Fiat 500L - Workshop Manual

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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

Main Page

The Engine2
Description2
Left Side View of the Power Plant to Suit3
Right Side Rear Three-Quarter View of the Power Plant for 500 Station Wagon3
Engine Section through Crankshaft, Pistons and Valves4
Engine Cross-Section through a Cylinder5
Engine Removal6
120.000 Engine Assembly: Cross-Section View through a Cylinder6
Engine Compartment Lid Open7
Engine Removal Using the Jack with Cross-Member7
Engine Components: Crankcase, Cylinder Head, Timing Sprockets Cover7
Tool A.40014 for Cylinder Head Removal8
Removing Crankshaft Sprocket with Puller A.460208
Cylinder Hold-Down Tool A.601 568
Removal of Stud from Crankcase by Puller A.400109
Engine Without Blower Cowling and Cylinder Head Cover9
Engine Disassembly (Station Wagon)9
Tool A.60084 for Valve and Valve Spring Removal9
Cylinder Head Removal, Servicing and Replacement10
Cleaning Valve Guides10
Installing a Valve Guide Using Tool A.60153 Provided with Pilot Bush10
Main Specifications of Intake and Exhaust Valves and Valves Guides11
Dismantling the Cylinder Head11
Inspection and Servicing of the Cylinder Head11
Valve Springs11
Cylinder Head Installation12
Timing Gear Overhaul12
Valve, Pushrod and Tappet Assembly12
Crankcase and Cylinders12
Finned Cylinder13
Cylinder Measurement Points13
Honing or Reboring Cylinder Bores13
Checking Cylinder Height13
Inspection of Tappet Seats14
Piston Assembly14
Checking Piston Ring-To-Land Clearance14
Reassembly of Piston14
Checking Ring Gap (Ring in Cylinder)15
Checking Rod Bearing Inserts and Crankpin Journals15
Checking Rod Bearing Insert to Crankpin Journal Clearance15
Connecting Rod Components15
Installation of Connecting Rod Bearing Inserts16
Little End Bushing16
Engine Front End Without Flywheel17
Piston-Connecting Rod Assembly17
Crankshaft and Main Bearings17
Camshaft End Crankshaft Supporting Member and Bearing Assembly, and Spare Main Bearing17
Flywheel and Starter Ring Gear18
The Oil Pump18
Engine Lubrication Diagram18
Pump Removal and Reassembly18
Lubrication Diagram of Engine 120.00019
Pump Dismantling, Inspection and Reassembly19
Station Wagon19
Pump Gears Removal, Inspection and Reassembly19
Lubrication, Oil Filter, Relief Valve20
Engine Longitudinal Section through Oil Pump20
Centrifugal Oil Filter Components20
Engine Detail Showing Lube Oil Passages21
Cleaning and Inspection21
Oil Pressure Indicator Sender Unit21
Valve Timing21
Valve Stem-To-Rocker Clearance Adjustment22
Engine Assembly22
Graduated Sector C.673 for Valve Gear Timing22
Cylinder Head Hold-Down Nuts Tightening Sequence 500 Sedan23
The Correct Position of Connecting Rod-Piston Assembly on Engine 120.00023
Engine Assembly (Station Wagon)24
Cylinder Head Stud Nut Tightening Sequence.500 D. F and L Sedan and Station Wagon24
Power Plant Rear Suspension24
Power Plant Mountings25
Adjustment of Generator and Fan Drive Belt25
Modifications25
Fault Diagnosis25
The Fuel System28
Fuel Pump Operating Principles28
Routine Maintenance28
Pump Removal, Dismantling and Examination28
Fuel Pump Components29
Reassembly, Installation and Adjustment29
Carburetter Operation and Adjustment, Weber 26.IMB29
Fuel Pump and Control Pushrod29
Carburetter Operation30
Diagrammatic Section of Weber 26.IMB Carburetter30
Starting Device (Choke) Diagrammatic Section30
Weber 26.IMB Carburetter Starting Device (Choke) End31
Starting Device31
Engine Starting31
Normal Car Driving32
Idle Speed Adjustment32
Adjustment of Fuel Level in Float Chamber:32
Float Adjustment Data32
Weber 26.IMB Carburetter Cover Components33
Jets, Jet Holders and Choke Valve33
Throttle Valve Components33
Carburetter Cleaning33
Carburetter Operation and Adjustment, Weber 26. OC34
Carburetter Operation, Starting Device:34
Section of Later Starting Device34
Diagrammatic Section Views of 26.OC Weber Carburetter through the Starting Device35
Diagrammatic Section Views of 26.OC Weber Carburetter35
Float Level Setting Diagram Weber Carburetter Type 26.OC36
Adjustment of Fuel Level in Float Chamber36
Removing the Air Cleaner, 500F, L36
Diagram of Blow-By Gases Re-Circulation Device37
Air Cleaner (Sedan)37
Air Cleaner—Engine 110 F.00037
Air Cleaner—Station Wagon38
Blow-By-Gases Recirculation Device38
Location of the Fuel Tank in Front Compartment, 500F, L38
The Ignition System40
Adjusting the Contact Breaker Points41
Cleaning the Contact Points41
Ignition Faults41
Testing the Low-Tension Circuit41
Capacitor42
Removing and Dismantling Distributor (Sedan and Sports)42
Ignition Distributor in Place on Engine42
Use of Fixture Ap.5030/1 to Check Ignition Timing43
Removing and Dismantling Distributor (Station Wagon)43
Timing the Ignition43
Sparking Plugs43
Sparking Plug Leads44
The Distributor Driving Spindle (Sedan and Sports Engine)44
The Cooling System46
Engine Cooling Air Circulation System47
Cooling Air Circulation System of Engine 120.00048
Air Outlet Thermostat and Shutter49
Tension Adjustment, Thermostat to Shutter Link49
Location of Cooling Air Outlet Thermostat and Shutter49
Diagram of the Heating System Safety Device (Sedan and Station Wagon)49
Heating System Safety Device50
The Clutch52
Removal and Installation53
Dismantling and Inspection of Clutch Cover53
Assembly and Adjustment53
Clutch Components (New 500, 500D Sedan and Early Station Wagon)54
Inspection-Diaphragm Clutch54
Clutch Assembly Installed on Engine54
Clutch Cover Assembly Inspection Diagram 500F, L and Later Station Wagon55
Installing the Clutch on Flywheel Using Pilot A.6202355
Pilot Bushing56
Clutch Controls and Adjusting Mechanism56
Withdrawal Mechanism56
Clutch Throw-Out Mechanism57
Gearbox and Differential Unit58
Gearbox-Differential Unit Longitudinal Section59
Removal of Gearbox/Differential Unit59
Gearbox Gears, Forks and Striker Rods60
Detail of Gearbox Section through Striker Rod Positioning Ball Springs60
Dismantling-Gearbox60
Differential Unit Complete with Axle Shafts61
Differential Components62
Inspection of Components62
Reassembly-Gearbox63
Dismantling-Differential and Final Drive63
Reassembly-Differential Unit64
Final Drive Gear Set Adjustment64
Graphic Demonstration of Values a and a65
Setting Dial Indicator to Zero on Tool A.6203765
Adjusting Final Drive Gear Set65
Ring Gear Clearance and Differential Bearing Pre-Load66
Check and Adjustment of Tooth Contact between Pinion and Ring Gear67
Replacement of Gearbox-Differential Unit67
Swing Axle Shafts and Slip Joints67
Location of Gearshift Lever on Control Passage Tunnel69
Gear Shift Control Mechanism69
Dismantling and Inspection69
Modified Items in Transmission-Differential Assembly70
End Sectional View of Transmission-Differential Assembly70
Rear Suspension and Wheels72
Removal of Rear Suspension Assembly72
Rear Suspension Assembly73
Servicing Swing Arms73
Right Rear Suspension Assembly, Sectioned through Brake Drum and Arm Mountings74
Wheel Bearing Adjustment75
Swinging Arm Adjustment76
Installation of Rear Suspension Assembly76
Adjusting Rear Wheel Toe-In Angle76
The Position of Rear Suspension for Rear Wheel Toe-In Inspection and Adjustment76
Checking Left Rear Wheel Toe-In77
Sectional View of Right Side Rear Wheel and Axle Shaft78
Front Suspension and Hubs80
Front Suspension Removal and Dismantling80
Front Suspension81
Leaf Spring81
Section through Left Swinging Arm81
Section through One Spring Mounting81
Front Leaf Spring, Loaded at Center82
Front Leaf Spring, Installed on Car82
Spring Deflection Test82
Swinging Arm Components83
Leaf Spring Inspection and Repair83
Swinging Arms83
Kingpin Housing84
Steering Knuckle and Wheel Hub84
Removing Right Front Wheel Hub Cap by Remover A.4602384
Removing Left Front Wheel Brake Drum by Puller A.4000584
Sectional View of Shock Absorber85
Leaf Spring Position under Full Static Loads on Fixture A.66061 or A.7406185
Hydraulic Damper86
Installing Right Front Wheel Hub Cap by Tool A.6605986
Front Suspension Assembly and Installation86
Swing Arm Setting87
Section through Steering Knuckle and Leaf Spring Mounting at Kingpin87
Castor, Camber Angles88
Steering Geometry88
Adjustment of Castor Angle88
Adjustment of Camber Angle88
Steering System90
Steering Wheel Removal and Refitting90
Steering Box Removal and Refitting90
Steering Box, Idler Member and Steering Linkage Arrangement on Vehicle91
Securing Steering Wheel Mounting Nut91
Steering Box Dismantling and Reassembly91
Layout of Steering Gear Components92
Section of Steering Box, through Worm Screw93
Steering Box Cutaway93
Refitting the Steering Box94
Relay Lever and Support94
Steering Rods (Tie Rods)94
Front Wheel Toe-In Checking Diagram94
The Braking System96
Brake Adjustment (Station Wagon)96
Preventative Maintenance96
Diagrammatic View of Service and Rear Wheel Parking Brake System97
Left Front Wheel Brake Assembly (500 Sedan)97
Front Brake Drum Removal97
Dismantling Brake Unit98
Brake Shoe Lining98
Reassembly of Front Brakes98
Rear Brake Drum Removal98
Reassembly of Rear Brakes99
Master Cylinder Removal99
Master Cylinder Section100
Dismantling Master Cylinder100
Refitting the Master Cylinder100
Wheel Cylinder Operation100
Brake Fluid Reservoir101
Reassembling Wheel Cylinders101
Self-Adjusting Device101
Removing a Flexible Hose101
Bleeding the System102
Removing the Hand Parking Brake Cable102
The Dual Circuit Braking System102
The Electrical Equipment104
The Battery104
Battery Location105
Cross-Section View of Battery105
The Generator105
Testing When Generator Is Not Charging105
Removing Generator106
Servicing Brushes106
Servicing the Commutator106
Components of Generator106
Components of Starter107
Testing Field Coils107
Reassembly and Refitting the Generator107
The Starter Motor107
Tests for a Starter Which Does Not Operate108
Removing the Starter108
Examining the Commutator and Brush Gear108
Testing the Field Coils108
Wiring Diagram for Checking the Cutout Closing Voltage109
Wiring Diagram for Checking the Reverse Current of Cutout109
Reassembling and Refitting the Starter109
The Control Box109
Checking Cut-Out110
Closing Voltage110
Reverse Current110
Checking Voltage/Current Regulator110
Wiring Diagram for Setting the Cut-Out Relay111
Wiring Diagram for Setting the Voltage Andcurrent Regulators111
Wiring Diagram for Setting the Cutout Relay112
Location of Electrical System Fuses112
Cut-Out Relay Adjustment112
Voltage Regulator Adjustment112
Windshield Wiper Wiring Diagram113
Faulty Operation of Flashers113
Windscreen Wipers113
Wiper Unit Faulty Operation113
Removal and Refitting the Motor114
Headlamp Removal114
The Lighting System114
Replacement of Bulb from Inside Front Compartment115
Disassembling Front Parking and Direction Indicator Lamp115
Beam Setting115
Disassembling Tail Parking, Stop, Direction Indicator Lamp and Reflector Lens115
Lamp Brilliance Varies with the Speed of the Car116
Fuel Reserve Supply Indicator Sender Unit116
Number Plate Lamp116
Horn (Opened)116
Lighting and Flasher Switch117
Switch Unit Removal117
Bodywork Finish120
Interior and Chrome Cleaning120
Cleaning Imitation Leather121
Chrome Plated Parts121
Door Trim and Accessories121
Weather Strip121
Inner Panels122
Door Handles and Locks122
Removing Window Regulator and Door Glass122
Regulator Removal/Reassembly122
Ventilation Panel Lower Pivot123
Removal of Windshield Glass123
Door Window Drop Glass and Weather Strip123
Removal of Door Glass123
Door Ventilator124
Adapting Windshield Weatherstrip124
Front Compartment Lid Lining and Rubber Buffers124
Removing Windshield Glass124
Sedan Rear Seat with Removable Cushion125
Removing Rear Side Windows125
Removing Rear Window Glass125
Front/Engine Compartment Lid125
Folding Top126
Sunroof126
Folded Top Retaining Strap126
Sun Roof Top in Locked Position126
Sun Roof Top in Unlatched Position127
Front Seats127
Diagrammatic View of Car Heating System127
Rear Seats128
Interior Heater128
Windshield Demisting128
Diagram of Booster128

Fiat 500L - Workshop Manual

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