Product Name:
Fiat 500 1957-1973 Service and Repair/Workshop Manual
Applicable Years:
1957, 1958, 1959, 1960, 1961, 1962, 1963, 1964, 1965, 1966, 1967, 1968, 1969, 1970, 1971, 1972, 1973
Chassis Codes:
110F, 110FB, 110FD, 110FDB, 120F, 120FB, 120FC, 120FCD, 130F, 210F, 210FB, 210FC, 230F, 230FC, 230FCD, 230FD
Segment:
Microcar/City Car
Target Audience:
Enthusiasts, DIY mechanics, and owners of classic Fiat 500 models seeking to maintain and repair their vehicles.
Competitors:
While the Fiat 500 had few direct competitors in its niche when launched, its DIY-friendly nature made it accessible for home mechanics compared to larger, more complex vehicles of the era.
Diy Focus:
Emphasizes user empowerment for home repairs, fostering a connection between owner and vehicle.
Historical Significance:
Covers an iconic Italian automotive design, essential for preserving these classic vehicles.
Tool Acquisition:
Promotes the acquisition of specialized tools and the satisfaction of hands-on work.
Engine:
Detailed overhaul, tuning, component replacement for air-cooled inline-twin engines (e.g., 110, 499.5cc, 500cc, 594cc, 650cc variants).
Fuel System:
Carburetor tuning, fuel pump, fuel lines, and tank maintenance/replacement (typically Solex or Weber carburetors).
Cooling System:
Air cooling system specifics, fan operation, and ducting.
Transmission:
Synchromesh gearbox service, clutch replacement, driveshaft and CV joint maintenance, gearbox fluid changes.
Brakes:
Hydraulic drum brake system overhaul, brake fluid replacement, shoe adjustment, and master cylinder service.
Suspension:
Front independent suspension (transverse leaf spring and trailing arms), rear semi-independent suspension, shock absorber replacement, and component wear checks.
Steering:
Steering box adjustment, tie rod end replacement, and wheel alignment procedures.
Electrical:
Ignition system (distributor, coil, spark plugs), starting and charging system (dynamo or alternator), lighting, horn, and dashboard instrumentation troubleshooting and repair.
Chassis Body:
Body panel alignment, rust repair considerations, door and window mechanism adjustment, jacking points, and frame integrity checks.
Interior:
Seat removal and repair, dashboard trim, carpeting, and heater control linkages.
Wiring Diagrams:
Detailed, often color-coded, wiring schematics for all electrical systems.
Engine Overhaul:
Complete engine rebuild, including piston and cylinder replacement, crankshaft and camshaft servicing, valve adjustments, and gasket replacement.
Carburetor Rebuild:
Step-by-step instructions for disassembling, cleaning, and reassembling common carburetor types.
Brake Bleeding:
Proper procedure for flushing and bleeding the hydraulic brake system.
Ignition Timing:
Setting ignition timing for optimal performance and emissions.
Valve Lash Adjustment:
Precise instructions for setting valve clearances on air-cooled engines.
Troubleshooting Guides:
Systematic approaches to diagnosing common faults and performance issues.
Wheel Bearing Service:
Repacking and adjustment of wheel bearings.
Clutch Adjustment:
Adjusting clutch cable for proper engagement and disengagement.
Body Repair Techniques:
Guidance on minor bodywork and rust remediation.
Depth:
Comprehensive. Covers everything from routine maintenance and adjustments to full engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications.
Engine Type:
Air-cooled, rear-mounted, inline-twin cylinder
Displacement Early:
479 cc (0.479 L)
Displacement Later:
499.5 cc (0.5 L), 594 cc (0.594 L), 650 cc (0.65 L) for sportier variants
Bore Stroke Early:
67.4 mm x 70 mm
Bore Stroke 500D:
67.4 mm x 74 mm
Bore Stroke 500F:
72 mm x 74 mm
Bore Stroke 500L:
72 mm x 74 mm
Bore Stroke 600:
74 mm x 74 mm
Horsepower Early:
Approx. 13-15 hp (SAE)
Horsepower 500D:
Approx. 17 hp (SAE)
Horsepower 500F:
Approx. 17 hp (SAE)
Horsepower 500L:
Approx. 18 hp (SAE)
Horsepower 600:
Approx. 21.5 hp (SAE)
Torque Early:
Approx. 22-26 Nm (16-19 lb-ft)
Carburetor Type:
Single Solex or Weber downdraft carburetor
Fuel Type:
Unleaded gasoline (may require lead substitute or additives for original engines).
Oil Type:
Specific viscosity grades recommended in manual, typically SAE 20W-50 or SAE 30 for older air-cooled engines.
Oil Capacity:
Approx. 2.5 - 3.0 liters (2.6 - 3.2 US quarts)
Type:
4-speed manual synchromesh gearbox
Automated Manual:
Some later models/conversions may feature automated manual transmissions, but the manual covers the standard gearbox.
Drive Layout:
Rear-wheel drive
Gear Ratios:
Specific ratios for each gear and final drive are detailed in the manual.
Gearbox Oil:
GL-4 gear oil, typically SAE 75W-90 or SAE 80W-90.
Gearbox Oil Capacity:
Approx. 1.2 - 1.5 liters (1.3 - 1.6 US quarts)
Crash Test Data:
No formal crash test data comparable to modern standards is available. Vehicle design predates rigorous crash safety regulations.
Braking System:
Hydraulic drum brakes on all four wheels.
Steering:
Direct steering system, contributing to maneuverability but offering limited power assistance.
Body Structure:
Lightweight steel monocoque construction.
Restraint Systems:
No airbags or pre-tensioned seatbelts standard. Seatbelts may have been optional or added later.
Oil Change:
Every 3,000-5,000 km (2,000-3,000 miles) or annually, whichever comes first.
Spark Plugs:
Inspection and cleaning every 5,000 km; replacement as needed, typically at 15,000-20,000 km.
Valve Adjustment:
Every 10,000-15,000 km (6,000-9,000 miles).
Brake Adjustment:
Periodic checks and adjustments, especially for drum brakes, as wear occurs.
Grease Points:
Regular lubrication of suspension and steering joints as per schedule.
Engine Oil:
Consult manual for specific grade (e.g., SAE 20W-50, SAE 30, or specific multigrade blends for air-cooled engines).
Brake Fluid:
DOT 3 or DOT 4 glycol-based brake fluid.
Gearbox Oil:
GL-4 rated gear oil, typically SAE 75W-90 or SAE 80W-90.
Coolant:
Not applicable (air-cooled engine).
Rust Prone Areas:
Wheel arches, floor pans, sills, battery tray, and lower door edges are common areas for corrosion.
Engine Overheating:
Can occur if cooling fins are blocked with debris or if the engine is under heavy load in hot conditions.
Carburetor Tuning:
Carburetors can be sensitive to altitude and require regular tuning for optimal performance.
Synchromesh Wear:
Older gearboxes may exhibit worn synchros, leading to crunchy gear changes.
Electrical Gremlins:
Wiring insulation can degrade over time, leading to intermittent electrical faults.
Fiat Legacy:
Fiat's history of producing affordable and popular small cars, beginning with the FIAT 500 'Topolino'.
Nuova 500 Launch:
Introduced in 1957 as the 'Nuova 500', replacing the more expensive Fiat 600 and representing post-war Italian economic recovery and personal mobility.
Key Variants:
Included various models such as the 500 Economica (1957), 500 D (1960), 500 F (1965, with suicide doors), 500 L (Lusso, 1968, more refined), and 500 R (Rinnovata, 1972, with larger engine).
Production Period:
1957-1975 (with the core models covered by this manual spanning 1957-1973).
Manufacturing Location:
Primarily Turin, Italy.
Total Production Numbers:
Over 4 million units produced across all variants.
