1959 FIAT 500 heater

13 Remove all the bolts and washers joining the sump
casting to the crankcase making a special note of the
location of bolts of different lengths.
14 Mark the flywheel and crankshaft to ensure correct
reassembly and release the six flywheel retaining bolts
together with the lockwashers and lift away the fly-
wheel.
15 Using Fiat tool A.60156 on the two central studs, lock
the t w o cylinder barrels in place (see FIG 1 :11).
16 Turn the engine upside down ensuring that no weight
is placed on the studs.
17 Mark the connecting rods and end caps to ensure cor-
rect reassembly and remove the end caps. Place the
engine on its side and remove the cylinder barrels
clamp. Ensure t h a t t h e studs are clean and carefully
slide off the connecting rod-piston-cylinder assem-
blies from the crankcase.
18 Remove the six screws holding the rear bearing hous-
ing to the crankcase and lift away the housing. Remove
the six screws holding the front main bearing housing
to the crankcase and lift away its housing.
19 Carefully ease t h e crankshaft from the crankcase
moving it diagonally to assist w i t h d r a w a l .
20 To ensure no damage occurs to the long cylinder
barrel mounting studs these may be removed using
Fiat puller A.40010 or a universal stud remover as
shown in FIG 1 :12.
1 :6 Cylinder head removal, servicing and replace-
ment
Description:
The aluminium cylinder head is finned to increase the
cooling surface. Through bolts secure the head and the
two cylinders to the crankcase. The valves are controlled
by a camshaft through tappets, pushrods and rockers. The
connection between the head and the crankcase is via five
sleeves mounted directly between the head and crankcase,
and these accommodate the pushrods, lubricating oil and
passage for the crankcase gases. The cylinder head has
been
modified for the 110 F and later 120 engines as
they now incorporate a heater safety device as described
in Section 4 : 4 .
FIG 1:15 Cylinder head
17F500
The cylinder head should be removed whenever the
valves require attention or the engine to be decarbonized.
To remove the cylinder head proceed as f o l l o w s :
1 Remove the air cleaner, carburetter, rocker cover and the
screws securing the blower conveyor to the cylinder Removal of cylinder head: FIG 1 :17 Installing a valve guide using Tool A.60153
provided with pilot bush TOOL A. 6 0 1 5 3 -
WITH PILOT BUSH FIG 1:16 Cleaning valve guides
W I R E BRUSH A.11417 / BIS

CHAPTER 4
THE COOLING SYSTEM
4:1
4:2
4:3Description
Air outlet thermostat and shutter
Tension adjustment4:4
4:5
4:6Heating system safety device
Maintenance
Fault diagnosis
4:1Description
Sedan:
A l l the Fiat new 500 models covered by this manual are
aircooled by the forced air circulation system from a
centrifugal blower which is mounted on the generator
output shaft. The blower fan has fourteen vanes which are
arranged at various angles to reduce operating noise
during high-speed operation. A specially designed
cowling as shown in FIGS 4 : 1 and 4:2 conveys the air
from the blower and distributes it to the various parts of
the exterior of the engine.
The main components of the air cooling system are as
follows:
1 Air intake compartment at the rear end of t h e body.
2 An elbow pipe for the admittance of incoming air.
3 A flexible air pipe connecting the elbow pipe to the
conveyor.
4 A spiral air conveyor which contains the centrifugal fan.
5 Distribution ducting for directing the air flow to various
parts of the engine.
6 A bellows type thermostat is fitted to the cowling which
operates a butterfly shutter controlling the air outlet
from the engine which ensures control of the engine
operating temperature.
F50053 When the shutter is in the open position, engine heated
air is allowed to disperse to the outside of the engine
cowling. With the shutter in its closed position, the air is
recirculated in the engine cowling so ensuring a quick
engine warm-up period.
It should be noted that by operating the heater lever
which is located on the centre tunnel at the rear seat,
warmed air flowing out from the engine cowling is passed
to the inside of the car for heating and demisting purposes.
Station wagon:
Refer to FIG 4 : 2 where it will be seen that as the engine
is located on its side underneath the luggage compartment
floor the ducting has been modified and the air intakes are
located at the rear of the side windows. A linear blower is
housed in the engine baffles and cowling and is attached
to the drive end of the generator.
The thermostat 'C' (see FIG 4 : 2) is located on the
righthand side of the engine cowling and should start
opening the engine heated air outlet shutter ' D ' when the
temperature of the air rises to 1 7 8 - 1 8 5 ° F and the shutter
should be wide open when the air is at a temperature of
196-207°F.

CHAPTER 12
THE BODYWORK
12:1
12:2
12:3
12:4
12:5
12:6
12:7Bodywork finish
Interior and chrome cleaning
Door trim and accessories
Door handles and locks
Removing regulator and door glass
Removing windshield glass
Removing rear side windows12:8
12:9
12:10
12:11
12:12
12:13
12:14Removing rear window glass
Front compartment lid
Engine compartment lid
Folding top
Sun roof
Seats
Interior heater
12:1 Bodywork finish
Large scale repairs to body panels are best left to
expert panel beaters. Even small dents can be tricky, as too
much hammering will stretch the metal and make things
worse instead of better. Filling minor dents and scratches
is probably the best method of restoring the surface. The
touching up of paintwork is well within the powers of
most car owners, particularly as self-spraying cans of
paint in the correct colours are now readily available. It
must be remembered, however, that paint changes colour
w i t h age and it is better to spray a whole wing rather than
try to touch up a small area.
Before spraying it is essential to remove all traces of
wax polish with white spirit. More drastic treatment is
required if silicone polishes have been applied. Use a
primer surfacer or paste stopper according to the amount
of filling required, and when it is dry, rub it down with
400 grade Wet or Dry paper until the surface is smooth
and flush with the surrounding area. Spend time on
getting the best finish as this will control the final effect.
Apply the retouching paint, keeping it wet in the centre
and light and dry round the edges. After a few hours of
drying, use a cutting compound to remove the dry spray
and finish with liquid polish.
F500127
12:2 Interior and chrome cleaning
The cloth upholstery of the seating and the rear
compartment lining must be regularly cleaned to ensure
long life and preserve its attractive appearance. Any dust
or dirt that is blown into the car will settle on the uphol-
stery and will tend to wear the cloth causing an unsightly
appearance. It is recommended that the dust is wiped off
using either a vacuum cleaner or a stiff brush. To remove
ordinary soiling of the upholstery cloth proceed as
follows:
1 Using luke warm water and a neutral soap and a piece
of clean cloth wipe over the upholstery in the direction
of the nap.
2 Repeat the operation using a clean damp cloth and
warm water but no soap.
3 Allow the upholstery cloth to dry, use a stiff brush
against the direction of the upholstery nap to restore
its original fluffy look.
To obtain best results, any stains must be removed as
soon as possible otherwise as time passes they will
become more difficult, if not impossible to remove.
Certain stains require specific solvents and the instruc-
tions must be strictly adhered to.

BOW
FIG 12:17 Sun Roof top in unlatched position
FIG 12:18 Diagrammatic view of car heating system
Key to Fig 12 :18 1 Thermostat controlling shutter 2 Shutter, engine cooling air outlet 3 Lever, heater hand control
4 Warm air outlet slots 5 Demister valve control knobs 6 Windshield demister diffusers
NOTE—The car may be also equipped, optionally, with a heating booster as shown in FIG 12:19
134
4 Rear moulding for the top lining mounting onto the
rear metal panel.
5 Top lining retaining strap which is secured to the front
end of t h e rear metal panel using a bridge bracket.
6 Bracket for strap which hooks up the top lining when
in the folded position.
Dismantling and reassembly is a straightforward
operation providing that careful note is made of the
location of all screws that are removed. To reassemble
it is suggested that the rear metal panel is mounted on
the body shell first. The collapsible top assembly is then
positioned and secured to the rear metal panel using eight
rivets. The top covering should be stretched to the closed
position and secured to both framing side arms to t h e
body shell wells using the special screws. 500F and L
models are similar, but with a single central sun roof latch:
t h e rear metal panel is no longer removable.
12:13 Seats
Front seats:
The front bucket seats comprise a one-piece tubular
frame covered with imitation leather or cloth padded

cushion and back rest. A number of rubber straps are
hooked across the frame under the cushion and in a
sheath covering on the seat back.
The bottom of the front seat frame ends are provided
with sliding guides which run in guide rails attached to
the floor. The sliding guides are pivoted on the frame
tubes to allow for forward tilting of the seats giving better
access to the rear compartment. Two rubber pads
provide cushioning of the seat frame on the guide rails
as shown in FIG 12:11. The control lever for seat
adjustment is fitted in the frame righthand tube to permit
unlocking of the seats so that they may be adjusted to
individual drivers requirements.
Rear seats (Sedan):
The rear seat comprises of a foam rubber cushion and
back. The seat back is cemented to the rear floor and
body shell bulkhead. The rear seat lining is of fabric and
imitation leather. The seat lining is held in place by four
self-tapping screws, t w o of which secure the floor below
the back window and two the lining at the base of t h e
back rest. Included with the seat assembly is a masonite
floor which is fitted below the rear window.
Rear Seat (Station Wagon):
The rear seat back rest is pivoted at the base of its
frame so that it can be folded down to form a load plat-
form surface. In the upright position it is retained in place
by t w o brackets mounted on either side of the body below
the side
windows.
12:14 Interior heater
Description:
Interior heating is accomplished by recirculation of
warm air from the engine cooling system through engine
cowling. Referring to FIG 12:18 a hose conveys warmed
air from the engine cowling to the centre tunnel floor
where warm air flows out through two slots being cut on
the windshield delivery hoses. Air admission can be
adjusted by turning the control lever to the right which
operates the tunnel throttle valve at the rear seat.
The heating system may be fitted with a booster which
comprises a casing on the front exhaust pipe being
connected to the engine cowling and the warmed air
passage tunnel. Warm air flowing to the car interior is
heated to higher temperature than that from the standard
version of heater (see FIG 12:19).
Windshield demisting:
As will be seen from FIG 12:18, t w o air hoses w i t h
throttle valves for airflow control are relayed from a casing
F500135
FIG 12:19 Diagram of booster
Key to Fig 12:19 1 Thermostat controlling shutter
2 Car interior heater booster 3 Hand control unit
in front of the centre of the floor tunnel. Flexible hoses
are connected to two air diffusers which are located on
the instrument panel and parallel to the windshield glass.
When the throttle valves 5 (see FIG 12:18) are operated
through the two control knobs, warmed air is directed
onto the windshield glass so preventing misting, frosting
or icing in adverse weather conditions.
Inspection:
Ensure that t h e lever, the lever spring and butterfly
valve hinge are not distorted. Check that the ducting to
the tunnel as well as the upper and lower hoses are air-
tight which if not, should be renewed.