Archive for the ‘ 500 Workshop ’ Category

This entry is part 3 of 3 in the series DIY Mechanic

Note: These are some awesome DIY postings found on an Italian website with literal translations from Google so please bare with the imperfect English.

The Original posting is here to give credit where credit is due.
http://www.cinquino.net/topic.asp?TOPIC_ID=2706

Disassembling the engine and gearbox from the 500

Materials:

- car jack,
- 2 jack stands,
- ratchet or wrenches # 7-8-10-13-17,
- Phillips screwdriver,
- large flat head screwdriver and a small on,
- pliers,

Raise up the back of the 500 and place it on the 2 jack stands high enough so you can get under it to work.
Disconnect the negative battery cable and unscrew the fuel cap to relieve the pressure.


1 - Open the hood, disconnect the wire of the license plate light, and the cable that holds the hood. Close the lid and unscrew the nut with a #10 wrench, and then remove it.
2 - Disconnect the wires from the spark plugs and remove the distributor cap, as well as the small ground wire that connects to the body with a #8 wrench shown below p.11


3 - Remove the belt guard heat shields where you see marked with 2 yellow dots....... [More]

This entry is part 2 of 3 in the series DIY Mechanic

Note: These are some awesome DIY postings found on an Italian website with literal translations from Google so please bare with the imperfect English.

The Original posting is here to give credit where credit is due.
http://www.cinquino.net/topic.asp?TOPIC_ID=2706

 

 Lower your Fiat 500 by modifying your leaf springs 

 Finally I will explain how to flip around your crossbow leaf spring to give your car a  lower profile without it being lowered way too much. With this job you will have a happy medium.
This was a technique used many years ago before they came out with those aftermarket lowering springs, for many it was too low. 

With this job you will have a middle way. 
I will Start by saying that if the crossbow is to be thrown away, the job will come out bad! So if thats the case buy a new one first.
So here is how  the crossbow  appears in my  Nuova original Fiat, slightly oxidized

 

Here we must first remove the clamps that hold the outer leaves of the crossbow, To do this all you need is.... [More]

This entry is part 2 of 3 in the series Charts

 Ratio chart
VersionIIIIIIIVREVERSEFinal
reduction
New 50036/1131/1526/2021/2424/11x36/198/41
500 sport36/1131/1526/2021/2424/11x36/198/39
500 D. 500 F. 500 L.
500 Giardiniera
500 Autobianchi
37/1031/1526/2021/2424/11x36/198/41
500 R37/1031/1526/2021/2424/11x36/198/39

This entry is part 1 of 3 in the series Charts

VersionPowerIntake open
before t . d. c
Intake close
After b.d.c.
Exhaust open
Before t.d.c.
Exhaust close
After b.d.c.
New 500
Until October 1957
13 Hp19°50°50°19°
New 500
Since 19/57 until 03/58
15 Hp20°50°50°20°
New 500
Since march 1958
16,5
Hp
70°50°19°
500 sport21 Hp25°51°64°12°
500 D, 500 SW
Giardiniera
And Autobianchi
17.5
Hp
25°51°64°12°
500 F and 500L18 Hp25°51°64°12°
500R18 Hp26°57°66°17°

Open and Shut Case

When does that valve open anyway? Well, to determine this we have to [More]

This entry is part 1 of 3 in the series DIY Mechanic

Note: These are some awesome DIY postings found on an Italian website with literal translations from Google so please bare with the imperfect English.

The Original posting is here to give credit where credit is due.
http://www.cinquino.net/topic.asp?TOPIC_ID=1516

 

Cleaning the oil flinger.  

Tools needed
- pipe wrench  #10
- container to drain oil

Inside the motor of 500 oil is filtered through two components:

1 - The retina at the start of the oil suction tube,

2 - The centrifugal filter.

The 500 does not have a cartridge filter, but a centrifugal Slinger that  causes the oil and heavy impurities to get stuck to the wall + the Slinger.
Then the flow continues into the crankshaft via the camshaft axis reaches the cylinder banks and the oil sensor and then  continues ... ... continues to fall in the cup from the valve cover.

PROCEDURE - With a key #10 removed the 6 nuts that hold the lid of the centrifuge (see photo), put a container under the lid to catch the oil trapped in the Slinger, under this cover you will find the real Slinger. Dis-assembly of the centrifugal device involves the extraction of the locking nut, the nut is tightened with a high torque and therefore not easy to remove.

- Check  the walls of the slinger and the walls of the lid that there is no residual sludge (see photo) if there is scrape the layer of loose dirt with a screwdriver and clean with a rag soaked in oil. Be careful not to leave any strands of cloth in the slinger, it could block the  flow of oil causing engine damage.
- Once cleaned reassemble the cap of the slinger putting a new gasket.
The correct mounting position of the cap is manditory because  it carries on its surface a references to the ignition timing (TDC)  (see photo).  [More]

TYPE OF LUBRICANTCORRECT CASTROL GRADE
ENGINEMonograde oil applicableCastrol Multigrade Oil
Air temperature constantly in the range of:
above 86 ºF
above 30 ºC
SAE 4020W - 50 Castrol GTX
32 - 86 ºF
0 - 30 ºC
SAE 3020W - 50 Castrol GTX
5 - 32 ºF
-15 - 0 ºC
SAE 20E10W - 40 Castrolite
below 5 ºF
below -15 ºC
SAE 10W10W - 40 Castrolite
TRANSMISSIONSAE 90 EPCastrol Hypoy
FIAT GREASESCASTROL PRODUCT
King pinsJOTA 1 High melting point lithium-based grease
Castrol LM Grease
HubsMR3
DynamoMR3Molybdenum di-sulphide based grease
Castrol MS3 Grease
Starter motorMR2
Brake fluidFIAT AzzuraFluid to Specification SAE J1703b
Castrol Girling Brake Fluid

Fiat 500 Chassis Numbers

by | September 30, 2009 | In 500 Workshop No Comments

Fiat 500 Chassis Numbers

Here is a chart to help you find out the year your Fiat 500 was built by reading the chassis number.

For help where to locate your chassis number see : Identifying Your Fiat & Engine

 

 

 

Year Model chassis#s From chassis#s
To
#Produced
1957 Nuova 500 (1)* 000,101 028,538 28,438
1958 Nuova 500 (2)* 028,539 051,383 22,845
1959 Nuova 500 (3)* 051,384 117,657 66,274
1960 Nuova 500 (3) 117,658 181,137 63,480
1960  500 D 182,001 202,091 20,091
1961  500 D 202,092 288,933 86,842
1962  500 D 288,934 421,569 132,636
1963  500 D 421,570 607,204 185,635
1964  500 D 607,205 800,834 193,629
1965  500 D 800,835 822,520 21,685
1965  500 F 824,001 1,056,856 232,855
1966  500 F 1,056,857 1,333,077 276,220
1967  500 F 1,333,078 1,674,690 341,612
1968  500 F- 500 L 1,674,691 2,001,357 336,666
1969  500 F- 500 L 2,011,358 2,362,389 351,031
1970  500 F- 500 L 2,362,390 2,742,562 380,172
1970  500 F- 500 L-Desio 6,003,760 6,030,952 27,193
1971  500 F- 500 L-SicilFiat 5,016,129 5,057,789 41,660
1971  500 F- 500 L 2,742,563 2,976,954 251,350
1971  500 F- 500 L-Desio 6,030,953 6,081,301 50,348
1972  500 F- 500 L 2,976,955 3,096,091 102,178
1972  500 F- 500 L-SicilFiat 5,057,890 5,096,649 38,759
1972  500 F- 500 L-Desio 6,082,433 6,120,574 33,998
1972  500 R-SicilFiat 5,096,796 5,104,051 7,255
1972  500 R-Desio 6,120,654 6,136,250 15,596
1973  500 R-SicilFiat 5,104,052 5,155,805 51,753
1973  500 R-Desio 6,136,251 6,154,362 18,111
1974  500 R-SicilFiat 5,155,806 5,203,179 47,373
1975  500 R-SicilFiat 5,203,180 5,231,518 28,338

Number of Fiat 500 produced from 1957 to 1975 (about)


3,770,908
*
(1) Models: Normal Economic
(2)Models: Economic-Normal-Sport
(3)Models: Transformable-Sunroof-Sport
 500 Giardiniera  
1960  500 Giardiniera 000,051 027,418

 27,368

1961  500 Giardiniera 027,419 062,437

 35,019

1962  500 Giardiniera 062,438 082,233

 19,796

1963  500 Giardiniera 082,234 113,706

 31,472

1964  500 Giardiniera 113,707 138,044

 24,337

1965  500 Giardiniera 138,045 161,182

 23,137

1966  500 Giardiniera-Desio 161,183
1967  500 Giardiniera-Desio 214,999

 53,817

1968  500 Giardiniera-Autobianchi 215,000 234,999

 20,000

1969  500 Giardiniera-Autobianchi 235,000 249,999

 15,000

1970  500 Giardiniera-Autobianchi 250,000 258,999

 9,000

1971  500 Giardiniera-Autobianchi 259,000 273,999

 15,000

1972  500 Giardiniera-Autobianchi 274,000 287,999

 14,000

1973  500 Giardiniera-Autobianchi 288,000 297,999

 10,000

1974  500 Giardiniera-Autobianchi 298,000 307,999

 10,000

1975  500 Giardiniera-Autobianchi 308,000 312,999

 5,000

1976  500 Giardiniera-Autobianchi 313,000 319,999

 7,000

1977  500 Giardiniera-Autobianchi 320,000 327,000

 7,001

 

 

 

This entry is part 3 of 3 in the series Charts


Original Fiat 500 colors  1957 - 1977, divided into periods and models of production . For some models, these colors were only available on certain versions.

Learn to where and how to read your Fiat 500s color code by clicking here:  Identifying Your Fiat & Engine

 

 

Nuova 500 Standard (1957 - 1960)

colornamecodedate used


Rosso corallo
Coral red
13510 -1957 / 03-1959


Avorio chiaro
Light ivory
21403-1958 / 03-1959


Avorio
Ivory
23510-1957 / 03-1958


Verde chiaro
Light green
36207-1957 / 12-1957


Verde chiaro
Light green
37212-1957 / 03-1959


Celeste medio
Medium blue
40303-1958 / 03-1959


Blu chiaro
Light blue
42907-1957 / 12-1957


Blu medio
Medium blue
44901-1959 / 12-1959


Blu scuro
Dark blue
45610-1957 / 03-1959


Celeste chiaro
Light sky
46107-1957 / 10-1957


Celeste crociera
Cruise sky
47210-1957 / 03-1958


Grigio chiaro
Light grey
67210-1957 / 03-1959
Grigio
Grey
49507-1957 /09-1957
[More]

This entry is part 5 of 5 in the series Routine Maintenance

Maintenance to be done every 6,000 Miles (10,000km) or 6 months if sooner:

Do all the more frequent tasks and in addition:

  1. Engine oil change. Use a top quality multigrade oil suitable to temperature (see page) without any other additives. Drain the oil from the plug on the right of the sump when the car is hot (17 mm spann) into a pan that will have plenty of room, to prevent spillage. Allow the oil to drip for at least 10min. Clean the drain plug, and check its washer. Refit the drain plug, and refill the sump with 4 pints. check the level on the dipstick and add a little more if required. The oil should be changed at 3,000 miles if the car is used mostly for town work, particularly in winter, or in dusty conditions.
    If you have just bought an old car and the oil is very black flush out first with flushing oil. When draining this jack up the left of the car once most of the oil is out to make any dregs flow out better.
  2. Air Cleaner. - Replace the cartridge. When dusty conditions prevail, replace cartridge more often.
  3. Spark plugs. - fit clean plugs. With the gap set to .025 in (.6mm) plugs are Marelli CW 6N, Champion L87Y (or L7) or Bosch W225 T 1.  The porcelain plug insulators and the leads, must be kept clean to ensure easy starting.
  4. Ignition distributor. Undo the clips and remove the cap. Pull off the rotor arm. Check that the points are not contaminated with oil or dirt. Check their gap. This should be .019 to .012in  (.47 - .53mm) This may be almost impossible to measure other than [More]
This entry is part 4 of 5 in the series Routine Maintenance

Maintenance to be done every 3,000 Miles (5,000km).

Do all the more frequent tasks and in addition:

  1. Check the car underneath. look at the rubber dirt excluders on the steering ball joints. Check the flexible hydraulic pipes for the brakes ( one at each front wheel, one just inside each rear suspension forward pivot), for rubbing or leaks.
  2. Check under the car for oil leaks (or new oil leaks if minor seepage already occurs).
  3. Lubricate the grease nippled on the king pins. Jack up the car to get the weight off the front suspension. Clean the nipples ( one each side ). Pump in grease till it extrudes clean at the ends of the king pin. Wipe off excess grease ( a little left around helps keep out wet ).
  4. Check the fan belt tension. It should be possible to press it down 1/2 inch ( 1cm ) using one finger and hard pressure. To tighten, undo the three nuts clamping the two parts of the dynamo pulley, and move a spacer from between the two halves to the outside. Do not over-tighten or the dynamo bearings will be overloaded. Excessive slackness wears the belt by slipping. New belts stretch, and require checking two or three times in their first few hundred miles.
  5. Gearbox and differential.Check oil level which must reach the bottom face of the plug fitted on the right side of gearbox. If necessary, add FIAT W 90 (SAE 90 EP) oil.
  6. Steering box.Check oil level which must reach the bottom face of the plug fitted on box left side. If necessary, add FIAT W 90
  7. Air cleaner.Clean cartridge accurately by shaking off the dust and blowing with a low-pressure air blast. Replace cartridge, if clogged.
    When dusty conditions prevail, clean and replace cartridge more often.
  8. Generator and fan drive belt.Check and, if necessary, adjust belt tension; correct sag under a pressure of 22 lbs (10 kg): about 3/8” (1 cm). (see page)
  9. Ignition distributor.Check breaker point gap which must be .0185” to .0209” (0,47 to 0,53 mm).
  10. Spark plugs.Clean spark plugs and check if electrode gap is .0 197” to .0236” (0,5 to 0,6 mm).
  11. Brake fluid reservoir.Check level and, if required, top up to the strainer. Use exclusively the special FIAT blue brake fluid (or equivalent non-mineral HI) fluid).
  12. Tires.To equalize tire wear, rotate tires in criss-cross fashion.
  13. Battery.Check terminals and clamps for tightness and cleanliness,

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