1982 FIAT 127 wheel size

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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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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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78 Slacken the tensioner bolts to tension the belt
and retighten the bolts (photo).
79 Turn the engine over for two complete
revolutions to even out belt tension. Then again
slacken the tensioner bolts to let the tensioner
take up any slack and
retighten the bolts. Never
turn the engine backwards or rock the camshaft
when tensioning the belt, as slack could develop
in the belt and it might jump a tooth.
80 Refit and tension the alternator/water pump
V-belt. Refit the drivebelt cover.
Valve clearances - adjustment
81 Checking the valve clearances should be
done at the 6000 miles servicing, or whenever
the cylinder head has been removed and
refitted for any reason. It is important that the
clearances are set correctly, otherwise the
timing will be wrong and the engine
performance will be poor. If there is no
clearance at all, the valves and seats will soon
get burnt. Set the clearances with the engine
cold.
82 Remove the camshaft cover. The engine can
be turned over by either using a spanner on the
crankshaft pulley nut, or by jacking up a front
wheel, engaging top gear and using the wheel
to turn the engine.
83 Each tappet must be checked when its
operating cam is pointing upwards, 1800 away
from the tappet. Check the clearances in the
firing order, No. 1 cylinder first and then 3, 4
and 2. Do the exhaust of one cylinder and the
inlet of the one after, at the same time to
minimise the amount of engine turning. Counting
from the timing belt end, exhaust valves are
1-4-5-8, inlet valves 2-3-6-7.
84 Insert the feeler gauge for the appropriate
valve. See the Specifications for correct
settings. The feeler should slide in readily
between cam and shim, but with slight frictional
drag. Try one a size thicker and one a size
thinner. The thick one should not go in and the
thinner one should be too loose (photo).
85 If the clearance is wrong, measure the
clearance and write it down with the number of
the valve. When all the clearances have been
checked, it will be necessary to remove those
shims which are fitted where the clearances are
wrong, and renew them with different thickness
shims. If a clearance is too big, use a thicker
shim. If a clearance is too small use a thinner
shim. Calculate by simple subtraction. 86 To change a shim, turn the engine until the
relevant cam is pointing upwards, then turn the
tappet in its housing so that the slot in the rim is
accessible.
87 The manufacturer provides special tools for
depressing tappets (Nos. A60480 and A60443).
These make the job easier if they can be
borrowed, but it is possible to do the job without
them. The best way is to make up a tool from a
piece of steel plate shaped as shown in the
photograph. Alternatively use a screwdriver to
lever the tappet down and another on
e, on edge,
to hold the tappet down by positioning it
between the camshaft and the rim of the tappet;
then remove the lever. This is quite tricky and
needs some care to avoid any damage. If in any
doubt about doing this job it should be left to a
FIAT agent. As well as having the right tools he
will also have a stock of shims from which to
choose those required to correct wrong
clearances. It is expensive buying shims that are
not required (photo).
88 With the tappet held down, prise the shim out
with a thin screwdriver. The FIAT way is to lift
the shim using compressed air, which is
effective if an air line is available. The shims are
held in quite strongly by the oil film and they
must be lifted up square or they will jam.
Remove the shim with long-nosed pliers
(photos).
89 When new, shims have their thickness
marked in millimetres on their undersides. This
marking may wear off and then it will be
necessary to measure their thickness with a
micrometer. From the thickness of the shim and
the error in the clearance, calculate the size of
shim required to produce the correct clearance.
90 Insert the new shim, numbered side down
towards the tappet. Remove the tools used for
depressing the tappet and repeat the operation
until all clearances are correct.
91 Using clean engine oil lubricate all moving
and sliding parts in the camshaft/tappet
assembly. Fit a new gasket and refit the
camshaft cover together with the nine bolts and
washers. Tighten the bolts progressively (photo).


Engine - final assembly
92 Completing assembly of the 1049 cc engine
follows broadly the procedure for that of the
smaller engine which is dealt with in Chapter 1,
Section 56.
93 The manifold gasket is supplied in two parts
for the 1049 cc engine (photo). These serve