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Fiat

Fiat 500 1957-1973 Service and Repair/Workshop Manual

Fiat 500 1957-1973 Service and Repair/Workshop Manual

$16.99
$16.99
Rea SlutsÄld
Frakt berÀknas i kassan.
Vehicle data plateRef 393363
Brand
Fiat
Vehicle
Cars
Models covered
500
Years
1957, 1958, 1959, 1960, 1961, 1962, 1963, 1964, 1965, 1966, 1967, 1968, 1969, 1970, 1971, 1972, 1973
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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đŸ·ïž Basic Information
Identification
Make:
Fiat
Model:
500
Generation:
Nuova 500
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
Codes
Chassis Codes:
110F, 110FB, 110FD, 110FDB, 120F, 120FB, 120FC, 120FCD, 130F, 210F, 210FB, 210FC, 230F, 230FC, 230FCD, 230FD
👋 Introduction
Market Position
Segment:
Microcar/City Car
Target Audience:
Enthusiasts, DIY mechanics, and owners of classic Fiat 500 models seeking to maintain and repair their vehicles.
Competitive Analysis
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.
Key Features
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.
📋 Manual Details
Coverage Areas
General Maintenance:
Included
Troubleshooting:
Included
Engine Service Repair:
Included
Transmission Service Repair:
Included
Brake System:
Included
Electrical System:
Included
Suspension:
Included
Wiring Diagram:
Included
Periodic Lubrication:
Included
Steering:
Included
Cooling System:
Included
Fuel Injection Fuel System:
Included
Emission System:
Included
Heater Air Conditioning:
Included
Engine Control System:
Included
Chassis Body:
Included
Restraint System:
Included
Interior:
Included
Differential Drive Axle:
Included
Page Count
Estimated Page Count:
Varies (typically 200-400 pages for comprehensive manuals of this era)
Manual Type
Type:
Service and Repair/Workshop Manual
Language
Language:
English
Format
File Format:
PDF
Compatibility:
All Versions of Windows & Mac
Software Requirement:
Adobe PDF Reader
📖 Manual Coverage
Systems Covered
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.
Procedures Included
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.
Technical Depth
Depth:
Comprehensive. Covers everything from routine maintenance and adjustments to full engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF, ensuring clear diagrams and readable text. Searchable text functionality is expected for efficient navigation.
Print Quality
Printability:
Designed to be printable, allowing for physical use in a workshop environment.
Binding Type
Digital Format:
Digital Download (PDF)
Paper Type
Digital Medium:
Electronic delivery via download link.
⚙ Engine Specifications
Primary Engine
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
Performance
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)
Fuel System
Carburetor Type:
Single Solex or Weber downdraft carburetor
Fuel Type:
Unleaded gasoline (may require lead substitute or additives for original engines).
Lubrication
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)
🔧 Transmission
Standard
Type:
4-speed manual synchromesh gearbox
Optional
Automated Manual:
Some later models/conversions may feature automated manual transmissions, but the manual covers the standard gearbox.
Features
Drive Layout:
Rear-wheel drive
Gear Ratios:
Specific ratios for each gear and final drive are detailed in the manual.
Fluid Type
Gearbox Oil:
GL-4 gear oil, typically SAE 75W-90 or SAE 80W-90.
Fluid Capacity
Gearbox Oil Capacity:
Approx. 1.2 - 1.5 liters (1.3 - 1.6 US quarts)
📐 Dimensions
Exterior
Length:
Approx. 2970 mm (117 in)
Width:
Approx. 1300 mm (51 in)
Height:
Approx. 1330 mm (52 in)
Wheelbase:
Approx. 1840 mm (72 in)
Weights
Curb Weight:
Approx. 400-470 kg (880-1040 lbs)
Gross Vehicle Weight Rating:
Varies by model, typically around 700-800 kg
Cargo
Trunk Volume:
Limited, located at the front, approximately 0.1 cubic meters (3.5 cubic feet)
đŸ›Ąïž Safety Features
Ratings
Crash Test Data:
No formal crash test data comparable to modern standards is available. Vehicle design predates rigorous crash safety regulations.
Active Features
Braking System:
Hydraulic drum brakes on all four wheels.
Steering:
Direct steering system, contributing to maneuverability but offering limited power assistance.
Passive Features
Body Structure:
Lightweight steel monocoque construction.
Restraint Systems:
No airbags or pre-tensioned seatbelts standard. Seatbelts may have been optional or added later.
💡 Technology Features
Infotainment
System:
Basic. Typically comprises a simple AM radio (often optional) and basic dashboard instrumentation (speedometer, fuel gauge, oil pressure warning light).
Driver Assistance
Features:
None by modern standards. Features are purely mechanical and rely on driver input.
Connectivity
Options:
None.
🔧 Maintenance
Service Intervals
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.
Fluid Specifications
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).
Known Issues
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.
📚 Vehicle History
Brand Heritage
Fiat Legacy:
Fiat's history of producing affordable and popular small cars, beginning with the FIAT 500 'Topolino'.
Model Evolution
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
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.
🏆 Awards & Recognition
Recognitions
Cultural Impact:
Iconic status as a symbol of Italian design and 'La Dolce Vita'. Frequently featured in films and media.
Ratings
Classic Car Status:
Highly regarded classic car, with strong collector appeal and participation in vintage rallies and events.

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Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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