Table Of Contents - Fiat 850 Sedan 1968 Shop Manual

Table of Contents

Section Index2
General Information4
Main Specifications6
Leading Dimensions Of Car (Metric)7
Capacities8
Unit Identification Data9
Spare Parts9
Car Keys9
Engine10
Table Of Contents10
Side Sectional View Of Engine Across Cylinders11
Removal And Installation12
Disassembly12
Assembly12
Engine Trouble Diagnosis And Corrections14
Engine Will Not Start14
Engine Stalls15
Engine Has No Power16
Engine Lopes Or Misses At Idle17
Engine Misses At High Speed18
Engine Misses While Idling19
Crankshaft Knocks19
Noisy Connecting Rods20
Noisy Pistons21
Noisy Piston Pins21
Noisy Valves And Tappets21
Vibrations Originating At Engine22
Low Oil Pressure22
High Oil Pressure22
Removal And Installation Of Engine24
Lifting Out Engine24
Engine Disassembly25
Removing Engine And Transmission Assembly25
Engine On Revolving Stand An. 2220425
Crankcase Without Oil Sump26
Pulling Timing Drive Sprocket26
T3 - Backing Out Hub-Pulley Lock Screw26
Lifting Out Crankshaft26
Engine Assembly27
Fitting Tappets27
Reaming Intermediate Camshaft Bushing27
Checking Driven Sprocket - To - Camshaft Spacer Clearance27
Tightening Camshaft Driven Sprocket Screw28
Tightening Hub-Pulley Nut28
Installing Crankshaft Front 011 Seal Cover28
Tightening Centrifugal 011 Filter Cover28
Fitting Oil Sump Gasket29
Installing Clutch Assembly29
Affixing Sector Scale29
Cylinder Block And Crankcase30
Checking Cylinder Barrels30
Honing Cylinder Barrels32
Reboring Cylinder Barrels32
Diagram For Measuring Cylinder Bores32
Using Dial Indicator To Measure Cylinder Bores32
Checking And Grinding Cylinder Head Mating Face33
Aligning Cylinder Bore, Preparatory To Boring Operation33
Reboring Cylinders33
Checking Camshaft Bushings And Seats34
Checking Lower Face Of Crankcase34
Bottom View Of Crankcase34
Checking And Reaming Tappet Seats35
Reaming Tappet Seats On Crankcase35
Critical Dimensions Of Crankcase35
Pistons - Connecting Rods36
Checking Piston Clearance In Bore And Piston Pin Clearance In Boss37
Checking Piston Clearance In Cylinder Bore38
Connecting Rod And Piston Assembly38
Piston Upside Down38
Checking Piston And Connecting Rod Weight39
Piston Rings39
Piston Ring Side Clearance39
Removing Piston Pin40
Piston, Pin, Connecting Rod Assembly40
Checking Piston Ring Side Clearance40
Pressing Out Piston Pin41
Electric Oven For Heating Connecting Rods41
Checking Piston Pin Drag.42
Location Of Connecting Rods In Oven42
Position Of Piston To Connecting Rod42
Connecting Rod Bearings43
Pistons· Connecting Rods44
Crankpin Diameters45
Connecting Rod Bearing Insert Thickness45
Securing Connecting Rod Bearing Caps45
Crankshaft And Main Bearings46
Checking And Grinding Crankpins And Journals47
Crankarm Fillet Specifications48
Flywheel And Ring Gear48
Crankshaft48
Checking Crankshaft Balance49
Checking Crankpin And Journal Alignment49
Cleaning Oil Passages49
Main Bearings50
Main Bearing Insert Thickness50
Main Bearing Caps With Bearing Inserts In Place50
Checking End Play51
Oil Seals51
Fitting Thrust Ring Halves51
Clutch Shaft Pilot Bushing52
Tightening Main Bearing Cap Screws52
Installing Crankshaft Front Seal Cover52
Checking Crankshaft End Play52
Cylinder Head54
Valves, Valve Guides, Springs And Rockers54
Miscellaneous55
Cylinder Head Screws Tightening Sequence56
Tightening Head Screws By Means Of Torque Wrench56
Removing Valves From Cylinder Head56
Decoking And Cleaning Combustion Chambers56
Checking And Grinding Head Bottom Face57
Checking Water Seal57
Checking And Reseating Valve Seats57
Valves59
Valve Seat Cutting Diagrams59
View Of Valve Seats In Head59
Narrowing Valve Seat At Top With 20 Cutter59
Valve Guides60
Valve Sealing Test60
Grinding Valve Face60
Valve Seal Test60
Valve Springs61
Valve - Valve Guide Fitting Specifications61
Reaming Valve Guides61
Cylinder Head With Valve Springs And Spark Plugs61
Rockers62
Checking Springs62
Rocker, Shaft And Support Assembly62
Critical Dimension. (Metric) Of Rockers, Shaft And Supports62
Valve Mechanism64
Camshaft And Bushings65
Checking And Reaming Bushings65
Critical Dimensions (Metric) Of Camshaft And Bushings65
Tappets66
Fitting Intermediate Camshaft Bushing66
Push Rods67
Valve Timing67
Tappet· Tappet Seat Fitting Specifications67
Adjusting Valve Tappet Clearance68
Tightening Reference69
Engine Bench Test70
Installing Engine On Test Bench70
Engine On Test Bench70
Detail Of Engine On Test Bench70
Horsepower Check-Up71
Overhaul After Bench Test71
Testing Range Of Rebuilt Engines71
Lubrication Cooling Fuel System72
Engine Lubrication Diagram (Cut-Away73
Oil Pump74
Oil Pump Assembly74
Oil Pump In Place In Crankcase74
Oil Pressure Relief Valve75
Oil Sump Gaskets75
Centrifugal Oil Filter75
Low Oil Pressure Indicator Sending Unit75
Oil Pump Fitting Data76
Bonding Oil Sump Gaskets76
Cooling77
Directions For Use77
Directions For Service78
Diagram Of Engine Cooling System78
Water Pump79
Radiator80
Thermostat80
Pressure Test80
Thermal Switch81
Lifting Out Radiator From Underside Of Car81
Detail Showing Radiator Mounting81
Adjusting Generator And Water Pump Drive Belts Tension82
Fitting Thermostat To Engine82
Fuel System83
Air Cleaner83
Air Cleaner Assembly83
Replacing Cleaner Element84
Fuel Pump84
Setting Fuel Pump Push Rod Projection84
Layout Of Fuel Pump Components84
Cleaning And Inspection84
Installation And Adjustment84
Fuel Tank85
Engine Transmlnlon And Dlre,Ential Anembly85
Carburetor86
Operation86
Accelerator Pump86
Instructions For Using The Easy Starting Device88
Starting Cold Engine88
Warming Up Engine88
Float Level Adjustment89
Engine Running Normally89
Solex 30 Pib 4 Carburetor90
Easy Starting Device90
Power Pump90
Setting Data Of Carburetors91
Idling Adjustment92
Trouble Diagnosis Guide92
Recirculation Device Of Blow-By Gases And Oil Vapours93
Clutch Transmission Differential94
Clutch96
Specifications And Data96
Pressure Plate Assembly And Driven Plate96
Noises Audible On Pedal Depression97
The Clutch Slips97
The Clutch Grabs97
Abnormal Lining Wear98
Noises Audible On Pedal Release98
The Clutch Drags99
Pedal Travel Adjustment99
Removing Clutch Throwout Yoke Rod100
Clutch Cover Assembly Inspecting Diagram101
Transmission - Differential102
Trouble Diagnosis And Corrections102
Transmission104
Transmission Assembly104
Engagement Of 2Nd, 3Rd And 4Th Gears.105
Engagement Of 1St Gear106
Transmission Side Cover Assembly106
Transmission Trouble Diagnosis And Corrections107
Noisy Transmission107
Transmission Shifts Hard107
Transmission Jumps Out Of Gear108
Oil Leakage108
Side Seetional View Of Transmission-Differential Assembly109
Prying Out Countershaft·drive Pinion Nut Lock Ring110
Checking Gear Backlash111
Drive Pinion Bearing In Place In Transmission Case111
Fitting The Reverse Shaft And Gear Lock Pin112
End Sectional View Of Transmission Across Shifter Rails112
End Sectional View Of Transmission Across Shlf1Er Rail113
Tightening Shifter Forks113
Differential114
Noise Diagnosis And Corrections114
Thumping114
Noises Due To Excessive Backlash114
Pulling Differential Cage Roller Bearing Cones115
Tightening Differential Carrier Cap Screws115
Removing Differential Carrier Caps115
Adjusting Final Drive Gear116
Fitting Bearing Adjuster Stop Plate116
Drive Pinion Ball Bearing116
Step For Figuring The Thickness Of Drive Pinion Shim117
Drive Pinion And Shim Fitting Diagram117
Checking Ring Gear-To-Pinion Tooth Contact119
Axle Shafts And Slip Joints119
Checking Ring Gear-Ta.pinion Backlash119
Bench Testing Differential Unit119
Checking And Adjusting Ring Gear-To-Pinion Tooth Contact120
Gearshift Mechanism121
Disassembling Gearshift Lever121
Removing Selector Leve(Rod121
Front Suspension And Wheels122
Wheel Bounce126
Excessive Tire Wear126
Pull To One Side127
Suspension Noise127
Wheel Wobble127
Tying Off Tie Rod From Knuckle Arm128
Pulling Wheel Hub Cap128
Removing Semi-Elliptic Spring Pin128
Pulling Upper Control Arm Bushings128
Semi-Elliptic Spring129
Center Loaded Spring130
Spring As Fitted On Car130
Front Suspension Assembly In Place On Car130
Control Arms131
Kingpin Housings131
Control Arm Installed On Fixture A. 74135131
Steering Knuckles And Wheel Hubs132
Reaming Kingpin Bushings132
Pulling Outer Bearing Cup132
Thickness Of Steering Knuckle Lower Thrust Washers132
• Front End Setting Diagram133
Pulling Inner Bearing Cup134
Installing Kingpin134
Instajllng Upper Control Arm Bushings134
Installing Wheel Hub Cap135
Staking Steering Knuckle Nut135
Securing Semi-Elliptic Spring To Body Shell135
Checking And Adjusting Front End Geometry136
Setting Semi-Elliptic Spring At136
Fitting Camber And Caster Adjusting Shims136
Checking Camber137
Checking Caster138
Front Sway Eliminator138
Front Wheels138
Checking Caster (Second Step)138
Wheel Hub139
Hub Cap139
Check With Wheel Off139
Check With Wheel On140
View Of Mechanical Units Of Car Front End140
Rear Suspension And Wheels142
Shock Absorbers142
Irregular Or Abnormal Tire Wear146
Squeaks, Thumps, Or Rattles146
Removing Suspension148
Pulling Rear Wheel Ball Bearing148
Pulling Rear Wheel Hub148
Removing Roller Bearing Cup149
Installing Control Arm Bushing149
Checking Control Arm And Drum Assembly149
Adjusting Rear Control Arm149
Coil Springs150
Installing Roller Bearing Cup150
Installing Roller Bearing Snap Ring150
Installing Suspension151
Installing Wheel Shaft Flexible Joint On Work Bench151
Securing Rear Control Arm To Body Shell151
Left Side Rear Suspension And Wheel Assembly151
Replacing Flexible Joint152
Loosening Wheel Shaft Flexible Joint Mounting Nut152
Taking Wheel Shaft Part Way Qut152
Tightening Flexible Joint Mounting Nut152
Checking And Adjusting Rear Wheel Toe-In154
Installing Coil Spring Compressor154
Rear Suspension Assembly In Place On Car154
Note On Self-Locking Nuts155
Hydraulic Shock Absorbers156
Compression Stroke157
Sectional View Of Shock Absorber,157
Detail Of Left Side Front Suspension And Wheel157
Steering System158
Steering System And Front Running Gear Units159
Jerky Steering161
Hard Steering161
Front Wheel Shimmy162
Tire Squeal On Turns162
Rattles162
Side-To-Side Wander163
Loose Steering163
Hard Turning When Stationary163
Steering Wheel164
Steering Gear164
Tightening Steering Wheel Mounting Nut164
Backing Out Sleering Wheel Mounting Nut164
Removing Steering Gear165
Steering Gear On Service Fixture165
Removing Steering Rods165
Removing Pitman Arm165
Adjusting Worm Bearings166
Sectional View Of The Steering Gear At Sector166
Adjusting Lash Between Worm And Sector167
Sectional View Of The Steering Gear Across The Worm167
Idler Arm And Support168
Steering Rods168
Reaming Eccentric Bushing168
Installing Pitman Arm168
Front Wheel Toe-In169
Brakes Wheels And Tires170
Brakes171
Locked Brake Pedal172
Brakes Locked Even After Releasing The Pedal172
Spongy Pedal173
Pedal Yields Under Slight Pressure173
Excessive Effort Required On Pedal173
Reduced Pedal Free Travel174
Excessive Pedal Travel174
Shoes Drag Permanently On Drums174
Service Brakes175
Unbalanced Braking175
Weak Braking175
Master Cylinder175
Wheel Cylinders176
Fluid Reservoir And Lines176
Side Section View Across Wheel Cylinder176
Master Cylinder And Wheel Cylinders176
Brake Shoes And Linings177
Removing Brake Drum177
Brake Drums178
Adjusting Shoe-To-Drum Clearance178
Turning Brake Drum On Lathe178
Refacing Brake Shoe Linings178
Brake And Clutch Pedal Mounting Board179
Emergency And Parking Brake180
Brake Pedal And Master Cylinder Assembly180
Handbrake Components At Left Side Rear Wheel181
Removing Brake And Clutch Pedal Mounting Board181
Wheels And Tires182
Tire Damages183
Uneven Tire Wear183
Wheel Balance184
Air Conditioning System185
Windshield Washer185
Summer Ventilation187
Mid-Season Ventilation187
Winter Heating187
Car Air Conditioner187
Removing Air Conditioner188
Fitting Electrofan188
Withdrawing Air Conditioner188
Removing Heater Radiator Cock189
Bleeding Cooling System189
Chassis Tightening Reference191
Electrical195
Battery196
Electrolyte Level197
Checking State Of Charge197
Arrangement Of Battery In Car197
Recharging Battery With External Means198
Conditions Entailing Battery Rundown198
Generator199
Fiat D 90/12/16/3 Cs Generator Tor Assembly200
Bench Testing201
Operation Tests201
Motoring Test201
Wiring Diagram For Motoring Test201
Ohmic Resistance Test202
Heating Test202
Mechanical Characteristics Check Data202
Service Procedures203
Commutator Re-Turning203
Broken Field Winding, With Shorted Or Grounded Coils203
Shorted, Grounded Or Open Armature Coil204
Replacing Brushes204
Generator Regulator205
Checking Cutout Relay206
Checking Voltage Regulator207
Checking Current Regulator207
Opening The Regulator208
Replacing Regulating Resistor208
Adjustments210
Adjusting Cutout Relay210
Adjusting Voltage Regulator211
Operation Test And Sealing211
Adjusting Current Regulator211
Trouble Diagnosis Of Recharging System212
Indicator Light Fails To Go Out212
No-Charge Indicator Fails To Light Up213
No-Charge Indicator Goes Out But Then Glows Feebly213
No-Charge Indicator Goes Out At High Speed214
No-Charge Indicator Lights Up And Goes Out Regularly214
Uneven Wear Of Commutator Bars In Generator215
Rapid Wear Of Generator Brushes216
Starting Motor217
Motor Fails To Operate219
Motor Operates But Very Slowly219
Returning Commutator222
Armature Disassembly And Assembly222
Replacing Starter Drive Mechanism222
Replacing Starter Switch222
Replacing Field Winding222
Ignition System223
Service Data223
Ignition Distributor224
Checking Distributor On Test Bench224
Vacuum Advance224
Checking The Automatic Advance Curve225
Checking The Vacuum-Operated Advance Device225
Checking Timing225
Checking Breaker Contact Points Opening-Closing Rate226
Checking Distributor Noises226
Checking Mechanical Components226
Ignition Coil227
Grounding Insulation227
Measuring Spark Length227
Test With Shunted Spark Tester227
Tightness Test228
Testing A Spark Plug For Gas Tightness228
Slowing A Spark Plug After Sanding And Washing228
Electric Test228
Ignition Timing229
Checking Ignition Timing229
View Of Engine Compartment With Disassembly In Progress229
Ignition System Trouble Diagnosis230
Ignition Faulty Or Completely Absent230
Ignition Extremely Advanced231
Ignition Coil Unserviceable231
Lighting System232
Headlights235
Headlamp Without Rim235
Type235
Side Direction Signal Lights236
Rear Parking Stop And Direction Signal Lights With Reflector Lens236
Front Parking And Direction Signal Lights236
License Plate Light237
Instrument Cluster Lights237
Rear View Mirror Light237
Engine Compartment Light238
Fuses238
Electrical System Fuses238
Instruments And Accessories239
Blinking Direction Signals240
Voltage240
Close-Up View Of The Instrument Cluster241
Instrument Cluster242
Coolant Temperature Warning Light242
Fuel Gauge242
Rear View Of The Instrument Cluster242
Windshield Wiper243
Horn243
Arrangement Of Windshield Wiper243
Radio Receiver244
Horn Diagram244
Antenna244
Radio Set245
Detail Of Antenna Mounting245
Setting Antenna Trimmer246
Interference Suppression Devices246
Loudspeaker246
Body247
Left Side View Of Car With Door Opened249
View Of Front Luggage Compartment250
Front View Of Car250
Rear View Of Car250
Doors251
Removing Ventilator Window251
Withdrawing Ventilator Window Assembly251
Taking Down Door Lock And Control252
Removing Drop Glass252
Taking Down Window Regulator252
Removing Door Handle252
Adjusting Drop Glass Travel253
Door And Window Conlrols253
Interior View Of Door Latch253
Door Alignment253
Front Compartment Lid254
Adjusting Door Lock Striker Plate254
Repositioning Front Compartment Tid254
Engine Compartment Lid Catch254
Engine Compartment Lid255
Glazing255
Removing And Installing Windshield Glass255
Bumpers256
Seats256
Back Window Glass256
Rear Quarter Window Glasses256
Repairing Accidented Cars257
Instrument Panel Lining257
Strap Hangers257
Removing Instrument Panel Lining257
Leakage Check258
Checking Underbody With Gauge A. 74141258
Body Upkeep259
Cleaning Upholstery Cloth259
Glass Panes259
Washing The Car259
Maintenance260
Tool Equipment260
Lubricant Specifications262
Special Service Tools263
Coupe Roadster Family Idroconvert266
Differences From Sedan Version268
Detail Of Rear Quarter Door Window Adjuster270
Detail Of Front Seat Back Rest Catch270
General Specifications271
Pistons272
Con Rods273
Valves - Valve Seats - Springs273
Valve Gear274
Specifications And Fits Of New Parts275
Front Brake Specifications286
Brake Lining-To-Disc Clearance Self-Adjusting Device286
Replacing Lining Pads287
Removing Bracket Clamp Pin Lock Plate287
Side Sectional View Of The Disc Brake Caliper287
Disassembling And Assembling Disc Brakes288
Brake Calipers288
Removing Brake Caliper Self-Adjusting Pin Nut289
Fitting Brake Caliper289
Brake Discs290
Spark Plugs291
Headlamps308
Aiming Headlights308
Interior View Of Right Side Head Lamp308
Front Corner Parking And Direction Signal Lights309
Rear Parking, Direction Signal And Stop Lights With Reflector Lens309
License Plate Lights310
Car Interior Lights310
Removal And Disassembly324
Inspection And Repair324
Assembly And Installation325
Checking And Adjusting Front End Camber And Caster327
Rear Suspension328
Setting328
Steering329
Removal And Disassembly Of Steering Gear330
Hydraulic Brakes Specifications And Data333
Adjusting Shoe-Lo-Drum Clearance333
Air Conditioning336