Fiat 500 D and F Models
1960-1973
Workshop Repair Manual

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This comprehensive workshop manual is the same manual issued by FIAT to their dealers and technicians.

Suitable for the home workshop mechanic or professional technician this manual will help you maintain and restore your Fiat 500. Very easy step by step instructions with lots of diagrams.

This workshop manual is for the following Fiat models made between 1960-1973:

• Fiat 500 D Sedan (Type 110D)
• Fiat 500 D Convertible
• Fiat 500 Station Wagon (Early type)
• Fiat 500 F Sedan (Type 110F)
• Fiat 500 Station Wagon (Late type)
• Fiat 500 L

Below is a comprehensive contents list:

GENERAL INFORMATION
Main specifications of engines
Main specifications of vehicle’s performances
Capacities
Unit identification data
Jacking up and towing the car
Ordering spare parts
Service hints
Car keys

ENGINE (479cc & 499cc)
Description of components
Miscellaneous operations
Crankcase and cylinders
Pistons - pins - rings
Connecting rods - rod bearings and bushings
Crankshaft and main bearings
Cylinder head - valves – guides and springs
Timing gear
Specifications - repair and rebuild standards
Tightening reference
Engine bench test
Troubles and corrections

FUEL SYSTEM, LUBRICATION SYSTEM, COOLING SYSTEM, POWER PLANT MOUNTINGS
Fuel system
Fuel pump
Air cleaner
Fuel tank
Weber 26 imb 1 and 26 imb 3 carburetors
Lubrication system
Centrifugal oil filter
Oil pump
Low oil pressure indicator sending unit
Cooling system
Air outlet thermostat and shutter
Generator and fan drive belt
Power plant mountings
Engine service equipment

CLUTCH, GEARBOX, DIFFERENTIAL
Clutch
Clutch servicing instructions
Clutch withdrawal mechanism
Gearbox-differential unit
Gearbox
Differential and final drive
Swing axle shafts and slip joints
Gearshift control mechanism

FRONT SUSPENSION AND WHEELS
Removal and disassembly
Leaf spring
Swinging arms
Kingpin housing
Steering knuckle and wheel hub
Assembly and installation
Checking and adjusting front
Wheel camber and caster
Tightening reference
Service equipment
Specifications
Trouble diagnosis and corrections

REAR SUSPENSION, WHEELS AND SHOCK ABSORBERS
Description
Removal
Swinging arms
Coil springs
Installation
Checking and adjusting rear wheel toe-in
Service equipment
Tightening reference
Specifications
Hydraulic shock absorbers
Trouble diagnosis and correction

STEERING GEAR AND LINKAGE
Servicing the steering gear
Steering rods
Checking front wheel toe in
Tightening reference
Service equipment
Specifications
Trouble diagnosis and corrections

BRAKES, WHEELS AND TYRES
Hydraulic service brakes
Hand parking brake
Brake tightening reference
Brake service equipment
Brake system specifications
Hydraulic brake system
Trouble diagnosis and
Corrections
Wheels and tires

AIR CONDITIONING, CHASSIS TIGHTENING REFERENCE
Car air conditioning
General chassis tightening reference

ELECTRIC SYSTEM
Battery
Generator
Generator regulator
Starter
Ignition system
Lighting system
Gauges and controls

BODY
Construction of body shell
Doors
Glazing
Inner trimming
Front compartment lid
Engine compartment lid
Bumpers
Front panel ornament
Folding top
Sun roof
Trim mouldings and strips
Seats
Repairing accident damaged cars
Floor alignment fixture
Car care

MAINTENANCE
Maintenance
Lubricant specifications
Tool equipment
Tool kit

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