Fiat 500

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]

CLUTCH SERVICING INSTRUCTIONS

This also frees the driven plate.

To install clutch on flywheel, use as a guide flywheel locating dowels.

Prior to tightening down clutch mounting screws, align driven plate.

(pic. installing the clutch on flywheel using pilot to center the driven plate)

Pilot Bushing.

Whenever clutch unit is disassembled, it is es­sential to check that pilot bush on crankshaft for,

- clutch shaft rear support

- is not damaged or ex­cessively worn.

Clutch shaft tang on bush end must also be found in good condition.

Max. clearance between clutch shaft tang and bush must not be greater than .0059" (0,15 mm), otherwise pilot bush must be replaced.

(pic. clutch assembly installed on engine)

Disassembly.

Unhook the withdrawal lever carrier ring springs and take out the ring.

Unscrew the withdrawal lever fixing nuts on bolts and remove the levers and washers; slacken gradually the three T-handles to relieve pressure of clutch springs.

Next, take off clutch cover, springs and lever mounting bolts.

(Pic.location dowels on flywheel for clutch centering)

Pressure Springs.

When servicing the clutch, always check springs for perfect efficiency. In case springs are exces­sively weak - i. e., the spring length of .9646 (24,5 mm), corresponding to the actual assembly value, is obtained with a load of less than 43 lbs (19,5 kg) - replace the springs.

(Pic. pressure spring specifications)

Withdrawal Lever Carrier Ring Retain­ing Springs.

The length of closed springs, under rated clutch load, is .7677' (19,5 mm), while the length of ex­panded springs (under a load of 4.85 .44 lbs -2,2 ± 0,2 kg) should be 1.1811" (30 mm). If an excessive weakening of springs is noticed, replace the springs.

(Pic. withdrawal lever carrier ring retaining spring specifications)

Withdrawal Levers.

Check the withdrawal levers and their bolts for excessive wear, and replace [More]