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850 Sedan 1968
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Fiat 850 Sedan 1968 Shop Manual
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
Section Index
General Information
Main Specifications
Leading Dimensions of Car (Metric)
Capacities
Unit Identification Data
Spare Parts
Car Keys
Table of Contents
Engine
Side Sectional View of Engine Across Cylinders
Main Specifications
Removal and Installation
Disassembly
Assembly
Engine Trouble Diagnosis and Corrections
Engine will Not Start
Engine Stalls
Engine Has no Power
Engine Lopes or Misses at Idle
Engine Misses at High Speed
Engine Misses While Idling
Crankshaft Knocks
Noisy Connecting Rods
Noisy Pistons
Noisy Piston Pins
Noisy Valves and Tappets
Vibrations Originating at Engine
Low Oil Pressure
High Oil Pressure
Removal and Installation of Engine
Lifting out Engine
Engine on Revolving Stand An. 22204
Removing Engine and Transmission Assembly
Engine Disassembly
Crankcase Without Oil Sump
Pulling Timing Drive Sprocket
T3 - Backing out Hub-Pulley Lock Screw
Lifting out Crankshaft
Engine Assembly
Fitting Tappets
Reaming Intermediate Camshaft Bushing
Checking Driven Sprocket - to - Camshaft Spacer Clearance
Tightening Camshaft Driven Sprocket Screw
Tightening Hub-Pulley Nut
Installing Crankshaft Front 011 Seal Cover
Tightening Centrifugal 011 Filter Cover
Fitting Oil Sump Gasket
Installing Clutch Assembly
Affixing Sector Scale
Checking Cylinder Barrels
Cylinder Block and Crankcase
Honing Cylinder Barrels
Reboring Cylinder Barrels
Diagram for Measuring Cylinder Bores
Using Dial Indicator to Measure Cylinder Bores
Checking and Grinding Cylinder Head Mating Face
Aligning Cylinder Bore, Preparatory to Boring Operation
Reboring Cylinders
Checking Camshaft Bushings and Seats
Checking Lower Face of Crankcase
Bottom View of Crankcase
Checking and Reaming Tappet Seats
Reaming Tappet Seats on Crankcase
Critical Dimensions of Crankcase
Pistons - Connecting Rods
Checking Piston Clearance in Bore and Piston Pin Clearance in Boss
Piston Upside down
Connecting Rod and Piston Assembly
Checking Piston Clearance in Cylinder Bore
Checking Piston and Connecting Rod Weight
Piston Rings
Piston Ring Side Clearance
Removing Piston Pin
Piston, Pin, Connecting Rod Assembly
Checking Piston Ring Side Clearance
Pressing out Piston Pin
Electric Oven for Heating Connecting Rods
Checking Piston Pin Drag.
Location of Connecting Rods in Oven
Position of Piston to Connecting Rod
Connecting Rod Bearings
Pistons· Connecting Rods
Connecting Rod Bearing Insert Thickness
Crankpin Diameters
Securing Connecting Rod Bearing Caps
Crankshaft and Main Bearings
Checking and Grinding Crankpins and Journals
Crankarm Fillet Specifications
Crankshaft
Flywheel and Ring Gear
Checking Crankpin and Journal Alignment
Checking Crankshaft Balance
Cleaning Oil Passages
Main Bearing Caps with Bearing Inserts in Place
Main Bearing Insert Thickness
Main Bearings
Checking End Play
Fitting Thrust Ring Halves
Oil Seals
Checking Crankshaft End Play
Clutch Shaft Pilot Bushing
Installing Crankshaft Front Seal Cover
Tightening Main Bearing Cap Screws
Cylinder Head
Valves, Valve Guides, Springs and Rockers
Miscellaneous
Cylinder Head Screws Tightening Sequence
Decoking and Cleaning Combustion Chambers
Removing Valves from Cylinder Head
Tightening Head Screws by Means of Torque Wrench
Checking and Grinding Head Bottom Face
Checking and Reseating Valve Seats
Checking Water Seal
Narrowing Valve Seat at Top with 20 Cutter
Valve Seat Cutting Diagrams
Valves
View of Valve Seats in Head
Grinding Valve Face
Valve Guides
Valve Seal Test
Valve Sealing Test
Cylinder Head with Valve Springs and Spark Plugs
Reaming Valve Guides
Valve - Valve Guide Fitting Specifications
Valve Springs
Checking Springs
Critical Dimension. (Metric) of Rockers, Shaft and Supports
Rocker, Shaft and Support Assembly
Rockers
Valve Mechanism
Camshaft and Bushings
Checking and Reaming Bushings
Critical Dimensions (Metric) of Camshaft and Bushings
Fitting Intermediate Camshaft Bushing
Tappets
Push Rods
Tappet· Tappet Seat Fitting Specifications
Valve Timing
Adjusting Valve Tappet Clearance
Tightening Reference
Detail of Engine on Test Bench
Engine Bench Test
Engine on Test Bench
Installing Engine on Test Bench
Horsepower Check-Up
Overhaul after Bench Test
Testing Range of Rebuilt Engines
Lubrication Cooling Fuel System
Engine Lubrication Diagram (Cut-Away
Oil Pump
Oil Pump Assembly
Oil Pump in Place in Crankcase
Centrifugal Oil Filter
Low Oil Pressure Indicator Sending Unit
Oil Pressure Relief Valve
Oil Sump Gaskets
Bonding Oil Sump Gaskets
Oil Pump Fitting Data
Cooling
Directions for Use
Diagram of Engine Cooling System
Directions for Service
Water Pump
Pressure Test
Radiator
Thermostat
Detail Showing Radiator Mounting
Lifting out Radiator from Underside of Car
Thermal Switch
Adjusting Generator and Water Pump Drive Belts Tension
Fitting Thermostat to Engine
Air Cleaner
Air Cleaner Assembly
Fuel System
Cleaning and Inspection
Fuel Pump
Installation and Adjustment
Layout of Fuel Pump Components
Replacing Cleaner Element
Setting Fuel Pump Push Rod Projection
Cleaning and Inspection
Engine Transmlnlon and Dlre,Ential Anembly
Fuel Tank
Removal and Installation
Accelerator Pump
Carburetor
Operation
Instructions for Using the Easy Starting Device
Starting Cold Engine
Warming up Engine
Engine Running Normally
Float Level Adjustment
Easy Starting Device
Float Level Adjustment
Operation
Power Pump
Solex 30 Pib 4 Carburetor
Setting Data of Carburetors
Idling Adjustment
Trouble Diagnosis Guide
Recirculation Device of Blow-By Gases and Oil Vapours
Clutch Transmission Differential
Clutch
Pressure Plate Assembly and Driven Plate
Specifications and Data
Noises Audible on Pedal Depression
The Clutch Grabs
The Clutch Slips
Abnormal Lining Wear
Noises Audible on Pedal Release
Pedal Travel Adjustment
The Clutch Drags
Removing Clutch Throwout Yoke Rod
Clutch Cover Assembly Inspecting Diagram
Specifications and Data
Transmission - Differential
Trouble Diagnosis and Corrections
Transmission
Transmission Assembly
Engagement of 2Nd, 3Rd and 4Th Gears.
Engagement of 1St Gear
Transmission Side Cover Assembly
Noisy Transmission
Transmission Shifts Hard
Transmission Trouble Diagnosis and Corrections
Oil Leakage
Transmission Jumps out of Gear
Side Seetional View of Transmission-Differential Assembly
Prying out Countershaft·drive Pinion Nut Lock Ring
Checking Gear Backlash
Drive Pinion Bearing in Place in Transmission Case
End Sectional View of Transmission Across Shifter Rails
Fitting the Reverse Shaft and Gear Lock Pin
End Sectional View of Transmission Across Shlf1Er Rail
Tightening Shifter Forks
Differential
Noise Diagnosis and Corrections
Noises Due to Excessive Backlash
Thumping
Pulling Differential Cage Roller Bearing Cones
Removing Differential Carrier Caps
Tightening Differential Carrier Cap Screws
Adjusting Final Drive Gear
Drive Pinion Ball Bearing
Fitting Bearing Adjuster Stop Plate
Drive Pinion and Shim Fitting Diagram
Step for Figuring the Thickness of Drive Pinion Shim
Axle Shafts and Slip Joints
Bench Testing Differential Unit
Checking Ring Gear-Ta.pinion Backlash
Checking Ring Gear-To-Pinion Tooth Contact
Checking and Adjusting Ring Gear-To-Pinion Tooth Contact
Disassembling Gearshift Lever
Gearshift Mechanism
Removing Selector Leve(Rod
Front Suspension and Wheels
Excessive Tire Wear
Wheel Bounce
Pull to One Side
Suspension Noise
Wheel Wobble
Pulling Upper Control Arm Bushings
Pulling Wheel Hub Cap
Removing Semi-Elliptic Spring Pin
Tying off Tie Rod from Knuckle Arm
Semi-Elliptic Spring
Center Loaded Spring
Front Suspension Assembly in Place on Car
Spring as Fitted on Car
Control Arm Installed on Fixture A. 74135
Control Arms
Kingpin Housings
Pulling Outer Bearing Cup
Reaming Kingpin Bushings
Steering Knuckles and Wheel Hubs
Thickness of Steering Knuckle Lower Thrust Washers
• Front End Setting Diagram
Instajllng Upper Control Arm Bushings
Installing Kingpin
Pulling Inner Bearing Cup
Installing Wheel Hub Cap
Securing Semi-Elliptic Spring to Body Shell
Staking Steering Knuckle Nut
Checking and Adjusting Front End Geometry
Fitting Camber and Caster Adjusting Shims
Setting Semi-Elliptic Spring at
Checking Camber
Checking Caster
Checking Caster (Second Step)
Front Sway Eliminator
Front Wheels
Check with Wheel off
Hub Cap
Wheel Hub
Check with Wheel on
View of Mechanical Units of Car Front End
Rear Suspension and Wheels
Shock Absorbers
Irregular or Abnormal Tire Wear
Squeaks, Thumps, or Rattles
Pulling Rear Wheel Ball Bearing
Pulling Rear Wheel Hub
Removing Suspension
Adjusting Rear Control Arm
Checking Control Arm and Drum Assembly
Installing Control Arm Bushing
Removing Roller Bearing Cup
Coil Springs
Installing Roller Bearing Cup
Installing Roller Bearing Snap Ring
Installing Suspension
Installing Wheel Shaft Flexible Joint on Work Bench
Left Side Rear Suspension and Wheel Assembly
Securing Rear Control Arm to Body Shell
Loosening Wheel Shaft Flexible Joint Mounting Nut
Replacing Flexible Joint
Taking Wheel Shaft Part Way Qut
Tightening Flexible Joint Mounting Nut
Checking and Adjusting Rear Wheel Toe-In
Installing Coil Spring Compressor
Rear Suspension Assembly in Place on Car
Note on Self-Locking Nuts
Hydraulic Shock Absorbers
Compression Stroke
Detail of Left Side Front Suspension and Wheel
Sectional View of Shock Absorber
Steering System
Steering System and Front Running Gear Units
Hard Steering
Jerky Steering
Front Wheel Shimmy
Rattles
Tire Squeal on Turns
Hard Turning When Stationary
Loose Steering
Side-To-Side Wander
Backing out Sleering Wheel Mounting Nut
Steering Gear
Steering Wheel
Tightening Steering Wheel Mounting Nut
Removing Pitman Arm
Removing Steering Gear
Removing Steering Rods
Steering Gear on Service Fixture
Adjusting Worm Bearings
Sectional View of the Steering Gear at Sector
Adjusting Lash between Worm and Sector
Sectional View of the Steering Gear Across the Worm
Idler Arm and Support
Installing Pitman Arm
Reaming Eccentric Bushing
Steering Rods
Front Wheel Toe-In
Brakes Wheels and Tires
Brakes
Brakes Locked Even after Releasing the Pedal
Locked Brake Pedal
Excessive Effort Required on Pedal
Pedal Yields under Slight Pressure
Spongy Pedal
Excessive Pedal Travel
Reduced Pedal Free Travel
Shoes Drag Permanently on Drums
Master Cylinder
Service Brakes
Unbalanced Braking
Weak Braking
Fluid Reservoir and Lines
Master Cylinder and Wheel Cylinders
Side Section View Across Wheel Cylinder
Wheel Cylinders
Brake Shoes and Linings
Removing Brake Drum
Adjusting Shoe-To-Drum Clearance
Brake Drums
Refacing Brake Shoe Linings
Turning Brake Drum on Lathe
Brake and Clutch Pedal Mounting Board
Brake Pedal and Master Cylinder Assembly
Emergency and Parking Brake
Handbrake Components at Left Side Rear Wheel
Removing Brake and Clutch Pedal Mounting Board
Wheels and Tires
Tire Damages
Uneven Tire Wear
Wheel Balance
Air Conditioning System
Windshield Washer
Car Air Conditioner
MID-Season Ventilation
Summer Ventilation
Winter Heating
Fitting Electrofan
Removing Air Conditioner
Withdrawing Air Conditioner
Bleeding Cooling System
Removing Heater Radiator Cock
Chassis Tightening Reference
Electrical
Battery
Arrangement of Battery in Car
Checking State of Charge
Electrolyte Level
Conditions Entailing Battery Rundown
Recharging Battery with External Means
Generator
Fiat D 90/12/16/3 Cs Generator Tor Assembly
Bench Testing
Motoring Test
Operation Tests
Wiring Diagram for Motoring Test
Heating Test
Mechanical Characteristics Check Data
Ohmic Resistance Test
Broken Field Winding, with Shorted or Grounded Coils
Commutator Re-Turning
Service Procedures
Replacing Brushes
Shorted, Grounded or Open Armature Coil
Generator Regulator
Checking Cutout Relay
Checking Current Regulator
Checking Voltage Regulator
Opening the Regulator
Replacing Regulating Resistor
Adjusting Cutout Relay
Adjustments
Adjusting Current Regulator
Adjusting Voltage Regulator
Operation Test and Sealing
Indicator Light Fails to Go out
Trouble Diagnosis of Recharging System
No-Charge Indicator Fails to Light up
No-Charge Indicator Goes out but then Glows Feebly
No-Charge Indicator Goes out at High Speed
No-Charge Indicator Lights up and Goes out Regularly
Uneven Wear of Commutator Bars in Generator
Rapid Wear of Generator Brushes
Starting Motor
Motor Fails to Operate
Motor Operates but very Slowly
Trouble Diagnosis and Corrections
Bench Testing
Operation Tests
Mechanical Characteristics Check Data
Ohmic Resistance Test
Armature Disassembly and Assembly
Replacing Brushes
Replacing Field Winding
Replacing Starter Drive Mechanism
Replacing Starter Switch
Returning Commutator
Service Procedures
Ignition System
Service Data
Checking Distributor on Test Bench
Ignition Distributor
Vacuum Advance
Checking the Automatic Advance Curve
Checking the Vacuum-Operated Advance Device
Checking Timing
Checking Breaker Contact Points Opening-Closing Rate
Checking Distributor Noises
Checking Mechanical Components
Grounding Insulation
Ignition Coil
Measuring Spark Length
Test with Shunted Spark Tester
Electric Test
Slowing a Spark Plug after Sanding and Washing
Testing a Spark Plug for Gas Tightness
Tightness Test
Checking Ignition Timing
Ignition Timing
View of Engine Compartment with Disassembly in Progress
Ignition Faulty or Completely Absent
Ignition System Trouble Diagnosis
Ignition Coil Unserviceable
Ignition Extremely Advanced
Lighting System
Headlamp Without Rim
Headlights
Type
Front Parking and Direction Signal Lights
Rear Parking Stop and Direction Signal Lights with Reflector Lens
Side Direction Signal Lights
Instrument Cluster Lights
License Plate Light
Rear View Mirror Light
Electrical System Fuses
Engine Compartment Light
Fuses
Instruments and Accessories
Blinking Direction Signals
Voltage
Close-Up View of the Instrument Cluster
Coolant Temperature Warning Light
Fuel Gauge
Instrument Cluster
Rear View of the Instrument Cluster
Arrangement of Windshield Wiper
Horn
Windshield Wiper
Antenna
Horn Diagram
Radio Receiver
Detail of Antenna Mounting
Radio Set
Interference Suppression Devices
Loudspeaker
Setting Antenna Trimmer
Body
Left Side View of Car with Door Opened
Front View of Car
Rear View of Car
View of Front Luggage Compartment
Doors
Removing Ventilator Window
Withdrawing Ventilator Window Assembly
Removing Door Handle
Removing Drop Glass
Taking down Door Lock and Control
Taking down Window Regulator
Adjusting Drop Glass Travel
Door Alignment
Door and Window Conlrols
Interior View of Door Latch
Adjusting Door Lock Striker Plate
Engine Compartment Lid Catch
Front Compartment Lid
Repositioning Front Compartment Tid
Engine Compartment Lid
Glazing
Removing and Installing Windshield Glass
Back Window Glass
Bumpers
Rear Quarter Window Glasses
Seats
Instrument Panel Lining
Removing Instrument Panel Lining
Repairing Accidented Cars
Strap Hangers
Checking Underbody with Gauge A. 74141
Leakage Check
Body Upkeep
Cleaning Upholstery Cloth
Glass Panes
Washing the Car
Maintenance
Tool Equipment
Lubricant Specifications
Special Service Tools
Coupe Roadster Family Idroconvert
Differences from Sedan Version
Detail of Front Seat Back Rest Catch
Detail of Rear Quarter Door Window Adjuster
General Specifications
Pistons
Con Rods
Valves - Valve Seats - Springs
Valve Gear
Specifications and Fits of New Parts
Brake Lining-To-Disc Clearance Self-Adjusting Device
Front Brake Specifications
Removing Bracket Clamp Pin Lock Plate
Replacing Lining Pads
Side Sectional View of the Disc Brake Caliper
Brake Calipers
Disassembling and Assembling Disc Brakes
Fitting Brake Caliper
Removing Brake Caliper Self-Adjusting Pin Nut
Brake Discs
Spark Plugs
Aiming Headlights
Headlamps
Interior View of Right Side Head Lamp
Front Corner Parking and Direction Signal Lights
Rear Parking, Direction Signal and Stop Lights with Reflector Lens
Car Interior Lights
License Plate Lights
Specifications and Data
Inspection and Repair
Removal and Disassembly
Assembly and Installation
Checking and Adjusting Front End Camber and Caster
Coil Springs
Rear Suspension
Setting
Specifications and Data
Steering
Inspection and Repair
Removal and Disassembly of Steering Gear
Assembly
Idler Arm and Support
Wheels and Tires
Adjusting Shoe-Lo-Drum Clearance
Brakes
Hydraulic Brakes Specifications and Data
Air Conditioning
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This manual is also suitable for:
850 coupe 1968
850 roadster 1968
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