key FIAT 500 1970 1.G Owner's Guide

FIG 7 : 3 Fixture A.66064, for swinging arm inspection
and adjustment
Key to Fig 7 : 3 1 Clamp screws, securing wheel shaft on
fixture 2 Alignment bracket, swinging arm member check-up
3 Nut, to secure swinging arm external support on fixture stud
4 Swinging arm external support centring pins
AB C
D
FIG 7 : 4 Adjusting right rear suspension swinging arm
on fixture A.66064
Key to Fig 7 : 4 A and B Swinging arm external support
adjustment shims C and D Swinging arm internal support
adjustment shims
torque wrench setting of 43.4 Ib/ft.
3 During assembly the bearings must be packed w i t h
Fiat MR grease, taking care not to overpack as this
can result in early bearing failure.
82
4 If the axle shaft to flexible joint tie sleeve has been
removed, the mating splines must be coated w i t h Fiat
B2G grease on re-installation.
5 Preload the wheel bearings and adjust the swinging
arm as described later on in this section.
Wheel bearing adjustment:
To ensure a long bearing life due to correct initial
adjustment the ballbearings should be preloaded and to
do this proceed as follows:
1 Tighten the wheel shaft nut gradually so that the
rotation torque does not exceed .36 Ib/ft.
2 To check the rotation torque install Fiat tool A.95697/2
on the wheel drum and insert the shank 2 (see FIG
7:5) of dynomometer A.95697 in the support and
securely hold the lever 3. Move the needle 5 to register
.36 Ib/ft on the dynomometer scale as shown in FIG
7:5 and using the operating lever 6 rotate the dyno-
mometer and the wheel shaft some turns in a clockwise
direction. During rotation check that the needle 5 does
not exceed the setting index 4. Should the rotation
torque prove to exceed .36 Ib/ft, this will indicate a
4
3
1
6
5 2
FIG 7 : 5 Bearing rotation torque dynamometer
KeytoFig7:5 1 Dynamometer A.95697 2 Dynamometer
shank to insert in item A.95697/2, fitted to wheel drum
3 Dynamometer grip lever 4 Rotation torque setting index
5 Adjustable needle 6 Dynamometer operating lever
Oil Sump Wheel Plane
HALF TRACK
FIG 7 : 6 Position of rear suspension and of vehicle for
rear wheel toe-in inspection and adjustment
Key to Fig 7:6 ~ 168 mm = 6.61 inch
567,5 ±1,5= 22.342 inch ± .059 inch

high bearing preload. To reset remove the wheel shaft
and fit a new resilient spacer. Repeat the rotation
torque test.
Swinging arm adjustment:
To adjust the swinging arm use Fiat fixture A.66064 as
shown in FIG 7 : 3 and proceed as follows:
1 At points A and B as indicated in FIG 7 : 4 between the
'estendblock' and the swinging arm to body front
mounting bracket fit three shims on each side. To
ensure that the shims are correctly centred use Fiat
alignment bar A.66057.
2 Whilst removing the alignment bar, carefully slip in the
mounting pin and screw on the nut. Once the rear
wheel geometry adjustment has been completed this
nut should be tightened to a torque wrench setting
of 43.4 to 50.6 Ib ft.
3 At points C and D (see FIG 7 : 4) , insert the number of
shims required to fill in the gap between the 'estend-
block' and the two fixture shoulders. Having deter-
mined the number of shims required both at locations
C and D, these must later be fitted between the
'estendblock' and the shoulders on the swinging arm
to body mounting bracket.
7 : 4 Coil springs
The coil springs should be thoroughly cleaned and all
traces of rust removed. Inspect the spring coils for hair
line cracks, which if evident, a new pair of springs must
be fitted to ensure correct vehicle height and stability.
Check the free
height and the height under loading of
the coil springs and these must correspond to the figures
quoted in Technical Data.
7:5 Installation of rear suspension assembly
To replace the rear suspension assembly proceed as
follows:
1 Insert the swinging arm inner end in the mounting
bracket which is welded onto the body floor. Place
between the 'estendblock' and bracket the number of
adjustment shims as previously determined using Fiat
fixture A.66064 as shown in FIG 7 : 4. Insert the Fiat
alignment bar A.66057 through 'estendblock' and
shims, aligning them with the holes in the mounting
bracket. Firmly hold the entire assembly using a garage
hydraulic jack if necessary, and carefully remove the
alignment bar and at the same time ease in t h e
mounting pin. Secure the nut which once the rear
wheels geometry has been checked must be tightened
to a torque wrench setting of 43.4 to 50.6 Ib/ft.
2 Screw in finger tight the three swinging arm external
bracket to body floor mounting screws together w i t h
the plain and spring washers. The screws will have to
be tightened to a torque wrench setting of 28.9 to
36.2 Ib/ft once the rear wheel geometry has been
adjusted.
3 Carefully insert the coil spring, lower insulator ring
onto the swinging arm, insert the spring on the shock
absorber which should be previously secured to the
arm and position the spring onto its seat on the arm.
Place the upper insulator ring onto the spring, raise the
suspension assembly using a garage hydraulic jack and
insert the spring onto its seating under the body floor.
F50083 4 Ensure that the shock absorber to floor rubber ring has
been correctly fitted and extend the shock absorber
until its upper mounting pin protrudes into the vehicle
through the hump in the floor panel. Secure the shock
absorber by its mounting nut and lockwasher having
first inserted the rubber ring and plain washer.
5 Refit the rear wheel housing in place, reconnect the
brake line to the connection on body floor and remove
the plug from the output hole in the brake fluid
reservoir. Bleed the hydraulic brake system as
described in Chapter 10.
Key to Fig 7:8 k Distance of centre rear bracket, for
jacking up the vehicle, from floor level (8.90 inch)
Half-track = 22.264 inch ±.059 inch
FIG 7 : 8 Position of rear suspension f o r rear wheel
toe-in inspection and adjustment ('500 Station Wagon') FIG 7 : 7 Adjusting rear wheel toe-in angle
Key to Fig 7 : 7 Rear wheel plane must be perpendicular to
ground and parallel to car longitudinal centerline with a
tolerance of 0° 10'
To adjust rear wheel geometry, move suitably the swinging arm
outer support. Slight movements are permitted by the play
existing between the support holes A and the mounting screws.
Screws B must be tightened to 28.9 to 36.2 Ibft (4000 to 5000
kg mm). Nuts C must be tightened to 43.4 to 50.6 Ib ft (6000
to 7000 kgmm), after adjustment has been carried out. (These
directions and specifications are also applicable to 500 Station
Wagon).

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

LEAF SPRING RESILIENT SUPPORTS
FIG 8 : 1 Front suspension
SHOCK ABSORBER
SWINGING ARM
SWINGING
ARM
PIN
KING PIN
LEAF SPRING
KING PIN
HOUSING
FIG 8 : 2 Right front suspension
hydraulic jack slowly so allowing the spring to be
lowered from the underside of the vehicle.
8 Using Fiat wrench A.56030, disconnect the hydraulic
shock absorber from the kingpin housing. Also remove
the swinging arm pin mounting nuts and remove the
pin.
9 Using Fiat drift A.66056 or a suitably sized drift
remove the 'estenblock' from the kingpin housing.
Using a suitably sized punch remove the block pin
from the kingpin, remove the lower plug and take off
the kingpin.
88FIG 8 : 4 Section through one spring mounting Key to Fig 8 : 3 1 Kingpin housing 2 Estendblock
3 Pin, swinging arm to kingpin housing 4 Half-arm
5 and 6 Nut and splitpin 7 Screw, welded on body
8 Nut, mounting, pin 13 to body 9 Rubber buffer
mounting nut 10 Body panel 11 and 12 Camber and
castor adjustment shims 13 Pin, swinging arm to body
14 Spacer 15 Cups, for rubber bush 16 Rubber bush FIG 8 :3 Section through left swinging arm
Description:
The spring comprises a main leaf and four assister
leaves. Specially shaped polyethylene insulation strips
are fitted between the leaves which are held together by a
centre bolt and two elastically mounted side clips as
shown in FIG 8 : 1. The leaf spring is attached to the 8 : 3 Leaf spring

FIG 8:6 Swinging arm components
Key to Fig8:6 1 Half-arms 2 Pin, arm to body mounting
3 Pin, arm to kingpin housing mounting 4 and 5 Washer and
nut 6 and 8 Cups, rubber bushes 7 Rubber bushes
9 and 10 Sptitpins and nuts, mounting, pin (2) to arms
TOOL A.66054
PULLER A.40005/
FIG 8 : 7 Removal of rubber bushes by universal puller
A.40005 and arm retainer tool A.66054
DRIFT ROD
A.66056
FIG 8:8 Drift rod A.66056 for kingpin housing Estend-
block' removal and installation
90Inspection:
Thoroughly clean the half arms and dry using a com-
pressed air jet. Then proceed as follows:
1 Thoroughly inspect the half arms to ensure that they
are not distorted or show signs of cracking which, if
evident, should be renewed. Compare the t w o half
arms to ensure that they have the same inclination and
that the holes are not elongated but are true and
properly aligned. kingpin housings by 'estendblocks' which are fitted in the
main leaf eyes. A specially shaped rubber buffer is
mounted on the spring centre bolt.
Leaf spring inspection and repair:
To dismantle the leaf spring assembly remove the t w o
side clips and the centre bolt. Thoroughly wash all parts
and to inspect proceed as follows:
1 Inspect carefully to check that the leaves are not
broken or show signs of cracking which, if evident,
the leaf must be renewed. It should be noted that the
third spring leaf is not available as a service replace-
ment part which means that if this leaf is damaged the
whole spring must be renewed.
2 Check that there is no paint or underseal present
between the leaves which, if evident, must be removed.
3 Ensure that the mating surfaces of the leaves are
perfectly smooth and clean. If there are signs of
rusting or slight indentations, these areas must be
cleaned using a file. Any deep indentations will be a
source of weakness and the leaf must be renewed.
4 The 'estendblocks' are press fitted into the main leaf
eyes and must be thoroughly inspected for excessive
wear, signs of seizure and dry operation of the rubber
parts. The 'estendblocks' should be renewed if there
is any doubt as to their condition. To remove and
replace the 'estendblocks' use Fiat .drift A.66056 or a
suitably sized drift as shown in FIG 8 : 8 .
5 Check the condition of all rubber pads, the centre
buffer and the polyethylene linings for signs of wear,
cracking or splits and, if evident, new parts must be
fitted.
6 Once the spring has been reassembled it should be
tested by loading as shown in FIG 8 : 5 .
8:4 Swinging arms
Description:
The swinging arms comprise t w o pressed steel sheet
half arms which are joined by two pins, one on the
kingpin housing and the other on the body (see FIG
8:6) . Rubber bushes ('flanblocks') are press fitted into
the half arms for the attachment of the swinging arm pin
to the body as shown in FIG 8 : 6 .
Dismantling:
1 Clamp the swinging arm into a vice and fit Fiat tool
A.66054 as shown in FIG 8 : 7. Remove the splitpin
and nut securing the half arms onto their pin.
2 Using a universal t w o leg puller or Fiat puller A.40005
together with items 1 and 5 pull out the rubber bushes
as shown in FIG 8 : 7. Remove tool A.66054 insert it
on the other half arm and repeat the operation
performed for the bush removal on the first arm.

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

FIG 8:14 Swing arm setting
car. Ensure t h a t the upper elastic supports on the
studs projecting from the underside of the vehicle
body are correctly located and insert the spring. Fit
the two support lower caps w i t h elastic pads and
screw onto the stud nuts to a torque wrench setting
of 28.9 Ib/ft.
2 Assemble the brake housing flange onto the steering
knuckle and tighten the nuts to a torque wrench
setting of 14.5 Ib/ft.
3 Assemble the roller bearings and seal into the drum
hub. Pack the bearings and fill the recess between the
bearings w i t h Fiat MR3 grease or an equivalent, and
lightly smear the stub axle. Fit the drum assembly over
the stub axle and replace the washer and nut. Note
that from vehcle number 043624 the righthand hub
has a lefthand thread, the nut being identified by a
circular groove on the outside face. On hubs locked
with a splitpin, tighten the nut to 21.7 Ib/ft, back it off
by approximately 60 deg. (one flat) and fit the splitpin.
On the later pattern hub, with no splitpin, fit a new nut
and make sure it screws in freely. Tighten it to 14.5
Ib/ft, while rocking the hub four or five times to make
sure the bearing is properly seated. Undo the nut
completely, then tighten it again to 5.1 Ib/ft. Back it
off 30 deg. (half a flat) and lock it by staking the rim
into the stub axle spline. Hub end play should be
.001 to .0039 inch.
4 Using Fiat tool A.66059 as shown in FIG 8:13,
reassemble the cap to the hub. Also reassemble the
steering knuckle to the kingpin housing replacing
the t w o upper
thrust rings, the snap ring and the
lower packing ring whose thickness has already been
selected as detailed in Section 8:6 to take up any
play between the knuckle and the kingpin housing.
Secure the steering knuckle pin with the cotter.
5 Reconnect the swinging arm to the wheel assembly
using the special nut and bolt. The nut must be
screwed onto the bolt A (see FIG 8:14), by arranging
the parts so that the angle between the arm plane
and the kingpin housing is approximately 95 deg. as
shown in FIG 8:14. Tighten the nut to a torque
wrench setting of 39.8 Ib/ft.
94
Key to Fig 8:15(9° = Kingpin housing castor angle) FIG 8:15 Section through steering knuckle and leaf
spring mounting at kingpin

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.

FIG 9 : 3 Layout of steering gear components
Key to Fig 9 : 3 1 Steering wheel and column assembly 2 Nut 3 Toothed washer 4 Plain washer
5 Steering column bracket-to-instrument panel screw 6 Steering column-to-worm screw locking screw 7 Lockplate
8 Plain washer 9 Cover screw 10 Toothed washer 11 Cover 12 Gasket 13 Pin 14Nut 15 Plain washer
16 Worm sector adjusting screw 17 Worm sector and shaft assembly 18 Worm screw 19 Thrust washer 20 Shim
21 Splitpin 22 Lower sleeve, bearing retainer and worm screw adjuster 23 Roller bearing 24 Worm screw bearing
upper seal 25 Roller bearing 26 Steering gear housing 27 Oil filling and draining plug 28 Eccentric bushing
29 Upper seal 30 Worm screw-to-sector lash adjusting plate 31 Toothed washer 32 Plate screw 33 Lower seal
34 Pitman arm 35 Self-locking nut Inset: Universally-jointed column fitted from late 1971
99F500

FIG 9 : 4 Section of steering box, through worm screw
Key to Fig 9 : 4 1 Worm screw 2 Seal 3 Roller bearing
4 Worm screw adjuster and bearing retainer 5 Pitman arm
6 Worm sector
FIG 9 : 6 Steering box cutaway
100FIG 9:5 Section of steering box, through worm sector
Key to Fig 9 : 5 1 Sector adjustment screw 2 Locking
nut and plain washer 3 Sector thrust washer 4 Shim
5 Eccentric bush 6 Bush adjusting plate 7 Plate screw
and toothed washer 8 Pitman arm 9 Sector lower seal
10 Upper seal 11 Worm sector 12 Worm screw
13 Oil filler and level plug
2 If play is excessive in the worm screw rollers, screw up
the lower adjuster ring 4 (see FIG 9 : 4) . Once adjust-
ment has been completed the adjuster ring must be
secured by the cotter. The ring should be positioned
so that the hole in the steering box lines up w i t h one
of the spaces between the ring castellations.
3 Should the meshing between the worm screw and the
sector not be at the correct central position this
condition may be rectified by moving the sector
axially. To do this add or remove shims (see FIG 9 :5)
below the thrust ring of the worm sector. The final
adjustment must be carried out by using the adjust-
ment screw 1 (see FIG 9 : 5) on the cover and then
locking the screw by nuts 2. In service shims are
supplied .0039 inch thick.
The above described adjustments must eliminate
any play and back lash in the steering gear without
rendering the steering gear stiff to operate between
the t w o locks.
4 During adjustment should any seal be found to be
damaged then it should be renewed.
Reassembly:
Reassembly is the reverse procedure to dismantling
but the following points should be noted:
1 All parts should be thoroughly cleaned before