light FIAT 500 1962 1.G Owner's Guide

Lamp brilliance varies w i t h the speed of t h e car:
Check the condition of the battery. Examine the battery
connections. Make sure they are tight and renew faulty
cables.
11:10 Panel and warning lights:
All the gauges are clustered in a single instrument
mounted on the dashboard above the steering column.
Incorporated in this cluster is the parking light pilot light,
generator charge indicator, fuel reserve supply indicator,
low oil pressure indicator, and the speedometer w i t h
mileage recorder.
The parking lamp indicator glows green when the
ignition lock switch key is in either position 1 or 2 once
the toggle switch on the instrument panel has been
operated.
The generator charge indicator shows red only when
the ignition is turned on. It should be extinguished when
the generator output is sufficient for battery charge
(12.6 ± 0.2 volts) with the engine running at a speed
of 1100 rev/min and the headlights switched off.
The fuel reserve supply indicator shows red only when
the ignition is turned on and the amount of fuel in the
petrol tank has dropped to approximately .8 to 1.1
Imp. gallons.
The low oil pressure indicator shows red only when the
ignition is turned on and should be extinguished when
the oil pressure reaches 7.1 to 21.3 Ib/sq in, and opens
the sending unit contacts. Once the engine is at normal
operating temperature but at a speed below 1000 rev/
min the indicator might light up even the pressure is under
control and with normal operation.
All the bulbs fitted to the above described units are of
the tubular 2.5W type and to renew a bulb extract the
bulb holder from the rear of t h e instrument cluster and
release the bulb which is attached by a normal bayonet
coupling.
Fuel reserve supply indicator sender u n i t:
The fuel reserve supply indicator should be checked for
correct indication by allowing the fuel tank to empty and
then inserting .8 to 1.1 Imp. gallons at which stage the
light should extinguish. Any failure to do so should be
checked as follows:
1 Ensure that the indicator bulb operates correctly.
2 Check for complete circuit between the sender unit and
the indicator bulb.
3 If the sender unit float bracket is distorted the bulb
will
indicate a reserve supply of fuel greater or smaller than
specified. The bracket should be adjusted to give
correct indication of fuel level.
4 The sender unit could have been inadvertantly
damaged in which case the unit must be renewed.
11 :11 The horn
The horn circuit comprises the horn, push button at the
centre of the steering wheel and normal earth return
electrical circuit through the car body. One terminal is
connected to the battery whilst the other to the push
button on the steering wheel which when the button is
depressed the circuit will be closed so causing the horn
to operate.
F500
FIG 11 : 21 Number plate lamp
Key to Fig 11 : 21 A Lens and light cap mounting screws
B Lens
FIG 11 : 22 Horn (opened)
Key to Fig 11:22 1 Body 2 Diaphragm 3 Armature
4,5,6 Core 7 Cable: terminal-condenser-stationary contact
8 Cable: terminal-magnetizing coil end 9 Magnetizing coil
FIG 11 :23 Horn sound adjustment. Obtained by adjust-
ing the armature air gap
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Before removing an apparently faulty horn check the
wiring and connections. Check that the mounting bolts
are tight and that the horn does not foul any adjacent part.
Removal and installation:
This is a straightforward operation and the only
precaution to be taken is to ensure that the rubber gasket
bonded to the horn body does not become detached. If
the horn is renewed, before installing the new horn bond
the rubber gasket to the new unit with adhesive in
the same position as was on the original horn unit fitted.
Should the horn fail to operate the following points
should be noted.
1 Damaged horn.
2 Broken connection between battery and horn.
3 Broken connection between horn and push button on
steering wheel
4 Damaged push button mechanism.
5 Directional signal and outer lighting changeover
switch blade contact failing to make contact with the
steering wheel hub ring contact.
6 Current lead displaced from the horn blade contact on
the directional signal and outer lighting switch.
7 Distorted or broken diaphragm in horn.
8 Connections or inner windings
broken or burnt.
9 Electro-magnet contact points dirty or excessively
worn.The contacts may be adjusted by the adjusting screw
after the points have been cleaned and refaced.
To adjust the tone of the horn use a ring spanner and
screwdriver as shown in FIG 11 :23.
It is recommended that if the horn unit operation is
unreliable a new unit should be fitted rather than the
original one repaired.
11:12 Lighting and flasher switch
Description:
The two switches provide a directional signal switch
which automatically returns to the rest position once a
turn has been negotiated and the steering wheel is
brought back to the straight-ahead position. The change
over switch controls the outer lights and the headlights
flasher. The complete unit is located under the steering
wheel on the steering column.
Switch unit removal:
1 Carefully pry off the horn push button at the steering
wheel centre using a fine blade screwdriver.
2 Disconnect the positive terminal of the battery.
3 Disconnect the plug in contact in the steering wheel
hub.
4 Unscrew the steering wheel retaining nut from the
inner column and remove the steering wheel from the
shaft.
5 Slacken the bolts securing the steering column support
to the body
6 Remove the plug in contacts from the switch unit
ensuring that their correct location is noted for re-
assembly.7 Remove the switch unit from the steering column.
124
Switch unit installation:
This is the reverse procedure to dismantling. It is
advisable after installation to check that the steering
wheel when in the straight-ahead position and the
directional signal switch lever in neutral, the reference
index on the outer face of the directional signal switch
drum is in line with the index on the steering wheel hub.
This will ensure correct sequence of operation.
11:13 Fault diagnosis
(a) Battery discharged
1 Lighting circuit shorted
2 Terminals loose or dirty
3 Generator not charging
4 Regulator or cut-out units not working properly
5 Battery internally defective
(b) Insufficient charging current
1 Loose or corroded battery terminals
2 Generator driving belt slipping
(c) Battery will not hold a charge
1 Low electrolyte level
2 Battery plates sulphated
3 Electrolyte leakage from cracked casing or top sealing
compound
4 Plate separators ineffective
(d) Battery overcharged
1 Voltage regulator needs adjusting
(e) Generator output low or nil
1 Belt broken or slipping
2 Regulator unit out of adjustment
3 Worn bearings, loose pole pieces
4 Commutator worn, burned or shorted
5 Armature shaft bent or worn
6 Insulation proud between commutator segments
7 Brushes sticking, springs weak or broken
8 Field coil wires shorted, broken or burned
( f ) Starter motor lacks power or will not operate
1 Battery discharged, loose cable connections
2 Starter pinion jammed in mesh with flywheel gear
3 Starter switch faulty
4 Brushes worn or sticking, heads detached or shorting
5 Commutator dirty or worn
6 Starter shaft bent
7 Engine abnormally stiff
(g) Starter motor inoperative
1 Check 1 in (f)
2 Armature or field coils faulty

(h) Starter motor rough or noisy
1 Mounting bolts loose
2 Damaged pinion or flywheel gear teeth
( i ) Lamps inoperative or erratic
1 Battery low, bulbs burned out
2 Faulty earthing of lamps or battery
3 Lighting switch faulty, loose or broken wiring
connections
F500
125
(j) Wiper motor sluggish, taking high current
1 Faulty armature
2 Bearings out of alignment
3 Commutator dirty or short-circuited
(k) Wiper motor operates but does not drive
arms
1 Gearbox components worn

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.

SEAT RUBBER PAD
SEAT ARTICULATION SUPPORT
SEAT MECHANISM
CONTROL LEVER
SEAT SLIDING GUIDE
SEAT FIXED GUIDE
FIG 12:11 Sedan front seat
42
3
1
FIG 12:12 Sedan rear seat w i t h removable cushion
Key to Fig 12:12 1 Striker plate for triple acting door latch
2 Seat cushion 3 Dowels (two) for seat cushion location
4 Seat back
t h e rear v i e w mirror to the side of the dashboard.
5 Using a special compound sealing gun inject sealer
between weather strip outer lip and body.
12:7 Removing rear side windows
The rear quarter glass panes are located to the body
using the weather strips. To remove the glass simply push
outwards ensuring that a second operator is ready to
catch the glass as the weather strip becomes detached
from the body.
To reassemble the glass pane proceed as directed for
refitting the front windshield. Finally seal as previously
described using sealing compound.
12:8 Removing rear window glass
The rear window glass is removed and replaced in the
same manner as described in Section 12:6 for the
132
FIG 12:13 Centre catch of Sedan and Station Wagon
folding top. Dotted lines show the folding top control
handle in open position removal and replacement of the windshield glass.
Ensure t h a t the weather strip inner groove is thoroughly
filled using correct sealing compound.
1 2 : 9 Front compartment lid
The front compartment lid is hinged at the centre w i t h
the lower half of the hinge welded to the body upper
crossmember. The hinge upper half is secured to the
lower half by nuts and washers which are screwed onto
the lid studs. The compartment lid is kept closed by a
catch as shown in FIG 1 2 : 9 with an additional safety
hook to avoid accidental opening.
The catch release mechanism is controlled by a handle
which is located under the lefthand side of the instrument
panel and connected to the lock by means of a bowden
cable. The cable is arranged inside the front compartment
and the inner wire passes through a bracket and secured
to the catch. A return spring is fitted onto the catch, the
latter pivoting on a locked pin.
A specially shaped weather strip is arranged on the
front and side flange of the front compartment opening.
To refit and renew the weather strip ensure that all the old
bonding compound is removed using a stiff brush.
Spread fresh adhesive to the body shell and carefully
locate and press home the weather strip.
Six rubber bumpers are press fitted into the body shell
and at both ends of the front compartment lid to ensure
correct location and freedom of rattles.
12:10 Engine compartment lid
The opening and closing movement of the lid is con-
trolled by a locking handle. The lid opens downwards and
pivots on two lower hinges. The hinge pin is welded onto
the lid and its socket is welded to the body rear lower
crossmember. To remove the engine compartment lid
proceed as follows:
1 Remove the number plate lamp cable terminal.
2 Unhook the check strap by manipulating the retaining
cross piece.
3 Release the righthand pin self-locking nut and exert
a slight pressure on the righthand side of the lid so
pushing it towards the left.
Reassembly is the reverse procedure to dismantling.