oil pressure FIAT 127 1977 1.G Workshop Manual

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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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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-o ut
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 1 2
Camshaft cap nuts 14 2

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Ignition distributor clamp nut 11 1.5
Oil pump to crankcase bolts 13 1.8
Cylinder head outlet pipe bolt 16 2.2
Water pump/alternator drive pulley nut 101 14
Alternator bracket to crankcase bolt 20 2.8
Alternator to lower bracket bolt 36 5
Cylinder head upper bracket bolt 20 2.8
Alternator to upper bracket nut 36 5
Upper bracket securing bolt 13 1.8
Oil pressure switch 24 3.3
Coolant temperature switch 36 5
Spark plug 27 3.8

Sport models only
Engine
Flexible mounting to body (engine side) 65 9.0
Flexible mounting support (engine side to body)
18 2.5
Flexible mounting upper support to gearbox 18 2.5
Engine crossmember to body 18 2.5
Flexible mounting support nut (gearbox side) 18 2.5
Flexible mounting support bolt to body
(gearbox LH side) 65 9.0
Steering and suspension
Steering wheel retaining nut 22 3.0
Front wheel bearing ring nut 44 6.0
Front wheel hub nut 160 22.0
Roadwheel bolts 64 8.8
Front suspension track control arm to body 20 2.7
Front suspension balljoint to hub carrier 40 5.5
Rear wheel hub nut 160 22
Transmission
Starter motor bolt to bellhousing lower support 18 2.5
Gear selector shaft nut 18 2.5
Upper gear lever relay lever 22 3.0
Idler support securing nut 18 2.5
Differential case flange to gearbox housing 18 2.5

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3.8 The half thrust washers are fitted each side of
the
centre bearing


3.9 Oil the bearings and crankshaft journals…





3.10 … and then fit the crankshaft into the crankca se 12 Refit the main bearing cap bolts and screw
them up fingertight. Spin the crankshaft and, if
all is well, tighten the bolts to the specified
torque load and turn the crankshaft again to
check freedom of rotation (photo).
13 Measure the crankshaft endfloat with feeler
gauges. If this exceeds the specified tolerance,
oversize thrust washers will have to be fitted.
Pision rings - refitting
14 Follow the procedure given in Chapter 1,
Section 42.
Pistons and connecting rods–reassembly
15 Follow the procedure given in Chapter 1,
Section 43 (photo).
Pistons – refitting
16 Follow the procedure given in Chapter 1,
Section 44.
17 Note that the connecting rods in the 1049 cc
engine have two oil jet holes leading from the
big-end bearing (photo).
18 When the piston is correctly fitted it will have

the valve depressions adjacent to the side of the
block with the cylinder head studs in (photo). C
onnecting rods to crankshaft-
r
eassembly
19 Follow the procedure given in Chapter 1,
Section 45.
20 Torque load the big-end cap nuts to the
reading quoted in the Specifications of this
Chapter 13 - it is different from the value quoted
for the 903 cc engine (photo).
Oil pump - reassembly
21 The oil pump fitted to the 1049 cc engine is a
Hobourn-Eaton rotor type of pump which is quite
different from the gear pump fitted to the 903 cc
engine. It consists of a four lobed rotor rotating
in a five slotted outer rotor which is mounted
eccentrically to the inner rotor. As the inner roto r
rotates the outer rotor is driven round, and the
spaces between the lobes on the inner rotor and
the slots in the outer rotor increase and
decrease once per revolution. The increasing
spaces are connected to the pump inlet and
cause oil to be drawn into the pump. The
decreasing spaces connect with the pump outlet
through which the oil is forced to feed the
engine. A springloaded relief valve in the outlet
of the pump vents excessive oil pressure into
the sump. The efficiency of the pump depends

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3.25 …and the inner to outer rotor clearance 3.27A Fit the oil pump pressure relief valve plunge r and
spring…


3.27B …followed by the retainer plate and circlip 3.28 Refit the pump lower half body


3.29 Fit the oil pump to the crankcase 3.30 The oil tube is secured by a bracket to the ce ntre main
bearing cap with a bolt and washer

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3.32 Fitting the crankshaft seal and carrier at fly wheel
and… 3.33 …and at the timing cover end



3.34 The timing indicator bracket is located behind the two
top bolts of the seal carrier 3.36 Fit the sump to the crankcase

on fine clearances and these should be checked
during assembly.
22 Fit the outer rotor to the pump body and then
fit the inner rotor (photos).
23 Lay an accurate straight edge across the
faces of the rotors and pump body and measure
the clearance with feeler gauges (photo).
24 Insert a feeler gauge between the outer rotor
and the pump body to measure the clearance
(photo).
25 Similarly insert a feeler gauge between the
inner rotor lobe tip and the outer rotor to
measure the clearance between the two (photo).

26 Compare the clearances with the tolerances
quoted in the Specifications to this Chapter. Any
excessive clearance could result in low oil
pressure, and as the inner and outer rotors are
matched pairs the only solution is a new or
reconditioned pump assembly. 27 Fit the oil pressure relief valve plunger to th
e
pump body followed in turn by the spring,
retainer plate and circlip (photos).
28 Lubricate the rotors with clean engine oil and
refit the pump lower half body and strainer
(photo).
29 With a new gasket, fit the assembled oil
pump to the crankcase block and secure with
the two long bolts (photo). Tighten to the
specified torque load.
30 Fit the oil tube to the crankcase securing it by
its bracket to the centre main bearing cap with
its retaining bolt. Tighten to the specified torque
load (photo).
Craknshaft oil seals and carriers-refitting
31 Clean the flywheel mounting spigot on the
end of the crankshaft and lubricate the
crankshaft seal with clean engine oil. Fit a new
gasket.