FIAT 127 Engine Repair Manual

Fiat 127 1049 cm 3 opis části servisního manuálu

Fiat 127 Internet Fan Club (http://fiat127.okruhy.cz) Fiat 127 - 1050 2/34 Supplement Contents Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 Specifications ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2 Engine … … … ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3 1049 cc engine - general Crankshaft - refitting Piston rings - refitting Pistons and connecting rods - reassembly Pistons - refitting Connecting rods to crankshaft - reassembly Oil pump - reassembly Crankshaft oil seals and carriers - refitting Sump - refitting Auxiliary shaft and seal - refitting Belt - pulleys and tensioner - refitting Cylinder head and valve gear - reassembly Distributor - refitting Toothed drive belt - removal, refitting and adjusting Valve clearances - adjustment Engine - final assembly Engine removal – 127 Special and 127 from chassis number 1104290 onwards Fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4 Carburettors - general Weber or Solex single venturi carburettors Weber dual venturi carburettor Carburettor overhaul - general Ignition system... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5 Automatic centrifugal advance curves Braking system... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6 Brake fluid reservoir and vacuum servo unit (Sport) Electrical system... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 7 Charging system Fuses (127 Special) Fuses (1049 cc models) Bodywork and fittings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8 Model variations Wing mouldings and front spoiler (Sport) - removal and refitting Rear spoiler (Sport) – removal and refitting

Fiat 127 Internet Fan Club (http://fiat127.okruhy.cz) Fiat 127 - 1050 3/34 1. Introduction Since its first introduction in 1971 the FIAT 127 has undergone a continuing programme of improvements concerned mainly with styling and trim alterations. However, in 1977 a new model range was introduced which included the option of a larger engine of 1049 cc capacity with a single overhead camshaft. In appearance, cars in the new range are broadly similar to the earlier models but they have a lower bonnet line, larger glass area and redesigned bumpers. In October 1978, the FIAT 127-Sport was launched. This is a high performance version of the three door hatchback having the 1049 cc engine with a twin choke carburettor. Apart from minor body styling changes, the Sport is equipped with a larger capacity sump, twin exhaust tailpipes, servo braking, additional instrumentation and a laminated windscreen. This supplement has been added to cater for some of the production changes which have been made, but principally to cover the 1049 cc engine. The material given in Chapters 1 to 12 still applies unless superseded by information contained in this Supplement. Therefore, always read this Chapter in conjunction with the rest of the book.

Fiat 127 Internet Fan Club (http://fiat127.okruhy.cz) Fiat 127 - 1050 4/34 2. Specifications Capacities (1049 cc models) Engine oil (including filter change) L, C and CL ... ... ... ... ... ... ... ... … 5.5 pints (3.1 litres) Sport ... ... ... ... ... ... ... ... ... 7.7 pints (4.4 litres) Coolant ... ... ... ... ... ... ... ... … 9.7 pints (5.5 litres) Fuel ... ... ... ... ... ... ... ... … 6.7 gallons (30.5 litres) including 6.2 pints (3.5 litres) reserve Transmission oil ... … ... ... ... ... ... ... . 4.2 pints (2.4 litres) 1049 cc OHC engine General Type number ... ... ... ... ... ... ... ... … 127 A 000 (C, L and CL); 127 A1.000 (Sport) Bore ... ... ... ... ... ... ... ... … 2.992 in (76 mm) Stroke ... ... ... ... ... ... ... ... ... 2.276 in (57.8 mm) Capacity ... ... ... ... ... ... ... ... … 64 cu in (1049 cc) Compression ratio ... ... ... ... ... … 9,3 : 1 (C, L and CL); 9,8 : 1 (Sport) Maximum horsepower (DIN) ... ... ... ... 50 HP at 5600 rpm (C, L and CL); 70 HP at 5600 rpm (Sport) Valve mechanism C, L and CL Sport Inlet : Opens ... ... ... ... ... ... ... ... ... 2° BTDC 6° BTDC Closes ... ... ... ... ... ... ... ... ... 42°ABDC 46°ABDC Exhaust : Opens ... ... ... ... ... ... ... ... ... 42° BBDC 47° BBDC Closes ... ... ... ... ... ... ... … … 2° ATDC 7° ATDC Valve clearances (cold) : For checking valve timing: Inlet ... ... ... ... ... ... ... ... 0.028 in (0.70 mm) 0.032 in (0.80 mm) Exhaust ... ... ... ... ... ... ... 0.028 in (0.70 mm) 0.032 in (0.80 mm) Adjustment for running (engine cold) : Inlet ... ... ... ... ... ... ... ... 0.012 in (0.30 mm) 0.016 in (0.40 mm) Exhaust ... ... ... ... ... ... ... 0.016 in (0 40 mm) 0.020 in (0.50 mm) Cylinder block and connecting rods inches mm Cylinder bore diameter * 2.992 to 2.994 76.00 to 76.05 * Cylinder bores are graded and have a variation of 0.0004 inch (0.01 mm) between each grade Main bearing housing bore diameter 2.044 to 2.045 51.921 to 51.934 Width of centre main bearing cap between thrust washers 1.088 to 1.091 27.64 to 27.70 Connecting rod big-end diameter 1.85 to 1.8560 47.130 to 47.142 Connecting rod small-end diameter 0.8638 to 0.8646 21.94 to 21.96 Big-end bearing shell thickness 0.0606 to 0.8646 1.539 to 1.55

Fiat 127 Internet Fan Club (http://fiat127.okruhy.cz) Fiat 127 - 1050 5/34 Big-end bearing shell undersize range 0.01; 0.02; 0.03; 0.04 0.254; 0,508; 0.762; 1.016 Gudgeon pin interference fit in small-end: C, L and CL 0.0004 to 0.0017 0.01 to 0.042 Sport 0.0004 to 0.0006 0.01 to 0.016 Crankpin to bearing fit clearance 0.0009 to 0.003 0.022 to 0.076 Maximum misalignment between big and small-end axes measured 4.92 in (125 mm) from Connecting rod ± 0.004 ± 0.10 Pistons, rings and pins inches mm Standard piston diameter, measured 0.925 inch (23.5 mm) from piston skirt base : Grade A 2.989 to 2.9894 75.92 to 75.93 Grade C 2.9898 to 2.9902 75.94 to 75.95 Grade E 2.9906 to 2.9909 75.96 to 75.97 Range of oversize pistons 0.0079; 0.0157; 0.0236 0.2; 0.4; 0.6 Piston boss diameter (C, L and CL): Grade 1 0.8654 to 0.8656 21.982 to 21.986 Grade 2 0.8655 to 0.8657 21.986 to 21.990 Grade 3 0.8657 to 0.8659 21.990 to 21.994 Piston boss diameter (Sport): Grade 1 0.7874 to 0.7875 19.999 to 20.002 Grade 2 0.7875 to 0.7876 20.002 to 20.005 Ring groove width (C,L and CL) : Top groove 0.0604 to 0.0612 1.535 to 1.555 Centre grove 0.0799 to 0.0807 2.030 to 2.050 Bottom groove 0.1562 to 0.1570 3.967 to 3.987 Ring groove width (Sport) : Top groove 0.0604 to 0.0612 1.535 to 1.555 Centre grove 0.0793 to 0.0801 2.015 to 2.035 Bottom groove 0.1558 to 0.1566 3.957 to 3.977 Standard gudgeon pin diameter (C, L and CL): Grade 1 0.8650 to 0.8651 21.970 to 21.974 Grade 2 0.8651 to 0.8652 21.974 to 21.978 Grade 3 0.8652 to 0.8654 21.978 to 21.982 Standard dudgeon pin diameter (Sport) : Grade 1 0.7872 to 0.7873 19.994 to 19.997 Grade 2 0.7873 to 0.7874 19 997 to 20.000 Oversize gudgeon pin diameter 0.0079; 0.0157; 0.0236 0.2; 0.4; 0.6 Piston ring thickness : Top compression ring 0.0582 to 0.0587 1.478 to 1.490 2nd oil control ring 0.0779 to 0.0783 1.978 to 1.990 3rd oil scraper ring 0.1545 to 0.1550 3.925 to 3.937 Piston to bore fit clearance 0.0028 to 0.0035 0.070 to 0.090 Gudgeon pin fit clearance in piston 0.0003 to 0.0006 0.008 to 0.016 Piston ring side clearance in groove: 1st compression ring 0.0018 to 0.003 0.045 to 0.077 2nd oil control ring 0.0010 to 0.0022 0.025 to 0.057 3rd oil scraper ring 0.0008 to 0.002 0.020 to 0.052 Piston ring end gap: 1st compression ring (C, L and CL) 0.0079 to 0.0157 0.20 to 0.40 1st compression ring (Sport) 0.0118 to 0.0197 0.30 to 0.50 2nd oil control ring 0.0118 to 0.0197 0.30 to 0.50 3rd oil scraper ring 0.0079 to 0.0138 0.20 to 0.35 Piston rings oversize range 0.0079; 0.0157; 0.0236 0.2; 0.4; 0.6

Fiat 127 Internet Fan Club (http://fiat127.okruhy.cz) Fiat 127 - 1050 6/34 Crankshaft inches mm Main bearing journal diameter 1.8972 to 1.898 48.189 to 48.209 Standard main bearing shell thickness 0.0721 to 0.0726 1.831 to 1.845 Main bearing shell undersize range 0.01; 0.02; 0.03; 0.04 0.254; 0.508; 0.762; 1.016 Standard crankpin diameter 1.7318 to 1.7326 43.988 to 44.008 Main bearing journal fit clearance 0.0009 to 0.033 0.022 to 0.083 Width of centre main bearing cap between thrust washers 1.2785 to 1.2805 32.475 to 32.525 Standard thrust washers thickness 0.0909 to 0.0929 2.31 to 2.36 Thrust washers oversize range 0.0959 to 0.0979 2.437 to 2.487 Crankshaft endfloat 0.0022 to 0.0104 0.055 to 0.265 Maximum misalignment of main bearing journals 0.0012 0.030 Maximum misalignment of main bearing journals to crankpins 0.0138 0.350 Maximum ovality of crankpins and main bearing journals after grinding 0.0002 0.005 Maximum taper of crankpins and main bearing journals after grinding 0.0002 0.005 Maximum run-out of crankshaft flange with dial gauge stylus 31 mm (1.22 ins) from crankshaft rotational axis 0.001 0.025 Maximum run-out between flywheel face and crankshaft flange, and between flywheel face and crankshaft axis 0.0039 0.10 Cylinder head inches mm Standard valve guide housing bore 0.5886 to 0.5896 14.950 to 14.977 Standard valve outside diameter 0.5921 to 0.5928 15.040 to 15.058 Oversize valve guide 0.002; 0.0039; 0.0098 0.05; 0.10; 0.25 Valve guide interference fit 0.0025 to 0.0043 0.063 to 0.108 Fitted valve guide internal diameter 0.3158 to 0.3165 8.022 to 8.040 Valve stem diameter 0.3139 to 0.3146 7.974 to 7.992 Valve stem fit clearance in guide 0.0012 to 0.0026 0.030 to 0.066 Valve head diameter: Inlet (C, L and CL) 1.3327 to 1.3445 33.85 to 34.15 Inlet (Sport) 1.4311 to 1.4429 36.35 to 36.65 Exhaust 1.1358 to 1.1476 28.85 to 29.15 Valve seat width 0.0787 to 0.0866 2.0 to 2.2 Valve seat internal diameter: Inlet (C, L and CL) 1.1063 to 1.1142 28.1 to 28.3 Inlet (Sport) 1.2244 to 1.2323 31.1 to 31.3 Exhaust (C, L and CL) 0.9882 to 0.9961 25.1 to 25.3 Inlet (Sport) 1.0276 to 1.0354 26.1 to 26.3 Angle of valve seat 45° ± 5' Angle of valve face 45° 30' ± 5' Valve springs: Inner spring part no. 4134900 Outer spring part no. 4170458 Valve gear inches mm Camshaft journal diameter: Valve gear end 1.1789 to 1.1795 29.945 to 29.960 Centre 1.0630 to 1.0636 27.000 to 27.015 Flywheel end 0.9843 to 0.9848 25.000 to 25.015

Fiat 127 Internet Fan Club (http://fiat127.okruhy.cz) Fiat 127 - 1050 7/34 Camshaft bearing bore diameter in head: Valve gear end 1.1807 to 1.1817 29.990 to 30.015 Centre 1.0648 to 1.0657 27.045 to 27.070 Flywheel end 0.9860 to 0.9870 25.045 to 25.070 Camshaft journals fit clearance 0.0012 to 0.0028 0.030 to 0.070 Cam lift (C, L and CL) 0.3425 8.700 Cam lift (Sport): Inlet 0.3622 9.200 Exhaust 0.3642 9.250 Standard tappet bore diameter 1.4567 to 1.4577 37.000 to 37.025 Standard tappet outside diameter 1.4557 to 1.4565 36.975 to 36.995 Tappet fit clearance 0.0002 to 0.0020 0.005 to 0.050 Shim thickness 0.1279; 0.1299; then 0.0039 steps to 0.1850 3.2b; 3.30; then 0.10 steps to 4.70 Auxiliary shaft inches mm Diameter of bush bores in crankcase: Front 1.6339 to 1.6350 41.500 to 41.530 Rear 1.5733 to 1.5745 39.962 to 39.992 Fitted bush internal diameter: Front 1.5143 to 1.5151 38.464 to 38.484 Rear 1.4553 to 1.4561 36.964 to 36.984 Diameter of shaft journals: Front 1.5115 to 1.5125 38.393 to 38.418 Rear 1.4525 to 1.4535 36.893 to 36.918 Bush fit There must always be an interference fit Shaft/bush fit clearance (front and rear) 0.0018 to 0.0036 0.046 to 0.091 Lubrication system Oil pump Four lobe rotor type Pump drive Through auxiliary shaft Oil pressure relief valve Incorporated in pump Pump rotors endfloat 0.0018 to 0.0047 0.045 to 0.120 Outer rotor to body clearance 0.0006 to 0.0022 0.016 to 0.055 Inner to outer rotor clearance 0.0010 to 0.0039 0.025 to 0.100 Oil pressure at 212°F (100°C) 50 to 70 Ibf/in 2 (3.5 to 5 kgf/cm 2 ) Cooling system Radiator fan thermal switch Cuts in . 194° to 201°F (90° to 94°C) Cuts out 185° to 192°F (85° to 89°C) Engine coolant thermostat Starts to open 176° to 183°F (80° to 84°C) Fully open 205°F (96°C) Impellor vanes to pump body fit clearance 0.0315 to 0.0512 in (0.8 to 1.3 mm) Radiator cap relief pressure 11.4 Ibf/in 2 (0.8 kgf/cm 2 ) Fuel system Weber 32 ICEV 16/150 carburettor (C, L and CL models) Venturi diameter 0.8465 in (21.5 mm) Main jet . 0.0453 in (1.15 mm)

Fiat 127 Internet Fan Club (http://fiat127.okruhy.cz) Fiat 127 - 1050 8/34 Air correction jet 0.0728 in (1.85 mm) Slow running jet 0.0177 in (0.45 mm) Emulsion tube type F74 Accelerator pump jet 0.0157 in (0.40 mm) Needle valve seat 0.0591 in (1.50 mm) Accelerator pump output (10 strokes) 2 to 3 cm 3 Cold starting device Automatic choke Float level 1.4016 to 1.4213 in (35.6 to 36.1 mm) CO level 2.5% Solex C32 TDI/4 carburettor (C, L and CL models) Venturi diameter 0.8465 in (21.5 mm) Main jet 0.0453 in (1.15 mm) Air correction jet 0.0768 in (1.95 mm) Slow running jet 0.0177 in (0.45 mm) Emulsion tube type 71 Accelerator pump jet 0.0177 in (0.45 mm) Needle valve seat 0.0630 in (1.60 mm) Accelerator pump output I10 strokes) 3 to 5 cm 3 Cold starting device Automatic choke Float level 0.8661 to 0.9449 in (22.0 to 24.0 mm) CO level 2.5% Weber 34 DMTR 47/250 carburettor (Sport models) Primary venturi Secondary venturi Venturi diameter 0.8661 in (22.0 mm) 0.9449 in (24.0 mm) Main jet 0.0421 in (1.07 mm) 0.0500 in (1.27 mm) Air correction jet 0.0728 in (1.85 mm) 0.0866 in (2.20 mm) Slow running jet 0.0177 in (0.45 mm) 0.0276 in (0.70 mm) Slow running air bleed 0.0413 in (1.05 mm) 0.0276 in (0.70 mm) Accelerator pump jet 0.0157 in (0.40 mm) --- Needle valve seat 0.0689 in (1.75 mm) Accelerator pump output (10 strokes) 8.55 cm 3 Cold starting device Manually operated strangler choke Float level 0.2657 to 0.2854 in (6.75 to 7.25 mm) Fuel pump Output 75 litres/hr (16.5 gal/hr) Actuating lever stroke (C, L and CL) 2.4 to 2.6 mm (0.0949 to 0.1024 in) Actuating lever stroke (Sport) 2.4 to 2.9 mm (0.0949 to 0.1142 in) Delivery pressure at 4000 engine rpm 0.17 kgf/cm2 (2.55 Ibf/in2) and fuel temp 30°C (86°F) lgnition system Distributor Type and code Magneti Marelli S155HX Automatic centrifugal advance 25° ± 2° at 4500 rpm Condenser capacity (50 to 1000 Hz) 0.20 to 0.25 μF Clutch Lining outer diameter 181.5 mm (7.146 in) Lining inner diameter 127.0 mm (5.0 in)

Fiat 127 Internet Fan Club (http://fiat127.okruhy.cz) Fiat 127 - 1050 9/34 Maximum run-out of driven plate linings 0.2 mm (0.008 in) Travel of release flange, corresponding to a pressure plate displacement of not less than 0.067 in ~1.7 mm) 8.5 mm (0.3346 in) Transmission Synchromesh 1st and 2nd, Borg-Warner baulk ring type, 3rd and 4th, Porsche spring ring type Gear ratios First 3.910 : 1 Second 2.055 : 1 Third 1.348 : 1 Fourth 0.963 : 1 Reverse 3.615 : 1 Final drive ratio (C,L and CL) 4.071 : 1 (14/57) Final drive ratio (Sport) 4.462 : 1 (13/58) Overall ratios Gears 1 st 2 nd 3 rd 4 th Reverse C, L and CL 15.92 8.7 5.49 3.92 14.72 Sport 17.45 9.17 6.01 4.30 16.13 Electrical system Alternator Type (C, L and CL) Magneti Marelli AA 108-14V-33A Type (Sport) Lucas 18ACR-A4V-45A Maximum output (approx) 570 watts Maximum current (approx) 40 amps (C, L and CL) 50 amps (Sport) Cut-in speed at 12V and 20°C (68°F) 1050 to 1150 rpm (C, L and CL) 1100 to 1200 rpm (Sport) Field winding resistance across slip rings at 20°C (68°F) 3.4 to 3.8 ohms (C, L and CL) 3.18 to 3.22 ohms (Sport) Direction of rotation (drive end) Clockwise Engine/alternator drive ratio 1.8 : 1 Alternator regulator (C, L and CL models) Type Magneti Marelli RTT 110 AB Alternator speed for adjustment 6000 rpm Current for thermal balance 20 amps Regulating voltage 14.2 +0.3 –0.2 volts

Fiat 127 Internet Fan Club (http://fiat127.okruhy.cz) Fiat 127 - 1050 10/34 Lamps Headlamps (C, L and CL) Headlamps (Sport) Brake and rear light Turn indicators Reversing lights Parking lights Number plate Courtesy light Boot light Turn repeaters Cigar lighter light Instrument panel Ignition warning Turn indicator warning Headlamp warning Coolant temperature warning (L models) Oil pressure warning Fuel warning Hazard warning Sidelamp (out) warning (Sport only) Brake warning (Sport only) Heated rear window warning (Sport only) 40/45 watts 55/60 watts (Halogen) 5/21 watts 21 watts 21 watts 5 watts 5 watts 5 watts 5 watts 4 watts 4 watts 3 watts 3 watts 1.2 watts 1.2 watts 1.2 watts 1.2 watts 1.2 watts 1.2 watts 3 watts 1.2 watts 1.2 watts Fuses For fuse details (127 Special, L, C, CL and Sport) see Sections 23 or 24 Steering and suspension (Sport only) Steering angles Inner wheel 34° 50’ Outer wheel 32° 10’ Front wheel alignment (toe setting) Laden 0.079 in (2.0 mm) toe-in to 0.079 in (2.0 mm) toe-out Unladen 0.138 in (3.5 mm) to 0.217 in (5.5 mm) toe-in Roadwheels Size 4½ B x 13 Tyres 135 SR-13 or 155/70 SR-13 All 1049 cc models Ibf ft kgf m Main bearing cap bolts 59 8.2 Engine mounting securing bolts 43 6 Cylinder head to block bolts and nuts: 1 st stage 30 4.1 2nd stage 45 6.2 Final stage 61 8.5 Manifold to head nuts 20 2.8 Connecting rod big-end nuts 38 5.2 Flywheel to crankshaft bolts 61 8.5 Driven gear (Plastic) to camshaft retaining bolt 87 12 Driven gear (steel) to camshaft retaining bolt 87 12 Camshaft cap nuts 14 2

FIAT 127 Engine Repair Manual

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