Fiat 125p 1967-1991 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Fiat Model: 125p Production Years: 1967-1991 Market Name Variant: Polski Fiat 125p Codes Platform Code: Zastava 125p (based on Fiat 125) 👋 Introduction Market Position Target Audience: Owners with basic mechanical skills and independent auto service professionals. Competitive Analysis Value Proposition: Provides the same specifications and procedures as authorized dealer service departments, empowering owners and saving costs on repairs. Key Features Download Type: Instant Download upon payment, eliminating shipping costs and delays. Compatibility: Viewable on PC, Mac, and various devices including phones and e-readers (like Kindle). Usability: Printable pages allow for clean, oil-stain-free reference, preserving the digital copy. 📋 Manual Details Coverage Areas Coverage Areas: Engine, Transmission, Chassis, Body, Wiring, Fuel System, Emission Control, Induction, Mechanical Systems, Control Systems, Differentials, Steering, Suspension, Brakes, ABS, General Information, Troubleshooting, Diagnostics, Full Specifications, Torque Settings, Service Work Page Count Page Count: Unknown (PDF format implies variable, but comprehensive) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine Service and Overhauling, Induction, Fuel System, Emission Control, Engine Mechanical Components Drivetrain Systems: Transmission, Differentials, Clutch, Driveshafts Chassis Systems: Chassis, Steering, Suspension, Brakes, Wheels, Tires Electrical Systems: Wiring Diagrams, Electrical Components, Lighting, Ignition System Bodywork Systems: Body Repair and Maintenance Procedures Included Diagnostic Procedures: Troubleshooting and Diagnostics, Fault Symptom Diagnosis, Component Testing Techniques Repair Procedures: Engine Overhauling, Transmission Rebuilding, Brake System Repair, Suspension Component Replacement, Body Panel Repair Maintenance Procedures: Routine Service Work, Fluid Changes, Lubrication, Inspection Schedules Technical Guidance: Wiring Diagram Tracing, Terminal Pin Connections, Expected Readings, Engine Management System Analysis, Mechanic Guidance, Post-Repair Verification Technical Depth Depth Of Coverage: Comprehensive, covering basic maintenance to advanced engine overhauling and diagnostics, suitable for both owners and independent professionals. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: Printable (allows users to print individual pages for clean reference) Binding Type Binding Type: Digital (Instant Download, no physical binding) Paper Type Paper Type: N/A (Digital file) ⚙️ Engine Specifications Primary Engine Engine Displacement: 1.3 Liters (1295 cc) and 1.5 Liters (1481 cc) Performance Engine Type: Inline-4 Cylinder, Overhead Valve (OHV) Horsepower Range: Approx. 60-75 HP (depending on variant and tuning) Torque Range: Approx. 90-110 Nm (depending on variant and tuning) Fuel System Fuel Delivery: Carbureted (typically single or twin Zenith/Weber carburetors) Ignition System: Distributor-based Ignition System Cooling System Cooling Method: Water-cooled Lubrication System Oil Type Specification: API SG or SH, SAE 15W-40 or 20W-50 (refer to manual for exact specification based on climate) Emission Control Emission System Details: Manual covers emission control systems relevant to the production era, potentially including early catalytic converters or air injection systems depending on market. 🔧 Transmission Standard Transmission Type: 4-speed or 5-speed Manual Transmission Optional Optional Transmission: 3-speed Automatic Transmission (less common) Features Clutch Type: Dry Single Plate Clutch Transmission Fluid Spec: GL-4 Hypoid Gear Oil, SAE 75W-90 or 80W-90 (refer to manual for specific recommendation) Differential Type: Rear Wheel Drive with Open Differential 📐 Dimensions Exterior Body Style: 4-door Sedan, 5-door Station Wagon (Kombi), 2-door Coupe (less common) Wheelbase: Approx. 2743 mm (108 inches) Length: Approx. 4490 mm (176.8 inches) Width: Approx. 1670 mm (65.7 inches) Height: Approx. 1450 mm (57.1 inches) Weights Curb Weight: Approx. 1100-1200 kg (2425-2645 lbs) Gross Vehicle Weight: Approx. 1500-1600 kg (3300-3530 lbs) Wheels Tires Wheel Bolt Pattern: 4x114.3 mm (4x4.5 inch) Standard Tire Size: 175 R13 or 185/70 R13 (refer to manual for specific fitments) 🛡️ Safety Features Ratings Safety Ratings: N/A (Vehicle manufactured before widespread standardized safety rating systems) Active Features Active Safety Features: Disc brakes (front), Drum brakes (rear), Dual circuit braking system Passive Features Passive Safety Features: Seat belts (front standard, rear optional depending on year/market), Padded dashboard, Collapsible steering column 💡 Technology Features Infotainment Infotainment System: Basic analog radio (AM/FM), potentially with cassette player in later models. No advanced features. Driver Assistance Driver Assistance Features: None (vehicle predates modern driver assistance systems). Connectivity Connectivity Features: None. Lighting Headlight Type: Halogen or sealed beam headlights (depending on year/market). 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 km or 6 months (refer to manual for precise interval based on usage). Spark Plug Replacement: Every 15,000-20,000 km. Timing Belt Replacement: N/A (Belt-driven OHC engines, likely chain-driven OHV in 125p variants. Refer to manual for specific timing chain inspection/replacement). Fluid Specifications Coolant Type: Ethylene Glycol based antifreeze, mixed with distilled water (50/50 ratio). Refer to manual for specific additive packages. Brake Fluid Type: DOT 3 or DOT 4 brake fluid. Power Steering Fluid: N/A (Manual steering system) Known Issues Common Wear Items: Carburetor tuning, ignition system components (points, condenser, spark plugs), suspension bushings, brake wear items, exhaust system corrosion. Body Corrosion: Prone to rust, especially in wheel wells, sills, and door bottoms, typical for vehicles of this era and origin....
Comprehensive, covering basic maintenance to advanced engine overhauling and diagnostics, suitable for both owners and independent professionals.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
Printable (allows users to print individual pages for clean reference)
Binding Type
Binding Type:
Digital (Instant Download, no physical binding)
Paper Type
Paper Type:
N/A (Digital file)
⚙️ Engine Specifications
Primary Engine
Engine Displacement:
1.3 Liters (1295 cc) and 1.5 Liters (1481 cc)
Performance
Engine Type:
Inline-4 Cylinder, Overhead Valve (OHV)
Horsepower Range:
Approx. 60-75 HP (depending on variant and tuning)
Torque Range:
Approx. 90-110 Nm (depending on variant and tuning)
Fuel System
Fuel Delivery:
Carbureted (typically single or twin Zenith/Weber carburetors)
Ignition System:
Distributor-based Ignition System
Cooling System
Cooling Method:
Water-cooled
Lubrication System
Oil Type Specification:
API SG or SH, SAE 15W-40 or 20W-50 (refer to manual for exact specification based on climate)
Emission Control
Emission System Details:
Manual covers emission control systems relevant to the production era, potentially including early catalytic converters or air injection systems depending on market.
🔧 Transmission
Standard
Transmission Type:
4-speed or 5-speed Manual Transmission
Optional
Optional Transmission:
3-speed Automatic Transmission (less common)
Features
Clutch Type:
Dry Single Plate Clutch
Transmission Fluid Spec:
GL-4 Hypoid Gear Oil, SAE 75W-90 or 80W-90 (refer to manual for specific recommendation)
Differential Type:
Rear Wheel Drive with Open Differential
📐 Dimensions
Exterior
Body Style:
4-door Sedan, 5-door Station Wagon (Kombi), 2-door Coupe (less common)
Wheelbase:
Approx. 2743 mm (108 inches)
Length:
Approx. 4490 mm (176.8 inches)
Width:
Approx. 1670 mm (65.7 inches)
Height:
Approx. 1450 mm (57.1 inches)
Weights
Curb Weight:
Approx. 1100-1200 kg (2425-2645 lbs)
Gross Vehicle Weight:
Approx. 1500-1600 kg (3300-3530 lbs)
Wheels Tires
Wheel Bolt Pattern:
4x114.3 mm (4x4.5 inch)
Standard Tire Size:
175 R13 or 185/70 R13 (refer to manual for specific fitments)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Vehicle manufactured before widespread standardized safety rating systems)
Active Features
Active Safety Features:
Disc brakes (front), Drum brakes (rear), Dual circuit braking system
Basic analog radio (AM/FM), potentially with cassette player in later models. No advanced features.
Driver Assistance
Driver Assistance Features:
None (vehicle predates modern driver assistance systems).
Connectivity
Connectivity Features:
None.
Lighting
Headlight Type:
Halogen or sealed beam headlights (depending on year/market).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 km or 6 months (refer to manual for precise interval based on usage).
Spark Plug Replacement:
Every 15,000-20,000 km.
Timing Belt Replacement:
N/A (Belt-driven OHC engines, likely chain-driven OHV in 125p variants. Refer to manual for specific timing chain inspection/replacement).
Fluid Specifications
Coolant Type:
Ethylene Glycol based antifreeze, mixed with distilled water (50/50 ratio). Refer to manual for specific additive packages.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
N/A (Manual steering system)
Known Issues
Common Wear Items:
Carburetor tuning, ignition system components (points, condenser, spark plugs), suspension bushings, brake wear items, exhaust system corrosion.
Body Corrosion:
Prone to rust, especially in wheel wells, sills, and door bottoms, typical for vehicles of this era and origin.
Engine Oil Leaks:
Potential for leaks from valve cover gasket, oil pan gasket, and crankshaft seals.
Electrical Issues:
Older wiring looms can degrade, leading to intermittent electrical faults.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Poland (licensed production from Italy's Fiat)
Model Evolution
Development Basis:
Based on the Italian Fiat 125, but heavily modified and adapted for Polish production and road conditions.
Key Modifications From Fiat 125:
Durable chassis, reinforced suspension, different engine options (derived from Fiat 132), and often simpler interior trim.
Production
Production Location:
Fabryka Samochodów Osobowych (FSO), Warsaw, Poland
Production Volume:
Over 1.4 million units produced, making it one of Poland's most iconic vehicles.
🏆 Awards & Recognition
Recognitions
Model Recognition:
Considered a symbol of Polish automotive industry and a robust, reliable workhorse for its time. Highly regarded by enthusiasts and owners for its simplicity and maintainability.
Ratings
Reliability Perception:
Generally perceived as reliable with proper maintenance, though susceptible to the common issues of older vehicles. Availability of parts can vary.