Cylinder Head Installation; Timing Gear Overhaul; Valve, Pushrod And Tappet Assembly; Crankcase And Cylinders - Fiat 500L Workshop Manual

Cylinder head installation:

To refit the cylinder head proceed as follows:
1 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.
2
Fit the washers and nuts to the studs and tighten to
fingertight.
3 Tighten the nuts in the order shown in FIG 1 :44 and
FIG 1 :46 to a torque wrench setting of 18.1 Ibft. Reset
the torque wrench to a new setting of 23.9 Ibft and
tighten the nuts once more in the recommended order.
Replace the pushrods in the correct order.
4 Refit the rocker shaft ensuring correct location of the
lubrication tube to the rocker shaft and replace the
plain and lockwashers. Tighten the nuts to a torque
wrench setting of 15.2 Ibft. Reset the tappet to rocker
clearance adjustment.
5 Connect the two exhaust side manifolds to the cylinder
head. Using new gasket refit the spark plugs and HT
cables. Replace the rocker cover fitted with a new cork
gasket and blower conveyor to the cylinder head
securing screws. Refit the carburetter and reconnect its
fuel line and controls. Refit the air cleaner and elbow
and connect the rocker cover breather pipe (if fitted).

1 :7 Timing gear overhaul

Camshaft:
The cast iron camshaft is located in the crankcase and is
supported at either end in sets machined directly in the
crankcase. No bushes are used. The camshaft is driven by
a chain from the crankshaft at half engine speed and
operates the overhead valves through tappets, pushrods
and rockers (see
FIG 1 :20).
During engine overhaul the camshaft journals and cam
faces should be free of score marks or signs of seizure and
have a bright mirror finish.
The distributor drive gear should be inspected for tooth
wear which if excessive means that the camshaft must be
replaced.
Tappets:
The tappets should be inspected for signs of seizure or
excessive wear. The end surface that is in contact with the
camshaft should be smooth without signs of excessive
wear. Any slight scratches or indentations may be
removed using a very fine oil stone.
Pushrods and sleeves:
The pushrods operate in special axially resilient sleeves
that are compressed on assembly between the cylinder
head and the crankcase. It is through these sleeves that
the engine sump is vented also through which the oil
returning from the cylinder head passes.
Two rubber O-ring seals are fitted to each sleeve to
ensure an oil tight seal between the cylinder head and
crankcase. The sleeves should be checked for distortion
and exact equal length and when refitting new seals must
always be fitted.
The pushrods should be checked for straightness and
the two ends that contact the rocker setscrew and the
F500
FIG 1:19 Camshaft. The arrow points to the lube oil
outlet port
FIG 1:20

Valve, pushrod and tappet assembly

Key to Fiq 1 :20
1 Intake valve
3 Oil shield (for intake valves only)
5 Rocker 6 Upper spring cup
8 Lower spring cup
11 Oil seal ring 12 Pushrod sleeve
tappet seat must not show any signs of roughness or
excessive wear.
Rocker and rocker shaft:
During valve gear overhauls the clearance between the
rocker shaft bore and the rocker must be checked. The
maximum permissable wear between these two parts is
.0059 inch. It is recommended that the part which is most
worn be renewed, or in extreme cases both parts.

1 :8 Crankcase and cylinders

The crankcase is an aluminium casting suitably ribbed
to ensure correct air cooling. The main bearing and cam-
shaft bearing bores are machined as also are the tappet
2 Upper cup lock
4 Snap ring
7 Valve spring
9 Pushrod 10 Tappet
13 Seal ring
19