Engine - 1301 cc Turbo ie

Supplement: Revisions and information on later models / Engine - 1301 cc Turbo ie

PART A: GENERAL
Description
1 This engine is similar in design to the 1301 cc engine described in Chapter 1, but the fuel and ignition systems are different, and a turbocharger, oil cooler and intercooler are fitted.

2 Many dimensions and tolerances have been altered for this engine, and reference should be made to the Specifications at the beginning of this Supplement.

3 Operations which differ from those described in Chapter 1 are given in the following sub-Sections.

Lubrication system - description 4 The lubrication system differs from the non-Turbo 1301 cc engine in the following respects.

5 An oil cooler is fitted, which comprises a matrix with inlet and outlet hoses connected to the oil filter cartridge mounting base.

6 A thermostatic control switch is fitted, which diverts the oil flow through the matrix only at oil temperatures above 84ºC (183ºF).

Note that a faulty switch will require renewal of the complete oil filter mounting base.

7 Special oil spray nozzles are located in the crankcase main bearing webs, to cool the underside of the pistons.

8 The ball-type valves in the nozzles open when the engine oil pressure reaches 1.2 bars (17.4 lbf/in2).

9 An oil pressure sender unit is screwed into 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).

6A.9 Oil pressure sender unit

10 Oil supply/return ducts provide the turbocharger lubrication.

Fig. 13.10 Cutaway view of the 1301 cc Turbo ie engine (Sec 6A)

Fig. 13.11 1301 cc Turbo ie engine lubrication system (Sec 6A)

1 Oil pick-up strainer 2 Oil pump
3 Oil pressure relief valve 4 Oil filter cartridge
5 Main oil gallery
6 Camshaft oil feed
7 Low oil pressure switch 8 Engine oil cooler
9 Filter mounting base
10 Turbocharger oil feed 11 Turbocharger oil return 12 Oil pressure sender unit 13 Oil temperature sender unit 14 Piston oil spray nozzle

Fig. 13.12 Piston oil spray nozzle locations - 1301 cc Turbo ie engine (Sec 6A)

Letters denote cylinder bore grade

PART B:
OPERATIONS POSSlBLE
WITH ENGINE IN CAR
Camshaft and camshaft
carrier - removal and
refitting
Warning: Refer to the beginning of Section 9 before starting any work.

1 Disconnect the battery, negative lead first.

2 Disconnect its leads and unbolt the distributor from the end of the camshaft, and place it to one side.

3 Disconnect the air intake hose from the throttle valve housing.

4 Disconnect the short throttle control cable from its sector.

5 Remove the throttle cable support bracket.

6 Disconnect the earth leads from the camshaft cover.

7 Refer to Section 9, Part C of this Supplement and remove the following components.

Supplementary air valve
Inlet manifold with fuel pressure regulator and excess pressure safety switch Injector cooling duct
8 Disconnect the wiring plug from the Microplex ignition anti-knock sensor.

9 Carry out the operations described in Chapter 1, Section 27, paragraphs 4 to 12.

10 Refitting is a reversal of removal, referring to Section 28 of Chapter 1 for the timing belt refitting procedure, and to Chapter 1, Section 27, paragraphs 15 to 18.

Cylinder head -
removal and refitting
11 Carry out the operations described in paragraphs 4 to 9 in the preceding sub-Section, then refer to Chapter 1, Section 29, but ignore all references to the carburettor.

12 Note the distributor mounting cover.

13 Four additional cylinder head bolts are used on these engines, adjacent to the spark plugs (photo). Note that their tightening torque differs from the other cylinder head bolts - see Specifications. These four bolts are tightened separately, after the ten main bolts (see Fig. 13.13).

6B.13 Two of the four additional cylinder head bolts (arrowed)

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 fixings of the individual mountings used on the turbocharged engine (photos).

6B.16A Engine/transmission centre mounting

6B.16B Engine/transmission right-hand mounting

Timing belt - renewal 17 The operations described in Chapter 1, Section 28 generally apply, but the following differences should be noted.

18 Remove the engine compartment right-hand shield. This is secured by plastic clips. To remove a clip, push out its centre pin.

19 The TDC sensor must be unbolted to provide room to remove and refit the timing belt, which can be carried out without having to remove the crankshaft pulley (photos).

6B.19A Removing the TDC sensor

6B.19B Removing the timing belt

20 The belt tensioner on later versions does not incorporate a spring, but is of eccentric centre bolt hole type. Have the pulley bolt released, and tension the belt by turning the pulley using a pin wrench or circlip pliers in the two holes provided.

Keep the tension applied while the lockbolt is tightened. Turn the crankshaft through two complete turns, and then check the belt tension. With moderate finger and thumb pressure, the belt should just twist through 90º when gripped at the mid-point of its longest run (photo). Note: This procedure serves only as a rough guide to setting the belt tension - having it checked by a FIAT dealer at the earliest opportunity is recommended.

6B.20 Belt tensioner pulley locknut (arrowed)

Oil pump drivegear cover plate 21 Due to the fact that the distributor is driven from the end of the camshaft, the oil pump gear does not have an extension to drive the distributor, which would be the case if it was mounted on the crankcase.

22 The crankcase aperture is therefore covered by a plate and gasket, together with a wiring clip (photo).

6B.22 Distributor drive hole cover plate (arrowed)

Engine oil cooler -
removal and refitting
23 The oil cooler is mounted behind the front bumper/spoiler (photo).

6B.23 Oil cooler

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).

6B.24A Oil cooler pipe connection (arrowed)

6B.24B Connections at oil filter cartridge mounting base

25 Unscrew the mounting bolts and remove the oil cooler heat exchanger (photo).

6B.25 Oil cooler mounting bolts (arrowed)

26 When refitting, make sure that the banjo union sealing washers are in good condition.

Fig. 13.13 Cylinder head bolt tightening sequence on the 1301 cc Turbo ie engine (Sec 6B)

Fig. 13.14 Piston ring arrangement on the 1301 cc Turbo ie engine (Sec 6B)

PART C: ENGINE REMOVAL, DISMANTLING, REASSEMBLY
AND REFITTING
Engine/transmission -
removal and separation
Warning: Refer to the beginning of Section 9 before starting any work.

1 Refer to Chapter 1, Section 35, and carry out the operations described in paragraphs 1 to 11.

2 Disconnect the excessive air pressure switch from the inlet manifold.

3 Disconnect the ducts and remove the airflow meter.

4 Disconnect the leads from the spark plugs and the distributor LT connector, and unbolt and remove the distributor from the rear end of the camshaft carrier.

5 Disconnect the fuel return hose from the pressure regulator.

6 Disconnect the fuel inlet hose from the injector rail.

7 Disconnect the wiring plugs from the fuel injectors.

8 Disconnect the leads from the oil pressure sender unit, the low oil pressure switch and the coolant temperature switch.

9 Remove the hose/pipe assemblies from the intercooler.

10 Disconnect the throttle control rod at the balljoint.

11 Disconnect the hoses and ducts from the turbocharger and the mechanical bypass valve.

12 Disconnect the leads from the engine speed and anti-knock sensors.

13 Raise the front of the car and support it securely. As the engine/transmission will eventually be lowered to the floor, make sure that there is sufficient clearance under the front end for the assembly to be withdrawn. If the car is over an inspection pit, then the car need only be raised enough to lift the roadwheels from the floor.

14 Remove the front roadwheels.

15 Disconnect the transmission earth cable.

16 Working under the car, remove the engine shields from under the wheel arches.

17 Remove the engine oil cooler, and the intercooler.

18 Unscrew the fixing screws and disconnect the driveshafts from the flanges at the transmission final drive. The right-hand driveshaft will not release until the upper bolt on the suspension strut-to-hub carrier clamp has been removed, and the hub assembly tilted downwards.

19 Disconnect the exhaust downpipe from the manifold, and then remove the front section of the exhaust system.

20 Disconnect the coolant return pipe from the turbocharger.

21 Disconnect the gearchange control rods from the transmission selector rod. Do this by unscrewing the self-locking nut from the bolt which connects the clevis fork.

22 Attach suitable lifting gear to the engine lifting eyes, and take the weight of the engine/transmission.

23 Disconnect the left-front, centre-rear and the right-hand engine/transmission mountings.

Do this by removing the bolts from the diamond-shaped mounting plates there is no need to disturb the flexible mounting centre bolts.

24 Lower the engine/transmission to the floor and withdraw it from under the car.

25 Carry out the operations described in Chapter 1, Section 35, paragraphs 27 to 31.

Engine dismantling and
reassembly
26 The operations are essentially as described for the 1301 cc engine in Chapter 1, but reference must be made to Sections 9 and 10 of this Chapter for the procedures for removing and refitting the components of the fuel injection, turbocharger and ignition systems.

Engine/transmission -
reconnection and refitting 27 The operations are a reversal of those described in paragraphs 1 to 25, but otherwise the following (photo).

6C.27 Filling the engine with oil

a) Tighten all nuts and bolts to the specified torque.

b) Use a new gasket at the exhaust downpipe-to-manifold flange.

c) Check and adjust the clutch pedal travel.

d) Refill the cooling system.

e) Refill the engine and transmission with oil.

f) Reconnect the battery, negative lead last.

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.