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Manuals
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Polski Fiat Manuals
Automobile
125p
Repair manual
Polski Fiat 125p Repair Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Contents
General Data
Leading Dimensions of 125P Vehicle
Fuels and Lubricants
Engine Specification
Vehicle Specification
Recommendations for Run-In Period
FIAT Engine Oil Brands
Index of Fuels, Lubricants and Fluids by FIAT
FIAT Lubricants Characteristic
Comparison of Designation of Lubricants and Fluids According to FIAT Standards with those According to International SAE Standards
Table of Equivalents for Fuels, Lubricants and Fluids
Fuels, Lubricants Recommended by CPN (Polish Make) for POLSKI FIAT 125P Car
Vehicle Identification Data
Servicing Directives
Engine Type and Serial Number Stamped on the Engine Block at the Side of the Alternator Near the Water Pump
Arrangement of Type and Serial Number of Chassis and of the Identification Plate
Directives for Vehicle Lifting and Towing
Placing the Hydraulic Lifting Jack While Raising the Vehicle Front Part
Placing the Hydraulic Lifting Jack While Raising the Rear Vehicle Part
Engine
Cross-Section of the Engine, through the Connecting Rod, Piston, Valves, Oil Pump and Distributor Drive
Component Parts
L.H. Side View of Complete Engine
R.H. Side View of Complete Engine
Typical Engine Faults
Front View of Complete Engine
Engine Stripping and Re-Assembly
Engine Dismantling off the Vehicle
Engine Compartment View
Engine Compartment Fragment
Engine Compartment Fragment View: Starter Motor Fixing
Flexible Joint Coupling Gearbox with Propeller Shaft
Fixing of Hydraulic Cylinder of Clutch Control to Clutch Housing
Removing Engine out of Engine Compartment with the Use of a Hoist and A.60537 Engine Lifting Device
Engine Stripping
Engine Fixing in Swivel Stand Arr.22204 with Securing Clamps
Complete Clutch Removal
Cooling, Fuel Supply and Exhaust Systems Elements
Ignition Distributor Dismantling
Screwing off the Oil Pressure Sensor
Detaching Water Hose off Thermostat Housing
Cylinder Head, Valve Rockers, Tappets
Detaching Thermostat Housing off Cylinder Head
Dismantling Breather off Engine Block
Unscrewing Nuts off Studs Securing Exhaust Manifold to Cylinder Head
Centrifugal Oil Filter
Unscrewing Valve Rocker Assembly Complete with Brackets and Shafts, off Cylinder Head
Unscrewing Cylinder Head Studs
Dismantling Valve Rocker Assembly Complete with Brackets and Shafts, off Cylinder Head Studs
Oil Sump, Timing Gears, Flywheel, Oil Pump
Dismantling Centrifugal Oil Filter Cover
Unscrewing Bolt off Centrifugal Oil Filter Cover
Arresting Crankshaft in Position
Crankshaft, Connecting Rods, Pistons, Camshaft
Unscrewing Timing Chain Bolt off Camshaft
Pulling Chain Pulley off Crankshaft
Flywheel Dismantling
Engine Re-Assembling
Rear Engine Block Cover Dismantling
Unscrewing Main Bearing Cap Bolts
Unscrewing Camshaft Locating Bush Bolts
Tightening Main Bearing Caps with Dynamometric Spanner, Using 10.5 Kgm Torque
Tightening Bolts Securing Flywheel to Crankshaft with Dynamometric Spanner, Using 8 Kgm Torque
Re-Fitting Oil Pump Together with Supply Pipe, into the Front Main Bearing Cap Inside Engine Block
Tightening Chain Sprocket of Camshaft with Dynamometric Spanner Using 5 Kgm Torque
Tightening Cylinder Head Bolts with Dynamometric Spanner Using 9 Kgm Torque
Tightening Nuts on Studs of Valve Rocker Shaft Brackets with Dynamometric Spanner Using 1.9 Kgm Torque
Centrifugal Oil Filter Hub
Tightening Bolts Od Centrifugal Oil Filter Hub
Tightening Bolts of Centrifugal Oil Filter Cover
Fuel Pump Securing
By-Pass Oil Filter Fitting
Nuts Securing Exhaust Manifold to Cylinder Head Studs
Ignition Advance Angle Check
Screwing Alternator Onto Engine Block
Replacing Engine in Vehicle
Engine Complete with Clutch and Gearbox, L.H. Side View
Engine Complete with Clutch and Gearbox, R.H. Side View
Engine Mounting Pad Fixing
Clutch Disc Hub Hole Positioning
Re-Fitting Gearbox Inside Vehicle
Engine Block Check and Inspection
Cylinder Bore Check with Inside Micrometer
Cylinder Bore Diameter Measurement Method
Engine Blcok-To-Cylinder Head Mating Surface Check
Cylinder Bore Diameters and Corresponding Piston Diameters
Spot for Stamping Letter Marks to Denote Selection Groups of Cylinder Bore - on Engine Block
Engine Block Holes and Surfaces Repair
Camshaft Bearing Seats and Tappet Guideways Check
Cylinder Bore Honing
Cylinder Hole Boring
Cylinder Bore Positioning for Machining
Measurement of Protrusion of Cutting Tool, with the Use of a Micrometric Gauge Fitted Device
Cylinder Re-Boring Operation View
Cylinder Liner Fitting
Inner and Outer Diameters of Cylinder Liners of a 116C076/56 Engine Prior to and Following Force-Fitting Inside the Engine Block
Engine Block-To-Cylinder Head Mating Surface Grinding and Tappet Guideways Reaming
Leading Engine Block Dimensions
Reaming Tappet Guide Inside Engine Block with A.90308 Reamer
Pistons, Gudgeon Pins and Piston Rings
Autothermic Type Pistons, Gudgeon Pins and Piston Rings Check and Inspection
Shape Difference between Piston Crowns of 116C.076/56 and 115C.076/52 Engines
Standard Sizes of Pistons, Rings and Piston Pins in a 115C.076/52 Engine
Piston-To-Cylinder Bearing Surface Clearance Check
Piston Rings Fit Inside Ring Grooves
116C.076/56 and 115C.076/52 Engine Cylinder Bore and Piston Standard Dimensions
Checking Piston Ring Clearance Inside Groove
Fit between Gudgeon Pin Hole - Gudgeon Pin-Small End Bush
Checking the Gudgeon Pin Clearance Inside Piston Hub
Checking Clearance Inside Compression Ring Joint by Means of a Gap Gauge
Piston Weight Check
Replacement and Fitting of Autothermic Pistons, Gudgeon Pins and Piston Rings
Piston Ring Ends Grinding and Fitting Rings over Pistons
Piston Weight Check on Two-Pan Tangent Scales
Piston Hub Reaming
Selecting Pistons to Match Connecting Rods
Piston Ring Ends Grinding in a Grinding Machine
Fitting Piston Rings over Piston with A.60183 Device
Fitting Piston-Connecting Rod Assembly Group into Cylinder Bore
Fitting Circlips Securing Piston Pin with A.60303 Device
Clearances Within Assembly Groups Piston-Cylinder-Gudgeon Pin-Piston Ring in 116C.076/56 and 115C.076/52 Engines
DSM Pistons
Cylinder Bore Diameters and Corresponding DSM Piston Diameters
Outer View of Pistons
Piston Rings Fit Inside Piston Grooves
Piston Weight Groups Markings
Fitting a Piston-Connecting Rod Assembly (with Standard Dimensions) into a Cylinder Bore
Connecting Rods, Big End Bearing Shells, Small End Bearing Bushes
Fit Within Assemblies: Piston Hub Hole-Gudgeon Pin-Small End Bearing Bush
Wear Check and Inspection of Parts
Small End Bearing Bush and Connecting Rod Weight Check
Connecting Rod Hole Axis Parallelity Check
Bearing Shells Replacement
Crankshaft Journal Diameters
Small End Bearing Bush Reaming and Replacement
Selection Groups and Dimensions of Small End Bearing Bush and of Gudgeon Pins
Dimensions of Small End Hole and Bearing Bush
Small End Bush Fitting and Removal
Small End Bush Oil Groove Milling Diagram
Crankshaft, Main Bearing Shells
Shank Straightening and Connecting Rod Marking
Re-Assembling Connecting Rods with Pistons and Fitting into Cylinder Bore
Wear Check and Inspection
Crankshaft and Bearing Shells Check
Crankshaft with Flywheel
Cross-Section of 115C.076/52 Engine through Crankshaft
Standard Dimensions of Crankshaft Journals and Bearing Bushes
Measurement of Diameter of Main Crankshaft Journal by Means of a Micrometer Screw
Measurement of Diameter of a Crankpin by Means of a Micrometer
Checking the Clearance between the Crankshaft Journals, and Bearing Shells
Thickness of Crankshaft Main Bearing Half-Shells
Crankshaft Axial Play Check
Thickness of Standard and Oversize Thrust Half-Rings (in MM)
Crankshaft Balance and Co-Axiality of Journals and Crankpins Check
Flywheel and Gear Ring Check
Checking the Leak Stoppers of Crankshaft, Disc, and the Sealing Ring
Crankshaft Repair
Clutch Shaft Ball Bearing Check
Diameters of Main Bearing Journals
Diameters of Crankpins
Crankshaft Balancing and Straightening
Crankshaft Oil Ducts Cleaning
Flywheel Gear Ring and Clutch Shaft Ball Bearing Replacement
Cylinder Head Dismantling and Fitting
Dismantling the Cylinder Head out of the Engine
Cylinder Head Stripping and Cleaning
Cylinder Head Re-Assembling
Check and Inspection of the Cylinder Head, Valves, Valve Seats and Springs
Checking the Mating Surface between the Cylinder Head and the Engine Block
Cylinder Head Tightness Check
Valve Fit Inside Guides
Valve Springs - Specification Data
Valve Springs Check
Cylinder Head-To-Engine Block Mating Surface Honing
Valve Guide Replacement
Valve Seats Grinding Inside Cylinder Head
Valve Grinding and Tightness Check
Camshaft, Camshaft Bearing Bushes
Tightening the Cylinder Head on the Engine Block
Check and Inspection of Camshaft, Bearing Bushes, and Valve Timing Check
Bearing Bush Check
Camshaft Bearing Bush Fit Inside Engine Block Seats
Camshaft Journal Fit Inside Bearing Bushes
Valve Gear Timing Check
Camshaft Bearing Bushes Replacement
Check and Inspection of the Individual Elements
Tappets and Tappet Rods Check
Valve and Mating Parts
Tappets, Tappet Seats Diameters and Fitting Clearances
Valve Rockers and Valve Rocker Shafts Check
Exhaust Valve Rocker
Valve Rockers
Valve Rocker Shafts and Brackets
Valve Rocker Assy. Re-Assembling
Valve Clearance Setting
Valve Rocker Assembly Component Parts
Valve Rockers and Rocker Shaft Brackets Assembly
Fitting Clearances in Valve Gear Unions
Valve Gear Timing
Dimensions, Tolerances, Fits of the Individual Engine Elements
Connecting Rods, Big End Bearings, Small End Bushes
Testing Procedure and Evaluation Cryteria
Engine at Testing Stand
Engine Check Following Stand Test
Requirements for Dynamometric Stand Test of 116C.076/56 and 115C.076/52 Engines
Engine Lubrication System
Camshaft Drive Chain Sprocket
Big End Bearing Cap
Oil Pump Check and Repair
Oil Pump Stripping
Camshaft Front Bush
Oil Pump Cleaning and Inspection
Fitting Clearances and Boundary Wear of Oil Pump Elements
Cleaning and Check of Oil Pressure Control Valve Accommodated Inside the Oil Pump Cover
Leading Dimensions of Oil Pump Component Parts
Cross-Section through the Oil Pressure Contro Valve
Oil Pressure Control Valve - Exploded View
Oil Pump Re-Assembling
Centrifugal Oil Filter Inspection and Servicing
Oil Filter Stripping, Cleaning and Inspection
Filter Re-Assembling
Filter Inspection and Replacement
Component Parts of Centrifugal Oil Filter
Oil Pressure Sensor Inspection
Cross Section through By-Pass Oil Filter Fixing (Seat)
By-Pass Oil Filter Unscrewing
Engine Block with Seats for Fixing the Oil Dipstick, By-Pass Oil Filter and Engine Breather Tube
Engine Cooling System
Oil Pressure Sensor Inside Engine Block
Water Pump Inspection and Check
Water Pump Stripping
Water Pump Cleaning and Inspection
Water Pump Re-Assembling
Water Pump Parts Fitting
Components Parts of Water Pump
Dismantling Fan V-Belt Pulley Hub off Pump Shaft with Bearing
Radiator Inspection and Repair
Radiator Faults Detection
Radiator Dismantling
Radiator Inspection and Check
Ventilation Fan Check, Repair and Setting
Ventilation Fan Faults and Removal Thereof
Replacement of V-Belt Pulley Complete with Electromagnet
Fuel Supply System
Setting the Tensioning of V-Belt for the Drive of Ventilation Fan, Water Pump and Alternator
Air Cleaner Check and Servicing
Dismantling the Air Cleaner off the Engine
Air Cleaner Filtering Element Cleaning and Replacement
Inspection, Repair, and Setting of Fuel Pump
Component Parts of Air Cleaner
Fuel Pump, Complete
Fuel Pump Head, Complete
Defect Location
Fuel Pump Stripping
Component Parts of Fuel Pump
Fuel Tank Inspection and Servicing
Cleaning and Inspection
Replacing Fuel Pump on Engine Block and Setting
Pushrod Positioning Inside Engine Block
Arrangement of Mating Elements of 34 DCHD1-13 WEBER Carburetor During Normal Engine Performance
Carburetor Design and Functioning
Design Explanation
Functioning Explanation
Carburetor Check and Servicing
Carburetor Dismantling
Throttle Component Parts Check and Inspection
Carburetor Servicing
WEBER Type 34DCHD1-13 and 34DCHD-12 Carburetor Tuning Data
Typical Carburetor Faults and Trouble Shooting Procedures
Power Transmission
Clutch
Typical Clutch Faults
Clutch Characteristic and Setting Data
Clutch Assembly
Typical Faults of Clutch and Hydraulic Control System and Trouble Shooting Procedures
Clutch Component Parts
Clutch Servicing, Check and Repair
Dismantling, Replacing and Stripping
Check and Repair of Clutch Elements
Clutch Hold-Down Spring Characteristic and Data
Clutch Disc
Partial Cross-Section through Clutch Assembly, Flywheel and Rear Crankshaft End
Clutch Re-Assembling and Setting
Servicing, Repair and Re-Setting of Hydraulic Clutch Control Mechanism
Clutch Pump and Cylinder Dismantling and Replacement
Hydraulic System Elements Stripping, Repair and Re-Assembling
Clutch Control Hydraulic System Air Bleeding
Gearbox
Clutch Pedal Free Travel Re-Setting
Typical Gearbox Faults
Gearbox Transmission Ratios
Typical Gearbox Faults and Trouble Shooting Procedures
Gearbox Checks, Inspection and Repair
Gearbox Dismantling out of the Vehicle
Gearbox Stripping at a Stand
Gearbox Inspection and Repair
Gearbox Re-Assembling in a Stand
Gearbox Replacing into the Vehicle
Propeller Shaft with Joints
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Table of Contents
Troubleshooting
Typical carburetor faults and trouble shooting procedures
123
Typical faults of clutch and hydraulic control system and trouble shooting procedures
127
Typical gearbox faults
139
Rear axle characteristic and data
161
Typical front suspension faults and trouble shooting procedures
200
Typical rear suspension faults and trouble shooting procedures
219
Typical shock absorber faults
227
Typical brake system faults and trouble shooting procedures
233
Typical faults of road wheels and tyres and trouble shooting procedures
256
Typical charging circuit faults and trouble shooting procedures
265
Starter motor check
275
Typical faults of ignition circuit and trouble shooting
280
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