- DL manuals
- Fiat
- Automobile
- 500 Abarth
- Workshop Manual
Fiat 500 Abarth Workshop Manual
Summary of 500 Abarth
Page 1
Fiat 500 1957-73 workshop manual autobooks models covered fiat new 500 fiat 500d fiat 500f fiat 500l fiat and autobianchi giardiniera.
Page 2: Chapter 1
Chapter 1 the engine 1 :1 1 :2 1 :3 1 :4 1 :5 1 :6 1 :7 1 :8 1:9 1 :10 1 :11 description engine removal (sedan—all versions) engine removal (station wagon) engine disassembly (sedan—all versions) engine disassembly (station w a g o n ) cylinder head removal, servicing and replacement timing gear ove...
Page 3
Fig 1:1 left side view of the power plant to suit 500 sedan 10 fig 1:2 right side rear three-quarter view of the power plant for 500 station wagon mounted on the top of the cylinder head is the overhead valve rocker mechanism that is operated by a chain driven camshaft through tappets and vertical p...
Page 4
Fig 1:3 engine section through crankshaft, pistons and valves f500 11.
Page 5
Fig 1:4 engine cross-section through a cylinder 12.
Page 6
The interior of the car can be heated by the engine warmed air being ducted into the front compartment and controlled by a lever on the heating system tunnel. Engine ignition is by a battery, ignition coil and distribu- tor which is driven by a gear on the camshaft. The engine is started by an elect...
Page 7
Lid check arm fig 1:6 engine compartment lid open lid locking hook number plate lamp cable number plate lamp cable junction cross member arr.2o74. Fig 1 :7 engine removal using the jack with cross- member arr.2074 6 using a garage hydraulic jack with a suitable cradle relieve the engine weight from ...
Page 8
6 release the ignition distributor support retaining nut and lift away the distributor together with its support. 7 remove all the mounting bolts of the engine cooling cowling and lift away the assembly. Release the two carburetter retaining nuts and carefully remove the carburetter together with it...
Page 9
Stud removal puller 40010 fig 1 :12 removal of stud from crankcase by puller a.40010 fig 1 :13 engine without blower cowling and cylinder head cover .Spacer and connection for rocker shaft lubrication tube oilvapor .Vent pipe casings for pushrods (and oil return to crankcase 21 to ensure no damage o...
Page 10
13 remove all the bolts and washers joining the sump casting to the crankcase making a special note of the location of bolts of different lengths. 14 mark the flywheel and crankshaft to ensure correct reassembly and release the six flywheel retaining bolts together with the lockwashers and lift away...
Page 11
Intake exhaust intake exhaust fig 1 :18 main specifications of intake and exhaust valves and valves guides (dimensions in mm) head. Disconnect the two side exhaust manifolds. Note the spark plug ht cables locations and dis- connect from spark plugs. 2 remove the rocker shaft pedestal- and lift away ...
Page 12
Cylinder head installation: to refit the cylinder head proceed as follows: place a new cylinder head joint on the cleaned faces of the cylinder barrels. Insert the rocker pushrod and lubrication pipe sleeves together with the relevant gaskets and rings. Fit the washers and nuts to the studs and tigh...
Page 13
Fig 1:21 finned cylinder. Letter a stamped on cylinder indicates the class to which cylinder belongs, as referred to its inside diameter class letter fig 1 :22 cylinder measurement points seats, gearbox companion flange and timing gear cover mounting flange. The cast iron cylinders are finned radial...
Page 14
Insert a .0079 ± .00197 inch thick oil paper gasket between the crankcase and cylinder bottom face and a .0236 to .0275 inch thick graphitized asbestos gasket between the cylinder and cylinder head. The compression of the gaskets on assembly will eliminate any very small differences between the two ...
Page 15
Feeler gauge checking ring gap (ring in cylinder) fig 1 :27 fig 1 :28. A universal piston ring compressor should be used to keep the rings tight in their grooves. The correct matching of the piston and connecting rod is described in a later section of this chapter. 1 :10 connecting rods checking rod...
Page 16
Tolerance range of .00043 to .00240 inch or less than .0059 inch the bearing inserts may be used again with- out any need for regrinding. Should however the clearance be greater than .0059 inch the inserts must be renewed, using undersize inserts if the crankpin journals have been reground. It shoul...
Page 17
Fig 1:33 checking crankshaft land-to-connecting rod shoulder clearance fig 1:34 engine front end without flywheel using an expanding reamer or fiat reamer u.0307 ease out the internal diameter of the bush to between .7874 to .7876 inch so that a standard piston may be fitted. 4 piston-connecting rod...
Page 18
After the crankshaft has been reground it is important that all traces of swarf are removed by constant washing and then drying with a non-fluffy rag. The clearance between the main bearings and journals must be checked before installing the crankshaft in the engine. It should also serve as a rechec...
Page 19
Fig 1:37 lubrication diagram of engine 120.000 key to fig 1:37 1 oil dipstick 2 oil filler with vent valve 3 centrifugal oil filter 4 crankshaft, with central oil gallery 5 low oil pressure indicator sending unit 6 oil pressure relief valve 7 gear pump 8 camshaft, with central oil gallery 9 oil suct...
Page 20
Drain the oil sump to ensure that the oil does not syphon out. Thoroughly clean the area around the pump body (see fig 1 :37). Remove the end cover plate by releasing the retaining bolts and washers. Carefully ease the driven gear down- wards followed by the driving gear and shaft clean all parts re...
Page 21
Fig 1 :40 engine detail showing lube oil passages key to fig 1 :40 1 splines in crankshaft for oil passage to filter 2 oil inlet into circuit from filter 3 hole for oil passage to main bearing fig 1 :41 timing marks on sprockets. On later cars the crankshaft key way is on the underside size that cen...
Page 22
5 using the graduated sector check that all the valve timing angles are as detailed in technical data. Readjust the valve stem to rocker arm clearance to the correct setting. 1 : 1 6 valve stem-to-rocker clearance adjustment it is important that the clearance between the valve stem and rocker is kep...
Page 23
Fig 1 :44 cylinder head hold-down nuts tightening sequence. 500 sedan timing chain end cylinder no. 1 cylinder no. 2 flywheel end camshaft expansion slot c/rod number rotation direction fig 1 :45 the correct position of connecting rod- piston assembly on engine 120.000 3 0 screws and together with n...
Page 24
Sections of the air conveyor securing with seven screws, seven toothed washers and five nuts. 22 slide the fuel pump control rod into its seating, assemble the insulator between oil wetted graphite gaskets and fit the pump to the crankcase using nuts and toothed washers. 23 fit the air conveyor cove...
Page 25
Fig 1 :48 power plant front support cross-section fig 1 :49 checking the generator and blower drive belt tension 1 :19 power plant mountings the combined power and transmission unit is elastic- ally mounted on two supports. The front of the unit rests on a crossmember which is secured under the car ...
Page 26
4 mixture too weak 5 water in fuel system 6 petrol tank vent blocked 7 incorrect valve clearance (c) engine idles badly 1 check 1 and 6 in (b) 2 air leak at manifold joints 3 slow-running jet blocked or out of adjustment 4 air leak in carburetter 5 over-rich mixture 6 worn piston rings 7 worn valve ...
Page 27
Blank page.
Page 28: Chapter 2
Chapter 2 the fuel system 2:1 description 2 : 2 fuel pump operating principles 2 : 3 routine maintenance 2 : 4 pump removal, dismantling and examination 2 : 5 reassembly, installation and adjustment 2 : 6 carburetter operation and adjustment, weber 26.1mb 2 : 7 modifications 2 : 8 carburetter operat...
Page 29
Control rocker from tank to carburetor fig 2:1 fuel pump. Arrows point to fuel inlet and outlet fig 2:2 fuel pump components k e y t o f i g 2 : 2 1 cover screw 2 screw gasket 3 cover gasket 4 cover 5 upper body 6 spring for inlet valve 7 inlet valve 8 outlet valve 9 spring for outlet valve 10 plate...
Page 30
Fig 2:5 starting device (choke) diagrammatic section keytofig2:5 a device fully inserted b device partially inserted c device disinserted 2 air inlet 16 bowl 19 throttle 21 primary venturi 24 secondary venturi 26 mixture duct 27 mixture leaning air orifice 28 transition duct 29 transition mixture or...
Page 31
Fig 2:6 weber 26.Imb carburetter starting device (choke) end key to fig 2:6 1 choke device cover 2 bowden mounting screw 3 nut and screw, choke bowden wire 4 choke control lever a position of lever 4 for 'fully inserted' choke b 'partially inserted' choke c 'disinserted' choke caused by the engine s...
Page 32
3 engine warm-up: as the engine begins to warm up to its normal operating temperature, gradually push home the starting device lever so as only to supply the engine with the richened charge enabling the cold engine operation to be smooth and regular. Position 'b' (fig 2 : 6 ) . 4 normal car driving:...
Page 33
Fig 2 : 9 weber 26.Imb carburetter cover components key tofig 2 : 9 1 float 2 carburetter cover 3 float pivot 4 needle valve gasket 5,6 needle valve seat and needle valve 7 cover gasket 8 filter strainer 9 gasket 10 filter inspection plug carburetter cleaning: to thoroughly clean the carburetter pro...
Page 34
Fig 2:12 illustrates the starting device fitted to 26.Imb.4 and later carburetters. It differs from earlier units in detail, principally in having fewer starting mixture orifices 30 and 32 into the mixture duct 26. 2 : 8 carburetter operation and adjustment, weber 26. Oc the new 500 station wagon is...
Page 35
39 38 28 29 30 a 31 32 33 28 29 30 3.1 b 28 29 30 31 c 34 34 34 37 36 35 23 fig 2:13 diagrammatic section views of 26.Oc weber carburetter through the starting device 1 2 .3 4 5 27 26. 25, 24. 23. 22 16 17 8 21 20 9 _ 6 .4 7 .8 10 19 18 17 16 15 9 5 10 11 12 13 14. Fig 2 :14 diagrammatic section vie...
Page 36
1 14,5 7,5 2 9 4 8 3 5 7 6 fig 2:15 float level setting diagram weber car- buretter type 26.Oc 7.5 = .29 inch 14.5 = .57 inch key to fig 2:15 1 carburetter cover 2 cover gasket 3 needle valve 4 valve needle 5 lug 6, 7 arms 8 needle ball 9 float idle speed adjustment: the idling speed is adjusted by ...
Page 37
Fig 2:18 diagram of blow-by gases re-circulation device key t o fig 2 : 1 8 1 head cover 2 blow-by gases and oil vapours breather valve 3 oil filler cap 4 strainer 9 air suction pipe, air cleaner to carburetter 8 flame trap 13 exhaust duct 12 crankcase 7 carburetter 6 air cleaner 11 filter gauze 10 ...
Page 38
Air cleaner—station wagon: a pleated paper air cleaner element is housed in a special air intake chamber connected to the front of the engine air cooling cowling (see fig 4 : 2 ) . This chamber will be seen located towards the rear of the power unit compartment. Remove the retaining wing nut, lift o...
Page 39
2:12 fault diagnosis (a) leakage or insufficient fuel delivered 1 air vent in tank restricted 2 petrol pipes blocked 3 air leaks at pipe connections 4 pump or carburetter filters blocked 5 pump gaskets faulty 6 pump diaphragm defective 7 pump valves sticking or seating badly 8 fuel vapourizing in pi...
Page 40: Chapter 3
3 : 1 3 : 2 3 : 3 3 : 4 3 : 5 description operation routine maintenance ignition faults removing and dismantling distributor (sedan and sports) chapter 3 the ignition system 3 : 6 3 : 7 3 : 8 3 : 9 3 : 1 0 removing and dismantling (station wagon) timing the ignition sparking plugs the distributor dr...
Page 41
Fig 3:1 i g n i t i o n system w i r i n g diagram battery switch breaker coil spark plug condenser fig 3:2 i g n i t i o n d i s t r i b u t o r in place on engine w i t h cap l i f t e d o f f current contact to spark plug breaker arm stationary contact carrier adjusting screw contact points high ...
Page 42
An 0—20 voltmeter. If the circuit is in order the meter should read approximately 12-volts. 3 battery to fuse box terminal 30. Connect the volt- meter between the terminal 30 and earth. No reading indicates a faulty cable or loose connection. 4 fuse box. Connect the voltmeter between the other auxil...
Page 43
Fig 3:4 use of fixture ap.5030/1 to check ignition timing reassembly is the reverse procedure to dismantling but the following points should be noted: 1 lubricate the parts of the centrifugal advance mecha- nism, the drive spindle and the part of the shaft which accepts the cam with fiat vs oil. 2 e...
Page 44
Indicates the condition inside the combustion chamber and may be used as a guide to engine tuning. Before the spark plugs are removed blow away any loose dirt from the plug recesses using a compressed air jet or tyre pump. Store the plugs in the order of removal ready for inspection. Examine the gas...
Page 45
Blank page.
Page 46: Chapter 4
Chapter 4 the cooling system 4:1 4 : 2 4 : 3 description air outlet thermostat and shutter tension adjustment 4:4 4:5 4:6 heating system safety device maintenance fault diagnosis 4:1 description sedan: all the fiat new 500 models covered by this manual are aircooled by the forced air circulation sys...
Page 47
Fig 4:1 engine cooling air circulation system key to fig4:1 a engine cooling air intake b carburetter air suction cleaner c centrifugal fan and air conveyor d oil pan cooling air passage e warmed air admission hose to car interior f engine air outlet control shutter, wide open position (at 178° to 1...
Page 48
55 f500 fig 4 : 2 cooling air circulation system of engine 120.000 key to fig 4 : 2 a air intakes b fan c thermostat, engine air draft shutter control d shutter enqine air draft e carburetter air cleaner f duct, warmed air-to-car interior g lever, air-to-car interior valve control.
Page 49
Oil drain plug cooling air ducts fig 4 : 3 oil sump with blower cowling. Arrows indicate air outlets blower shaft generator armature vent tube fig 4 : 4 cooling blower mounted on generator shaft extension 4 : 2 air outlet thermostat and shutter refer to figs 4 :1 and 4 :2 where it will be seen that ...
Page 50
4 : 4 heating system safety device 110f series sedan engines and later station wagon engines incorporate a modification to the cylinder head designed so that in the event of cylinder head gasket failure exhaust gases are expelled outside the engine and not leaked into the heating system. The safety ...
Page 51
Blank page.
Page 52: Chapter 5
Chapter 5 the clutch 5:1 5:2 5 : 3 5:4 description removal and installation dismantling and inspection of clutch cover assembly and adjustment 5:1 description new 500, 500d sedan and early station wagon: the clutch is a single plate dry disc type operating on the inner face of the flywheel. Fig 5 :1...
Page 53
*dimension to be obtained by adjusting the throwout lever. Fig 5:1 clutch assembly longitudinal section (new 500, 500d sedan and early station wagon) 5:2 removal and installation to remove the clutch unit from the vehicle proceed as follows: 1 remove the engine (chapter 1) or separate the gear- box ...
Page 54
Fig 5:2 clutch components (new 500, 500d sedan and early station wagon) driven plate pressure plate lever carrier lever bolts bolt nuts pressure springs withdrawal levers clutch cover lever carrier ring spring washer fig 5:3 clutch assembly installed on engine (new 500, 500d sedan and early station ...
Page 55
Fig 5 . 4 clutch cover assembly inspection diagram 500f, l and later station wagon k e y t o f i g 5 : 4 1 clutch cover 2 pressure plate 3 clutch release flange plate 4 diaphragm spring rings 5 diaphragm spring retainer plate 6 diaphragm spring 7 clutch release flange x =1.463 ± .043 inches f = dire...
Page 56
Lubricated using fiat jota 3 grease. 1 pressure plate—boss outer faces. 2 clutch cover—withdrawal lever fulcrum. 3 withdrawal lever stopnuts—contact face. 4 withdrawal lever carrier ring — lever contact face. 5 crankcase end pilot bushing lubricated with fiat kg.15 grease. 6 lubricate contact faces ...
Page 57
Fig 5:10 clutch throw-out mechanism key to fig 5:10 1 clutch throw-out yoke 2 yoke return spring 3 rod nut and counternut 4 adjustable rod 5 clutch throw-out onto this shaft the outer operating lever is attached by means of a key. A return spring connected to the outer operating lever is anchored on...
Page 58: Chapter 6
Chapter 6 gearbox and differential unit 6:1 6:2 6:3 6:4 6:5 6:6 description removal of gearbox/differential unit dismantling — gearbox reassembly — gearbox dismantling — differential and final drive reassembly— differential and final drive 6:7 6:8 6:9 6:10 6:11 6:12 final drive gear set adjustment r...
Page 59
Primary shaft-to-clutch shaft mounting pin clutch shaft seal primary shaft with 1st, 3rd and 4th speed gear cluster 2nd speed drive gear primary shaft front ball bearing primary shaft rear ball bearing primary shaft-to-clutch i shaft joining sleeve joining sleeve lockring speed selector lever clutch...
Page 60
Fig 6 :2 gearbox gears, forks and striker rods k e y t o f i g 6 : 2 1 rear roller bearing 2 layshaft with bevel pinion 3 front ballbearing 4 front bearing plate 5 bushing 6 fourth-speed driven gear 7 third- and fourth-speed sliding sleeve 8 first and reverse sliding gear 9 sliding sleeve hub 10 thi...
Page 61
1st a n d 2nd speed striker rod lock roller 1st a n d 2nd speed striker rod 3rd a n d 4th speed striker rod 3rd a n d 4th speed striker rod lock - roller reverse striker rod lock roller reverse striker rod fig 6 : 4 detail of gearbox section through striker rod lock rollers 2nd speed driven gear 2nd...
Page 62
Fig 6:7 differential components key tofig 6:7 1 axle shafts 2 sleeve retainment lockrings 3 slip joint casings 4 axle shaft-to-wheel shaft coupling sleeve 5 differential case cover with bearing inner race 6 side gears 7 oil boot retainment cover 8 side gear thrust ring 9 idle pinion shaft 10 idle pi...
Page 63
3 check the layshaft and the primary shaft between centres and using a dial gauge ensure that there is no distortion. The out of true reading for bearing seats should be less than .0008 inch. Inspect the splines and ensure that the side and outerfaces are not indented. Replace if there are signs of ...
Page 64
Of wear, distorting or unevenness of the surfaces as this part is very heavily pressed when the vehicle is negotia- ting a corner. If the clearance to the idle pinions exceeds .0059 inch the shaft must be renewed. 2 inspect the ring gear and pinion seat, the side gears.And the idle pinions for corre...
Page 65
Fig 6:9 graphic demonstration of values a and a 'a' distance between pinion front bearing inner shoulder and the axis passing through the differential bearing housing centre 'a' difference between the minimum value called out on drawing (5.9268inches — 150.54mm) and actual machining value of the dis...
Page 66
Fig 6:12 graphic demonstration of c and c key to fig 6:12 1 bevel pinion rear roller bearing inner race 2 bush, fourth-speed driven gear 3 hub, third- and fourth-speed engagement sleeve 4 bush, third-speed driven gear 'c total height of items 1, 2, 3 and 4 which must be mounted on final drive pinion...
Page 67
Tool a 62039 tool a. 62040 pin wrench a. 52022 fig 6:15 adjusting ring gear-to-pinion backlash and differential bearing play, using special wrench a.52022 reading on the dial gauge should be between .0031 to .0047 inch. The actual clearance is adjusted by screwing in one adjusting nut and screwing o...
Page 68
Correct tooth contact. Excessive contact on tooth flank: move pinion out from ring gear by reducing thickness of shim. Excessive contact on tooth toe: move pinion out from ring gear by reducing thickness of shim. Fig 6 :16 ring gear to pinion tooth contact f500 75 move pinion in towards ring gear by...
Page 69
Lever support screws boot mounting screws gearshift lever boot gearshift lever fig 6:17 location of gearshift lever on control passage tunnel repair and inspection : whilst servicing the assembly thoroughly check the condition of the slip joints sliding surfaces and the housing in the differential s...
Page 70
Fig 6:19 modified items in transmission-differential assembly key to fig 6:19 1 reverse shifter shaft 2 third and fourth shifter shaft 3 first and second shifter shaft 4 countershaft pinion (and ring gear) 5-7 transmission-differential case 6 housing 8 clutch shaft fig 6:20 end sectional view of tra...
Page 71
Although these do not affect the service procedures that have been previously described. 6:12 fault diagnosis (a) noisy transmission 1 excessive backlash of gears in mesh due to gear wear 2 gears, bearings or gear bushings damaged 3 shafts misaligned or out of centre due to loose mount- ing nuts 4 d...
Page 72: Chapter 7
Chapter 7 rear suspension and wheels 7:1 7:2 7:3 7:4 description removal of rear suspension assembly servicing swinging arms coil springs 7:1 description the rear wheels are independently sprung by means of coil springs and v-shaped swinging arms acting on coil springs and telescopic double acting h...
Page 73
Fig 7:1 rear suspension assembly key to fig 7:1 1 brake shoe control cable and sheath 2 coil spring 3 oil boot 4 axle shaft 5 bumper 6 flexible joint 7 swinging arm 8 cable adjusting nut 9 swinging arm-to-front bracket mounting pin 10 swinging arm front bracket-to-underbody mounting screw 11 engine ...
Page 74
Fig 7 :2 right rear suspension assembly, sectioned through brake drum and arm mountings 5 check the mating surface of the bearing inner rings on the wheel shaft and ensure that it is perfectly smooth. Also check that the shaft splines to flexible joint splines are not distorted or show signs of exce...
Page 75
Fig 7:3 fixture a.66064, for swinging arm inspection and adjustment key to fig 7 : 3 1 clamp screws, securing wheel shaft on fixture 2 alignment bracket, swinging arm member check-up 3 nut, to secure swinging arm external support on fixture stud 4 swinging arm external support centring pins a b c d ...
Page 76
High bearing preload. To reset remove the wheel shaft and fit a new resilient spacer. Repeat the rotation torque test. Swinging arm adjustment: to adjust the swinging arm use fiat fixture a.66064 as shown in fig 7:3 and proceed as follows: 1 at points a and b as indicated in fig 7 : 4 between the 'e...
Page 77
Fig 7:9 adjusting rear wheel toe-in on '500 station wagon' fig 7:10 checking left rear wheel toe-in 84 6 insert the inner spring between the axle shaft and the wheel shaft and couple the spline sleeve to the joint and tighten the screws to a torque wrench setting of 20.3 ib/ft. 7 reconnect the parki...
Page 78
Tool a.66062 support c. 696/3 gauge c.696 fig 7:12 checking left rear wheel toe-in arm c. 696/3 gauge c.696 fig 7:11 checking left rear wheel toe-in f500 fig 7:13 sectional view of right side rear wheel and axle shaft note—this assembly differs from the early design in the following items: control a...
Page 79
A tolerance of — 1 0 ' . + 15' is permitted providing that the value is the same for both rear wheels. It is important that both rear wheels are set to the same angle otherwise uneven tyre wear and adverse handl- ing conditions will result. When the wheel is parallel to the centre line of the vehicl...
Page 80: Chapter 8
Chapter 8 front suspension and hubs 8:1 8:2 8 : 3 8 : 4 8:5 8 : 6 description front suspension removal and dismantling leaf spring swinging arms kingpin housing steering knuckle and wheel hub 8:1 description the independent front suspension assembly fitted to the 'new 500' range comprises a transver...
Page 81
Leaf spring resilient supports fig 8:1 front suspension shock absorber swinging arm swinging arm pin king pin leaf spring king pin housing fig 8 : 2 right front suspension hydraulic jack slowly so a l l o w i n g the spring to be lowered from the underside of the vehicle. 8 using fiat wrench a . 5 6...
Page 82
3 440.9* 2 220.5 5.3936 ± .2362 • when testing the spring never exceed 440.9 lbs load. 4.9212 ± .2362 2.23 ±.10 in/100 lbs in flexibility, between pos. 2 and pos. 3 elastic give-in from pos. 2 camber in lbs position load p front leaf spring, loaded at center 125 ± 6 mm free spring 60 mm (2.3622") 13...
Page 83
Fig 8 : 6 swinging arm components key to f i g 8 : 6 1 half-arms 2 pin, arm to body mounting 3 pin, arm to kingpin housing mounting 4 and 5 washer and nut 6 and 8 cups, rubber bushes 7 rubber bushes 9 and 10 sptitpins and nuts, mounting, pin (2) to arms tool a.66054 puller a.40005/ fig 8:7 removal o...
Page 84
2 check that the surface of the pin that is in contact with the camber and castor adjuster shims does not show any signs of indentation or roughness which could affect the accuracy of adjustment on reassembly. If there are any signs of rust or small markings these should be smoothed out using a file...
Page 85
1 2 6 3 8 11 13 17 19 22 25 27 29 31 33 36 35 32 34 30 28 26 24 23 21 20 ,18 16 15 14 12 10 .9 .1 5 4 fig 8:11 sectional view of shock absorber key to fig 8:11 1 threaded shank, floor m o u n t i n g 2 rod 3 cylinder upper b l a n k i n g threaded ring 4 seal h o u s i n g 5 rod seal 6 tab spring 7 ...
Page 86
8:7 hydraulic damper: description: the front and rear shock absorbers are of the telescopic double acting type. Their dampening action takes place directly on the suspension without the use of any intermediate linkage. The shock absorber comprises a cylindrical body formed by to coaxial tubes 14 and...
Page 87
Fig 8:14 swing arm setting car. Ensure that the upper elastic supports on the studs projecting from the underside of the vehicle body are correctly located and insert the spring. Fit the two support lower caps with elastic pads and screw onto the stud nuts to a torque wrench setting of 28.9 ib/ft. 2...
Page 88
Vertical line d b s e b oil sump f g f fig 8:16 castor, camber angles 6 insert the swinging arm pin onto the two studs that are welded to the body sides so as to support the front suspension and wheel assembly. 7 reconnect the kingpin housing to the spring eye by inserting the bolt and tightening th...
Page 89
To the body and proceed as follows: 1 if the camber angle requires to be increased (see fig 8:16) add the same number of shims s on both screws d and e. 2 if the camber angle requires to be reduced (see fig 8:16) remove the same number of shims from both screws d and e. The addition or removal of sh...
Page 90: Chapter 9
Chapter 9 the steering system 9 : 5 relay lever and support 9 : 6 steering rods 9 : 7 front wheel toe-in 9 : 8 fault diagnosis 9:1 description 9 : 2 steering wheel removal and refitting 9 : 3 steering box removal and refitting 9 : 4 steering box dismantling and reassembly 9:1 description the steerin...
Page 91
Right hand tie rod relay lever support intermediate tie rod! Steering box! Left hand tie rod fig 9 :1 steering box, idler member and steering linkage arrangement on vehicle fig 9 : 2 securing steering wheel mounting nut key t o fig 9 : 2 (tightening torque: 29 to 36 ib ft) 9:4 steering box dismantli...
Page 92
Fig 9:3 layout of steering gear components key to fig 9 : 3 1 steering wheel and column assembly 2 nut 3 toothed washer 4 plain washer 5 steering column bracket-to-instrument panel screw 6 steering column-to-worm screw locking screw 7 lockplate 8 plain washer 9 cover screw 10 toothed washer 11 cover...
Page 93
Fig 9:4 section of steering box, through worm screw key to fig 9 : 4 1 worm screw 2 seal 3 roller bearing 4 worm screw adjuster and bearing retainer 5 pitman arm 6 worm sector fig 9:6 steering box cutaway 100 fig 9:5 section of steering box, through worm sector key to fig 9 : 5 1 sector adjustment s...
Page 94
Reassembling and during assembly liberally lubricated using fiat w90/m oil (sae90 ep). 2 the pitman arm nut should be correctly positioned on reassembly to the sector shaft and both are marked with notches or a master tooth on the sector will mate with a double tooth on the pitman arm which will pre...
Page 95
Normal straight-ahead position with the spokes horizontal. Check that the wheels are in the straight- ahead position. 2 load the vehicle to static load conditions or with four average size passengers. 3 move the vehicle forwards for a distance of approxi- mately six yards so that the suspension may ...
Page 96: Chapter 10
Chapter 10 the braking system 10:1 description 10:2 maintenance 10:3 front brakes 10:4 rear brakes 10:5 master cylinder 10:6 wheel cylinder 10:7 self-adjusting device 10:8 removing a flexible hose 10:9 brake fluid reservoir 10:10 bleeding the system 10:11 hand parking brake 10:12 fault diagnosis 10:...
Page 97
Fig 10:1 diagrammatic view of service and rear wheel parking brake system key to fig 10:1 1 bleeder connections 2 brake fluid reservoir 3 service brake pedal 4 hand lever, mechanical parking brake on rear wheels 5 hand lever travel adjustment stretchers 6 stop lamps 7 mechanical brake operating leve...
Page 98
2 using fiat puller a.46023 as shown in fig 8 : 9 remove the wheel grease cap. 3 using a universal two leg puller or fiat puller a.40005 together with items 1 and 9 remove the wheel hub/ drum assembly having first extracted the splitpin if fitted and released the hub retaining nut (see fig 8:10). Di...
Page 99
Fig 10:5 section view of right side rear brake assembly (500 station wagon) fig 10:6 sectional view of a self-adjusting device for automatic brake shoe-to-drum clearance take-up (500 sedan) key to fig 10:6 1 pin 2 friction washers 3 load spring 4 bushing 5 shoe 6 self-adjustment slot 7 stud 2 make a...
Page 100
Fig 10:7 master cylinder section key to fig 10:7 1 plug and spring seat 2 body 3 front wheel brake line duct 4 plunger return spring 5 compensating hole 6 plug 7 supply duct 8 fluid inlet hole 9 plunger 10 plunger snap ring 11 boot 12 pushrod 13 terminal, stoplight switch 14 rear wheel brake line du...
Page 101
Fig 10:9 brake fluid reservoir key to fig 10:9 1 reservoir 2 strainer 3 cap, vented parking brake control cable and sheath .Cable adjusting nuts shoe operating lever lever return spring fig 10:10 parking brake control and adjusting mech- anism at lefthand side rear wheel inspect the surfaces of the ...
Page 102
10:9 brake fluid reservoir the reservoir is located in the front compartment to the side of the fuel tank as shown in fig 10:9. Should it be necessary to detach the fluid outlet line from the reservoir the outlet hole must be blanked off using a tapered wooden peg of suitable length so that the cap ...
Page 103
When the pedal is applied, it moves the rear (primary) piston to pressurise the front brakes through the rear port. This, in turn, forces the front (secondary) piston down the bore to pressurise the rear brake circuit through the front port. In the event of a failure in the primary circuit, the prim...
Page 104: Chapter 11
Chapter 11 the electrical equipment 11:1 description 11:2 battery 11:3 the generator 11:4 the starter 11:5 the control box 11:6 fuses 11:7 flasher unit 11:1 description all models covered by this manual have 12 volts electrical systems in which the negative battery terminal is earthed. There are thr...
Page 105
Fig 11:1 battery location clamp locking nuts i g n i t i o n lock ! Switch cable*"? Battery clamp minus g r o u n d cable starting motor plus cable 6 5 4 3 2 1 fig 1 1 : 2 cross-section view of battery key to fig 1 1 : 2 1 battery container 2 sealing compound 3 cell plug 4 filler neck with vent slot...
Page 106
Indicates a break in the cable from the generator to regulator. Repeat the test on terminal 67. Finally, remove the temporary link from the generator. If the readings are correct, test the regulator as described in section 11:5. Removing generator: 1 disconnect the leads from the generator. 2 remove...
Page 107
1 7 9 10 11 8 2 3 4 11 10 16, 15 14 13 12 6 5 fig 11:5 components of starter key to fig 1 1 : 5 1 drive end head 2 head shield 3 frame 4 switch 5 commutator cover band 6 and 7 pin and spring for lever 8 8 starting engagement lever 9 head shield 10 and 11 head fixing tie rods and tubes 12 pinion, com...
Page 108
Switch contacts. The starter motor rotates driving the engine through the pinion and ring gear. As soon as the engine fires the starter hand lever must be released which will open the starter switch contacts so stopping the starter motor and the pinion will return under the action of a spring to a n...
Page 109
4 5 3 2 1 7 6 fig 11 :6 regulator assembly gn 1.12.16 key to fig 11:6 1 voltage regulator adjusting spring 2 current regulator adjusting spring 3 cutout adjusting spring 4 voltage regulator adjustment arm 5 current regulator adjustment arm 6 cutout adjustment blade spring 7 soldering of cutout shunt...
Page 110
Checking cut-out: 1 closing voltage: this test should be carried out at a temperature of 25°±10°c and the regulator should be connected to a generator test bed as shown in fig 11:7. The unit should be operated under no load conditions for between 15 - 18 minutes with the cover installed and with a v...
Page 111
Checking cut-out: 1 closing voltage: this test should be carried out at a temperature of 25°±10°c and the regulator should be connected to a generator test bed as shown in fig 11:7. The unit should be operated under no load conditions for between 15 - 18 minutes with the cover installed and with a v...
Page 112
Fig 11:12 wiring diagram for setting the cutout relay key to fig 11 :12 b 2 v battery b 20 v battery a ammeter, 15 a scale ( 1 % accuracy) v voltmeter, 20 v scale (0.5% accuracy), directly connected to terminals 31-51 p potentiometer for voltage adjustment, having such a capacity that the current dr...
Page 113
Windshield wiper motor assy wiper motor screws wiper motor bracket fig 11:15 arrangement of windshield wiper unit on vehicle b m int f s c 12 v 31 d a s w i t c h p a r k i n g 0 on s w i t c h l e v e r positions fig 11:16 windshield wiper wiring diagram key to fig 11 :16 a series winding b shunt w...
Page 114
Parking position the trouble will be found in the sliding sector which fails to open the switch d (see fig 11 :16). Check by removing the four motor cover mounting screws and uncover the sliding sector. If possible suitably bend the sector to bring it against into contact with the rod tip of switch ...
Page 115
Fig 11:18 replacement of bulb from inside front compartment key to fig 11 :18 1 double-filament bulb 2 bulbholder 3 side direction indicator light 4 bulbholder shield parking lamp lens side direction indicator fig 11 :19 disassembling front parking and direction indicator lamp replacement of the bul...
Page 116
Lamp brilliance varies with the speed of the car: check the condition of the battery. Examine the battery connections. Make sure they are tight and renew faulty cables. 11:10 panel and warning lights: all the gauges are clustered in a single instrument mounted on the dashboard above the steering col...
Page 117
Before removing an apparently faulty horn check the wiring and connections. Check that the mounting bolts are tight and that the horn does not foul any adjacent part. Removal and installation: this is a straightforward operation and the only precaution to be taken is to ensure that the rubber gasket...
Page 118
(h) starter motor rough or noisy 1 mounting bolts loose 2 damaged pinion or flywheel gear teeth (i) lamps inoperative or erratic 1 battery low, bulbs burned out 2 faulty earthing of lamps or battery 3 lighting switch faulty, loose or broken wiring connections f500 125 (j) wiper motor sluggish, takin...
Page 119
Blank page.
Page 120: Chapter 12
Chapter 12 the bodywork 12:1 12:2 12:3 12:4 12:5 12:6 12:7 bodywork finish interior and chrome cleaning door trim and accessories door handles and locks removing regulator and door glass removing windshield glass removing rear side windows 12:8 12:9 12:10 12:11 12:12 12:13 12:14 removing rear window...
Page 121
Fig 12:1 detail of right door (early type). Upper arrow points to vent wing lock handle. Lower arrow points to window regulator handle fig 12:2 sedan right side door (later type). Front-hinged. Door latch is of the triple acting type. Later (pull-out) type interior lock handles have an escutcheon wh...
Page 122
Inner panels: imitation leather-lined masonite trim panels are fitted to all versions of the new 500' models. The panels are secured in the housing below the door window by means of four stiff clips located at the top and seven spring clips located at the bottom equally spaced around the panel borde...
Page 123
Nut and jam nut for adjusting pin friction fig 1 2 : 5 ventilation panel lower pivot fig 12:6 removal of windshield glass. Simply press out as shown reassemble the regulator to the door is the reverse procedure to dismantling. The following points should however, be noted: 1 before the lining is ref...
Page 124
8 refit the intermediate protection lining ensuring that it is properly located and well glued. Refit the door lining panel, key and crank handle. Door ventilator: the door ventilator comprises the glass, weather strip placed between the glass and chromium plated frame, the chromium plated frame tog...
Page 125
Seat rubber pad seat articulation support seat mechanism control lever seat sliding guide seat fixed guide fig 12:11 sedan front seat 4 2 3 1 fig 12:12 sedan rear seat with removable cushion key to fig 12:12 1 striker plate for triple acting door latch 2 seat cushion 3 dowels (two) for seat cushion ...
Page 126
12:11 folding top the folding top assembly comprises the following items: 1 imitation leather top with vinylite back window. 2 front end frame complete with two handles and catches. A movable bow which slides on the frame guide rails. 3 three stiffening bows fixed by chrome plated buttons and tipped...
Page 127
Bow fig 12:17 sun roof top in unlatched position fig 12:18 diagrammatic view of car heating system key to fig 12 :18 1 thermostat controlling shutter 2 shutter, engine cooling air outlet 3 lever, heater hand control 4 warm air outlet slots 5 demister valve control knobs 6 windshield demister diffuse...
Page 128
Cushion and back rest. A number of rubber straps are hooked across the frame under the cushion and in a sheath covering on the seat back. The bottom of the front seat frame ends are provided with sliding guides which run in guide rails attached to the floor. The sliding guides are pivoted on the fra...