Fiat 500 1957-1973 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Fiat Model: 500 Generation: Nuova 500 (Type 110F) Codes Chassis Code: Type 110F 👋 Introduction Market Position Positioning: Iconic city car, celebrated for its compact...

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Type: Car

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Sku: 425254

Tags: 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 1967 1968 1969 1970 1971 1972 1973 500 Car Cars Fiat

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Generation:

Nuova 500 (Type 110F)

Codes

Chassis Code:

Type 110F

👋 Introduction

Market Position

Positioning:

Iconic city car, celebrated for its compact size, charming design, and affordability.

Competitive Analysis

Competitors:

Renault 4CV, Volkswagen Beetle, Mini Cooper, Citroën 2CV.

Key Features

Design:

Distinctive 'smiley face' front end, suicide doors (early models), minimalist interior, rear-engine, rear-wheel drive layout.

Engineering:

Simple, robust, and economical engineering, making it accessible for home mechanics.

Versatility:

Available in various body styles including sedan, station wagon (Giardiniera), and panel van.

📋 Manual Details

Coverage Areas

Applicable Years:

1957-1973

Page Count

Estimated Page Count:

Hundreds (typical for comprehensive workshop manuals)

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete disassembly, assembly, overhaul, troubleshooting, and tuning.

Fuel System:

Carburetor, fuel pump, fuel lines, fuel tank maintenance and repair.

Ignition System:

Distributor, spark plugs, ignition coil, wiring, timing adjustments.

Lubrication System:

Oil pump, oil filter, oil pan, lubrication passages, fluid specifications.

Exhaust System:

Exhaust manifold, muffler, pipes, hangers, leak detection, replacement.

Electrical System:

Wiring diagrams, battery, starter, alternator, lighting, instrumentation, fuses.

Body:

Body panel repair, door mechanisms, window regulators, trim, rust prevention.

Cooling System:

Radiator, fan, thermostat, hoses, coolant specifications, leak repair.

Suspension:

Front and rear suspension components, springs, shock absorbers, alignment procedures.

Steering:

Steering box, tie rods, steering column, alignment, lubrication.

Brakes:

Hydraulic system, brake shoes, drums, wheel cylinders, master cylinder, bleeding procedures.

Clutch:

Clutch disc, pressure plate, release bearing, clutch linkage, adjustment, replacement.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, lubrication, fluid level checks, tune-ups.

Troubleshooting:

Diagnostic procedures for common and uncommon faults across all systems.

Repair Overhaul:

Detailed step-by-step instructions for component removal, disassembly, repair, and reassembly.

Diagnostics:

Specific diagnostic trees and symptom-based troubleshooting for various issues.

Engine Rebuild:

Comprehensive instructions for complete engine disassembly and rebuilding.

Transmission Service:

Removal, disassembly, repair, and reassembly of the gearbox.

Electrical Diagnostics:

Troubleshooting electrical circuits using wiring diagrams and test equipment.

Body Repair:

Procedures for panel alignment, rust repair, and fitting body components.

Special Tool Usage:

Identification and usage instructions for specialized Fiat tools.

Technical Depth

Depth:

Comprehensive, covering all aspects from basic maintenance to complete mechanical and electrical system overhauls.

📊 Manual Specifications

File Format

Format:

Print Quality

Quality:

Printable at high resolution

Binding Type

Binding:

Not Applicable (Digital PDF)

Paper Type

Paper:

Not Applicable (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, two-cylinder, overhead-valve (OHV)

Displacement:

479 cc (early models), later 500 cc, 600 cc (in 500L and 500R variants).

Performance

Horsepower:

13-22 hp (depending on variant and year)

Torque:

Approx. 30-40 Nm (depending on variant and year)

Fuel System

Carburetor:

Solex 28-PCI or similar downdraft carburetor.

Fuel Type:

Unleaded gasoline (historically, leaded gasoline was common).

Lubrication

Oil Capacity:

Approx. 2.5 - 3.0 liters (depending on model).

Cooling

Cooling Method:

Forced air cooling via a fan driven by the crankshaft.

🔧 Transmission

Standard

Type:

Manual

Gear Count:

4-speed manual (non-synchromesh on earlier models, synchromesh on later models).

Optional

Type:

Semi-automatic ('Autostick' on some models, involving a clutch pedal but automatic gear changes).

Features

Layout:

Transaxle design, integrating gearbox and rear differential.

Fluid Type:

Hypoid gear oil (e.g., SAE 90).

📐 Dimensions

Exterior

Length:

Approx. 2.97 meters (117 inches)

Width:

Approx. 1.32 meters (52 inches)

Height:

Approx. 1.32 meters (52 inches)

Weights

Curb Weight:

Approx. 400-500 kg (depending on model).

Gross Vehicle Weight Rating:

Approx. 700-800 kg.

🛡️ Safety Features

Ratings

Crash Safety:

Limited by contemporary safety standards; early models lacked significant passive safety features. Manual will detail basic safety system checks.

Active Features

Braking System:

Hydraulic drum brakes on all four wheels.

Parking Brake:

Mechanical handbrake operating on rear wheels.

Passive Features

Seatbelts:

Optional on early models, standard fitment on later versions.

Body Construction:

Monocoque construction with integrated body and chassis.

💡 Technology Features

Infotainment

Radio:

Optional radio, often a simple AM unit.

Dashboard:

Basic instrumentation including speedometer, fuel gauge, and warning lights. Minimalist design.

Driver Assistance

Features:

No advanced driver assistance systems (ADAS) found in modern vehicles. Focus on basic mechanical and safety system operation.

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000 km or 6 months (whichever comes first).

Spark Plugs:

Inspect every 10,000 km, replace as needed.

Ignition Timing:

Check and adjust at every major service or if running issues occur.

Fluid Specifications

Engine Oil:

SAE 20W-50 or SAE 30 (depending on climate and manufacturer recommendation). Check manual for specific API ratings.

Coolant:

Specific coolant mix as per Fiat recommendations (usually a 50/50 antifreeze/water mix).

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid.

Gearbox Oil:

SAE 90 hypoid gear oil.

Known Issues

Rust:

Prone to rust, especially around wheel arches, sills, and floor pans. Thorough inspection and preventative treatment are crucial.

Engine Overheating:

Due to the air-cooled nature and small displacement, overheating can occur in sustained high temperatures or heavy traffic. Ensure cooling fan and shrouds are in good condition.

Synchromesh Wear:

Early transmissions lack synchromesh, requiring careful gear changes. Synchromesh units can wear over time, leading to difficult shifting.

Carburetor Tuning:

The simple carburetor requires periodic adjustment for optimal performance and fuel economy.

Electrical Connections:

Older wiring can degrade, leading to intermittent electrical faults. Inspection and maintenance of connections are important.

📚 Vehicle History

Brand Heritage

Manufacturer:

Fiat (Fabbrica Italiana Automobili Torino)

Model Evolution

Introduction Year:

Evolution Highlights:

Significant updates included improved engines (500cc, 600cc), the longer-wheelbase Giardiniera estate, revised interiors, and the more powerful 500 Sport and Abarth versions.

Production End Year:

1975 (for the original 'Nuova 500' platform, though the successor 'Fiat 126' carried on similar design cues).

Production

Manufacturing Locations:

Turin, Italy, and various licensed production facilities worldwide.

Production Numbers:

Over 3.8 million units produced across all variants.

🏆 Awards & Recognition

Recognitions

Iconic Status:

Widely recognized as a cultural icon of the 1960s, synonymous with Italian design and lifestyle.

Classic Car Status:

Highly collectible classic car, popular in vintage rallies, shows, and everyday classic driving.