Fiat 850 Roadster 1968 Vintage Car Manuals

Manuals and User Guides for Fiat 850 Roadster 1968 Vintage Car. We have 1 Fiat 850 Roadster 1968 Vintage Car manual available for free PDF download: Shop Manual

Fiat 850 Roadster 1968 Shop Manual

Fiat 850 Roadster 1968 Shop Manual (377 pages)

Brand: Fiat | Category: Automobile | Size: 82 MB

Table of Contents

Section Index
2
General Information
4
Main Specifications
6
Leading Dimensions of Car (Metric)
7
Capacities
8
Unit Identification Data
9
Spare Parts
9
Car Keys
9
Table of Contents
10
Engine
10
Side Sectional View of Engine Across Cylinders
11
Main Specifications
12
Removal and Installation
12
Disassembly
12
Assembly
12
- Engine Trouble Diagnosis and Corrections
  14
- Engine will Not Start
  14
- Engine Stalls
  15
- Engine Has no Power
  16
- Engine Lopes or Misses at Idle
  17
- Engine Misses at High Speed
  18
- Engine Misses While Idling
  19
- Crankshaft Knocks
  19
- Noisy Connecting Rods
  20
- Noisy Pistons
  21
- Noisy Piston Pins
  21
- Noisy Valves and Tappets
  21
- Vibrations Originating at Engine
  22
- Low Oil Pressure
  22
- High Oil Pressure
  22
- Removal and Installation of Engine
  24
- Lifting out Engine
  24
- Engine on Revolving Stand An. 22204
  25
- Removing Engine and Transmission Assembly
  25
- Engine Disassembly
  25
- Crankcase Without Oil Sump
  26
- Pulling Timing Drive Sprocket
  26
- T3 - Backing out Hub-Pulley Lock Screw
  26
- Lifting out Crankshaft
  26
- Engine Assembly
  27
- Fitting Tappets
  27
- Reaming Intermediate Camshaft Bushing
  27
- Checking Driven Sprocket - to - Camshaft Spacer Clearance
  27
- Tightening Camshaft Driven Sprocket Screw
  28
- Tightening Hub-Pulley Nut
  28
- Installing Crankshaft Front 011 Seal Cover
  28
- Tightening Centrifugal 011 Filter Cover
  28
- Fitting Oil Sump Gasket
  29
- Installing Clutch Assembly
  29
- Affixing Sector Scale
  29
- Checking Cylinder Barrels
  30
Cylinder Block and Crankcase
30
Pistons· Connecting Rods
44
- Connecting Rod Bearing Insert Thickness
  45
- Crankpin Diameters
  45
- Securing Connecting Rod Bearing Caps
  45
- Crankshaft and Main Bearings
  46
- Checking and Grinding Crankpins and Journals
  47
- Crankarm Fillet Specifications
  48
- Crankshaft
  48
- Flywheel and Ring Gear
  48
- Checking Crankpin and Journal Alignment
  49
- Checking Crankshaft Balance
  49
- Cleaning Oil Passages
  49
- Main Bearing Caps with Bearing Inserts in Place
  50
- Main Bearing Insert Thickness
  50
- Main Bearings
  50
- Checking End Play
  51
- Fitting Thrust Ring Halves
  51
- Oil Seals
  51
- Checking Crankshaft End Play
  52
- Clutch Shaft Pilot Bushing
  52
- Installing Crankshaft Front Seal Cover
  52
- Tightening Main Bearing Cap Screws
  52
- Cylinder Head
  54
- Valves, Valve Guides, Springs and Rockers
  54
- Miscellaneous
  55
- Cylinder Head Screws Tightening Sequence
  56
- Decoking and Cleaning Combustion Chambers
  56
- Removing Valves from Cylinder Head
  56
- Tightening Head Screws by Means of Torque Wrench
  56
- Checking and Grinding Head Bottom Face
  57
- Checking and Reseating Valve Seats
  57
- Checking Water Seal
  57
- Narrowing Valve Seat at Top with 20 Cutter
  59
- Valve Seat Cutting Diagrams
  59
- Valves
  59
- View of Valve Seats in Head
  59
- Grinding Valve Face
  60
- Valve Guides
  60
- Valve Seal Test
  60
- Valve Sealing Test
  60
- Cylinder Head with Valve Springs and Spark Plugs
  61
- Reaming Valve Guides
  61
- Valve - Valve Guide Fitting Specifications
  61
- Valve Springs
  61
- Checking Springs
  62
- Critical Dimension. (Metric) of Rockers, Shaft and Supports
  62
- Rocker, Shaft and Support Assembly
  62
- Rockers
  62
- Valve Mechanism
  64
- Camshaft and Bushings
  65
- Checking and Reaming Bushings
  65
- Critical Dimensions (Metric) of Camshaft and Bushings
  65
- Fitting Intermediate Camshaft Bushing
  66
- Tappets
  66
- Push Rods
  67
- Tappet· Tappet Seat Fitting Specifications
  67
- Valve Timing
  67
- Adjusting Valve Tappet Clearance
  68
- Tightening Reference
  69
- Detail of Engine on Test Bench
  70
- Engine Bench Test
  70
- Engine on Test Bench
  70
- Installing Engine on Test Bench
  70
- Horsepower Check-Up
  71
- Overhaul after Bench Test
  71
- Testing Range of Rebuilt Engines
  71
- Lubrication Cooling Fuel System
  72
- Engine Lubrication Diagram (Cut-Away
  73
- Oil Pump
  74
- Oil Pump Assembly
  74
- Oil Pump in Place in Crankcase
  74
- Centrifugal Oil Filter
  75
- Low Oil Pressure Indicator Sending Unit
  75
- Oil Pressure Relief Valve
  75
- Oil Sump Gaskets
  75
- Bonding Oil Sump Gaskets
  76
- Oil Pump Fitting Data
  76
- Cooling
  77
- Directions for Use
  77
- Diagram of Engine Cooling System
  78
- Directions for Service
  78
- Water Pump
  79
- Pressure Test
  80
- Radiator
  80
- Thermostat
  80
- Detail Showing Radiator Mounting
  81
- Lifting out Radiator from Underside of Car
  81
- Thermal Switch
  81
- Adjusting Generator and Water Pump Drive Belts Tension
  82
- Fitting Thermostat to Engine
  82
- Air Cleaner
  83
- Air Cleaner Assembly
  83
- Fuel System
  83
- Cleaning and Inspection
  84
- Fuel Pump
  84
- Installation and Adjustment
  84
- Cleaning and Inspection
  85
- Engine Transmlnlon and Dlre,Ential Anembly
  85
- Fuel Tank
  85
- Removal and Installation
  85
- Accelerator Pump
  86
- Carburetor
  86
- Operation
  86
- Instructions for Using the Easy Starting Device
  88
  - Starting Cold Engine
    88
  - Warming up Engine
    88
  - Engine Running Normally
    89
- Float Level Adjustment
  89
- Easy Starting Device
  90
- Float Level Adjustment
  90
- Operation
  90
- Power Pump
  90
- Solex 30 Pib 4 Carburetor
  90
- Setting Data of Carburetors
  91
- Idling Adjustment
  92
- Trouble Diagnosis Guide
  92
- Recirculation Device of Blow-By Gases and Oil Vapours
  93
  - Clutch Transmission Differential
    94
  - Clutch
    96
  - Pressure Plate Assembly and Driven Plate
    96
  - Specifications and Data
    96
  - Noises Audible on Pedal Depression
    97
  - The Clutch Grabs
    97
  - The Clutch Slips
    97
  - Abnormal Lining Wear
    98
  - Noises Audible on Pedal Release
    98
  - Pedal Travel Adjustment
    99
  - The Clutch Drags
    99
  - Removing Clutch Throwout Yoke Rod
    100
  - Clutch Cover Assembly Inspecting Diagram
    101
- Specifications and Data
  102
- Transmission - Differential
  102
- Trouble Diagnosis and Corrections
  102
  - Transmission
    104
  - Transmission Assembly
    104
  - Engagement of 2Nd, 3Rd and 4Th Gears.
    105
  - Engagement of 1St Gear
    106
  - Transmission Side Cover Assembly
    106
  - Noisy Transmission
    107
  - Transmission Shifts Hard
    107
  - Transmission Trouble Diagnosis and Corrections
    107
  - Oil Leakage
    108
  - Transmission Jumps out of Gear
    108
  - Side Seetional View of Transmission-Differential Assembly
    109
  - Prying out Countershaft·drive Pinion Nut Lock Ring
    110
  - Checking Gear Backlash
    111
  - Drive Pinion Bearing in Place in Transmission Case
    111
  - End Sectional View of Transmission Across Shifter Rails
    112
  - Fitting the Reverse Shaft and Gear Lock Pin
    112
  - End Sectional View of Transmission Across Shlf1Er Rail
    113
  - Tightening Shifter Forks
    113
  - Differential
    114
  - Noise Diagnosis and Corrections
    114
  - Noises Due to Excessive Backlash
    114
  - Thumping
    114
  - Pulling Differential Cage Roller Bearing Cones
    115
  - Removing Differential Carrier Caps
    115
  - Tightening Differential Carrier Cap Screws
    115
  - Adjusting Final Drive Gear
    116
  - Drive Pinion Ball Bearing
    116
  - Fitting Bearing Adjuster Stop Plate
    116
  - Drive Pinion and Shim Fitting Diagram
    117
  - Step for Figuring the Thickness of Drive Pinion Shim
    117
- Axle Shafts and Slip Joints
  119
- Gearshift Mechanism
  121
  - Removing Selector Leve(Rod
    121
  - Front Suspension and Wheels
    122
  - Excessive Tire Wear
    126
  - Wheel Bounce
    126
  - Pull to One Side
    127
  - Suspension Noise
    127
  - Wheel Wobble
    127
  - Pulling Upper Control Arm Bushings
    128
  - Pulling Wheel Hub Cap
    128
  - Removing Semi-Elliptic Spring Pin
    128
  - Tying off Tie Rod from Knuckle Arm
    128
  - Semi-Elliptic Spring
    129
  - Center Loaded Spring
    130
  - Front Suspension Assembly in Place on Car
    130
  - Spring as Fitted on Car
    130
  - Control Arm Installed on Fixture A. 74135
    131
  - Control Arms
    131
  - Kingpin Housings
    131
  - Pulling Outer Bearing Cup
    132
  - Reaming Kingpin Bushings
    132
  - Steering Knuckles and Wheel Hubs
    132
  - Thickness of Steering Knuckle Lower Thrust Washers
    132
  - • Front End Setting Diagram
    133
  - Instajllng Upper Control Arm Bushings
    134
  - Installing Kingpin
    134
  - Pulling Inner Bearing Cup
    134
  - Installing Wheel Hub Cap
    135
  - Securing Semi-Elliptic Spring to Body Shell
    135
  - Staking Steering Knuckle Nut
    135
  - Checking and Adjusting Front End Geometry
    136
  - Fitting Camber and Caster Adjusting Shims
    136
  - Setting Semi-Elliptic Spring at
    136
  - Checking Camber
    137
  - Checking Caster
    138
  - Checking Caster (Second Step)
    138
  - Front Sway Eliminator
    138
  - Front Wheels
    138
  - Check with Wheel off
    139
  - Hub Cap
    139
  - Wheel Hub
    139
  - Check with Wheel on
    140
  - View of Mechanical Units of Car Front End
    140
  - Rear Suspension and Wheels
    142
  - Shock Absorbers
    142
  - Irregular or Abnormal Tire Wear
    146
  - Squeaks, Thumps, or Rattles
    146
  - Pulling Rear Wheel Ball Bearing
    148
  - Pulling Rear Wheel Hub
    148
  - Removing Suspension
    148
  - Adjusting Rear Control Arm
    149
  - Checking Control Arm and Drum Assembly
    149
  - Installing Control Arm Bushing
    149
  - Removing Roller Bearing Cup
    149
  - Coil Springs
    150
  - Installing Roller Bearing Cup
    150
  - Installing Roller Bearing Snap Ring
    150
  - Installing Suspension
    151
  - Installing Wheel Shaft Flexible Joint on Work Bench
    151
  - Left Side Rear Suspension and Wheel Assembly
    151
  - Securing Rear Control Arm to Body Shell
    151
  - Loosening Wheel Shaft Flexible Joint Mounting Nut
    152
  - Replacing Flexible Joint
    152
  - Taking Wheel Shaft Part Way Qut
    152
  - Tightening Flexible Joint Mounting Nut
    152
  - Checking and Adjusting Rear Wheel Toe-In
    154
  - Installing Coil Spring Compressor
    154
  - Rear Suspension Assembly in Place on Car
    154
  - Note on Self-Locking Nuts
    155
  - Hydraulic Shock Absorbers
    156
  - Compression Stroke
    157
  - Detail of Left Side Front Suspension and Wheel
    157
  - Sectional View of Shock Absorber
    157
  - Steering System
    158
  - Steering System and Front Running Gear Units
    159
  - Hard Steering
    161
  - Jerky Steering
    161
  - Front Wheel Shimmy
    162
  - Rattles
    162
  - Tire Squeal on Turns
    162
  - Hard Turning When Stationary
    163
  - Loose Steering
    163
  - Side-To-Side Wander
    163
  - Backing out Sleering Wheel Mounting Nut
    164
  - Steering Gear
    164
  - Steering Wheel
    164
  - Tightening Steering Wheel Mounting Nut
    164
  - Removing Pitman Arm
    165
  - Removing Steering Gear
    165
  - Removing Steering Rods
    165
  - Steering Gear on Service Fixture
    165
  - Adjusting Worm Bearings
    166
  - Sectional View of the Steering Gear at Sector
    166
  - Adjusting Lash between Worm and Sector
    167
  - Sectional View of the Steering Gear Across the Worm
    167
  - Idler Arm and Support
    168
  - Installing Pitman Arm
    168
  - Reaming Eccentric Bushing
    168
  - Steering Rods
    168
  - Front Wheel Toe-In
    169
  - Brakes Wheels and Tires
    170
  - Brakes
    171
  - Brakes Locked Even after Releasing the Pedal
    172
  - Locked Brake Pedal
    172
  - Excessive Effort Required on Pedal
    173
  - Pedal Yields under Slight Pressure
    173
  - Spongy Pedal
    173
  - Excessive Pedal Travel
    174
  - Reduced Pedal Free Travel
    174
  - Shoes Drag Permanently on Drums
    174
  - Master Cylinder
    175
  - Service Brakes
    175
  - Unbalanced Braking
    175
  - Weak Braking
    175
  - Fluid Reservoir and Lines
    176
  - Master Cylinder and Wheel Cylinders
    176
  - Side Section View Across Wheel Cylinder
    176
  - Wheel Cylinders
    176
  - Brake Shoes and Linings
    177
  - Removing Brake Drum
    177
  - Adjusting Shoe-To-Drum Clearance
    178
  - Brake Drums
    178
  - Refacing Brake Shoe Linings
    178
  - Turning Brake Drum on Lathe
    178
  - Brake and Clutch Pedal Mounting Board
    179
  - Brake Pedal and Master Cylinder Assembly
    180
  - Emergency and Parking Brake
    180
  - Handbrake Components at Left Side Rear Wheel
    181
  - Removing Brake and Clutch Pedal Mounting Board
    181
  - Wheels and Tires
    182
  - Tire Damages
    183
  - Uneven Tire Wear
    183
  - Wheel Balance
    184
  - Air Conditioning System
    185
  - Windshield Washer
    185
  - Car Air Conditioner
    187
  - MID-Season Ventilation
    187
  - Summer Ventilation
    187
  - Winter Heating
    187
  - Fitting Electrofan
    188
  - Removing Air Conditioner
    188
  - Withdrawing Air Conditioner
    188
  - Bleeding Cooling System
    189
  - Removing Heater Radiator Cock
    189
  - Chassis Tightening Reference
    191
  - Electrical
    195
  - Battery
    196
  - Arrangement of Battery in Car
    197
  - Checking State of Charge
    197
  - Electrolyte Level
    197
  - Conditions Entailing Battery Rundown
    198
  - Recharging Battery with External Means
    198
  - Generator
    199
  - Fiat D 90/12/16/3 Cs Generator Tor Assembly
    200
  - Bench Testing
    201
  - Motoring Test
    201
  - Operation Tests
    201
  - Wiring Diagram for Motoring Test
    201
  - Heating Test
    202
  - Mechanical Characteristics Check Data
    202
  - Ohmic Resistance Test
    202
  - Broken Field Winding, with Shorted or Grounded Coils
    203
  - Commutator Re-Turning
    203
  - Service Procedures
    203
  - Replacing Brushes
    204
  - Shorted, Grounded or Open Armature Coil
    204
  - Generator Regulator
    205
  - Checking Cutout Relay
    206
  - Checking Current Regulator
    207
  - Checking Voltage Regulator
    207
  - Opening the Regulator
    208
  - Replacing Regulating Resistor
    208
  - Adjusting Cutout Relay
    210
  - Adjustments
    210
  - Adjusting Current Regulator
    211
  - Adjusting Voltage Regulator
    211
  - Operation Test and Sealing
    211
  - Indicator Light Fails to Go out
    212
  - Trouble Diagnosis of Recharging System
    212
  - No-Charge Indicator Fails to Light up
    213
  - No-Charge Indicator Goes out but then Glows Feebly
    213
  - No-Charge Indicator Goes out at High Speed
    214
  - No-Charge Indicator Lights up and Goes out Regularly
    214
  - Uneven Wear of Commutator Bars in Generator
    215
  - Rapid Wear of Generator Brushes
    216
  - Starting Motor
    217
  - Motor Fails to Operate
    219
  - Motor Operates but very Slowly
    219
- Trouble Diagnosis and Corrections
  219
- Bench Testing
  220
- Operation Tests
  220
- Mechanical Characteristics Check Data
  221
- Ohmic Resistance Test
  221
- Armature Disassembly and Assembly
  222
- Replacing Brushes
  222
- Replacing Field Winding
  222
- Replacing Starter Drive Mechanism
  222
- Replacing Starter Switch
  222
- Returning Commutator
  222
- Service Procedures
  222
- Ignition System
  223
- Service Data
  223
  - Checking Distributor on Test Bench
    224
  - Ignition Distributor
    224
  - Vacuum Advance
    224
  - Checking the Automatic Advance Curve
    225
  - Checking the Vacuum-Operated Advance Device
    225
  - Checking Timing
    225
  - Checking Breaker Contact Points Opening-Closing Rate
    226
  - Checking Distributor Noises
    226
  - Checking Mechanical Components
    226
  - Grounding Insulation
    227
  - Ignition Coil
    227
  - Measuring Spark Length
    227
  - Test with Shunted Spark Tester
    227
  - Electric Test
    228
  - Slowing a Spark Plug after Sanding and Washing
    228
  - Testing a Spark Plug for Gas Tightness
    228
  - Tightness Test
    228
  - Checking Ignition Timing
    229
  - Ignition Timing
    229
  - View of Engine Compartment with Disassembly in Progress
    229
  - Ignition Faulty or Completely Absent
    230
  - Ignition System Trouble Diagnosis
    230
  - Ignition Coil Unserviceable
    231
  - Ignition Extremely Advanced
    231
  - Lighting System
    232
  - Headlamp Without Rim
    235
  - Headlights
    235
- Type
  235
  - Front Parking and Direction Signal Lights
    236
  - Rear Parking Stop and Direction Signal Lights with Reflector Lens
    236
  - Side Direction Signal Lights
    236
  - Instrument Cluster Lights
    237
  - License Plate Light
    237
  - Rear View Mirror Light
    237
  - Electrical System Fuses
    238
  - Engine Compartment Light
    238
  - Fuses
    238
  - Instruments and Accessories
    239
  - Blinking Direction Signals
    240
- Voltage
  240
  - Close-Up View of the Instrument Cluster
    241
  - Coolant Temperature Warning Light
    242
  - Fuel Gauge
    242
  - Instrument Cluster
    242
  - Rear View of the Instrument Cluster
    242
  - Arrangement of Windshield Wiper
    243
  - Horn
    243
  - Windshield Wiper
    243
  - Antenna
    244
  - Horn Diagram
    244
  - Radio Receiver
    244
  - Detail of Antenna Mounting
    245
  - Radio Set
    245
  - Interference Suppression Devices
    246
  - Loudspeaker
    246
  - Setting Antenna Trimmer
    246
  - Body
    247
  - Left Side View of Car with Door Opened
    249
  - Front View of Car
    250
  - Rear View of Car
    250
  - View of Front Luggage Compartment
    250
  - Doors
    251
  - Removing Ventilator Window
    251
  - Withdrawing Ventilator Window Assembly
    251
  - Removing Door Handle
    252
  - Removing Drop Glass
    252
  - Taking down Door Lock and Control
    252
  - Taking down Window Regulator
    252
  - Adjusting Drop Glass Travel
    253
  - Door Alignment
    253
  - Door and Window Conlrols
    253
  - Interior View of Door Latch
    253
  - Adjusting Door Lock Striker Plate
    254
  - Engine Compartment Lid Catch
    254
  - Front Compartment Lid
    254
  - Repositioning Front Compartment Tid
    254
  - Engine Compartment Lid
    255
  - Glazing
    255
  - Removing and Installing Windshield Glass
    255
  - Back Window Glass
    256
  - Bumpers
    256
  - Rear Quarter Window Glasses
    256
  - Seats
    256
  - Instrument Panel Lining
    257
  - Removing Instrument Panel Lining
    257
  - Repairing Accidented Cars
    257
  - Strap Hangers
    257
  - Checking Underbody with Gauge A. 74141
    258
  - Leakage Check
    258
  - Body Upkeep
    259
  - Cleaning Upholstery Cloth
    259
  - Glass Panes
    259
  - Washing the Car
    259
  - Maintenance
    260
  - Tool Equipment
    260
  - Lubricant Specifications
    262
  - Special Service Tools
    263
  - Coupe Roadster Family Idroconvert
    266
  - Differences from Sedan Version
    268
  - Detail of Front Seat Back Rest Catch
    270
  - Detail of Rear Quarter Door Window Adjuster
    270
  - General Specifications
    271
  - Pistons
    272
  - Con Rods
    273
  - Valves - Valve Seats - Springs
    273
  - Valve Gear
    274
  - Specifications and Fits of New Parts
    275
  - Brake Lining-To-Disc Clearance Self-Adjusting Device
    286
  - Front Brake Specifications
    286
  - Removing Bracket Clamp Pin Lock Plate
    287
  - Replacing Lining Pads
    287
  - Side Sectional View of the Disc Brake Caliper
    287
  - Brake Calipers
    288
  - Disassembling and Assembling Disc Brakes
    288
  - Fitting Brake Caliper
    289
  - Removing Brake Caliper Self-Adjusting Pin Nut
    289
  - Brake Discs
    290
  - Spark Plugs
    291
  - Aiming Headlights
    308
  - Headlamps
    308
  - Interior View of Right Side Head Lamp
    308
  - Front Corner Parking and Direction Signal Lights
    309
  - Rear Parking, Direction Signal and Stop Lights with Reflector Lens
    309
  - Car Interior Lights
    310
  - License Plate Lights
    310
- Specifications and Data
  323
- Inspection and Repair
  324
- Removal and Disassembly
  324
- Assembly and Installation
  325
- Checking and Adjusting Front End Camber and Caster
  327
- Coil Springs
  328
- Rear Suspension
  328
- Setting
  328
- Specifications and Data
  329
- Steering
  329
- Inspection and Repair
  330
- Removal and Disassembly of Steering Gear
  330
- Assembly
  331
- Idler Arm and Support
  332
- Wheels and Tires
  332
- Adjusting Shoe-Lo-Drum Clearance
  333
- Brakes
  333
- Hydraulic Brakes Specifications and Data
  333
- Air Conditioning
  336

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