Fiat 500 (1957-73)_Haynes.pdf

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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
CHAPTER 1
THE ENGINE
Description
Engine removal (sedan—all versions)
Engine removal (station wagon)
Engine disassembly (sedan—all versions)
Engine disassembly (station
wagon)
Cylinder head removal, servicing and
replacement
1 :7 Timing gear overhaul
1 :8 Crankcase and cylinders
1:9 Piston assembly
1 :10 Connecting rods
1 :11 Crankshaft and main bearings
1 :1
1 :2
1 :3
1 :4
1 :5
1 :6
1
1
1
1
1
1
1
1
1
1
1
:12
:13
:14
:15
:16
:17
:18
:19
:20
:21
:22
Flywheel and starter ring gear
The oil pump
Lubrication, oil filter, relief valve
Valve timing
Valve stem to rocker clearance
Engine assembly (sedan—all versions)
Engine assembly (station wagon)
Power plant mounting
Adjustment of generator and fan belt drive
Modifications
Fault diagnosis
1 :1 Description
The 'New 500' two-cylinder aircooled engine operates
on the four-stroke 'Otto Cycle' and is fitted directly to
the transmission unit which incorporates the rear drive
assembly as shown in
FIG 1 :1
and
FIG 1 :2.
With the power unit fitted at the rear several advantages
are obtained including better load distribution to the
wheels when the vehicle is loaded, elimination of propeller
shaft reducing the size of centre tunnel and better use of
available space.
The cylinder block comprises two cast iron cylinder
barrels with cooling fins. The bottom of the cylinders fit
into machined seats in the aluminium crankcase.
The aluminium crankcase carries eight studs on which
are located the two cylinder barrels with the aluminium
cylinder head on the top.
A two bush crankshaft of special cast iron is fitted into
the lower half of the crankcase. The crankshaft is
provided with a counterweight and is hollow to allow for
lubrication.
The steel connecting rods have thin wall bearing halves
on the big-end, and bronze bushes in the small-end. The
offset piston pin is of steel and retained in the piston by
two circlips.
Light alloy pistons are used and are of the taper-oval-
shaped type with a maximum diameter at the base of the
skirt, along an axis perpendicular to the piston pin. Pistons
are fitted with four rings as follows, one compression at
the top, two standard oil scraper rings and one side slotted
oil scraper ring.
The one-piece aluminium cylinder head is finned to
provide a larger cooling surface and carries the inlet and
exhaust manifolds.
The inlet passages merge into a single centralized
flange onto which is mounted the carburetter. The exhaust
passages run almost parallel to the axis of the engine.
F500
9
FIG 1:1 Left side view of the power plant to suit
500 Sedan
Mounted on the top of the cylinder head is the overhead
valve rocker mechanism that is operated by a chain driven
camshaft through tappets and vertical pushrods.
The carburetter is of the downdraft type fitted with a
starting device that is controlled by a lever on the central
floor tunnel. A pleated paper element air cleaner and
silencer is fitted to the carburetter air intake. A mechanical
diaphragm type fuel pump operated from the camshaft by
a pushrod, supplies petrol to the carburetter from a fuel
tank located at the front of the vehicle.
Engine lubrication is provided by a gear pump driven
from the camshaft and mounted within the timing cover
drawing oil from the engine sump. The oil is cleaned by a
centrifugal filter situated at the rear end of the crankshaft
and pressure is controlled by a valve mounted on the
pump body. Crankcase ventilation is provided for through
a rubber hose connected to the top of the rocker cover.
The engine is cooled by air from a centrifugal blower
mounted on the generator shaft and housed in a specially
designed cowling conveying air to and around the engine.
The air temperature is governed by a special thermostat
fitted in the engine cowling.
FIG 1:2
Right side rear three-quarter view of the power plant for 500 Station Wagon
10
FIG 1:3
Engine section through crankshaft, pistons and valves
F500
11
FIG 1:4
Engine cross-section through a cylinder
12

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