1972 FIAT 500 lift

*Dimension to be obtained by
adjusting the throwout lever.
FIG 5:1 Clutch assembly longitudinal section (new
500, 500D sedan and early station wagon)
5 : 2 Removal and installation
To remove the clutch unit from the vehicle proceed as
follows:
1 Remove the engine (Chapter 1) or separate the gear-
box from the engine as described in Chapter 6.
2 Remove the six screws and washers that secure the
clutch cover to the flywheel and gently ease the cover
assembly from the location dowels in the flywheel and
lift away. This will also free the driven plate.
3 Carefully clean the driven plate and clutch cover using a
compressed air jet.
4 To refit the clutch cover assembly to the flywheel
ensure that the driven plate is assembled the correct
way round as shown in FIG 5 :1 and place the cover
onto the flywheel using the locating dowels.
5 To ensure that the driven plate is correctly centred use
Fiat pilot A.62023 (see FIG 5 : 5) or a suitably sized
mandrel. Tighten the clutch mounting screws diagonally
a turn at a time to ensure correct location of the cover
onto the flywheel face. Finally, tighten to a torque
wrench setting of 5.8 to 7.2 Ib ft.
5 :3 Dismantling and inspection of clutch cover
New 500, 500D sedan and early 500 station wagon :
To dismantle the clutch cover assembly proceed as
follows:
60
To assemble the clutch cover assembly proceed as
follows:
1 Place the pressure plate complete with carrier ring bolts
and springs on Fiat fixture 62038 (see FIG 5 : 2).
2 Fit the six pressure springs in their respective seats on
the pressure plate. Insert the cups on the springs and
replace the cover.
3 Compress the clutch cover, continually checking that
the withdrawal lever supporting bolts are properly
guided into their holes in the cover. Onto the bolts, fit
the three withdrawal levers w i t h their relevant nuts and
washers.
4 Replace the carrier ring on the levers and hook up the
retaining springs. 5 :4 Assembly and adjustment
N e w 500 sedan1 Place the clutch cover assembly on Fiat fixture A.62038
as shown in FIG 5 :6 and lock the cover using the three
T-handles provided.
2 Release the w i thdrawal lever carrier ring springs and lift
away the ring.
3 Unscrew the withdrawal lever fixing nuts on the bolts
and lift out the levers and washers. Gradually slacken
the three T-handles so relieving the pressure of the
clutch springs. Remove the clutch cover, springs and
lever mounting bolts. Carefully mark all the components
to ensure that they are assembled correctly so ensuring
that correct balance of the clutch unit is obtained.
Inspection:
Thoroughly clean all parts using a compressed air jet
and proceed as follows:
1 Thoroughly check the springs for signs of overheating
causing loss of tension and compare the effective length
of the springs which when fitted new should have a
length of .9646 inch under a load of not less than 43 Ib.
If the spring length is less t h a n t h e recommended
dimension fit a complete new set of springs.
2 The length of the withdrawal lever carrier ring retaining
springs should be checked which under a normal clutch
load should be .7677 inch whilst the length'of the
expanded spring under a load of 4.85 ± .44 Ib should
be 1.1811 inch. If the springs show sign of heating or
weakening a new set should be fitted.
3 Check the withdrawa l levers and their bolts for exces-
sive wear and fit new parts as necessary.
4 Inspect the pressure plate for an excessively ridged sur-
face or signs of cracking. If the ridges are not too severe
the face may be refaced by turning on a centre lathe.
Also inspect the flywheel friction surface which may
also be refaced providing that the ridges are not too
severe.
5 Whenever the clutch driven plate linings are worn a new
driven plate should be fitted.
6 Inspect the clutch shaft splines and these should not
have a lengthwise clearance in excess of .0039 inch and
side clearance of .0118 inch w i t h respect to the driven
plate hub. Ensure that the driven plate slides easily on
the clutch shaft protruding from the rear of the gearbox
differential unit as any plate drag may be the cause of
d i f f i c u l t y in gear selection.

FIG 7:9 Adjusting rear wheel toe-in on '500 StationWagon'
FIG 7:10 Checking left rear wheel toe-in
84
6 Insert the inner spring between the axle shaft and the
wheel shaft and couple the spline sleeve to the joint
and tighten the screws to a torque wrench setting of
20.3 Ib/ft.
7 Reconnect the parking brake tie rod and adjust the
position of the cable using the two stretchers.
8 Refit the wheels and draw up the mounting screws to
a torque wrench setting of 32.5 to 39.8 Ib/ft. Carefully
lower the vehicle to the floor.
7 :6 Checking and adjusting rear wheel toe-in
This check should be carried out by a Fiat agent as
special setting equipment is necessary. However, details
of this check are given for reference purposes:
To check and adjust the rear wheel geometry proceed
as follows:
1 Place the vehicle on firmly based stands and remove
the front and rear wheels.
2 Install Fiat fixtures A.66062 as shown in FIG 7:12 to
enable correct spring compression and wheel location
in the vertical position.
3 Lift the rear suspensions by compressing the coil
springs and shock absorbers using garage hydraulic
jacks. Screw on the fixture lower shank until the
index registers with the mark 'Nuova 500' stamped on
the bracket. In this position the wheel plane is vertical
and the centre O (see FIG 7 : 6) of wheel shaft results
at 5.00 inch from the buffer stop bracket.
4 Secure Fiat support C.696/3 to the wheel drum and
connect gauge C.696 to the support. Tighten the two
clamping screws as shown in FIG 7:12.
5 Apply at the front of Fiat gauge C.696 bracket
numbered C.696/3 as shown in FIG 7:11.
6 Check that the pin mounted on the front end of the
bracket C.696/3 is in touch with the front suspension
swinging arm pin (see FIG 7:11). If these conditions
are not complied with, proceed with item 7.
Wheel toe-in angle
will vary by 0° 10' under
a movement of some 7/32 inch measured at 72.476 inch
from wheel centre for Model 500D, and at 76.413 inch
from wheel centre for 500 Station Wagon NOTE - - that the toe-in angle
Key to Fig 7 : 9 A Front support B Screw holes for
fixing support to underbody C Swinging arm pin nuts

CHAPTER 8
FRONT SUSPENSION AND HUBS
8:1
8:2
8:3
8:4
8:5
8:6Description
Front suspension removal and dismantling
Leaf spring
Swinging arms
Kingpin housing
Steering knuckle and wheel hub
8:1 Description
The independent front suspension assembly fitted to
the 'new 500' range comprises a transverse leaf spring
which is anchored to the body through two rubber
mountings and kingpins through 'estendblocks' as
shown in FIG 8:1. The leaf spring also acts as an anti-
roll bar which gives normal spring reaction even when the
front road wheels encounter a rough road surface.
Special polyethylene insulating strips are fitted
between the five springs leaves which are all clamped
together by t w o rubber cushioned clamps.
Upper movement of the kingpins in the swinging arm
is obtained by 'estendblocks'. The half arms are anchored
to the body as shown in FIG 8 : 3 and pivot on their pins
through rubber bushes. Double acting hydraulic shock
absorbers are fitted to the kingpin housings at the lower
end and anchored at the top to the vehicle body. Two
rubber buffers are secured to brackets mounted onto the
body to limit the spring oscillations. The spring centre
bolt is also fitted with a rubber pad.
8 : 2 Front suspension removal and
dismantling
To remove the front suspension assembly proceed as
follows:
F50087
1 Remove the hub caps and carefully slacken the road
wheel retaining bolts. Using a garage hydraulic jack
raise the front of the vehicle and place on firmly
based stands. Remove the road wheels.
2 Disconnect the steering linkages from the pitman arm,
the drag link and the steering knuckle arms.
3 Remove the shock absorber upper mounting nut from
the body, lift away the half rubber bush and push d o w n
the outer cylinder.
4 Blank off the brake fluid reservoir outlet by inserting
a suitable wooden peg through the reservoir filler
opening and disconnect the brake hydraulic lines at
the wheel cylinders.
5 Fit Fiat crossbeam Arr.2072 under the leaf spring
and support this, using a garage hydraulic jack.
6 Remove the self-locking nut securing the leaf spring
to the kingpin housing and ease o u t the spring
mounting bolt taking care not to damage the thread.
Also remove the nuts securing the swinging arm pin
to studs on the body and remove the swinging arm
assembly. Carefully lift out the adjusting shims and
spacers from the studs making a careful note of the
number of the shims and their locations.
7 Remove the nuts securing the leaf spring elastic
mounting to the body (see FIG 8 : 4) , and lower the 8:7
8:8
8:9
8:10
8:11Hydraulic damper
Front suspension assembly and
installation
Steering geometry
Modifications
Fault diagnosis

1
2
6
3
8
11
13
17
19
22
25
27
29
31
33
36
35 323430 28
26
24232120 ,1816 15 14 12 10 .9 .15 4
FIG 8:11 Sectional view of shock absorber
Key to Fig 8:11 1 Threaded shank, floor mounting
2 R o d 3 Cylinder upper blanking threaded ring
4 Seal housing 5 Rod seal 6 Tab spring 7 Spring cup
8 Gasket packing spring 9 Casing gasket 10 Vapour
pocket drain and chamber 11 Rod guide bush
12 Vapour pocket drain capillary hole 13 Dust shield
92
14 Casing 15 Working cylinder 16 Vapour pocket drain
passage 17 Valve lift limiting disc 18 Fluid passage orifice
19 Valve lift adjustment washer 20 Valve star-shaped spring
21 Inlet valve 22 Piston 23 Compression ring
24 Inlet valve holes in piston 25 Rebound valve holes
in piston 26 Rebound valve 27 Valve guide cup
28 Rebound valve spring 29 Piston mounting plug
30 Compensating valve 31 Compensating valve annular
passage 32 Compensating-and-compression valve carrier
plug 33 Compression valve 34 Compression valve orifices
35 Lower plug 36 Threaded shank, lower mounting
FIXTURE
FIG 8:12 Leaf spring position under full static loads'
on fixture A.66061 or A.74061
no signs of distortion or cracking which, if evident,
new parts must be fitted.
2 Check the steering knuckle surfaces, that are in con-
tact with the bearing inner races for any signs of
scoring or seizure.
3 Inspect the condition of the two upper thrust rings and
of the lower packing ring. Parts which show sign of
excessive wear must be renewed. Lower packing rings
are supplied in service in the thicknesses tabulated
below.
Once the items have been reassembled no appreciable
clearance should be evident between the steering
knuckle and the kingpin housing. This adjustment
is obtained by installing the lower packing ring of
suitable size.
4 Check that the seating on the drums for the roller
bearing outer races are smooth as no clearance is
allowable between the races and their seatings. Care-
fully inspect that the bearing cages and the rollers
show no signs of chipping, breakage, or discolouration
due to overheating.
5 Carefully inspect the seal which must not be torn and it
should locate perfectly both on the drum and the
steering knuckles.
Reassembly:
Reassembly is the reverse procedure to dismantling.
OversizesUnder-
sizes
.002 .004 .006 .008 .010 .012
.0979 .1016 .1036 .1056 .1076 .1095
.100 .102 .104 .106 .108 .110
.002 .004
.0957 .0938
.096 .094
Stand.
in.
in..0977
in..098

CHAPTER 9
THE STEERING SYSTEM
9 : 5 Relay lever and support
9 : 6 Steering rods
9 : 7 Front wheel toe-in
9 : 8 Fault diagnosis 9:1 Description
9 : 2 Steering wheel removal and refitting
9 : 3 Steering box removal and refitting
9 : 4 Steering box dismantling and reassembly
9:1 Description
The steering gear fitted to the new 500 range of
vehicles is of the worm screw and sector type with a
steering ratio of 1:13. The steering gearbox is located on
the front lefthand side of the dash wall on the scuttle as
shown in FIG 9:1. The steering gear comprises a pitman
arm and relay lever pivoting on a pin supported on the
body. A central track rod connects the pitman arm to the
relay lever. T w o track rods connect the pitman arm and
relay lever to the knuckle arms.
9:2 Steering wheel removal and refitting
To remove the steering wheel proceed as follows:
1 Disconnect the battery positive terminal clamp and
remove the horn control from the steering wheel.
2 Remove the cable from the push button seating and the
cable insulation sleeve.
3 Using a suitably sized box spanner or Fiat wrench
A.8279 unscrew the steering wheel to shaft nut as
shown in FIG 9:2.
4 Using the palm of the hands against the back of the
steering wheel rim gently tap the steering wheel
forwards so releasing it from the inner shaft.
F50097 5 Reassembly is the reverse procedure to dismantling.
Care should be taken to ensure that the front wheels
are located in the straight ahead position when the
steering wheel is being replaced otherwise the steering
wheel spokes will not be correctly positioned.
9 : 3 Steering box removal and refitting
To remove the steering box from the vehicle proceed
as follows:
1 From inside the vehicle remove the steering column
clamp bolt 6 (see FIG 9 : 3) after flattening the lock-
washer 7.
2 From the underside of the vehicle remove the t w o
tie rod locking nuts from the pitman arm and then using
Fiat tool A.46006 or a suitable t w o leg puller withdraw
the pins from the seats.
3 Remove the three nuts holding the steering box to the
body panel. Ease out the worm screw from the
steering shaft and lift away the steering box.
4 To refit the steering box is the reverse procedure to
dismantling. The steering box to body mounting nuts
should be tightened to a torque wrench setting of
14 Ib/ft to 18 Ib/ft.

RIGHT HAND TIE ROD
RELAY LEVER SUPPORTINTERMEDIATE TIE ROD!
STEERING BOX!
LEFT HAND TIE ROD
FIG 9 :1 Steering box, idler member and steering linkage arrangement on vehicle
FIG 9 : 2 Securing steering wheel mounting nut
Key
to Fig 9:2(Tightening torque: 29 to 36 Ib ft)
9 : 4 Steering box dismantling and reassembly
1 Remove the steering gear housing cover complete
with the adjusting screw and locking nut and drain the
oil from the unit.
2 Using Fiat puller A.4005.1.5 or a universal t w o leg
puller remove the pitman arm.
3 Remove the cotter pin from the lower thrust bearing
adjusting nut and unscrew this nut.
4 Remove the sealing ring at the sector shaft lower end
and using Fiat tool A.8065 loosen the eccentric bush
adjuster plate bolt and remove both the bolt and the
adjusting plate. Also remove the upper sealing ring.
98
5 Lift out the sector together with the upper thrust
washer and shims.
6 Remove the steering worm screw by pulling out from
below. The two bearing inner rings will remain on the
worm screw whilst the lower bearing outer ring will
remain in the housing.
7 Remove the oil seal using Fiat tool A.10110 followed
by the worm screw upper bearing outer ring using
Fiat tool A.66040 or a suitably sized drift.
Inspection:
1 Carefully inspect the sector teeth and the worm screw
threads to see that there are no signs of seizure,
indentations or scoring. Check that the contact faces
indicate that meshing between the two parts is taking
place at the centre.
2 Check the clearance between the eccentric bush 5
(see FIG 9 : 5) and the worm sector 11 which must not
exceed .0039 inch. These items have an initial
assembly clearance of .00 to .0016 inch. It should be
noted that if the eccentric bushing to sector shaft
clearance exceeds .0039 inch a new bushing should
be installed and its inner face reamed using Fiat
reamer U.0360.20.
3 Ensure that the worm screw is not distorted. The
permissible out of true is .0019 inch.
Adjustment:
1 If the backlash between the worm screw and the
sector is excessive it should be adjusted by first dis-
connecting the pitman arm and its relevant seal.
Remove the screw 7 (see FIG 9 : 5) fixing the abut-
ment plate 6. Rotate the eccentric bush 5 by the
adjustment plate and move the sector in towards the
worm screw. The adjustment plate should be secured
again using the second fixing hole.
Should the adjustment plate already be fixed in the
second hole remove the plate from the bush and
rotate one or more serrations and re-secure.

2 Using Fiat puller A.46023 as shown in FIG 8 : 9
remove the wheel grease cap.
3 Using a universal t w o leg puller or Fiat puller A.40005
together w i t h items 1 and 9 remove the wheel hub/
drum assembly having first extracted the splitpin if
fitted and released the hub retaining nut (see FIG
8:10).
Dismantling brake unit:
1 Using a compressed air jet thoroughly clean all com-
ponents of the brake assembly.
2 Make a note of the location of the shoe return springs
and gently ease the shoes away from the brake
backplate (see FIG 10:2).
3 Disconnect the hydraulic line from the rear of t h e
wheel cylinder and remove the t w o cylinder retaining
bolts. Lift away the hydraulic cylinder.
Brake shoe lining:
Check the lining thickness and if found to be exces-
sively reduced service replacement shoes must be fitted.
The minimum allowable brake lining thickness is .059
inch.
Thoroughly check the linings for signs of oil or grease
which, if evident, the shoes must be renewed and the
drums and oil seals thoroughly inspected for the cause
of oil ingress and the cause remedied before reassembly.
Do not fit odd brake shoes and do not mix materials or
unbalanced braking will result.
Do not allow grease, oil or paint to contact the friction
linings.
Brake drums:
Whilst servicing the brakes, thoroughly inspect the
drums for scoring, ovality or distortion as well as inspect-
ing for minute hair line cracks. The drums may be refaced
by using a centre lathe and finally finishing by lapping
the drums to smooth out possible tool marks. The
maximum permissible oversize beyond the nominal drum
diameter of 6.702 to 6.712 inch is .039 inch. This limit
must never be exceeded otherwise the strength of the
drum will be impaired or a reduction in braking efficiency
caused by the increase of shoe expansion travel and the
consequent diminished contact pressure.
No brake adjustment will be required on the new 500
Saloon models after the drum has been reassembled as
the self-adjusting device will accommodate for the shoe
position to the new drum diameter during the first
operation of the brake pedal.
Reassembly of front brakes:
This is the reverse procedure to dismantling. Ensure
that the pull-off springs are correctly fitted to the holes in
the webs of the brake shoes and that the shoes register
correctly in the slotted ends of the pistons and the
side
mounting plate.
Upon assembly of the hub and brake drum assembly
liberally pack the space between the two bearings w i t h
Fiat MR grease, and remount the hub according to the
instructions in Chapter 8.
F500
FIG 10:3 Section view of left side f r o n t brake assembly
(500 Station Wagon)
Key to Fig 10:3 1 Wheel cylinder 2 Shoe return spring
3 Adjusting cams 4 Shoe guide pin 5 Shoe with lining
6 Drum 7 Housing flange
BRAKE SHOE
ADJUSTING DEVICE
SHOE WEDGE
SELF
WHEEL CYLINDER
SHOE RETURN SPRING
PARKING BRAKE
SHOE CONTROL
RETURN SPRINGS
LEVER
SHOE LOCK PLATEBRAKE SHOES
SHOE RETURN SPRING
SHOE MOUNTING PLATE
FIG 1 0:4 Right rear wheel brake assembly (500 Sedan)
10:4 Rear brakes
Rear brake drum removal:
1 Remove the wheel trims and carefully slacken the road
wheel retaining bolts. Using a garage hydraulic jack
raise the rear of t h e vehicle and place on firmly based
stands. Remove the road wheels.
2 Remove the four drum to hub retaining bolts and
spring washers and carefully withdraw the drum from
the backplate assembly.
Dismantling brake unit:
1 Using a compressed air jet thoroughly clean all
components of the brake assembly.
105

FIG 10:5 Section view of right side rear brake assembly
(500 Station Wagon)
FIG 10:6 Sectional view of a self-adjusting device for
automatic brake shoe-to-drum clearance take-up (500
Sedan)
Key to Fig 1 0 : 6 1 Pin 2 Friction washers 3 Load spring
4 Bushing 5 Shoe 6 Self-adjustment slot 7 Stud
2 Make a note of the location of the shoe return springs
and gently ease t h e shoes away from the backplate
(see FIG 10:4)
3 Disconnect the hydraulic line from the rear of t h e
wheel cylinder and also the shoe operating lever return
spring, the pin, washer and clevis from the lever so
releasing the handbrake inner operating cable.
4 Remove the t w o cylinder retaining bolts and lift away
the hydraulic cylinder.
106
Brake shoe linings:
Refer t o Section 10:3.
Brake drums:
Refer to Section 10:3.
Reassembly of rear brakes:
This is the reverse procedure to dismantling. Ensure
that the pull-off springs are correctly fitted to the holes
in the webs of the brake shoes and that the shoes
register in the slotted ends of the pistons and the side
mounting plate.
Carefully retract the position of the brake shoes and
ease t h e d r u m towards the hub ensuring that the four
bolt holes line up correctly. Replace the four bolts
together with their spring washers, reconnect the hand
brake cable. Refit road wheel and wheel trim.
10:5 Master cylinder
Operation:
Hydraulic fluid is admitted to the master cylinder
through hole 8 (see FIG 10:7), it seeps through the gap
between the valve carrier ring 17 and the master cylinder
dowel and flows through the valve carrier ring holes 15
so reaching the hydraulic lines, therefore filling the
system w i t h fluid. When the brake pedal is depressed the
plunger is moved forwards by the pushrod 12. This
forward action of the plunger 9 and valve carrier 17 brings
the valve 16 to rest against the valve front face. The
forward movement is continued so causing the valve ring
16 to pass over the compensation hole 5 and cutting off
communication with the fluid reservoirs. From this point
compression of the hydraulic fluid commences.
Hydraulic fluid acting on the front and inner faces of
the valve enables perfect valve sealing even under high
operation pressures. When the pressure reaches the fluid
in the wheel cylinders (see FIG 10:8) , it forces the
plungers 3 apart and through the plungers stems so
operating the brake shoes.
After releasing the brake pedal, the combined action
of the brake shoe and master cylinder plunger return
springs sends the fluid back to the master cylinder and
all parts resume their original position. The connection
between the hydraulic
system and the reservoir is
restored.
As there are no conventional valves fitted in the master
cylinder and the communication orifice between the
system a n d the reservoir is amply dimensioned the
bleeding operation is very straightforward.
Master cylinder removal:
1 Disconnect the stoplight cables from the pressure
operated switch.
2 Using a tapered w o o d plug of suitable size blank t h e
hole in the brake f l u i d reservoir.
3 Screw out the four front and rear cylinder brake fluid
delivery line connections at the master cylinder.
4 Remove the t w o master cylinder retaining nuts and
spring washers and carefully ease the hydraulic
cylinder from the body.