1981 FIAT 127 wheel

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Crankshaft inches mm
Main bearing journal diameter 1.8972 to 1.898 48.1 89 to 48.209
Standard main bearing shell thickness 0.0721 to 0.0 726 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 2.43 7 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 0.31 65 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 2 5.3
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 29.96 0
Centre 1.0630 to 1.0636 27.000 to 27.015
Flywheel end 0.9843 to 0.9848 25.000 to 25.015

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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. 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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3.11A Fit the bearing shell ti the main bearing cap s… 3.11B …and then fit caps to the crankcase after oil ing the
shells


3.11C Ensure that each cap is the right way round i n its
own location with the one with four marks at the fl ywheel
end of the crankcase 3.12 Tighten main bearing cap bolts with a torque w rench


3.15 Piston and connecting rod assembly 3.17 One of the oil jet holes in the big-end – the other is on
the other side of the rod

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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.

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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