Target Audience:
Professional technicians and serious DIY mechanics working on classic Fiat 500 models.
Value Proposition:
Provides factory-level repair and maintenance information, essential for preserving and operating classic vehicles, with the convenience of instant digital access.
Content Source:
Designed to mirror factory service manuals and owner's manuals, offering comprehensive guidance.
Ease Of Use:
Step-by-step procedures for clarity, bridging the gap between professional and amateur repair knowledge.
Applicable Years:
1957, 1958, 1959, 1960, 1961, 1962, 1963, 1964, 1965, 1966, 1967, 1968, 1969, 1970, 1971, 1972, 1973
Estimated Page Count:
Varies significantly based on specific edition, but typically 200-400 pages for comprehensive service manuals of this era.
Manual Type:
Repair Service Manual
Delivery Format:
PDF Download
Engine Mechanical:
Engine disassembly, assembly, inspection, overhaul, timing, lubrication system, cooling system, fuel system (carburetor adjustments).
Fuel System:
Fuel tank, fuel lines, fuel pump, carburetor (Solex models common).
Electrical System:
Ignition system (distributor, coil, spark plugs), charging system (generator/alternator), starting system (starter motor), lighting, instrumentation, wiring diagrams.
Transmission Drivetrain:
Manual transmission disassembly, assembly, inspection, clutch, differential, drive axles.
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, steering gear, linkages.
Brakes:
Hydraulic brake system, master cylinder, wheel cylinders, brake shoes, brake drums, parking brake.
Bodywork Chassis:
Body panel repairs, doors, windows, interior trim, chassis lubrication points.
Maintenance:
Regular service checks, fluid changes, filter replacements, lubrication.
Troubleshooting:
Diagnostic tables and procedures for common problems.
Repair Overhaul:
Step-by-step instructions for component repair and rebuilding.
Disassembly Assembly:
Detailed procedures for removing and reinstalling various vehicle components.
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts with basic mechanical and electrical knowledge.
Engine Type:
Air-cooled, two-cylinder, four-stroke OHV
Engine Codes:
110.000, 110.002, 110.004, 110.006 (representing various engine displacements and power outputs)
Displacement:
Primarily 479cc (early models), 499.5cc (later models), and 594cc (Abarth variants and later standard models).
Horsepower Range:
Approximately 13-18 hp for standard models, up to 27 hp for Abarth versions.
Torque Range:
Low torque figures, typical of small-displacement engines of the era.
Carburetor Examples:
Solex 28 PCI, Solex 32 PAIA (depending on model and year).
Cooling Method:
Forced air cooling via a belt-driven fan.
Oil Capacity:
Approx. 2.5 liters (oil type: SAE 20W-50 or similar multi-grade oil suitable for air-cooled engines).
Transmission Type:
Manual synchromesh gearbox
Standard Gears:
Typically 4 forward gears and 1 reverse gear.
Clutch Type:
Single dry plate, hydraulically operated (early models may differ slightly).
Synchromesh:
Synchromesh on all forward gears (introduced progressively).
Overall Length:
Approx. 2,970 mm (117 in)
Overall Width:
Approx. 1,320 mm (52 in)
Overall Height:
Approx. 1,300 mm (51 in) (varied slightly with roof type)
Curb Weight:
Approx. 400-475 kg (882-1047 lb)
Wheelbase:
Approx. 1,840 mm (72.4 in)
Front Track:
Approx. 1,130 mm (44.5 in)
Rear Track:
Approx. 1,150 mm (45.3 in)
Crash Test Standards:
Vehicle safety standards of the era were significantly less stringent than modern standards. This manual focuses on mechanical safety and proper assembly.
Braking System:
Hydraulic drum brakes on all four wheels. Effective for the vehicle's performance envelope.
Seat Belts:
Likely optional or not fitted as standard on earliest models; became more common as regulations evolved.
Construction:
Monocoque chassis construction with integrated body. Emphasis on structural integrity for its size.
Radio:
Optional period-correct radio, typically AM band.
Speaker Configuration:
Basic, usually a single dashboard-mounted speaker.
ABS:
Not applicable for the era.
Traction Control:
Not applicable for the era.
Heating:
Basic cabin heating, often utilizing engine heat exchangers.
Instrumentation:
Simple dashboard with speedometer, fuel gauge, oil pressure warning light, and indicator lights.
Oil Change Interval:
Typically every 3,000-5,000 km (2,000-3,000 miles) or annually.
Tune Up Interval:
Regular checks of ignition timing, carburetor settings, and valve clearances (e.g., every 10,000 km or annually).
Engine Oil:
SAE 20W-50 (or similar multi-grade suitable for air-cooled engines)
Brake Fluid:
DOT 3 or DOT 4, depending on original specifications and caliper/master cylinder materials.
Gearbox Oil:
GL-4 Hypoid Gear Oil (viscosity typically SAE 80W-90 or SAE 75W-90).
Rust:
Prone to rust in common areas like sills, wheel arches, floor pans, and around window seals, especially in damp climates.
Engine Overheating:
Air-cooled engines can overheat if cooling fins are clogged, fan belt is loose, or the thermostat for the fan shroud is malfunctioning.
Carburetor Tuning:
Carburetors require regular adjustment for optimal performance and fuel economy due to wear and environmental factors.
Suspension Wear:
Bushings, ball joints, and kingpins can wear over time, leading to sloppy steering and handling.
Manufacturer Origin:
Italy
Key Variants:
Fiat 500 'Nuova' (original), 500 D, 500 F, 500 L, 500 R, and the sporting Abarth versions.
Design Philosophy:
Designed as a highly economical, compact city car, intended to be affordable and practical for post-war Italy.
Production Period:
1957-1975 (Nuova 500 generation)
Production Volume:
Over 3.8 million units produced across all variants.
Cultural Impact:
Iconic status as a symbol of Italian design and automotive culture, often featured in films and fashion.
Fuel Efficiency:
Excellent for its time, typically around 5-6 L/100km (40-47 MPG).
Historical Significance:
Considered a landmark vehicle in the development of microcars and affordable personal transportation.
