Chapter the engine : 1



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FIAT 500 1957-73
FIAT 500 1957-73 Workshop Manual
Autobooks
Models Covered
Fiat New 500 Fiat D Fiat F Fiat L Fiat and Autobianchi Giardiniera


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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 wagon )
Cylinder head removal, servicing and
replacement
Timing gear overhaul
Crankcase and cylinders
Piston assembly
Connecting rods
Crankshaft and main bearings
1 :1 Description
The 'New 500' two-cylinder aircooled engine operates on the four-stroke 'Otto Cycle' and is fitted directly to the transmission unit which incorporates the rear drive assembly as shown in FIG 1 :1 and FIG 1 :2.
With the power unit fitted at the rear several advantages are obtained including better load distribution to the wheels when the vehicle is loaded, elimination of propeller shaft reducing the size of centre tunnel and better use of available space.
The cylinder block comprises two cast iron cylinder barrels with cooling fins. The bottom of the cylinders fit into machined seats in the aluminium crankcase.
The aluminium crankcase carries eight studs on which are located the two cylinder barrels with the aluminium cylinder head on the top.
A two bush crankshaft of special cast iron is fitted into the lower half of the crankcase. The crankshaft is
F500 provided with a counterweight and is hollow to allow for lubrication.
The steel connecting rods have thin wall bearing halves on the big-end, and bronze bushes in the small-end. The offset piston pin is of steel and retained in the piston by two circlips.
Light alloy pistons are used and are of the taper-oval- shaped type with a maximum diameter at the base of the skirt, along an axis perpendicular to the piston pin. Pistons are fitted with four rings as follows, one compression at the top, two standard oil scraper rings and one side slotted oil scraper ring.
The one-piece aluminium cylinder head is finned to provide a larger cooling surface and carries the inlet and exhaust manifolds.
The inlet passages merge into a single centralized flange onto which is mounted the carburetter. The exhaust passages run almost parallel to the axis of the engine.


Fig 1:3 engine section through crankshaft, pistons and valves
Fig 1:5 120.000 engine assembly cross-section view
Fig 1:8 engine components crankcase, cylinder head,
Fig 1:9 tool a for cylinder head removal
Fig 1:11 cylinder hold-down tool a 56
Fig 1 :14 tool a for valve and valve spring
Fig 1:15 cylinder head
Dismantling the cylinder head:
Reassembly of the cylinder head
Cylinder head installation:
Pushrods and sleeves:
Key to fiq 1 :20
Fig 1 :24).checking cylinder height:
Honing or reboring cylinder bores:
Inspection of tappet seats:
Reassembly of piston:
Checking rod bearing inserts and crankpin jour-
Checking rod bearing insert to crankpin journal
Fig 1 :29 connecting rod components piston installer a.60154
Little end bushing:
Revolutiondirection
Fig 1:35 camshaft end crankshaft supporting mem-
Crankshaft oil seals:
Fig 1:36 engine lubrication diagram
Pump gears removal, inspection and reassembly:
Centrifugal oil filter:
Fig 1 :40 engine detail showing lube oil passages
Cleaning and inspection:
Fig 1 :43 adjusting the rocker clearances using the
Fig 1 :44 or 1 :46
Key to fig 1 :47
Figs 1 :47 and 1 :49.
Key to fig 1 :49
Fig 2:1 fuel pump. arrows point to fuel inlet and outlet
Fig 2:5 starting device (choke) diagrammatic section
Fig 2 : 4 diagrammatic section of weber 26.imb
Carburetter operation:
Fig 2:6 weber 26.imb carburetter starting device
Starting device:
Engine starting:
Idle speed adjustment:
Adjustment of fuel level in float chamber:
Fig 2:8 float adjustment data
Fig 2:10 jets, jet holders and choke valve
Carburetter operation, starting device:
Fig 2:11 mounting flange modification a earlier, b
Fig 2:13.key to fig 2:13
Fig 2:18diagram of blow-by gases re-circulation device
Air cleaner—engine 110 f.000:
Carburetter cleaning:
Fuel tank—sedan (110 f) and station wagon (120)
Key to fig 2 :20
Cleaning the contact points:
Testing the low-tension circuit:
Fig 3 : 3 ignition distributor in place on engine
Sparking plug leads:
Chapter 4the cooling system
Station wagon:
Fig 4:1 engine cooling air circulation system
Fig 4 : 3 oil sump with blower cowling. arrows indicate
K e y to fig 4 : 6
Installation of clutch on flywheel
New 500, d sedan and early 500 station wagon :
New 500 sedan
Fig 5:2 clutch components (new 500, d sedan and early station wagon)
Fig 5:6 fixture a for clutch disassembly, re-
Fig 5:9 clutch controls and adjusting mechanism
Chapter 6gearbox and differential unit
Fig 6:1gearbox-differential unit longitudinal section
Fig 6 :2 gearbox gears, forks and striker rods
Fig 6 : 3 detail of gearbox section through striker rod
Fig 6:7 differential components
Inspection of components:
Fig 6:8 layshaft with final drive pinion. the arrow
Fig 6:10 reading value a on gauge c to determine
Adjusting final drive gear set
Ring gear clearance and differential bearing pre-
Fig 6:14 reading value con dial indicator
Check and adjustment of tooth contact between
Excessive contact on tooth flank.
Correct tooth contact.
Fig 6:18 gearshift control mechanism
Dismantling and inspection:
Chapter 7rear suspension and wheels
Fig 7:1 rear suspension assembly
Inspection :thoroughly clean all the parts and install the swinging arm on fiat fixture a as shown in fig 7:4
Fig 7 :2 right rear suspension assembly, sectioned through brake drum and arm mountings
Fig 7:3 fixture a, for swinging arm inspection
Wheel bearing adjustment:
Fig 7:5 bearing rotation torque dynamometer
Fig 7:9 adjusting rear wheel toe-in on '500 station
Note -- that the toe-in anglekey to fig 7:9
Technical data.
Hydraulic damper
Fig 8 : 4 section through one spring mounting
Leaf spring inspection and repair:
Dismantling:1 to remove the wheel hubcap use fiat puller a.46023as shown in fig 8 :9.
Fig 8 : 9 removing right front wheel hubcap by
Leaf spring position under full static loads'
Oversizesunder-
Key to fig 8:15
Adjustment of castor angle:
Checking and adjusting castor and camber angles:
Chapter 9the steering system
Fig 9 :1 steering
Fig 9:3 layout of steering gear components
Fig 9:4 section of steering box, through worm screw
Refitting the steering box:
Fig 9:7 relay
Chapter 10the braking system
Brake adjustment station wagon)
Preventative maintenance
Fig 1 0 : 2 left front wheel brake assembly (500 sedan)
Front brake drum removal
Brake shoe lining
Reassembly of front brakes
Rear brake drum removal
Brake shoe linings:
Operation:hydraulic fluid is admitted to the master cylinder through hole 8 (see fig 10:7),
Master cylinder removal:
Fig 10:8 wheel cylinder section
Checking wheel cylinders:
Refitting the master cylinder:
Fig 10:9 brake fluid reservoir
Inspection and assembly:
Fig 10:11 an exploded view showing the components of
Removing the hand parking brake cable:
Chapter 11the electrical equipment
It is highly dangerous to add water to acid.
For climates above cor 80°f:
Fig 11 :3.testing when generator is not charging
Section 11:5.
Servicing brushes:
Servicing the commutator:
Fig 11 :4 commutator end head of generator dsv
Fig 11:5 components of starter
Generator bearings:
Operation:when operating the starter hand lever through a flexible coupling a lever is operated (see fig 11:5)
Tests fora starter which does not operate:
Removing the starter:
Dismantling the starter:
Servicing the brushes
Testing the field coils:
Examining the armature:
The pinion drive:
Checking cut-out:
Checking voltage regulator:
Checking current regulator:
Fig 11 :10 wiring diagram for setting the cutout relay
R rheostat, 4 , 1 2 a r
Cut-out relay adjustment:
Voltage regulator adjustment:
Fig 11:15 arrangement of windshield wiper unit on
Wiper unit faulty operation :
Removal and refitting the motor:
Fig 11 :17 headlamp removal
Headlamp removal:
Fig 11 : 20 disassembling tail parking, stop, direction
Rear parking, direction indicator, stop lamps and
Lamp brilliance varies with the speed of the car:
Fuel reserve supply indicator sender unit
Fig 11 : 21 number plate lamp
Folding topsun roof
Fig 12:1 detail of right door
Chrome plated parts:
Window regulator:
Regulator removal:
Fig 1 2 : 5 ventilation panel lower pivot
Fig 12:7 positioning the windshield after tilting wiper
Door ventilator:
Fig 1 2 : 8 adapting windshield weatherstrip. simply
Fig 12:11 sedan front seat
Fig 12:14 folded top retaining strap
Fig 12:17 sun rooftop in unlatched position
Rear seats (sedan):



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