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Fiat 500D User Manual

Fiat 500D
128 pages
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FIAT 500 1957-73
Workshop Manual
Autobooks
Models Covered
Fiat New 500
Fiat 500D
Fiat 500F
Fiat 500L
Fiat and Autobianchi Giardiniera

Table of Contents

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Fiat 500D Specifications

General IconGeneral
BrandFiat
Model500D
CategoryAutomobile
LanguageEnglish

Summary

CHAPTER 1 THE ENGINE

1:1 Description

Provides an overview of the Fiat 500's two-cylinder aircooled engine.

1:2 Engine removal (sedan—all versions)

Step-by-step guide for removing the engine from sedan models.

1:4 Engine disassembly (sedan—all versions)

Detailed instructions for dismantling the engine in sedan versions.

1:6 Cylinder head removal, servicing and replacement

Procedures for removing, servicing, and replacing the cylinder head.

1:17 Engine assembly (sedan — all versions)

Step-by-step guide for reassembling the engine in sedan models.

CHAPTER 2 THE FUEL SYSTEM

2:1 Description

Overview of the mechanical diaphragm fuel feed pump and carburetters used.

2:4 Pump removal, dismantling and examination

Procedures for removing, dismantling, and examining the fuel pump.

2:6 Carburetter operation and adjustment, Weber 26.IMB

Details on the operation and adjustment of the Weber 26.IMB carburetter.

CHAPTER 3 THE IGNITION SYSTEM

3:1 Description

Overview of the ignition system components and circuits.

3:7 Timing the ignition

Guide on how to retime the ignition system for correct engine performance.

3:10 Fault diagnosis

Troubleshooting common ignition system faults.

CHAPTER 4 THE COOLING SYSTEM

4:1 Description

Overview of the air-cooled system for Fiat 500 models.

4:2 Air outlet thermostat and shutter

Details on the thermostat and shutter controlling engine air outlet.

4:6 Fault diagnosis

Troubleshooting common cooling system issues like overheating.

CHAPTER 5 THE CLUTCH

5:1 Description

Overview of the single plate dry disc clutch system.

5:2 Removal and installation

Step-by-step guide for removing and installing the clutch unit.

5:8 Fault diagnosis

Troubleshooting common clutch system problems.

CHAPTER 6 GEARBOX AND DIFFERENTIAL UNIT

6:1 Description

Overview of the aluminium alloy cased gearbox and differential unit.

6:2 Removal of gearbox/differential unit

Instructions for removing the complete gearbox/differential unit.

6:3 Dismantling — gearbox

Detailed steps for dismantling the gearbox assembly.

6:7 Final drive gear set adjustment

Guide on adjusting the final drive gear set for correct mesh.

CHAPTER 7 REAR SUSPENSION AND WHEELS

7:1 Description

Overview of the independent rear suspension with coil springs.

7:2 Removal of rear suspension assembly

Steps for removing the rear suspension assembly.

7:6 Checking and adjusting rear wheel toe-in

Procedures for checking and adjusting rear wheel toe-in.

7:8 Fault diagnosis

Troubleshooting common rear suspension and wheel issues.

CHAPTER 8 FRONT SUSPENSION AND HUBS

8:1 Description

Overview of the independent front suspension assembly.

8:2 Front suspension removal and dismantling

Steps for removing and dismantling the front suspension.

8:9 Steering geometry

Checking and adjusting front wheel geometry (camber, castor).

CHAPTER 9 THE STEERING SYSTEM

9:1 Description

Overview of the worm screw and sector type steering gear.

9:3 Steering box removal and refitting

Procedures for removing and refitting the steering box.

9:7 Front wheel toe-in

How to check and adjust the front wheel toe-in.

9:8 Fault diagnosis

Troubleshooting common steering system faults.

CHAPTER 10 THE BRAKING SYSTEM

10:1 Description

Overview of the hydraulic braking system.

10:5 Master cylinder

Operation, removal, and reassembly of the master cylinder.

10:10 Bleeding the system

Procedure for bleeding air from the hydraulic brake system.

CHAPTER 11 THE ELECTRICAL EQUIPMENT

11:1 Description

Overview of the 12-volt electrical system.

11:2 Battery

Maintenance and testing procedures for the 12-volt battery.

11:3 The generator

Testing and servicing procedures for the generator.

11:4 The starter

Operation, testing, and dismantling of the starter motor.

11:13 Fault diagnosis

Troubleshooting common electrical system faults.

CHAPTER 12 THE BODYWORK

12:1 Bodywork finish

Guidance on repairing and painting body panels.

12:2 Interior and chrome cleaning

Instructions for cleaning upholstery, interior, and chrome parts.

12:5 Removing window regulator and door glass

Procedures for removing the window regulator and glass.

12:6 Removing windshield glass

Steps for removing and refitting the windshield glass.

12:14 Interior heater

Description and inspection of the interior heating system.

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