Segment:
Compact City Car / Microcar
Era:
Post-war European mobility solution
Competitors:
Volkswagen Beetle, Citroën 2CV, Mini Cooper (though the 500 is smaller)
Design Philosophy:
Simplicity, affordability, practicality, and iconic Italian style
Target Audience:
Individuals and small families seeking economical transportation
Primary Coverage:
All Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Refurbishment, Renovation, Diagnostics
Estimated Page Count:
Varies by specific edition, typically 200-400 pages for comprehensive coverage
Type:
Service Manual / Workshop Manual / Repair Manual
Engine Service Repair:
Complete overhaul, component replacement, timing adjustments, tuning
Transmission Service Repair:
Gearbox overhaul, clutch service, synchronization, fluid changes
Brake System:
Drum brake service, hydraulic system bleeding, component replacement
Electrical System:
Wiring diagrams, lighting, ignition system, starter, generator, battery
Suspension:
Front and rear suspension components, shock absorbers, spring replacement
Steering:
Steering box adjustments, tie rod replacement, alignment basics
Cooling System:
Air-cooled engine management, fan and shroud maintenance
Fuel System:
Carburetor overhaul (Solex), fuel pump, fuel lines, tank maintenance
Chassis Body:
Bodywork repair, panel replacement, door mechanism service, underbody protection
Emission System:
Basic emissions control for the era, exhaust system maintenance
General Maintenance:
Oil changes, filter replacements, tune-ups, lubrication schedules
Troubleshooting:
Diagnostic procedures for common problems, symptom-based solutions
Disassembly Reassembly:
Detailed step-by-step instructions for all major components
Refurbish Renovate:
Guidance on restoration and bringing the vehicle back to original specifications
Depth:
Comprehensive: Covers everything from basic preventative maintenance to full engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs.
Engine Type:
Air-cooled, two-cylinder, inline (OHV)
Displacement Cc:
479 cc (later models 499.5 cc, but 1965 typically refers to the 499.5 cc variant)
Bore X Stroke:
67.4 mm x 70.0 mm (approximate for 499.5 cc)
Horsepower:
17-22 hp (depending on variant, e.g., 500D, 500F)
Torque:
33-37 Nm (approximate)
Carburetor:
Solex 26/26-26
Fuel Type:
Unleaded Gasoline (though leaded was common at the time, the manual may reference octane ratings)
Ignition System:
Distributor, coil, points, and condenser
Type:
4-speed manual synchromesh (typically on later models like the 'F')
Optional Type:
N/A (Automatics were rare or not factory for this year/model)
Clutch Type:
Single dry plate, hydraulically operated
Gear Ratios:
Specific ratios provided in the manual for each gear
Crash Test Ratings:
N/A (No standardized crash testing as we know it today)
Braking System:
Hydraulic drum brakes on all four wheels
Steering Stability:
Basic steering geometry, can be affected by wear and tire pressure
Seatbelts:
Optional or not standard equipment depending on initial market and regulations
Body Structure:
Unibody construction, providing basic structural integrity
Oil Change Interval:
Every 3,000 - 5,000 km (1,800 - 3,000 miles) or 6 months
Grease Points:
Regular lubrication of kingpins, steering linkages, and pedal shafts as per manual
Valve Adjustment:
As needed, typically checked every 10,000-15,000 km (6,000-9,000 miles)
Engine Oil:
SAE 20W-50 or 20W-40 (API SC/SD classification, check manual for specific recommendations)
Transmission Oil:
GL-4 Hypoid Gear Oil, SAE 80W-90
Brake Fluid:
DOT 3 or DOT 4 (check manual for specific type)
Coolant:
N/A (Air-cooled engine)
Common Problems:
Rust ingress (especially floor pans, sills, and wheel arches), oil leaks from engine seals, carburetor tuning issues, clutch wear, synchronizer wear in gearbox.
Ignition Issues:
Points and condenser wear, coil failure, spark plug fouling common with air-cooled engines.
Manufacturer:
Fiat S.p.A. (Fabbrica Italiana Automobili Torino)
Predecessor:
Fiat Topolino (pre-war era)
Successor:
Fiat 126 (though the 500 continued production in various forms)
Production Start Year:
1957
Production End Year:
1975 (for the original Nuova 500 series)
Key Variants 1965:
500 D, 500 F (berlina), 500 L (Lusso), 500 Giardiniera (station wagon)
