AUX FIAT 127 1982 3.G Workshop Manual

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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 adjust ing
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

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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 37.0 00 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 0.05 0
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 pu mp
Pump rotors endfloat 0.0018 to 0.0047 0.045 to 0.120
Outer rotor to body clearance 0.0006 to 0.002 2 0.016 to 0.055
Inner to outer rotor clearance 0.0010 to 0.00 39 0.025 to 0.100
Oil pressure at 212°F (100°C) 50 to 70 Ibf/in
2 (3.5 to 5 kgf/cm2)

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/cm2)

Fuel system
Weber 32 ICEV 16/150 carburettor (C, L and CL model s)
Venturi diameter 0.8465 in (21.5 mm)
Main jet . 0.0453 in (1.15 mm)

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3. Engine

1049 cc engine - general
1 This engine is of overhead camshaft design,
using shims for valve clearance adjustment. The
crankshaft is supported in five main bearings,
the centre one incorporating the thrust washers
which control crankshaft endfloat.
2 An auxiliary shaft, driven by the toothed
camshaft belt, is used to drive the distributor and
the fuel pump. 3 Most major engine components
can be removed while the engine is in the car,
but operations on the crankshaft, main bearings
and flywheel can only be carried out after the
engine has been removed.
4 Engine removal and subsequent dismantling
follows closely the information given for the
overhead valve engine in Chapter 1, but the
following sequence for complete engine
dismantling is recommended:
(a) Engine ancillaries (alternator, fuel pump, distributor)
(b) Timing belt cover
(c) Water pump
(d) Timing belt tensioner and belt
(e) Manifolds
(f) Cylinder head complete with camshaft
(g) Crankshaft pulley
(h) Auxiliary shaft sprocket
(i) Sump
(j) Oil pump and auxiliary shaft
(k) Connecting rods and pistons
(l) Flywheel and crankshaft oil seal carriers
(m) Crankshaft and main bearings

5 If the cylinder head is to be dismantled, before

withdrawing the camshaft, have a suitably divided
container ready so that the valve clearance
adjusting shims can be extracted and kept in strict
originally installed order together with their
appropriate valves, springs etc.
6 All engine parts must be thoroughly cleaned
and examined as explained in Chapter 1. Where
required, all defective parts should be renewed
before reassembly starts.
Crankshaft – refitting
7 Fit the main bearing shells to their seats in the
crankcase after making sure that both shells and
seats are spotlessly clean and dry (photos).
8 With a light smear of grease, fit the two half
thrust washers each side of the centre bearing
with the oil grooves in each washer facing away
from the bearing shell (photo).
9 Using clean engine oil lubricate the bearing
shells and crankshaft main bearing journals
(photo).
10 Carefully lower the crankshaft into its bearings
in the crankcase after making sure that it is the
right way round. Spin the shaft to distribute the o il
(photo).
11 Fit the clean and dry bearing shells to the main
bearing caps. Oil the bearing face and fit the
bearing caps to the crankcase. Make sure that
each cap is fitted to its own location by checking
the groove marks in the base, and that each cap
is the right way round. This is achieved when the
axial locating tags in each half bearing shell butt
on the same side (photos).



3.7A Thoroughly clean the bearing shells and seats
before
assembly 3.7B Note that central bearing shell has no oil gro ove but all
shell are axially located by an offset tag

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3.39 Fitting the auxiliary shaft… 3.40 …and its seal and carrier


3.42 This face of the pulley fits towards the shaft 3.43 Fit the belt tensioner bracket a new gasket to the
block …


3.44 …followed by the spring-loaded plunger… 3.45 …and then the tensioning wheel

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32 Carefully ease the lip of the seal onto the
spigot and secure the carrier with the bolts and
washers (photo).
33 Similarly clean the crankshaft at the timing
belt end and fit the seal and carrier. Retain by
the two bottom bolts (photo). 34 Put the timing
indicator bracket over the two top bolt holes in
the seal carrier and fit the two top bolts (photo).

Sump - refitting
35 Make sure that there are no remnants of the
old gasket on the sump flange and fit a new
gasket using a little grease to hold it in position .
Check that it is bedded down evenly all round
the flange.
36 Fit the sump to the crankcase. Put the load
spreading washers on each bolt and screw into
the crankcase (photo).
37 Tighten the bolts evenly to avoid warping the
flange.
Auxiliary shaft and seal - refitting
38 Clean the auxiliary shaft bearings and
lubricate with clean engine oil.
39 Insert the shaft into the crankcase bushes
and rotate the shaft to spread the oil (photo).
40 Lubricate the auxiliary shaft seal in its carrie r
and carefully ease the seal over the shaft spigot
(photo).
41 Fit the seal carrier retaining bolts and
washers and tighten.
Belt pulleys and tensioner - refitting
42 Fit the toothed pulley to the auxiliary shaft.
The recess in the pulley fits on the auxiliary shaf t
with the dowel on the shaft in the hole in the
pulley (photo). Fit the retaining bolt and washer
and partially tighten, as it will be necessary to
wait until the drivebelt has been fitted before
finally tightening this bolt. Alternatively, it is
possible to hold the auxiliary shaft carefully in a
vice, fit the seal and carrier to the shaft, follow ed
by the toothed pulley and its retaining bolt and
washer, and then tighten the bolt fully before
fitting the complete assembly to the block.
43 The belt tensioner bracket can now be fitted.
Clean off all traces of old gasket from the
bracket and block and use a new gasket on
assembly. Fit the retaining bolts and washers
and tighten (photo).
44 Insert the spring-loaded plunger assembly
into the tensioner bracket (photo).
45 The tensioning wheel in its carrier can now
be fitted. Put the top bolt and washer in first and
then bear down to compress the spring and fit the bottom bolt through the kidney-shaped slot.
Note that this latter bolt has an additional, large
washer against the wheel carrier. Temporarily
tighten the two bolts they will have to be
retightened after the belt has been fitted (photo).

46 If the key had previously been removed from
the pulley end of the crankshaft, clean the key
slot and refit the key. Then slide on the bevelled
washer, making sure that the bevel is on the
side away from the crankcase (photo).
47 Refit the crankshaft toothed pulley (photo).
Then the V-belt pulley can be refitted together
with its retaining nut and washer. Final
tightening of this nut can wait until the flywheel
has been fitted, when a 'gag' can be fitted to the
flywheel to hold the crankshaft whilst tightening
the nut - see Chapter 1, photo 23.2A.

Cylinder head and valve gear-reassembly

48 It is assumed that the valves will have
already been examined and renovated as
described in Chapter 1, Section 31. Follow the
procedure given in Chapter 1, Section 51 to
reassemble the valves, but note that new oil
seals should be fitted to this engine when the
valves have been inserted in the guides and
before the springs are fitted (photos).
49 Each tappet bucket contains a shim in the
head which is used to control the valve
clearance. Before assembling the buckets to
their valves, prise out each shim and take a note
of the thickness. This is etched on the lower face
of the shim and indicates the thickness in
millimetres to two decimal places. If the number
has worn off, use a micrometer to check the
shim thickness. Make a table showing each
valve by number and the thickness of shim on
assembly. Reassemble each shim to its bucket
and after lubricating with clean engine oil fit the
buckets to their respective valves (photos).
50 Lubricate the two camshaft bearings in the
cylinder head and carefully thread the camshaft
through the driving end hole and lower it onto its
bearings. The cams will rest on the tappet
buckets and the camshaft should now be turned
so that the two cams over No. 1 cylinder (driving
end) are pointing upwards (compression/firing
stroke). This is to reduce the bending load on
the camshaft as the two bearing halves are
being tightened down (photo).
51 Lubricate the camshaft bearing halves and fit
them to their respective studs in the head. Put
the steel bridge plates in position and fit the
washers and nuts (photo).
52 Tighten the four nuts a little at a time

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3.68 Fitting the distributor



3.70 Distributor clamp bolt


extension length and the torque wrench length
and is calculated by using the formula:

where A is the specified torque loading (Ibf ft or
kgf m), B is the torque to be set, or read, when
using an extension (Ibf ft or kgf m), y is the
length of extension (ft or m), and z is the length
of torque wrench (ft or m).
Example: Specified torque is 60 Ibf ft, length of
extension is 6 in, and length of torque wrench is
2 ft, then B = (60 x 2) = (6/12 + 2) = 120 =2'/z =
48 Ibf ft; torque wrench setting or indication.
When measuring, use centres of bolts/nuts and
centre of torque wrench drive square. When
calculating, keep values constant, that is, don't
mix inches and feet for example (photos). 63 Fit
the drivebelt as described later in this Section.
When fitted, the auxiliary shaft pulley bolt and
the camshaft pulley bolt can be torque loaded to
the specified settings if these were not done on
assembly.
Distributor - refitting
64 The distributor is mounted nearly vertical on
the oil filter side of the engine and is driven by
skew gears from the auxiliary shaft. In turn the
distributor shaft also drives the oil pump through
a splined coupling (photo).
65 It is more convenient to set the contact
breaker gap before fitting the distributor to the
engine. Adjust to the specified clearance
(photo).
66 Turn the crankshaft in the normal direction of
rotation until the line on the crankshaft pulley is
adjacent to the first of the three pointers on the
timing bracket. This is 100 BTDC, the second
pointer is 50 BTDC and the large, third pointer is
TDC. Note which cylinder, either 1 or 4, is on the
compression stroke. This is indicated by both of
the inlet and exhaust cams pointing upwards
causing their relative valves to be shut. 67
Rotate the distributor shaft until the rotor is
opposite the terminal in the distributor cap
serving the same cylinder number as the one
which was on compression stroke and with the
contact breaker points just breaking.
68 Lubricate the distributor skew gear with clean
engine oil and insert the distributor into the
engine block. Watch the rotor carefully to see
how much it turns as the skew gears mesh.
Then withdraw the distributor, reset the rotor and
then preset it the same amount that it turne d


3.77 Fitting the toothed drivebelt-crankshaft V-bel t pulley
removed for clarity

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3.78 Setting the belt tensioner


3.84 Checking a valve clearance


3.87 Made-up tool for depressing tappet buckets


when initially inserted; then reinsert it into the
engine. Ideally the contact points should be just
breaking with the rotor opposite the correct
numbered terminal in the cap. If this is not the
case, repeat on a trial and error basis until this
is
achieved (photo).
69 Fit the clamp washer and nut and lightly
tighten temporarily.
70 With a lamp and battery across the contact
breaker points and the clamp nut just loosened,
move the distributor body round its axis until the
light just goes out. Tighten the clamp nut to the
specified torque load (photo).
Toothed drivebelt - removal, refitting and
adjusting
Note: If adjustment is necessary on an old belt
or if the belt is removed for any reason, always
change the belt for a new one, never adjust
using the old belt.
71 The toothed drivebelt should be renewed at
36 000 miles (60 000 km). This can be done with
the engine in the car. 72 Using a spanner on the
crankshaft pulley nut turn the engine over until
the timing mark on the crankshaft pulley is
aligned with the TDC pointer (long one).
73 Remove the drivebelt cover and the
alternator/water pump drivebelt.
74 Check that the camshaft pulley timing hole is
aligned with the cast ridge on the seal housing;
refer to paragraph 59 of this Section. If it isn't,
turn the engine over one revolution to get it lined
up.
75 Before removing the drivebelt it must be
remembered that neither the camshaft nor the
crankshaft must be moved with the belt off, If
this precaution is not observed the pistons and
valves could impact causing serious damage.
76 Release the tension on the drivebelt by
slackening the bolt in the kidney-shaped slot on
the tensioner bracket, loosening the other
(pivot) bolt, pushing the tensioner wheel against
the spring unit and tightening both bolts. Slide
the drivebelt off the pulleys.
77 Fit the new belt. Start at the crankshaft drive
pulley and, taking care not to kink or strain the
belt, ease it into place over the auxiliary shaft
pulley and the camshaft pulley. It might be
necessary to slightly turn the camshaft to get the
belt to mesh. This should always be done in the
direction of least movement to achieve a mesh,
Fit the belt on the tensioner pulley last. If this is
difficult do not lever or force the belt on but
recheck it and try again (photo).