seat adjustment FIAT 500 1971 1.G Workshop Manual

CHAPTER 1
THE ENGINE
1 :1
1 :2
1 :3
1 :4
1 :5
1 :6
1 :7
1 :8
1:9
1 :10
1 :11Description
Engine removal (sedan—all versions)
Engine removal (station wagon)
Engine disassembly (sedan—all versions)
Engine disassembly (station wagon)
Cylinder head removal, servicing and
replacement
Timing gear overhaul
Crankcase and cylinders
Piston assembly
Connecting rods
Crankshaft and main bearings
1 :1 Description
The 'New 500' two-cylinder aircooled engine operates
on the four-stroke 'Otto Cycle' and is fitted directly to
the transmission unit which incorporates the rear drive
assembly as shown in FIG 1 :1 and FIG 1 :2.
With the power unit fitted at the rear several advantages
are obtained including better load distribution to the
wheels when the vehicle is loaded, elimination of propeller
shaft reducing the size of centre tunnel and better use of
available space.
The cylinder block comprises t w o cast iron cylinder
barrels w i t h cooling fins. The bottom of the cylinders fit
into machined seats in the aluminium crankcase.
The aluminium crankcase carries eight studs on which
are located the t w o cylinder barrels w i t h the aluminium
cylinder head on the top.
A two bush crankshaft of special cast iron is fitted into
the lower half of the crankcase. The crankshaft is
F5009 provided with a counterweight and is hollow to allow for
lubrication.
The steel connecting rods have thin wall bearing halves
on the big-end, and bronze bushes in the small-end. The
offset piston pin is of steel and retained in the piston by
two circlips.
Light alloy pistons are used and are of the taper-oval-
shaped type with a maximum diameter at the base of the
skirt, along an axis perpendicular to the piston pin. Pistons
are fitted with four rings as follows, one compression at
the top, two standard oil scraper rings and one side slotted
oil scraper ring.
The one-piece aluminium cylinder head is finned to
provide a larger cooling surface and carries the inlet and
exhaust manifolds.
The inlet passages merge into a single centralized
flange onto which is mounted the carburetter. The exhaust
passages run almost parallel to the axis of the engine. 1 :12
1 :13
1 :14
1 :15
1 :16
1 :17
1 :18
1 :19
1 :20
1 :21
1 :22Flywheel and starter ring gear
The oil pump
Lubrication, oil filter, relief valve
Valve timing
Valve stem to rocker clearance
Engine assembly (sedan—all versions)
Engine assembly (station wagon)
Power plant mounting
Adjustment of generator and fan belt drive
Modifications
Fault diagnosis

Cylinder head installation:
To refit the cylinder head proceed as follows:
Place a new cylinder head joint on the cleaned faces of
the cylinder barrels. Insert the rocker pushrod and
lubrication pipe sleeves together with the relevant
gaskets and rings.
Fit the washers and nuts to the studs and tighten to
fingertight.
Tighten the nuts in the order shown in FIG 1 :44 and
FIG 1 :46 to a torque wrench setting of 18.1 Ibft. Reset
the torque wrench to a new setting of 23.9 Ibft and
tighten the nuts once more in the recommended order.
Replace the pushrods in the correct order.
Refit the rocker shaft ensuring correct location of the
lubrication tube to the rocker shaft and replace the
plain and lockwashers. Tighten the nuts to a torque
wrench setting of 15.2 Ibft. Reset the tappet to rocker
clearance adjustment.
Connect the t w o exhaust side manifolds to the cylinder
head. Using new gasket refit the spark plugs and HT
cables. Replace the rocker cover fitted with a new cork
gasket and blower conveyor to the cylinder head
securing screws. Refit the carburetter and reconnect its
fuel line and controls. Refit the air cleaner and elbow
and connect the rocker cover breather pipe (if fitted).
1
2
3
4
5
1 :7 Timing gear overhaul
Camshaft:
The cast iron camshaft is located in the crankcase and is
supported at either end in sets machined directly in the
crankcase. No bushes are used. The camshaft is driven by
a chain from the crankshaft at half engine speed and
operates the overhead valves through tappets, pushrods
and rockers (see
FIG 1 :20).During engine overhaul the camshaft journals and cam
faces should be free of score marks or signs of seizure and
have a bright mirror finish.
The distributor drive gear should be inspected for tooth
wear which if excessive means that the camshaft must be
replaced.
Tappets:
The tappets should be inspected for signs of seizure or
excessive wear. The end surface that is in contact with the
camshaft should be smooth without signs of excessive
wear. Any slight scratches or indentations may be
removed using a very fine oil stone.
Pushrods and sleeves:
The pushrods operate in special axially resilient sleeves
that are compressed on assembly between the cylinder
head and the crankcase. It is through these sleeves that
the engine sump is vented also through which the oil
returning from the cylinder head passes.
Two rubber O-ring seals are fitted to each sleeve to
ensure an oil t i g h t seal between the cylinder head and
crankcase. The sleeves should be checked for distortion
and exact equal length and when refitting new seals must
always be fitted.
The pushrods should be checked for straightness and
the t w o ends that contact the rocker setscrew and the
F50019
The crankcase is an aluminium casting suitably ribbed
to ensure correct air cooling. The main bearing and cam-
shaft bearing bores are machined as also are the tappet 1 :8 Crankcase and cylinders During valve gear overhauls the clearance between the
rocker shaft bore and the rocker must be checked. The
maximum permissable wear between these t w o parts is
.0059 inch. It is recommended that the part which is most
worn be renewed, or in extreme cases both parts. Rocker and rocker shaft: tappet seat must not show any signs of roughness or
excessive wear. 3 Oil shield (for intake valves only) 4 Snap ring
5 Rocker 6 Upper spring cup 7 Valve spring
8 Lower spring cup 9 Pushrod 10 Tappet
11 Oil seal ring 12 Pushrod sleeve 13 Seal ring 1 Intake valve 2 Upper cup lock Key t o Fiq
1 :20 FIG 1:20 Valve, pushrod and tappet assembly FIG 1:19 Camshaft. The arrow points to the lube oil
outlet port

5 Using the graduated sector check that all the valve
timing angles are as detailed in Technical Data.
Readjust the valve stem to rocker arm clearance to the
correct setting.
1:16 Valve stem-to-rocker clearance adjustment
It is important that the clearance between the valve
stem and rocker is kept to the recommended figure
of .0059 inch, measured when the engine is cold.
If the clearance is excessive operating noise will occur
and if less than recommended the valves will stay open
too long which will result in damage to the valve face
and its seating.
Inspect the contacting surfaces for scoring or pitting:
if it is excessive, new parts must be fitted. Also check
the condition of the rocker-to-valve and rocker ball
head-to-pushrod contact surfaces are free from wear or
pitting. The faces must have a mirror finish.
The oilway in the rockers and shaft must be thoroughly
inspected and free from sludge, otherwise lubrication
failure will occur.
The assembly clearance between the rocker arm and
shaft should be .00063 to .00217 inch and the clearance
between the rocker shaft and the shaft support should
be .00020 to .00138 inch with a maximum wear limit of
0039 inch.
Turn the engine until the valves of one cylinder are in
balance, that is, the inlet valve opening and the exhaust
valve closing. The other cylinder will now have both valves
fully closed. Adjust the valves on this second cylinder by
loosening the locknut, and turning the
adjuster as shown in
FIG 1 : 43 to obtain the desired clearance measured with
a feeler gauge. Adjust the clearances on the other cylinder
in the same manner.
1 :17 Engine assembly (sedan — all versions)
To reassemble the engine proceed as follows:
1 Thoroughly clean and dry all the parts, ensure that all
drillings are free from dirt or sludge and place on a
clean dry surface.
2 Carefully install the cylinder-piston-connecting rod
assemblies w i t h new paper gaskets between the
cylinders and crankcase seats.
3 Refit the big-end bearing shells to the connecting
rods, ensuring that they are free from any dirt or
metallic particles. Carefully ease t h e crankshaft into
the crankcase, lubricate the main journals with clean
engine oil, place a new paper gasket between the
supporting member and the flywheel end of the
crankcase. Install the supporting member and bearing
assemblies. Secure the supporting members with the
screws and special toothed washers.
4 Locate the connecting rod big-end half onto the
crankpin journals, liberally lubricate the journals with
fresh engine oil, fit the remaining shell half, matching
bearing end cap and tighten the bearing cap nuts to a
torque wrench setting of 23.9 Ib ft.
5 Inspect the camshaft bearing bores and remove any
burrs w i t h a hand scraper wetted with oil. Carefully
slide in the camshaft ensuring the cam lobes or gear
teeth do not score the front bearing bore.
6 Fit a new timing gear cover paper gasket held in
place w i t h a little grease. Install the outer thrust ring,
F50029 inner thrust ring, shoulder washer and slide on the
camshaft drive sprocket, locking it with the Woodruff
key. Assemble the timing chain and driven sprocket,
ensuring that the timing marks on the sprocket are
indexing as shown in FIG 1 :41. Secure the driven
sprocket with six screws and lockplates and care-
fully bend down the lockplates.
7 Install the timing gear cover, the oil pump, oil pressure
relief valve and seal assembly. Secure w i t h nuts,
special toothed washers and plain washers located
in the same manner as was noted on dismantling.
Locate the oil pump suction horn and secure with the
nuts and toothed washers.
8 Install the flywheel in the same relative position to the
crankshaft as was noted on dismantling. Replace the FIG 1 : 4 3 Adjusting the rocker clearances using the
optional service tools. Refer to Technical Data for the
correct clearance on early and late engines FIG 1 :42 Graduated sector C.673 for valve gear
timing
TIMING MARK

4 Mixture too weak
5 Water in fuel system
6 Petrol tank vent blocked
7 Incorrect valve clearance
(c) Engine idles badly
1 Check 1 and 6 in (b)
2 Air leak at manifold joints
3 Slow-running jet blocked or out of adjustment
4 Air leak in carburetter
5 Over-rich mixture
6 Worn piston rings
7 Worn valve stems or guides
8 Weak exhaust valve springs
(d) Engine misfires
1 Check 1, 2, 3, 4, 5, 8, 10, 13, 14, 1 5, 16, 17 in (a);
2, 3, 4 and 7 in (b)
2 Weak or broken valve springs
(e) Engine overheats
1 Generator and fan drive belt too loose
2 Shutter or thermostat seized in closed position
(f) Compression low
1 Check 14 and 15 in (a), 6 and 7 in (c) and 2 in (d)
2 Worn piston ring grooves
3 Scored or worn cylinder bores
(g) Engine lacks power
1 Check 3, 10, 1 1 , 13, 14, 15, 16 and 17 in (a), 2, 3, 4
and 7 in (b) 6 and 7 in (c) and 2 in (d). Also check (e)
and (f)
2 Leaking joint washers
3 Fouled sparking plugs
4 Automatic centrifugal advance not operating
(h) Burnt valves or seats
1 Check 14 and 15 in (a), 7 in (b) and 2 in (d). Alsocheck (e)
2 Excessive carbon around valve seat and head
(j) Sticking valves
1 Check 2 in (d)
2 Bent valve stem
3 Scored valve stem or guide
4 Incorrect valve clearance
(k) Excessive cylinder wear
1 Check 11 in (a) and see Chapter 4
2 Lack of oil
3 Dirty oil
4 Piston rings gummed up or broken
5 Badly fitting piston rings
6 Connecting rods bent
(l) Excessive oil consumption
1 Check 6 and 7 in (c) and check (k)
2 Ring gaps too wide
3 Oil return holes in piston choked with carbon
4 Scored cylinders
5 Oil level too high
6 External oil leaks
7 Ineffective valve stem oil seals
(m) Crankshaft and connecting rod bearing failure
1 Check 2 in (k)
2 Restricted oilways
3 Worn journals or crank pins
4 Loose bearing caps
5 Extremely low oil pressure
6 Bent connecting rod
(n) High fuel consumption (see Chapter 2)
(o) Engine vibration
1 Loose generator bolts
2 Blower blade assembly out-of-balance
3 Incorrect clearance for rear engine mounting rubber
F50033

FIG 2:5 Starting device (choke) diagrammatic section
KeytoFig2:5 A Device fully inserted B Device partially inserted C Device disinserted 2 Air inlet 16 Bowl
19 Throttle 21 Primary venturi 24 Secondary venturi 26 Mixture duct 27 Mixture leaning air orifice
28 Transition duct 29 Transition mixture orifice 30 Starting mixture orifice 31 Transition orifice
32 Starting mixture orifice 33 Starting valve 34 Mixture duct 35 Starting device air orifices 36 Rocker
37 Lever return spring 38 Starting device control lever 39 Control wire screw 40 Cover with support for starting
device control bowden 41 Starting valve spring 42 Spring casing. 43 Starting jet emulsion air orifice
44 Air emulsion reserve well orifice 45 Starting reserve well 46 Starting jet
F50037
FIG 2 : 4 Diagrammatic section of Weber 26.IMB
carburetter
KeytoFig2:4 1 Air corrector jet 2 Air inlet
3 Idle speed mixture duct 4 Idle speed jet holder
5 Idle speed air orifice 6 Filter cover 7 Filter
8 Fuel inlet connection 9 Needle valve seat 10 Needle
11 Float pivot 12 Float 13 Idle speed jet
14 Main jet holder 15 Main jet 16 Bowl
17 Idle speed mixture adjustment screw 18 Idle speed
mixture orifice 19 Throttle 20 Transition hole
21 Primary venturi (not interchangeable) 22 Emulsion
orifices 23 Emulsion well 24 Secondary venturi
(not interchangeable) 25 Main nozzle
design with a 1.0236 inch diameter throat measured at the
height of the throttle shaft. The amount of charge passing
to the manifold is controlled by a throttle butterfly valve
from an accelerator pedal operating a lever secured to the
throttle valve shaft via a cable. The carburetter is fitted with
a progressive action starting device which enables the
driver to suit the mixture richness to the most arduous of
starting conditions, and will enable the engine to run
evenly until it reaches its normal operating temperature.
A dampened needle valve ensures a smooth running
engine as it is not affected by engine vibrations and there-
fore giving a constant fuel level in the carburetter bowl. A
secondary venturi is incorporated in the single casting of
the carburetter body and this has a diameter of 0.8268 inch.
Carburetter operation:
Filtered air flows through the venturi 24 (see FIG 2 :4)
where it mixes w i t h fuel flowing from the nozzle 25 and
the charge is then conveyed to the cylinders through the
primary venturi 21 and throat, where the throttle butterfly
19 controls the amount of charge.
Petrol flows from the main fuel line to the bowl 16
through a gauze filter 7 and needle valve 10, where the
float 12 pivoting at point 1 1 , controls the opening of the
needle 10 so maintaining a constant fuel level. From the
bowl 16 fuel reaches the emulsion well 23 via the metered
main jet 15 where, after having been mixed with the air
coming from the metered air corrector screw 1, through
the emulsion orifices 22 and spray nozzle 25, it finally
reaches the Venturis where it mixes w i t h the air stream

FIG 2 : 6 Weber 26.IMB carburetter starting device
(choke) end
Key to Fig 2 : 6 1 Choke device cover 2 Bowden
mounting screw 3 Nut and screw, choke bowden wire
4 Choke control lever A Position of lever 4 for 'fully
inserted' choke B 'Partially inserted' choke
C 'Disinserted' choke
caused by the engine suction and the charge is then drawn
into the cylinders.
The secondary venturi 24 is to increase the vacuum
around the nozzle 25 and to carry the charge to the centre
of the primary venturi 2 1 .
When the engine is idling, fuel is carried from the well
23 via an appropriate passage to the idle speed jet 13
where it is mixed with the air coming from the air inlet 5.
Through duct 3 and idle speed orifice 18 (adjustable by
means of a taper point screw 17), the fuel reaches the
carburetter throat, past throttle butterfly 19 where it is
further mixed with the air stream drawn in by the engine
vacuum through the gap around the throttle in the idling
speed position.
From the d u c t 3 the mixture can also reach the car-
buretter throttle chamber through a transition hole 20
which is located in exact relation to the throttle butterfly.
The purpose of this progression hole is to permit a smooth
acceleration of the engine from the idling speed, this being
proportional to the increase in the throttle opening.
Starting device:
This enables the engine to be started when it is cold
under the most arduous of weather conditions. It is con-
trolled by means of a lever placed behind the gearshift
lever and must be progressively adjusted to its normal
rest
position as the engine reaches the normal operating tem-
perature. The starting device comprises a valve 33 (see
FIG 2 : 5) actuated by the lug of the rocker 36 which is
connected to the control lever 38 by a suitable shaft. By
38
pulling the device control fully across through lever 38
and rocker 36, the valve 33 is lifted from its seating and
brought into the 'fully open' position. Refer to diagram 'A'
(FIG 2 : 5) . Under these conditions the valve 33 closes
the air hole 27 and the mixture hole 29 and uncovers
mixture orifices 30 and 32 which also communicate with
the starting jet 46 through a duct 26 and air holes 35.
With the valve 33 partially open the hole 29 may com-
municate with the carburetter throat through the valve
central slot, duct 28 and the hole 31 drilled in the venturi
21 corresponding with the venturi restriction.
When the throttle is set at the idling speed position, the
engine vacuum caused by the operation of the starter
enables the fuel contained in the recess of jet 4 6 , in the jet
and in the reserve well 45 to be mixed w i t h the air coming
from holes 43 and 44. The mixture arrives through the duct
26 and holes 30 and 32, at the same time as air passing
from the holes 35, past the throttle through duct 34 so
permitting easy starting of the engine.
After the engine has fired initially, the device will deliver
a charge with a rich petrol/air ratio so as to permit regular
running of the engine whilst it is cold. As soon as the
engine has warmed up to normal operating temperature
this charge would obviously be too rich and therefore it is
necessary to gradually ease o f f the operation of the starting
device as the engine reaches its normal operating tempera-
ture. During this adjustment the valve 43 slowly uncovers
the hole 27 which will permit a greater amount of air to
enter through the spring guide hole 42 so weakening the
mixture at the same time as closing the progression holes
30 and 32 and air holes 35 the amount of mixture is also
reduced. See diagram ' B ' (FIG 2 : 5).
The hole 29, the duct 28 and the hole 3 1 , which are
drilled in the venturi 21 permit a regular progression of
acceleration whilst the engine is cold as well as when it is
at normal operating temperature. By opening the throttle
butterfly 19 to increase the speed of the engine the
vacuum acting on the duct 34 is decreased. This causes a
drop in the amount of fuel delivered through duct 34 with
consequent irregular running of the engine but, through
hole 3 1 , duct 28 and hole 29 some charge is sucked in by
the vacuum formed in the restriction of the venturi, caused
by the opening of the throttle and this automatically com-
pensates for the reduction in the delivery through the duct
34.
When the starting device is not in operation, valve 33
covers the hole 29 and so preventing the passing of fresh
charge. Diagram ' C (FIG 2:5).
Engine s t a rting:
So that full advantage may be taken of the progressive
action starting device the engine should be started as
follows:
1 Cold starts:
The starting device should be moved across the position
'A', (FIG 2 : 6) . Once the engine has fired push the control
in partially.
2 Warm starts:
Only partially move the starting device as shown in
position 'B' (FIG 2 : 6).

3 Engine warm-up:
As the engine begins to warm up to its normal operating
temperature, gradually push home the starting device
lever so as only to supply the engine with the richened
charge enabling the cold engine operation to be smooth
and regular. Position ' B ' (FIG 2:6).
4 Normal car driving:
Once the engine has reached its normal operating
temperature the starting device should be completely
brought out of operation by bringing the control lever to
the position 'C (FIG 2:6).
Idle speed adjustment:
The idling speed of the engine is adjusted by means of a
throttle setscrew and the mixture setscrew, the position of
which are shown in FIG 2:7. The throttle screw allows for
the adjustment of the throttle butterfly opening, the coni-
cal mixture setscrew meters the amount of charge issuing
from the idling speed passage which causes the mixture
to blend with the air flowing past the throttle that leaves a
gap between its edges and the throat walls. This ensures
a correct petrol/air mixture ratio best suited to the engine
requirements giving smooth operation.
The engine idling speed must always be adjusted when
the engine is at its normal operating temperature and then
setting the throttle butterfly position to its minimum open-
ing position by adjusting the throttle setscrew so giving a
steady engine speed. Turn the mixture screw in or out so
as to set the mixture richness to the most suitable ratio for
the selected throttle opening. This will accomplish a fast
but steady idling. Reduce the minimum throttle opening
slightly by adjusting the throttle setscrew until the best
idling speed is obtained.
Adjustment of fuel level in float chamber:
The needle valve, seating and float are easily accessible
for inspection by removing the carburetter top cover. Before
checking the petrol level in the float chamber, ensure that
the needle valve seat is screwed well home and that the
gasket is in place. Also check that the calibrated orifice in
the valve seat is unobstructed and not worn and finally
check that the needle slides freely in its guide. Should the
valve and seating be leaking, then the valve assembly must
be renewed. Check that the float is not distorted or punc-
tured and that it moves on its pivot without resistance or
excessive play. Again renew the float assembly if there is
any doubt. To check the level proceed as follows:
1 Check that the needle valve 3 (see FIG 2 : 8) is screwed
tight on its seat.
2 Keep the carburetter cover 1 upright or else the weight
of the float 9 will lower the ball 8 fitted on the needle 4.
Check that with the cover held in the vertical position
and the float arm 6 in slight contact with the ball 8 of the
needle 4, the float is 5/16 inch away from the cover with
its gasket 2
fitted flat against the cover face.
3 Check that the float travel is 5/16 inch and if necessary
bend the lug 5 to give the required settings.
4 If the float 9 is not correctly positioned, bend the float
arms 7 until the correct adjustment is obtained. Ensure
that the arm 6 is perpendicular to the needle axis and
F50039
does not show any rough spots or indentations which
might impair free movement of the needle. Check that
the float 9 freely moves about its pivot pin.
Every time a new float or needle valve assembly is fitted
the above detailed adjustment operations must be com-
pleted to ensure correct fuel levels. FIG 2 : 8 Float adjustment data
Key to Fig 2: 8 1 Carburetter cover 2 Cover gasket
3 Needle valve seat 4 Needle 5 Lug 6, 7 Arms
8 Needle ball 9 Float 7 .2756 inch 15 .5906 inch FIG 2 : 7 Weber 26.IMB carburetter in place on
engine. Idle speed is adjusted by working respectively
on throttle setting screw and mixture metering screw
THROTTLE SETTING SCREW
MIXTURE METERING SCREW

FIG 2 : 9 Weber 26.IMB carburetter cover components
Key toFig 2 : 9 1 Float 2 Carburetter cover 3 Float pivot 4 Needle valve gasket 5 , 6 Needle valve seat and needle valve
7 Cover gasket 8 Filter strainer 9 Gasket 10 Filter inspection plug
Carburetter cleaning:
To thoroughly clean the carburetter proceed as follows:
1 Passages. All fuel passages have a diameter that is
specially calibrated to ensure best operating conditions.
It is therefore essential that any dirt or scale that has
been deposited by petrol must be removed. Thoroughly
clean with petrol and blow dry using a compressed air
jet directed through all the passages in the castings. It is
essential that no drills or other metal objects be passed
through the jets or the passages otherwise these could
alter the finely calibrated diameters.
2 Calibrated parts. Idling and main jet holders, and the
relevant bayonet coupled jets are easily removed by
using a suitably sized wrench or screwdriver. To clean
the different calibrated parts, thoroughly wash in petrol
and blow dry using a compressed air jet. Do not use any
fine drills or metallic points as these may alter the fine
calibration of the orifices. Should it be necessary to dis-
mantle the carburetter adjustment components for
inspection always ensure that after reassembly of the
parts that they are seated correctly to avoid possible
operating troubles in the future.
3 Filter. To clean the filter unscrew and remove its plug
10 (see FIG 2 : 9) located on the top of the carburetter
cover and then gently ease o u t t h e filter. Wash the filter
carefully in petrol, also ensure that the filter seat is clean
and then blow dry using a compressed air jet.
2:7 Modifications
The Weber 26.IM B carburetter has undergone a number
of minor changes during the development of the Fiat 500
models, but no changes in servicing procedure are made
necessary. Jet sizes and other calibrations are detailed
in Technical Data.
From 1970, the mounting flange of the carburetter is
slightly modified to incorporate a different mixture
adjustment screw, as shown in FIG 2:11.
40
Throttle valve components:
The throttle valve shaft should rotate freely in its guides
and this should be checked when the engine is at its
normal operating temperature. Any excessive clearance
caused by wear or the throttle valve butterfly distorted are
liable to cause irregular engine operation which will be
more pronounced at idling speed. Should the above con-
ditions be evident then the throttle valve butterfly and the
shaft assembly together with its sealing rings must be
renewed.
FIG 2:10 Jets, jet holders and choke valve
Key to Fig 2:10 1 Choke valve 2 Spring
3 Spring retainer and guide 4 Lock ring 5 Air bleed jet
6 Emulsion well 7 Choke jet 8 Idling jet holder and jet
9 Main jet holder and jet 10 Main jet holder gasket

FIG 2:12 illustrates the starting device fitted to
26.IMB.4 and later carburetters. It differs from earlier
units in detail, principally in having fewer starting mixture
orifices 30 and 32 into the mixture duct 26.
2 : 8 Carburetter operation and adjustment,
Weber 26. OC
The new 500 station wagon is fitted with the Weber
26.OC carburetter which is of a horizontal draft design to
suit the engine which is fitted in the horizontal position.
The carburetter is fitted with a progressive action starting
device which enables the driver to adjust the mixture rich-
ness to the most arduous of starting conditions, and will
enable the engine to run eyenly until it reaches normal
operating temperature.
A dampened needle valve ensures a smooth running
engine as it is not affected by engine vibrations and there-
fore giving a constant fuel level in the carburetter bowls.
A secondary venturi is incorporated in the single casting
of the carburetter body.
Carburetter operation, starting device:
The petrol from bowl 23 (see FIG 2:13) reaches the
starting jet 37 through the duct 35. By operating the choke
lever 31 to the end of its stroke, the valve 30 is lifted from
its seat and brought to the 'fully open' position as shown
in diagram 'A' (FIG 2:13). Under these conditions the
valve 30 uncovers both the starting mixture ducts 28 and
29. With the throttle set in the idling speed position the
engine vacuum created by the operation of the starter
motor causes the fuel contained in the recess of j e t 37 in
the jet and the reserve
well 36 to be mixed with the air
coming from the air jet 38.
The mixture arrives through the ducts 28 and 29 at the
same time as air from holes 34, past the throttle so per-
mitting easy starting of the engine.
A
B
C
FIG 2:12 Section of later starting device
Key to Fig 2:12 A Cold starting position B Warming up position C Normal running position
2 Air inlet 21 Primary venturi 24 Secondary venturi 26 Mixture duct 27 Air bleed 30,32 Starting mixture orifices
33 Valve 34 Mixture duct 35 Air orifices 38 Rocker 39 Lever return spring 40 Control lever 41 Control wire screw
42 Cover and cable support 43 Valve spring 44 Spring guide and retainer 45 Starting jet emulsion air duct 46 Emulsion
air reserve well duct 47 Reserve well 48 Starting jet
F50041 Once the engine has initially fired the starting device will
deliver a mixture whose petrol/air ratio is such that the
engine will run regularly even though it is cold. As soon as
the engine warms up this rich charge would be excessive
and therefore it becomes necessary to gradually ease back
the operation of the starting device. As this is occurring,
the valve 30 gradually covers up the mixture duct orifice 28
so as to weaken the mixture while by closing the duct 29
gradually. It also reduces the amount of mixture delivered
by the carburetter as shown in diagram ' B ' (FIG 2:13). FIG 2:11 Mounting flange modification: A earlier, B
later (dimensions in mm)

1
14,5
7,52 9 48 35
76
FIG 2:15 Float level setting diagram Weber car-
buretter type 26.OC
7.5 = .29 inch 14.5 = .57 inch
Key to Fig 2:15 1 Carburetter cover 2 Cover gasket
3 Needle valve 4 Valve needle 5 Lug 6, 7 Arms
8 Needle ball 9 Float
Idle speed adjustment:
The idling speed is adjusted by movement of the throttle
setscrew and the mixture setscrew. The throttle screw
allows for the adjustment of the throttle opening whereas
the conical mixture setscrew has the purpose of metering
the amount of charge issuing from the idling speed pas-
sage, which will then mix with the air flowing past the
throttle which when correctly set for normal idling speed
should leave a gap between its edges and the throat walls.
This ensures a correct petrol/air ratio best suited to the
engine requirements and smooth operation.
The idling speed should always be adjusted with the
engine running and at its normal operating temperature
by first setting the throttle to its minimum opening by
turning the throttle setscrew so enabling an accurate
adjustment to be made. Then slowly turn the mixture set-
screw either in or out so as to adjust the mixture petrol/air
ratio to the most suitable for the throttle opening, this will
accomplish a fast and steady idling speed which should be
then reduced by closing the throttle opening slightly by
easing back the throttle setscrew. This adjustment should
continue until the best idling speed is obtained.
Adjustment of fuel level in float chamber:
To check and adjust the level of fuel in the carburetter
float chamber proceed as follows:
1 Check that the needle valve 3 (see FIG 2:15) is
screwed tight on its seat.
2 Keep the carburetter cover 1 upright or else the weight
of the float 9 will lower the ball 8 fitted on the needle 4.
F50043
Key to Fig 2:17 1 Filter housing 2 Spring hooks
3 Filter element 4 Cover 5 Air suction pipe, hoses
and clamps 6 Re-circulation pipe for blow-by gases and
oil vapoursFIG 2:17 Removing the air cleaner, 500F, L
2
1 3
4.
6
5
FIG 2:16 Taking out the filter element, 500, 500D AIR CLEANER ELBOW
HOSE
AIR CLEANER BODY
FILTER ELEMENT Check that with the cover held in the vertical position
and the float arm 6 in slight contact with the ball 8 of the
needle 4, the float is .2953 inch away from the cover
w i t h its gasket 2 fitted flat against the cover face.
3 Check that the float level is .5709 inch from the cover
face and if necessary bend the lug 5 to give the required
setting.
4 If the float 9 is not correctly positioned bend the float
arm 7 until the correct adjustment is obtained. Ensure
that the arm 6 is perpendicular to the needle axis and
does not show any rough spots or indentations which
might impair free movement of the needle. Check that
the float 9 moves about its pivot pin.
Every time a new float or needle valve is fitted the above
detailed adjustment operations must be completed to
ensure correct fuel levels.