Fiat X 1/9 1977 Manuals

Manuals and User Guides for Fiat X 1/9 1977. We have 1 Fiat X 1/9 1977 manual available for free PDF download: Service Manual

Fiat X 1/9 1977 Service Manual (348 pages)

Brand: Fiat | Category: Automobile | Size: 40.65 MB

Introduction
3
How to Use the Manual
3
General Information - Maintenance Contents
4
Product View
5
General Information
5
Engine Specifications
6
Fuel System
6
Lubrication System
6
Cooling System
6
Chassis Specifications
7
Weights - Performances
8
Dimensions
8
Capacities
9
Identification Data
10
Spare Parts
11
Car Keys
11
Maintenance
12
Tune-Up
13
Spark Plugs
13
Valve Clearance
13
Ignition Distributor
14
Fuel Filter
15
Air Cleaner
15
Engine Oil
15
Air Pump Filter
16
Ignition Timing
16
Fiat Lubricant Specifications
18
Engine Contents
19
Cylinder Block-Con-Rods
20
Pistons - Pins - Rings
21
Cylinder Head
22
Valve Springs
22
Valve Mechanism - Camshaft
23
Auxiliary Shaft
23
Crankshaft - Main Bearings
24
Fuel System
25
Lubrication
26
Tightening Reference
27
Longitudinal Section of Engine Cylinders
28
Engine Specifications
28
Cross Section of Engine through Cylinder
29
Power Plant Mounts
30
Power Plant Removal
30
Crankcase and Cylinder Head
34
Removing Cylinder Head
34
Checking Cylinder Head Gasket Surface
36
Checking Depth of Combstion Chambers
36
Inspecting and Refacing Valve Seats and Valves
37
Cylinder Head Torqueing Sequence
39
Crankcase
40
Checking Cylinder Bores
40
Oil Sump and Crankcase Covers
42
Crankshaft and Flywheel
44
Connecting Rods and Pistons
47
Pistons-Connecting Rods
47
Checks
47
Connecting Rods and Pistons
49
Camshaft Mechanism
51
Replacing Timing Belt
51
Valve Mechanism
53
Camshaft
53
Exploded View of Valve Mechanism Components
53
Main Data on Camshaft and Bores in Housing
53
Main Data of Auxiliary Shaft and Bushing
54
Replacing Tappets and Valve Guides
55
Model X 1/9
56
Fuel Tank and Lines
59
Fuel Evaporative Emission Control System
59
Fuel Pump and Lines
61
Fuel Pump Removal
61
Inspections
61
Adjustment
62
Carburetor and Air Cleaner
63
Float Level Setting
63
Idle Speed Adjustment
63
Idle Co Adjustment
63
Exploded View of Carburetor
64
Choke
65
Idle and Transfer
65
Acceleratig Pump
65
Recirculating Device of Blow-By Gases
65
Cruise
66
Air Cleaner Removal and Installation
67
Carburetor Cooling Fan
68
Cooling Fan Removal and Installation
68
Thermostatic Switch Removal
68
Exhaust Pipe
69
Removal
69
Exhaust Emission Control System
71
Air Pump Removal and Installation
72
Air Injection Manifold Removal and Installation
72
Exploded View of Engine Lubrication System Components
73
Engine Lubrication Diagram
74
Oil Pump Removal
75
Inspection
75
Oil Filter Replacement
76
Crankcase Emission Control System
77
Radiator
79
Inspecting Cooling System
79
Water Pump and Ducts
81
Water Pump Removal and Installation
81
Longitudinal Section of Water Pump
81
Thermostat Removal
82
Electric Fan Operation
83
Exploded View of Fan Removal
83
Tool Equipment
85
Clutch Contents
86
Clutch Specifications
87
Clutch Cover and Clutch Disc with Linings
88
Clutch Release Hydraulic Control
89
Section of Clutch Assembly and Thrust Pad
89
Clutch Release Hydraulic Circuit
89
Section Thru Forked Lever and Release Sleeve
89
Fluid Check
90
Bleeding Clutch Circuit
90
Clutch Pedal Release Travel
90
Operating Cylinder Adjustment
91
Clutch Release Control Components
91
Master Cylinder
92
Removal and Installation
92
Exploded View of Master Cylinder
92
Operating Cylinder
93
Exploded View of Operating Cylinder
93
Removal and Installation
93
Clutch
94
18A Tool Equipment
94
Transmission - Differential Contents
95
Speedometer Sproket Support Section
96
Longitudinal Section of Gearshift Rod
96
Section through Reverse Idle Gear
96
Longitudinal Section of Transmission
96
Outer Gearshift Control
97
Adjusting Gearshift Linkage
98
Gearshift Control Assembly
98
Axle Shaft
99
Left Axle Shaft Assembly
102
Differential Gear Train
103
Disassembly and Assembly
103
Differential Section
104
Exploded View of Differential Assembly
105
Differential Bearing Setting
106
21A-27A Tool Equipment
108
Brakes Contents
109
Brakes Specifications
110
Hydraulic Brakes and Hand Brake System
111
Brake Master Cylinder
112
Bleeding Hydraulic System
113
Front and Rear Wheel Brakes
114
Replacing Wheel Brake Calipers
114
Brake Disc Inspection
115
Refacing Brake Disc
115
Front Brake Caliper and Bracket Components
116
Overhaul Front Caliper
116
Rear Brake Caliper and Bracket Components
118
Overhaul Rear Caliper
118
Adjusting Hand Brake
120
Hand Brake Linkage
120
33A Tool Equipment
121
Steering System Contents
122
Steering System Specifications
123
Steering Column and Gear Disassembled
124
Cross Section of Steering Column
125
Steering Gear
125
Steering Shaft
126
Steering Box
127
Unmodified Rack and Steering Gear Cross Section
128
Modified Rack and Steering Gear Cross Section
129
Disassembly
130
Reassembly and Adjustment
130
Steering Box - Model X 1/9
132
Steering Box Section Across Drive Pinion
132
Unmodified/Modified Steering Box
133
Front Wheel Toe-In
134
41A Tool Equipment
134
Suspension and Wheels Contents
135
Suspension and Wheels Specifications
136
Front Suspension
136
Front Suspension
140
Front Wheel Alignment
144
Coil Springs
145
Front Shock Absorbers and Bars
146
Control Arm
146
Exploded View of Control Arm Componets
146
Strut Bar Attachment Points
148
Exploded View of Strut Bar Attachments to Body and Control Arm
148
Rear Suspension
150
Rear Wheel Alignment
152
View of Control Arm Attachment Points
154
Exploded View of Control Arm
154
Coil Springs
154
Shock Absorbers
156
Removal and Installation Front and Rear
156
Front Shock Absorbers Attachments
157
Rear Shock Absorber Attachments
157
Disassembly and Assembly
158
Wheels
160
Front Wheel Hub Removal and Installation
160
Electrical Contents
164
Electrical Specifications
165
Electrical Specifications
167
Electrical Wiring Diagram
171
Ignition
172
Exploded View of Ignition Distributor
173
Ignition Coil
174
Starting
176
Starter Disassembly and Assembly
176
Changing Brushes
178
Replacing Field Coils
178
Refacing Commutator
178
Longitudinal Section of Starter Assembly
179
Cross Section through Pinion Drive
179
Section through Pole Shoes and Field Winding
179
Section through Commutator End Frame and View of Brushes
179
Alternator
180
Exploded View of Alternator
180
Lighting
182
Headlight Adjustment
182
Retractable Headlight Motor Replacement
183
Fuses
183
Instruments and Controls
184
Seatbelt Interlock System
185
Checkout
185
Instruments and Controls
185
Seatbelt Interlock Checkout (1974 Models)
186
Body Contents
188
General Information
189
Body
189
Instrument Panel
191
View of Instrument Panel Components
193
Body Shell-Sheet Metal
195
Alignment
195
Dust and Water Leaks
195
Body Shell Inner Components
198
Body Shell Outer Components
199
Hard Top
200
Exploded View of Hard Top Components
200
Doors
202
Removing Door Panel
202
Window Adjustment
202
Door Lock Adjustment
203
Exploded View of Door
204
Windshield
206
Self-Adhesive Moltoprene on Glass
206
Back Window
208
Front Luggage Compartment Lid Replacement and Adjustment
210
Lid Lock Replacement and Adjustment
210
View of Front Luggage Compartment Lid Compartments
211
Rear Luggage Compartment Lid Replacement and Adjustment
212
Key Lock Replacement
212
View of Rear Luggage Compartment Lid Components
213
Air Intakes and Lids
214
Engine Compartment Lid Replacement and Adjustment
214
Exploded View of Lid Components and Air Inlets
215
Front Seats
216
Electrical System Troubleshooting Contents
218
Battery and Charging System Contents
219
Battery Charge Indicator Stays on after Engine Starts
220
Indicator Stays off with Ignition Switch on and with Engine Running
222
E Lectr Ical System Troubleshooting
222
Battery Boils Over, Lights Burn out Frequently
224
Battery Does Not Stay Charged
224
Starting System Contents
227
Starter will Not Start Car
228
Starter will Not Crank Engine
229
Starter Cranks Slowly
233
Ignition System Contents
237
Engine will Not Start
238
Check Spark Plugs
238
Engine Misses at Idle
245
Engine Runs but Lacks Power or Misses at High Speed
248
Timing Ignition with Timing Light
249
Engine Stalls
250
Ignition System
250
Radiator and Carburetor Cooling Systems Contents
255
Engine Overheats - Radiator Cooling Fan will Not Run
257
Radiator Cooling Fan Runs All the Time
258
Carburetor Cooling Fan will Not Run
259
Carburetor Cooling Fan Runs All the Time
260
Seat Belt Interlock and Remove Key Warning System Contents
265
Seat Belt Interlock System
266
Driver's Seat Circuit Faulty
266
Driver's Seat Belt Circuit Faulty
267
Passenger's Seat Circuit Faulty
267
Passenger's Seat Bealt Circuit Faulty
268
Transmission Switch Circuit Faulty
268
Seat Belt Indicator and Buzzer Circuit Faulty
270
Starter Relay Circuit Faulty
271
By-Pass Switch Circuit Faulty
272
Key Buzzer will Not Work
273
Interior Light Contents
277
Courtesy Light Not on with Door Open
278
Brake Indicator Light will Not Work with Lever Pulled up
280
Instruments Lights will Not Work
281
Optical Fiber Illumination will Not Work
282
Vehicle Warning Indicator Light will Not Work
283
Electrical System Troubleshooting
283
Interior Lights
283
Directional Indicator Light will Not Work
284
Exterior Lights Table of Contents
286
Left or Right High Beam will Not Work
287
Headlight Motors will Not Work
290
Left or Right Low Beam will Not Work
293
Exterior Lights
296
Parking/Side Marker/License Plate Lights will Not Work
297
Parking Light Indicator out
297
Brake Lights Wil Not Work
301
Electrical System Troubleshooting
301
Back-Up Lights Do Not Work
302
Vewhicle Warning Lights will Not Work
303
Directional Lights will Not Work
304
Instruments Contents
309
Temperature Gage Inoperative
311
Fuel Gage Inoperative
312
Low Fuel Warning Inoperative
313
Oil Pressure Gage Inoperative
314
Low Oil Pressure Warning Inoperative
316
Tachometer Inoperative
317
Accessories Contents
320
Horn will Not Stop Blowing
322
Horns will Not Blow
322
Electrical System Troubleshooting
322
Windshield Washer Pump will Not Work
324
Windshield Wipers will Not Work
324
Heater Fan will Not Work
326
Fuses Contents
329
Fuse Location
330
Protected Circuits
330
Fuse a Blows Repeatedly
331
Electrical System Troubleshooting
337
Fuse B Blows Repeatedly
338
Fuse C Blows When High Beams Are Turned on
339
Fuse D/F Blows When High Beams Are Turned on
340
Fuse G Blows Repeatedly
341
Fuse H Blows Repeatedly
343
Fuse I Blows Repeatedly
344
Fuse L Blows Repeatedly
345
Fuse M/N Blows Repeatedly
346

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Fiat X 1/9 1977 Service Manual (348 pages)

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