degrees Fahrenheit = (°C x 1.8) + 32 Degrees Celsius (Degrees Centigrade; °C) = (°F - 32) x 0.56 * It is common practice to convert from miles per gallon (mpg) to litres/100 kilometres (l/100km), where mpg x l/100 km = 282
1·1
Chapter 1 Engine
For modifications, and information applicable to later models, see Supplement at end of manual
Contents
Part 1: General
Crankcase ventilation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Major operations possible without removing the engine from the car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 2 4 Sump pan - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Timing chain and sprockets - removal and refitting . . . . . . . . . . . . . 6 Valve clearances - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Part 3: 1116 cc and 1301 cc engines
Camshaft and camshaft carrier - removal and refitting . . . . . . . . . . 27 Cylinder head - dismantling and decarbonising . . . . . . . . . . . . . . . . 39 Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 29 Engine - complete dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Engine - complete reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Engine - dismantling (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Engine - initial start-up after major overhaul . . . . . . . . . . . . . . . . . . . 45 Engine - method of removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Engine - reassembly (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Engine ancillary components - refitting . . . . . . . . . . . . . . . . . . . . . . . 43 Engine ancillary components - removal . . . . . . . . . . . . . . . . . . . . . . 37 Engine mountings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Engine/transmission - reconnection and refitting . . . . . . . . . . . . . . . 44 Engine/transmission - removal and separation . . . . . . . . . . . . . . . . . 35 Examination and renovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Fault finding - all engines . . . . . . . . . . . . . . . . . . . . See end of Chapter Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Pistons/connecting rods - removal and refitting . . . . . . . . . . . . . . . . 32 Sump pan - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Timing belt - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Valve clearances - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Valve clearances - checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Part 2: 903 cc engine
Cylinder head - dismantling and decarbonising . . . . . . . . . . . . . . . . 17 Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine - complete dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine - complete reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Engine - dismantling (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine - initial start-up after overhaul or major repair . . . . . . . . . . . . 24 Engine - method of removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine - reassembly (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine - refitting ancillary components . . . . . . . . . . . . . . . . . . . . . . . 21 Engine - removing ancillary components . . . . . . . . . . . . . . . . . . . . . 15 Engine mountings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine/transmission - reconnection . . . . . . . . . . . . . . . . . . . . . . . . . 22 Engine/transmission - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Engine/transmission - removal and separation . . . . . . . . . . . . . . . . . 13 Examination and renovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fault finding - all engines . . . . . . . . . . . . . . . . . . . . See end of Chapter Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pistons/connecting rods - removal and refitting . . . . . . . . . . . . . . . . 9
1
Degrees of difficulty
Easy, suitable for novice with little experience
1
Fairly easy, suitable for beginner with some experience
2
Fairly difficult, suitable for competent DIY mechanic
3
Difficult, suitable for experienced DIY mechanic
4
Very difficult, suitable for expert DIY or professional
5
Specifications
903 cc engine Type
................................................... Four cylinder in-line, liquid cooled, overhead valve. Transversely mounted with end-on transmission 65.0 mm (2.56 in) 68.0 mm (2.68 in) 903 cc (55 cu in) 9.0 : 1 9.7 : 1 33.1 kW at 5600 rev/min (45 bhp) 68 Nm at 3000 rev/min (49 lbf ft) 69 Nm at 3000 rev/min (51 lbf ft) 9.3 to 10.35 bar (135 to 150 lbf/in2) 0.69 bar (10 lbf/in2) 1 - 3 - 4 - 2 (No. 1 at crankshaft pulley end)
General
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression ratio: 900 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 ES models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum torque (DIN): 900 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 ES models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum pressure difference between cylinders . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1·2 Engine general
Cylinder block and crankcase
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of camshaft bearing bores in crankcase timing gear end: Grade B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum cylinder bore taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum cylinder bore ovality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast-iron 65.000 to 65.050 mm (2.5591 to 2.5610 in) 50.505 to 50.515 mm (1.9882 to 1.9886 in) 50.515 to 50.525 mm (1.9886 to 1.9890 in) 50.705 to 50.715 mm (1.9960 to 1.9964 in) 50.715 to 50.725 mm (1.9964 to 1.9968 in) 46.420 to 46.450 mm (1.8275 to 1.8287 in) 35.921 to 35.951 mm (1.4142 to 1.4154 in) 0.015 mm (0.0006 in) 0.015 mm (0.0006 in)
Pistons and piston rings
Piston diameter: Grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston clearance in cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring groove width: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring thickness: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring groove clearance: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring end gap: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oversize piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gudgeon pin diameter: Grade 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.940 to 64.950 mm (2.5566 to 2.5570 in) 64.960 to 64.970 mm (2.5574 to 2.5578 in) 64.980 to 64.990 mm (2.5582 to 2.5586 in) 0.2, 0.4, 0.6 mm (0.008, 0.016, 0.024 in) 0.050 to 0.070 mm (0.0020 to 0.0028 in) 1.785 to 1.805 mm (0.0703 to 0.0711 in) 2.015 to 2.035 mm (0.0793 to 0.0801 in) 3.975 to 3.977 mm (0.1566 to 0.1567 in) 1.728 to 1.740 mm (0.0680 to 0.0685 in) 1.978 to 1.990 mm (0.0779 to 0.0784 in) 3.925 to 3.937 mm (0.1545 to 0.1550 in) 0.045 to 0.077 mm (0.0018 to 0.0030 in) 0.025 to 0.057 mm (0.0010 to 0.0022 in) 0.020 to 0.052 mm (0.0008 to 0.0020 in) 0.25 to 0.45 mm (0.0098 to 0.0177 in) 0.20 to 0.35 mm (0.0078 to 0.0137 in) 0.20 to 0.45 mm (0.0078 to 0.0177 in) 0.2, 0.4, 0.6 mm (0.008, 0.016, 0.024 in) 19.970 to 19.974 mm (0.7862 to 0.7863 in) 19.974 to 19.978 mm (0.7863 to 0.7865 in) 19.978 to 19.982 mm (0.7865 to 0.7866 in) 0.2 mm (0.008 in)
Crankshaft
Journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard main bearing shell thickness . . . . . . . . . . . . . . . . . . . . . . . . . . Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard big-end shell bearing thickness . . . . . . . . . . . . . . . . . . . . . . . Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.785 to 50.805 mm (1.9994 to 2.0002 in) 1.832 to 1.837 mm (0.0721 to 0.0723 in) 0.254, 0.508, 0.762,1.016 mm (0.010, 0.020. 0.030, 0.040 in) 0.06 to 0.26 mm (0.0024 to 0.0102 in) 39.985 to 40.005 mm (1.5741 to 1.5750 in) 1.807 to 1.813 mm (0.0712 to 0.0714 in) 0.254, 0.508, 0.762, 1.016 mm (0.010, 0.020, 0.030, 0.040 in)
Camshaft
Diameter of camshaft journals: Timing end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bush reamed diameters: Timing gear end* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *Supplied reamed to size Cam lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside diameter of cam follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam follower running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.975 to 38.000 mm (1.4951 to 1.4961 in) 43.348 to 43.373 mm (1.7079 to 1.7088 in) 30.975 to 31.000 mm (1.2194 to 1.2205 in) 38.025 to 38.050 mm (1.4971 to 1.4981 in) 43.404 to 43.424 mm (1.7088 to 1.7096 in) 31.026 to 31.046 mm (1.2215 to 1.2223 in) 5.1 mm (0.201 in) 13.982 to 14.000 mm (0.5505 to 0.5512 in) 0.05 to 0.010 mm (0.002 to 0.004 in) 0.010 to 0.046 mm (0.0004 to 0.0018 in)
Engine general 1·3
Cylinder head and valves
Material (cylinder head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide bore in head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside diameter of valve guide (reamed) . . . . . . . . . . . . . . . . . . . . . . . . . Guide fit in head (interference) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum clearance (valve stem to guide) . . . . . . . . . . . . . . . . . . . . . . . Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve face angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve head diameter: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact band (valve to seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve clearance: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve timing: Inlet valve: Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust valve: Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light alloy 0.05 mm (0.002 in) 12.950 to 12.977 mm (0.5099 to 0.5109 in) 13.010 to 13.030 mm (0.5122 to 0.5130 in) 0.5, 0.10, 0.25 mm (0.002, 0.004, 0.010 in) 7.022 to 7.040 mm (0.2765 to 0.2772 in) 0.033 to 0.080 mm (0.0013 to 0.0032 in) 6.982 to 7.000 mm (0.2748 to 0.2756 in) 0.022 to 0.058 mm (0.0009 to 0.0023 in) 44º 55' to 45º 05' 45º 25' to 45º 35' 29.0 mm (1.1417 in) 26.0 mm (1.0236 in) 1.3 to 1.5 mm (0.0512 to 0.0591 in) 0.15 mm (0.006 in) 0.20 mm (0.008 in) 0.60 mm (0.024 in)
7º BTDC 36º ABDC 38º BBDC 5º ATDC
1
Lubrication system
Oil pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tooth tip to body clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pressure at normal operating temperature and average road/ engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil capacity (with filter change) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear, driven by shaft from camshaft 0.05 to 0.14 mm (0.0020 to 0.0055 in) 0.020 to 0.105 mm (0.0008 to 0.0041 in) 2.94 to 3.92 bar (42 to 57 lbf/ in2) 3.42 litre (6.0 pint) Multigrade engine oil, viscosity SAE 15W/40 Champion C101 Nm 30 59 49 69 41 98 44 39 25 49 20 25 49 272 49 86 53 34 9 lbf ft 22 43.5 36 51 30 72 32 29 18 36 15 18 36 200 36 63 39 25 7
Torque wrench settings
Cylinder head bolts: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Big-end bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker pedestal nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine mounting bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine mounting centre nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature sender switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveshaft to hub nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub carrier to strut clamp bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake caliper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tie-rod end balljoint nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveshaft inboard boot retainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . .
1·4 Engine general
1116 cc and 1301 cc engine
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four cylinder in-line, liquid cooled single overhead camshaft. Transversely mounted with end-on transmission 1116 cc 1301 cc 80.0 mm (3.15 in) 86.4 mm (3.40 in) 55.5 mm (2.19 in) 55.5 mm (2.19 in) 1116 cc (68.08 cu in) 1301 cc (79.36 cu in) 9.2 : 1 9.1 : 1 40.5 kW (55 bhp) at 5600 rev/min 50 kW (68 bhp) at 5700 rev/min 86.3 Nm (64 lbf ft) at 100 Nm (74 lbf ft) 2900 rev/min at 2900 rev/min 10.35 to 11.73 bar (150 to 170 lbf/in2) 0.96 bar (14 lbf/ in2) 1 - 3 - 4 - 2 (No. 1 at crankshaft pulley end)
General
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum power (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum torque (DIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression pressure (bore wear test) . . . . . . . . . . . . . . . . . . . . . . . . . Pressure difference between cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and piston rings
Piston diameter - 1116 cc: Grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston diameter - 1301 cc: Grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston clearance in cylinder bore: 1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring groove width - 1116 cc: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring groove width - 1301 cc: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring thickness: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring groove clearance - 1116 cc: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring groove clearance - 1301 cc: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring end gap - 1116 cc: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring end gap - 1301 cc: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gudgeon pin diameter - 1116 cc: Grade 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gudgeon pin diameter - 1301 cc: Grade 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.940 to 79.950 mm (3.1496 to 3.1500 in) 79.960 to 79.970 mm (3.1504 to 3.1508 in) 79.980 to 79.990 mm (3.1512 to 3.1516 in) 86.320 to 86.330 mm (3.4010 to 3.4014 in) 86.340 to 86.350 mm (3.4018 to 3.4022 in) 86.360 to 86.370 mm (3.4025 to 3.4030 in) 0.2, 0.4, 0.6 mm (0.008, 0.016, 0.023 in) 0.050 to 0.070 mm (0.0020 to 0.0027 in) 0.070 to 0.090 mm (0.0027 to 0.0035 in) 1.535 to 1.555 mm (0.1442 to 0.1461 in) 2.015 to 2.035 mm (0.0794 to 0.0802 in) 3.957 to 3.977 mm (0.1559 to 0.1567 in) 1.535 to 1.555 mm (0.0605 to 0.0613 in) 2.030 to 2.050 mm (0.0800 to 0.0808 in) 3.967 to 3.987 mm (0.1563 to 0.1571 in) 1.478 to 1.490 mm (0.0582 to 0.0587 in) 1.978 to 1.990 mm (0.0779 to 0.0784 in) 3.925 to 3.937 mm (0.1546 to 0.1551 in) 0.2, 0.4, 0.6 mm (0.008, 0.016, 0.023 in) 0.045 to 0.077 mm (0.0018 to 0.0030 in) 0.025 to 0.057 mm (0.0010 to 0.0022 in) 0.020 to 0.052 mm (0.0008 to 0.0020 in) 0.045 to 0.077 mm (0.0018 to 0.0030 in) 0.040 to 0.072 mm (0.0016 to 0.0028 in) 0.030 to 0.062 mm (0.0012 to 0.0024 in) 0.30 to 0.45 mm (0.0012 to 0.0018 in) 0.20 to 0.35 mm (0.008 to 0.014 in) 0.20 to 0.35 mm (0.008 to 0.014 in) 0.30 to 0.45 mm (0.012 to 0.016 in) 0.30 to 0.50 mm (0.012 to 0.020 in) 0.25 to 0.40 mm (0.010 to 0.016 in) 21.970 to 21.974 mm (0.8656 to 0.8658 in) 21.974 to 21.978 mm (0.8658 to 0.8659 in) 21.978 to 21.982 mm (0.8659 to 0.8661in) 21.991 to 21.994 mm (0.8664 to 0.8666 in) 21.994 to 21.997 mm (0.8666 to 0.8667 in) 0.2 mm (0.008 in)
Engine general 1·5
Crankshaft
Journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard main bearing shell thickness . . . . . . . . . . . . . . . . . . . . . . . . . . Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard big-end shell bearing thickness . . . . . . . . . . . . . . . . . . . . . . . Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.785 to 50.805 mm (1.9994 to 2.0002 in) 1.825 to 1.831 mm (0.0719 to 0.0721 in) 0.254, 0.508, 0.762, 1.016 mm (0.010. 0.020, 0.030, 0.040 in) 0.06 to 0.26 mm (0.0024 to 0.0102 in) 45.498 to 45.518 mm (1.7926 to 1.7934 in) 1.531 to 1.538 mm (0.0603 to 0.0606 in) 0.254, 0.508, 0.762, 1.016 mm (0.010, 0.020, 0.030, 0.040 in)
Camshaft
Number of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of camshaft journals: No. 1 (timing end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft bearing diameters in carrier: No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside diameter of cam follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam follower running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 29.944 to 29.960 mm (1.1798 to 1.1804 in) 47.935 to 47.950 mm (1.8886 to 1.8892 in) 48.135 to 48.150 mm (1.8965 to 1.8971 in) 48.335 to 48.350 mm (1.9044 to 1.9050 in) 48.535 to 48.550 mm (1.9122 to 1.9129 in) 8.8 mm (0.3467 in) 29.990 to 30.014 mm (1.1816 to 1.1825 in) 47.980 to 48.005 mm (1.8904 to 1.8913 in) 48.180 to 48.205 mm (1.8982 to 1.8992 in) 48.380 to 48.405 mm (1.9062 to 1.9072 in) 48.580 to 48.605 mm (1.9141 to 1.9150 in) 36.975 to 36.995 mm (1.4568 to 1.4576 in) 0.005 to 0.050 mm (0.0002 to 0.0020 in)
1
Lubrication system
Oil pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tooth tip to body clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pressure at normal operating temperature and average road/ engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil capacity (with filter change) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear driven from auxiliary shaft 0.110 to 0.180 mm (0.0043 to 0.0071 in) 0.020 to 0.105 mm (0.0008 to 0.0041 in) 3.43 to 4.9 bar (50 to 71 lbf/in2) 4.05 litre (7.1 pint) Multigrade engine oil, viscosity SAE 15W/40 Champion C106
Cylinder head and valves
Head material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide bore in head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside diameter of valve guide (reamed) . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide fit in cylinder head (interference) . . . . . . . . . . . . . . . . . . . . . Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum clearance (valve stem to guide) . . . . . . . . . . . . . . . . . . . . . . . Valve face angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve head diameter: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact band (valve to seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve clearance: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve clearance adjusting shim thicknesses . . . . . . . . . . . . . . . . . . . . . Valve timing: Inlet valve: Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust valve: Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light alloy 0.05 mm (0.002 in) 13.950 to 13.977 mm (0.5496 to 0.5507 in) 14.040 to 14.058 mm (0.5532 to 0.5539 in) 0.05, 0.10, 0.25 mm (0.002, 0.004, 0.010 in) 8.022 to 8.040 mm (0.3161 to 0.3168 in) 0.063 to 0.108 mm (0.0025 to 0.0043 in) 7.974 to 7.992 mm (0.3142 to 0.3149 in) 0.030 to 0.066 mm (0.0012 to 0.0026 in) 45º 25' to 45º 35' 44º 55' to 45º 05' 35.850 to 36.150 mm (1.4125 to 1.4243 in) 30.850 to 31.450 mm (1.2155 to 1.2391 in) 1.3 to 1.5 mm (0.0512 to 0.0591 in) 0.40 mm (0.0158 in) 0.50 mm (0.0197 in) 0.80 mm (0.0315 in) 3.25 to 4.70 mm (0.128 to 0.185 in), in increments of 0.05 mm (0.002 in)
7º BTDC 35º ABDC 37º BBDC 5º ATDC
1·6 Engine general
Auxiliary shaft
Bearing internal diameter (reamed): No. 1 (timing belt end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft journal diameter: No. 1 (timing belt end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.664 to 35.684 mm (1.4052 to 1.4059 in) 32.000 to 32.020 mm (1.2608 to 1.2616 in) 35.593 to 35.618 mm (1.4024 to 1.4033 in) 31.940 to 31.960 mm (1.2584 to 1.2592 in) Cast-iron 80.000 to 80.050 mm (3.152 to 3.154 in) 86.400 to 86.450 mm (3.404 to 3.406 in) 0.015 mm (0.0006 in) 0.015 mm (0.0006 in) Nm 20 40 Turn through 90º Turn through 90º 20 80 51 83 83 44 28 83 59 49 32 25 86 272 34 53 49 9 98 lbf ft 15 30 Turn through 90º Turn through 90º 15 59 38 61 61 32 21 61 44 36 24 18 63 200 25 39 36 7 7 12 The oil pump is located within the sump pan and incorporates a pressure relief valve. 13 Pressurised oil passes through a cartridge type oil filter. 14 The crankshaft main bearings are supplied under pressure from drillings in the crankcase from the main oil gallery whilst the connecting rod big-end bearings are lubricated from the main bearings by oil forced through the crankshaft oilways. The camshaft bearings are fed from a drilling from the main oil gallery. The cams and tappets are lubricated by oil mist from outlets in the camshaft bearings. 15 The cylinder walls, pistons and gudgeon pins are lubricated by oil splashed up by the crankshaft webs. An oil pressure warning light is fitted to indicate when the pressure is too low.
Cylinder block and crankcase
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bore diameter: 1116 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1301 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum cylinder bore taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum cylinder bore ovality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque wrench settings
Cylinder head bolts: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft carrier to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Big-end cap nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt tensioner bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary shaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flexible mounting bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flexible mounting centre nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveshaft/hub nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tie-rod end balljoint nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake caliper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front strut lower clamp bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveshaft inboard boot retainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part 1: General
1 Description
cartridge type oil filter. An oil pressure relief valve is incorporated in the oil pump. The engine oil is independent of the transmission lubricant.
1116 cc and 1301 cc
1 The Uno may be powered by one of three engines depending upon the particular model. 6 These engines are of single overhead camshaft type, the camshaft being driven by a toothed belt. 7 The difference in engine capacity is achieved by increasing the cylinder bore on the 1301 cc engine. 8 The cylinder head is of light alloy while the cylinder block and crankcase are of cast-iron construction. 9 A five bearing crankshaft is use