FIAT 500D Manuals

Manuals and User Guides for FIAT 500D. We have 1 FIAT 500D manual available for free PDF download: Workshop Manual

FIAT 500D Workshop Manual (129 pages)

FIAT 500 1957-73

Brand: FIAT | Category: Automobile | Size: 9.45 MB

The Engine
2
Description
2
Left Side View of the Power Plant to Suit
3
Right Side Rear Three-Quarter View of the Power Plant for 500 Station Wagon
3
Engine Section through Crankshaft, Pistons and Valves
4
Engine Cross-Section through a Cylinder
5
Engine Removal
6
120.000 Engine Assembly: Cross-Section View through a Cylinder
6
Engine Compartment Lid Open
7
Engine Removal Using the Jack with Cross-Member
7
Engine Components: Crankcase, Cylinder Head, Timing Sprockets Cover
7
Tool A.40014 for Cylinder Head Removal
8
Removing Crankshaft Sprocket with Puller A.46020
8
Cylinder Hold-Down Tool A.601 56
8
Removal of Stud from Crankcase by Puller A.40010
9
Engine Without Blower Cowling and Cylinder Head Cover
9
Engine Disassembly (Station Wagon)
9
Tool A.60084 for Valve and Valve Spring Removal
9
Cylinder Head Removal, Servicing and Replacement
10
Cleaning Valve Guides
10
Installing a Valve Guide Using Tool A.60153 Provided with Pilot Bush
10
Main Specifications of Intake and Exhaust Valves and Valves Guides
11
Dismantling the Cylinder Head
11
Inspection and Servicing of the Cylinder Head
11
Valve Springs
11
Cylinder Head Installation
12
Timing Gear Overhaul
12
Valve, Pushrod and Tappet Assembly
12
Crankcase and Cylinders
12
Finned Cylinder
13
Cylinder Measurement Points
13
Honing or Reboring Cylinder Bores
13
Checking Cylinder Height
13
Inspection of Tappet Seats
14
Piston Assembly
14
Checking Piston Ring-To-Land Clearance
14
Reassembly of Piston
14
Checking Ring Gap (Ring in Cylinder)
15
Checking Rod Bearing Inserts and Crankpin Journals
15
Checking Rod Bearing Insert to Crankpin Journal Clearance
15
Connecting Rod Components
15
Installation of Connecting Rod Bearing Inserts
16
Little End Bushing
16
Engine Front End Without Flywheel
17
Piston-Connecting Rod Assembly
17
Crankshaft and Main Bearings
17
Camshaft End Crankshaft Supporting Member and Bearing Assembly, and Spare Main Bearing
17
Flywheel and Starter Ring Gear
18
The Oil Pump
18
Engine Lubrication Diagram
18
Pump Removal and Reassembly
18
Lubrication Diagram of Engine 120.000
19
Pump Dismantling, Inspection and Reassembly
19
Station Wagon
19
Pump Gears Removal, Inspection and Reassembly
19
Lubrication, Oil Filter, Relief Valve
20
Engine Longitudinal Section through Oil Pump
20
Centrifugal Oil Filter Components
20
Engine Detail Showing Lube Oil Passages
21
Cleaning and Inspection
21
Oil Pressure Indicator Sender Unit
21
Valve Timing
21
Valve Stem-To-Rocker Clearance Adjustment
22
Engine Assembly
22
Graduated Sector C.673 for Valve Gear Timing
22
Cylinder Head Hold-Down Nuts Tightening Sequence 500 Sedan
23
The Correct Position of Connecting Rod-Piston Assembly on Engine 120.000
23
Engine Assembly (Station Wagon)
24
Cylinder Head Stud Nut Tightening Sequence.500 D. F and L Sedan and Station Wagon
24
Power Plant Rear Suspension
24
Power Plant Mountings
25
Adjustment of Generator and Fan Drive Belt
25
Modifications
25
Fault Diagnosis
25
The Fuel System
28
Fuel Pump Operating Principles
28
Routine Maintenance
28
Pump Removal, Dismantling and Examination
28
Fuel Pump Components
29
Reassembly, Installation and Adjustment
29
Carburetter Operation and Adjustment, Weber 26.IMB
29
Fuel Pump and Control Pushrod
29
Carburetter Operation
30
Diagrammatic Section of Weber 26.IMB Carburetter
30
Starting Device (Choke) Diagrammatic Section
30
Weber 26.IMB Carburetter Starting Device (Choke) End
31
Starting Device
31
Engine Starting
31
Normal Car Driving
32
Idle Speed Adjustment
32
Adjustment of Fuel Level in Float Chamber:
32
Float Adjustment Data
32
Weber 26.IMB Carburetter Cover Components
33
Jets, Jet Holders and Choke Valve
33
Throttle Valve Components
33
Carburetter Cleaning
33
Carburetter Operation and Adjustment, Weber 26. OC
34
Carburetter Operation, Starting Device:
34
Section of Later Starting Device
34
Diagrammatic Section Views of 26.OC Weber Carburetter through the Starting Device
35
Diagrammatic Section Views of 26.OC Weber Carburetter
35
Float Level Setting Diagram Weber Carburetter Type 26.OC
36
Adjustment of Fuel Level in Float Chamber
36
Removing the Air Cleaner, 500F, L
36
Diagram of Blow-By Gases Re-Circulation Device
37
Air Cleaner (Sedan)
37
Air Cleaner—Engine 110 F.000
37
Air Cleaner—Station Wagon
38
Blow-By-Gases Recirculation Device
38
Location of the Fuel Tank in Front Compartment, 500F, L
38
The Ignition System
40
Adjusting the Contact Breaker Points
41
Cleaning the Contact Points
41
Ignition Faults
41
Testing the Low-Tension Circuit
41
Capacitor
42
Removing and Dismantling Distributor (Sedan and Sports)
42
Ignition Distributor in Place on Engine
42
Use of Fixture Ap.5030/1 to Check Ignition Timing
43
Removing and Dismantling Distributor (Station Wagon)
43
Timing the Ignition
43
Sparking Plugs
43
Sparking Plug Leads
44
The Distributor Driving Spindle (Sedan and Sports Engine)
44
The Cooling System
46
Engine Cooling Air Circulation System
47
Cooling Air Circulation System of Engine 120.000
48
Air Outlet Thermostat and Shutter
49
Tension Adjustment, Thermostat to Shutter Link
49
Location of Cooling Air Outlet Thermostat and Shutter
49
Diagram of the Heating System Safety Device (Sedan and Station Wagon)
49
Heating System Safety Device
50
The Clutch
52
Removal and Installation
53
Dismantling and Inspection of Clutch Cover
53
Assembly and Adjustment
53
Clutch Components (New 500, 500D Sedan and Early Station Wagon)
54
Inspection-Diaphragm Clutch
54
Clutch Assembly Installed on Engine
54
Clutch Cover Assembly Inspection Diagram 500F, L and Later Station Wagon
55
Installing the Clutch on Flywheel Using Pilot A.62023
55
Pilot Bushing
56
Clutch Controls and Adjusting Mechanism
56
Withdrawal Mechanism
56
Clutch Throw-Out Mechanism
57
Gearbox and Differential Unit
58
Gearbox-Differential Unit Longitudinal Section
59
Removal of Gearbox/Differential Unit
59
Gearbox Gears, Forks and Striker Rods
60
Detail of Gearbox Section through Striker Rod Positioning Ball Springs
60
Dismantling-Gearbox
60
Differential Unit Complete with Axle Shafts
61
Differential Components
62
Inspection of Components
62
Reassembly-Gearbox
63
Dismantling-Differential and Final Drive
63
Reassembly-Differential Unit
64
Final Drive Gear Set Adjustment
64
Graphic Demonstration of Values a and a
65
Setting Dial Indicator to Zero on Tool A.62037
65
Adjusting Final Drive Gear Set
65
Ring Gear Clearance and Differential Bearing Pre-Load
66
Check and Adjustment of Tooth Contact between Pinion and Ring Gear
67
Replacement of Gearbox-Differential Unit
67
Swing Axle Shafts and Slip Joints
67
Location of Gearshift Lever on Control Passage Tunnel
69
Gear Shift Control Mechanism
69
Dismantling and Inspection
69
Modified Items in Transmission-Differential Assembly
70
End Sectional View of Transmission-Differential Assembly
70
Rear Suspension and Wheels
72
Removal of Rear Suspension Assembly
72
Rear Suspension Assembly
73
Servicing Swing Arms
73
Right Rear Suspension Assembly, Sectioned through Brake Drum and Arm Mountings
74
Wheel Bearing Adjustment
75
Swinging Arm Adjustment
76
Installation of Rear Suspension Assembly
76
Adjusting Rear Wheel Toe-In Angle
76
The Position of Rear Suspension for Rear Wheel Toe-In Inspection and Adjustment
76
Checking Left Rear Wheel Toe-In
77
Sectional View of Right Side Rear Wheel and Axle Shaft
78
Front Suspension and Hubs
80
Front Suspension Removal and Dismantling
80
Front Suspension
81
Leaf Spring
81
Section through Left Swinging Arm
81
Section through One Spring Mounting
81
Front Leaf Spring, Loaded at Center
82
Front Leaf Spring, Installed on Car
82
Spring Deflection Test
82
Swinging Arm Components
83
Leaf Spring Inspection and Repair
83
Swinging Arms
83
Kingpin Housing
84
Steering Knuckle and Wheel Hub
84
Removing Right Front Wheel Hub Cap by Remover A.46023
84
Removing Left Front Wheel Brake Drum by Puller A.40005
84
Sectional View of Shock Absorber
85
Leaf Spring Position under Full Static Loads on Fixture A.66061 or A.74061
85
Hydraulic Damper
86
Installing Right Front Wheel Hub Cap by Tool A.66059
86
Front Suspension Assembly and Installation
86
Swing Arm Setting
87
Section through Steering Knuckle and Leaf Spring Mounting at Kingpin
87
Castor, Camber Angles
88
Steering Geometry
88
Adjustment of Castor Angle
88
Adjustment of Camber Angle
88
Steering System
90
Steering Wheel Removal and Refitting
90
Steering Box Removal and Refitting
90
Steering Box, Idler Member and Steering Linkage Arrangement on Vehicle
91
Securing Steering Wheel Mounting Nut
91
Steering Box Dismantling and Reassembly
91
Layout of Steering Gear Components
92
Section of Steering Box, through Worm Screw
93
Steering Box Cutaway
93
Refitting the Steering Box
94
Relay Lever and Support
94
Steering Rods (Tie Rods)
94
Front Wheel Toe-In Checking Diagram
94
The Braking System
96
Brake Adjustment (Station Wagon)
96
Preventative Maintenance
96
Diagrammatic View of Service and Rear Wheel Parking Brake System
97
Left Front Wheel Brake Assembly (500 Sedan)
97
Front Brake Drum Removal
97
Dismantling Brake Unit
98
Brake Shoe Lining
98
Reassembly of Front Brakes
98
Rear Brake Drum Removal
98
Reassembly of Rear Brakes
99
Master Cylinder Removal
99
Master Cylinder Section
100
Dismantling Master Cylinder
100
Refitting the Master Cylinder
100
Wheel Cylinder Operation
100
Brake Fluid Reservoir
101
Reassembling Wheel Cylinders
101
Self-Adjusting Device
101
Removing a Flexible Hose
101
Bleeding the System
102
Removing the Hand Parking Brake Cable
102
The Dual Circuit Braking System
102
The Electrical Equipment
104
The Battery
104
Battery Location
105
Cross-Section View of Battery
105
The Generator
105
Testing When Generator Is Not Charging
105
Removing Generator
106
Servicing Brushes
106
Servicing the Commutator
106
Components of Generator
106
Components of Starter
107
Testing Field Coils
107
Reassembly and Refitting the Generator
107
The Starter Motor
107
Tests for a Starter Which Does Not Operate
108
Removing the Starter
108
Examining the Commutator and Brush Gear
108
Testing the Field Coils
108
Wiring Diagram for Checking the Cutout Closing Voltage
109
Wiring Diagram for Checking the Reverse Current of Cutout
109
Reassembling and Refitting the Starter
109
The Control Box
109
Checking Cut-Out
110
Closing Voltage
110
Reverse Current
110
Checking Voltage/Current Regulator
110
Wiring Diagram for Setting the Cut-Out Relay
111
Wiring Diagram for Setting the Voltage Andcurrent Regulators
111
Wiring Diagram for Setting the Cutout Relay
112
Location of Electrical System Fuses
112
Cut-Out Relay Adjustment
112
Voltage Regulator Adjustment
112
Windshield Wiper Wiring Diagram
113
Faulty Operation of Flashers
113
Windscreen Wipers
113
Wiper Unit Faulty Operation
113
Removal and Refitting the Motor
114
Headlamp Removal
114
The Lighting System
114
Replacement of Bulb from Inside Front Compartment
115
Disassembling Front Parking and Direction Indicator Lamp
115
Beam Setting
115
Disassembling Tail Parking, Stop, Direction Indicator Lamp and Reflector Lens
115
Lamp Brilliance Varies with the Speed of the Car
116
Fuel Reserve Supply Indicator Sender Unit
116
Number Plate Lamp
116
Horn (Opened)
116
Lighting and Flasher Switch
117
Switch Unit Removal
117
Bodywork Finish
120
Interior and Chrome Cleaning
120
Cleaning Imitation Leather
121
Chrome Plated Parts
121
Door Trim and Accessories
121
Weather Strip
121
Inner Panels
122
Door Handles and Locks
122
Removing Window Regulator and Door Glass
122
Regulator Removal/Reassembly
122
Ventilation Panel Lower Pivot
123
Removal of Windshield Glass
123
Door Window Drop Glass and Weather Strip
123
Removal of Door Glass
123
Door Ventilator
124
Adapting Windshield Weatherstrip
124
Front Compartment Lid Lining and Rubber Buffers
124
Removing Windshield Glass
124
Sedan Rear Seat with Removable Cushion
125
Removing Rear Side Windows
125
Removing Rear Window Glass
125
Front/Engine Compartment Lid
125
Folding Top
126
Sunroof
126
Folded Top Retaining Strap
126
Sun Roof Top in Locked Position
126
Sun Roof Top in Unlatched Position
127
Front Seats
127
Diagrammatic View of Car Heating System
127
Rear Seats
128
Interior Heater
128
Windshield Demisting
128
Diagram of Booster
128

FIAT Categories

Automobile Automobile Accessories Car Receiver

Car Stereo System Scooter

More FIAT Manuals

FIAT 500D Manuals

FIAT 500D Workshop Manual (129 pages)

Table of Contents

Related Products

FIAT Categories