Fiat 850 Coupe 1968 Shop Manual Download Page 376

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Summary of Contents for 850 Coupe 1968

Page 1: ......

Page 2: ...NG REFERENCE BRAKES WHEELS AND TIRES STEERING 17 157 I Q 9 LUBRICATION COOLING FUEL SYSTEM CLUTCH TRANSMISSION 4 DIFFERENTIAL FRONT SUSPENSION AND WHEELS REAR SUSPENSION AND WHEELS SHOCK ABSORBERS MAN...

Page 3: ...hown in this publication are the official ones Dimensions are also given in British and American units for prompt reference and they have been calculated to a degree of ap proximation according to the...

Page 4: ...Section 1 GENERAL INfORMATION MAIN SPECIFICATIONS PERFORMANCES CAPACITIES UNIT IDENTIFICATION DATA SPARE PARTS CAR KEYS Page 11 7 8 8 8...

Page 5: ...4 FIAT 850 PASSENGER CARS u 0 0 u E u 0 E...

Page 6: ...3 rom Independent wheel Transversal semi elliptic spring upper control arms hydraulic shock absorbers sway bar Toe in full load 079 to 157 2 to 4 rom Camber full load angle 20 10 IS amount at wheel r...

Page 7: ...first gear second gear third gear fourth gear Speed maximum under full load with level road in good condition and run in engine first gear 19 mph second gear 34 mph third gear 53 mph fourth gear abt S...

Page 8: ...tity shown in the table applies to routine oil changes which should be made every 6 000 miles 10 000 km or siJ months Every 300 miles 500 kin check oil level I The coolant has non oxidizing non corros...

Page 9: ...n engine compartment and fuel tank SPARE PARTS CAR KEYS When placing orders for spare parts state car Model engine serial number or serial number for spare parts according to whether parts for engine...

Page 10: ...AL AND INSTALLATION DISASSEMBLY Page 11 13 23 24 2 ASSEMBLY 26 CYLINDER BLOCK AND CRANKCASE 29 PISTONS CONNECTING RODS 35 CRANKSHAFT AND MAIN BEARINGS 45 CYLINDER HEAD VALVES VALVE GUIDES SPRINGS AND...

Page 11: ...10 FIAT 850 PASSENGER CARS Fig 6 Side sectional view of engine across cylinders...

Page 12: ...800 r p m 5 000 I p rn Maximum horsepower SAE 40 42 at S 300 r p m 5 300 r p m Maximum torque DIN 39 8 it lbs 5S0 kgcm 40 5 it lbs 560 kgcm at 3 200 r p m 3 400 r p m Maximum torque SAE 42 7 it lbs 59...

Page 13: ...tered pressure gear centrifugal 42 7 to 56 9 psi 3 to 4 kg em Cooling Type Pump type Radiator type Fan and pump drive Thermostat permanent mixture centrifugal fin and tube belt engine outlet duct batt...

Page 14: ...Dirt or water in fuel line or carburetor 17 Defective fuel pump REMEDIES t Cheek and recharge battery as recommended under Battery 2 Clean examine and tighten clamps to battery terminals Replace cable...

Page 15: ...denser 15 Exhaust system restricted 16 Incorrect valve tappet clearance as adjusting screws have become loose from poor tightening 17 Engine overheating 4 Check and adjust fuel level 5 Proceed as reco...

Page 16: ...or and replace damaged pans 7 Replace distributor breaker arm spring and point assembly 8 Overhaul distributor and replace cam body 9 Adjust point dwell angle as recommended under u Ignition Distribut...

Page 17: ...nd lines 4 Remove and rebuild carburetor paying particular attention to fuel level In bowl 5 Check carburetor mounting flange for distortion replace gaskets and tighten nuts properly 6 Check intake ma...

Page 18: ...covering chapter 4 Bench test call and condenser and replace by new ones if necessary 5 Clean and adjust points 6 Replace distributor rotor 7 Check wiring cables and reset contacts 8 Rebuild ignition...

Page 19: ...r and replace them if required 5 Replace cap 6 Replace distributor rotor 7 Rebuild ignition distributor and replace worn parts 8 Overhaul cylinder head and replace valves Proceed u recommended under C...

Page 20: ...usually more intense than main bearing knocks The noise is more evident as a rule with the engine idling and in neutral and becomes louder when engine speed is increased Connecting rod noise can be be...

Page 21: ...pin clearance In piston bon Noisy Valves and Tappets REMEDIES 1 II1 tall over in piston pins proceeding as dlreded under Pistons Connecting Rods Noisy valve action has a characteristic clicking noise...

Page 22: ...estricted 011 passagu REMEDIES 1 Check and overhaul Ignition as outlined In covering chapter 2 Check and blow clean carburetor jets and panage and adjust Idling peed 3 Remove and balance crankshaft as...

Page 23: ...22 FIAT 850 PASSENGER CARS u u u 0 c ii...

Page 24: ...e lock ring securing the air conveyor to radiator l ff f f1 II I Fig I Removing engine 1 Adapter A 60534 2 Hydraulic lack Fig 9 Lifting out engine 1 Holst hook 2 Fixture A 60511 1 2 3 Adapter A 60534...

Page 25: ...then proceed as follows Fig 11 Engine on revolving stand An 22204 Remove air cleaner Remove the ignition distributor complete with cap and spark plug feeding cables Disconnect the carburetor fuel inl...

Page 26: ...il NOTE During engine disassembly or rebuild use care to keep main and connecting bearing inserts of each journal well apart Fig t3 Backing out hub pulley lock screw 1 Flywheel stop A 60282 2 Ratchet...

Page 27: ...nce between main bearings and journals against data on page 50 check crankshaft end play see page 50 Fit timing end oil seals on crankshaft Fit the timing drive drive sprocket spacer Install the camsh...

Page 28: ...assembly into the cylinder bore with rings arranged as specified on page 39 use tool A 60273 shown in fig 62 in this step Fig 20 Installing crankshaft front 011 seal cover 1 Inserter A 60281 2 Cranks...

Page 29: ...his step use crank A 60186 Set the distributor with the breaker points about to open using feeler gauge A 95316 check the points for a gap of 0177 0 45 nun and lock the distributor in position Place t...

Page 30: ...65 54 507 to 54 520 Length of intennediate transverse member between thrust ring seats 9149 to 9173 23 240 to 23 300 f Piston clearance in cylinder 0008 to 0016 0 020 to 0 040 Wear limit 006 0 15 Cyli...

Page 31: ...30 FIAT 850 PASSENGER CARS ENGINE ASSEMBLY Fig 2 a Side etlonal view of engine aero cylinders...

Page 32: ...rom and to the recommended piston clearance of 0008 to 0016 0 020 to 0 040 nun Fig 27 Diagram for measuring cylinder bores l First 2 Second Misurazlone _ Measurement Honing Cylinder Barrels As shown...

Page 33: ...be rebored with the portable boring bar Ap 5022 as well Fig 31 Aligning cylinder bore preparatory to boring operation 1 Centering plunger 2 Micrometer caliper shoulder setting screw Fig 32 Measuring...

Page 34: ...ccording to its diameter The same applies to the bushing seats on crankcase Always make sure that there is enough inter ference at intermediate and flywheel end bushings lest they are apt to revolve i...

Page 35: ...necessary Tappets come for service in two oversizes 002 and 004 0 05 and 0 10 mrn Use reamer A 90318 1 if 002 0 05 mrn oversize tappets must be fitted while reamer A 90318 2 will ream seat for 004 0...

Page 36: ...ns for service 5td 0079 0157 02360 5 0 2 0 4 0 6 Class I 7867 to 7868 19 982 to 19 986 Piston boss bore Class 2 7868 to 7870 19 986 to 19 990 Class 3 7870 to 787l 19 990 to 19 994 Top groove 0703 to 0...

Page 37: ...necting rod big end bore 1 7188 to 1 7193 43 657 to 43 670 Connecting rod small end bore 7850 to 7856 19 943 to 19 954 Standard con rod bearing shell thickness 0711 to 0713 1 807 to 1 813 Connecting r...

Page 38: ...tamped on the boss base fig 42 while the division of pins is stamped on pin face The clearance specified between piston pin and bosses is 0003 to 0006 0 008 to 0 QI6 rom Fig 42 Piston up ide down show...

Page 39: ...set of pistons ranging in the above weight limit is not available mill the necessary amount of stock from the base of pin bosses as shown in figures 41 and 46 so to equalize the weight of the piston s...

Page 40: ...moval of piston pin special tools should be used To assemble the connecting rod piston pin assembly the connecting Fig 47 Checking piston ring side clearance 1 Feeler gauge A 95316 2 Piston ring 3 Pis...

Page 41: ...Installation 1 Arbor 2 Guide pin 3 Slop screw CAUTION The connecting rod will cool off very rapidly For a correct fit of piston pin in the small end the pin must be driven in as quickly as possible A...

Page 42: ...e brought horizontally to abut against the small end so as the pin boss contacts the small end eye fig 55 The pin will slide thus into seat without difficulty Checking Piston Pin Drag After the connec...

Page 43: ...od by a new one because there is not the press fit as specified Now prior to fitting the piston pin and connect ing rod assembly to engine proceed as follows Using fixture Ap 5051 check the assembly f...

Page 44: ...bearings Check clearance between connecting rod bear ings and journals using Plastigage It calibrated wire type PC1 as follows Thoroughly wipe all components Tie piston connecting rod assemblies to c...

Page 45: ...type connecting rod bear ings shown in fig 58 can be safely replaced by the late type In case the connecting rod is to be renewed install late type connecting rod and bearings CRANKPIN DIAMETERS Unde...

Page 46: ...diameter 1 5742 to 1 5750 39 985 to 40 005 Main bearing to journal clearance of new parts 0008 to 0024 0 020 to 0 066 wear limit 004 0 10 Length of center main bearing journal shoulder to shoulder 1 1...

Page 47: ...lt in operation If light scores are noticedI reface by a very fine carborundum stone In case of deep notches or if journals are found to be out of round in excess of 002 0 05 nun regrind journals havi...

Page 48: ...the flywheel by means of an arbor press pre heat the ring gear in an oil bath at 1760 F 600 C Mating faces of flywheel to crankshaft and driven plate should be mirror like and free from scores Moreov...

Page 49: ...ns max out of true to journals 020 0 5 rom fig 73 out of round of crankpins and journals max out or true after grinding 0002 0 005 rom taper of crankpins and journals max out of true after grinding 00...

Page 50: ...k their clearance to crankshaft journals as follows Place a piece of Plastigage _ calibrated wire on journal fig 76 Install main bearing journals and inserts Fig 74 Main bearing caps with bearing Inse...

Page 51: ...prescribed torque fig 79 The crankshaft rotating freely indicates that it was installed correctly with specified c1eaxance of bearings to journals Checking End Play After the crankshaft has been insta...

Page 52: ...Shaft Pilot Bushing An oilless type bronze bushing for clutch support is press fitted into crankshaft end shalt Fig 8f Installing crankshaft front seal cover t Inserter A 60 2 81 2 Crankshaft front s...

Page 53: ...52 0 FIAT 850 PASSENGER CARS ENGINE ASSEMBLY o o Fig 83 Side se tional view of engine across valve mechanism...

Page 54: ...to 13 030 Bore of valve guides fitted in head 2765 to 2772 7 022 to 7 040 Valve guide to seat press fit 0013 to 0031 0 033 to 0 080 Valve stem diameter 2750 to 2756 6 985 to 7 000 Valve stem ta guide...

Page 55: ...fit clearance of new parts 0004 to 0016 0 010 to 0 042 wear limit 006 0 15 Rocker spring I D 6102 15 5 free height 2 0363 51 7 height under 4 9 33 lbs 2 2 0 15 kg of load 9843 25 MISCELLANEOUS Remova...

Page 56: ...spring parts and back out spark plugs Fig 85 Removing valves from cylinder head 1 Spring compressor A 60084 2 Valve locks 3 Supporting plate A 60283 Fig 88 Tightening head screws by means of torque w...

Page 57: ...rectly against the following clearances between gauge shoulder and head face engine lOOG OOO 01 0 25 rnrn max engine lOOG OO2 04 to 05 I to 1 25 rnrn Should head undercutttng exceed reconunended limit...

Page 58: ...control lever t Cutter travel control knob 5 Cutter locking screw 6 Diamond cutter 7 Working angle graduation scale 8 Work ing angle adjusting knob Fig 93 _ Using 200 cutter to narrow valve seats 1 S...

Page 59: ...seat VALVES Checking and Refacing Remove carbon from valves using electric wire brush M 1042 Check valve stern for cracks or distortions and replace valve if either condition is evident The stern dia...

Page 60: ...s with a press fit of 0013 to 0031 0 033 to 0 080 rom Check valve guides for a loose condition or a weak snap ring Check valve guide to stem clearance as shown in fig 100 The fit of new parts is 0009...

Page 61: ...49 check the spring load comparing data obtained in various conditions with specifications in fig 105 and chart here below NOTE Valve guides are supplied for service in a finished condition In case th...

Page 62: ...0 15 rom If on inspection clearance turns out to exceed above figures replace the item more worn or both NOTE Rocker shaft support nuts must be drawn up wilh 1 5 ft lbs 2 kgm of torque Checking Sprin...

Page 63: ...62 FIAT 850 PASSENGER CARS c u 2 u 0 c c u c u c w...

Page 64: ...mediate 1 8320 to 1 8335 46 533 to 46 571 flywheel end 1 4185 to 1 4200 36 030 to 36 068 Bushing bore seated reamed chain end 1 4970 to 1 4980 38 025 to 38 050 1 4970 to 1 4980 38 025 to 38 050 intenn...

Page 65: ...ress check that the lobe lift is 3386 8 6 rom this figure applies to both intake and exhaust valve camshaft lobes H the camshaft turns out to be still serviceable check timing data at each cylinder as...

Page 66: ...he flywheel end bushings should be finish reamed to the camshaft journal Fig 11 Fitting intermediate camshaft bushing 1 Driver A 60292 2 Flywheel end bushing Fig 115 Reaming Intermediate camshaft bush...

Page 67: ...haft and camshaft by placing tool A 60282 on the flywheel use a torque wrench and draw up the driven sprocket screw with 36 2 it lbs 5 kgm of torque then bend down the lock plate Should the necessity...

Page 68: ...y should tappet clearance be reduced to nil valves will stay in part open position all the time with most harmful consequences on valve and valve seat life To adjust tappet clearance proceed as follow...

Page 69: ...25 R 80 stud R 100 14 5 2 Drive pulley cover screw 1 38236 21 M6x I R 80 Znt 5 8 0 8 _ R 50 Znt Generator Ian and water pump drive hub pulley to crankshaft nut 4064759 M 18 x 1 5 shaft 72 3 10 C 40 B...

Page 70: ...the oil delivery line to bench oil gauge Eventually wire up the ignition distributor and generator to the control board Fig 120 Detail of engine on test bench Fig 12 Engine on test bench In foreground...

Page 71: ...nch test the engine should be over hauled just in case running troubles have been detected Correct as required and then necessarily submit the engine to a new bench test to make sure of im reguhcr ope...

Page 72: ...4 OIL SUMP GASKETS 74 I LOW OIL PRESSURE INOICATOR SEND ING UNIT 74 COOLING 76 GENERAL 76 WATER PUMP 78 RADIATOR 79 THERMOSTAT 79 THERMAL SWITCH 80 ADJUSTING GENERATOR AND WATER PUMP DRIVE BELTS TENSI...

Page 73: ...ir cleaner pipe for recirculation of blow by gases and oil vapours in engine interior _ 2 Oil filter cap 3 Oil dip stick 4 Low oil pressure indicator sending unit 5 Oil pressure relief valve 6 Centrif...

Page 74: ...sing must not exceed 006 0 15 mm fit of new parts 0004 to 004 om to 0 10 mm Fig 125 Ojl pump in place in crankcase Fig 126 Ojl pump assembly 1 Drive shaft 2 Pump hous ing 3 Oil delivery pipe to front...

Page 75: ...or distortion are found re place parts affected It is good practice to always renew the gasket between cover and hub After assembly has been completed reset tension of generator and water pump drive...

Page 76: ...ITTING DATA FITS OF NEW PARTS WEAR LIMITS DESCRIPTION in rom in rom Pinch fit of Drive shaft guide bushing ta seat in crank 0010 to 0028 I 0 02S to 0 070 case at all times I Drive shaft la crankcase b...

Page 77: ...and to the formation of vapor bubbles The level should then be checked only with engine stopped and cold Under these conditions the coolant level in tank should have a head of about 2 3 7 cm above th...

Page 78: ...s 7 5 Its To fill up pull the heater radiator control lever red coloured Remove radiator and expansion tank caps and pour coolant into the expansion tank until it over flows from radiator neck Start t...

Page 79: ...le the float is at letter F observe the table on bottom of device and read the actual rate of Paratlu 11 present in the circuit this rate is the number say 35 on column F lined up with the temperature...

Page 80: ...place unserviceable parts by new ones Pump housing to cover gasket should be always renewed RADIATOR Removal and Installation Removal of radiator is made as follows remove engine right side apron remo...

Page 81: ...n conjunction with ratchet wrench A 89854 Check thermostat operation as follows plunge thermostat deeply into a 50 50 mixture of water and FlAT Paraflu 11 fluid and heat uniformly using care that temp...

Page 82: ...ive belts may adversely affect engine operation A slack belt tends to slip causing engine overheat due to insufficient speed of fan and water pump Reduced belt speed causes also low generator charge O...

Page 83: ...page 82 82 83 83 83 83 84 84 84 85 85 85 86 87 87 88 89 89 89 89 89 90 91 91 92 AIR CLEANER Removal and Installation Take down the air cleaner from engine as follows remove the spark plug cables moun...

Page 84: ...springs 17 Operating lever reaction spring 18 Yoke lever _ 19 Thrust washer 20 Yoke lever pin Fig 140 Setting fuel pump push rod projection A Gasket 0106 to 0130 0 27 to 0 33 mm thick B Gasket 0276 t...

Page 85: ...line and the tank breather tube Disconnect fuel gauge tank unit wires removing cover from engine compartment wall Disconnect accelerator and choke control cables as well as heater radiator coolant in...

Page 86: ...gh the needle valve 10 into the bowl 14 where the float 13 hinged to the pivot 12 controls the opening of the needle 11 to maintain a constant fuel level From the bowl the fuel controlled by the main...

Page 87: ...on through the gaps between the barrel walls and the butterfly in the idling position From the passage 5 the mixture can also reach the throttle chamber through the idle transfer port 29 located in ex...

Page 88: ...engine Once the engine has started the suction vacuum causes the throttle 44 to open partially against the spring 47 so that the mixture delivered will be rich enough to enable the engine to run prop...

Page 89: ...ace as the even move ment of the valve needle might be affected Make sure that the float 8 can move freely around its pivot Float Level Adjustment 7 6 5 4 Fig 146 Float level adjustment diagram Weber...

Page 90: ...aring an additional mixture passage as soon as the engine has been started the speed rate in creases and so does vacuum causing the plunger to drop to the down position as a result the ad ditional pas...

Page 91: ...4 WEBER or SOLEX 30 pm 4 HOLLEY 30 ICF HOLLEY 30 ICF 7 Throat bore 1 181 30 rnm 1 181 30 rnm 1 181 30 rnm 1 181 30 rnm Primary Venturi 827 21 rnm 827 21 rnm 8SS 22 rnm 8SS 22 rnm Main jet 045 1 15 rnm...

Page 92: ...further mixed with the air drawn in by engine suction through the reduced gaps between the main barrel wall and the throttle valve when the latter is in the idling position thus enabling the appropri...

Page 93: ...blow by gases and oil vapours are sucked back through line l As the throttle valve 4 opens also the breather valve 6 does and most blow by gases and oil vapours are flown directly into the intake man...

Page 94: ...95 SPECIFICATIONS ANO DATA 95 TROUBLE DIAGNOSIS AND CORRECTIONS 96 TRANSMISSION DIFFERENTIAL 101 SPECIFICATIONS AND DATA 101 TRANSMISSION 103 TROUBLE DIAGNOSIS AND 14 CORRECTIONS 106 DIFFERENTIAL 113...

Page 95: ...94 FIAT 850 PASSENGER CARS e e e e It...

Page 96: ...5 8 rom distance of 071 to 075 1 8 to 1 9 rom 055 1 4 rom min Description Single plate dry with diaphragm pressure spring This type of clutch differs from the conventional clutch design because the pr...

Page 97: ...ate linings 2 loose driven plate linings due to poor rivet tight ness 3 Driven plate hub does nol slide freely on clutch shaft REMEDIES 1 Replace the throwout sleeve assembly 2 Adjust clutch pedal tra...

Page 98: ...r worn 1 Excessive play between throwout sleeve and flange CLUTCH REMEDIES 4 Replace the clutch cover assembly 5 Locate defective point and if possible reset alignment or replace distorted parts 6 Loc...

Page 99: ...utch pedal is 29 32 to I 23 to 25 nun corresponding to a clearance of 019 2 rom fig 160 between the throwout sleeve and ring Should pedal free travel be less than specified as a result of the wear of...

Page 100: ...e transmission avoid resting the clutch shaft against the clutch release flange lest the flange supporting plates may be cocked I Fig 160 Side sectional view of clutch and throwout mec hanism Figure 0...

Page 101: ...he thickness of which is in a new condition 075 to 079 1 9 to 2 rom If distance is not within above values replace the clutch cover assembly by a new one The face of the release flange ring should be...

Page 102: ...Final Drive Gear I 115 Adjusting Ring Gear la Pinion Backlash I 117 Checking Ring Gear ta Pinion Tooth Contact I 118 Installation I 118 AXLE SHAFTS AND SLIP JOINTS I 118 GEARSHIFT MECHANISM I 120 Adju...

Page 103: ...102 FIAT 850 PASSENGER CARS E i c e c o c o fi u...

Page 104: ...rear wheels by two axle shafts coupled with 0 differential through slip joints Lube oil grade 0 0 0 0 FIAT W 90 M 5AE 90 EP capacity 0 0 0 0 3 70 G B pts 4 44 U S pts 2 10 lts 1 90 kg TRANSMISSION De...

Page 105: ...nchromesh ring 2 Synchronizer spreader springs 3 Slop plate 4 Third speed gear with toothed crown for synchromesh 5 Thrust plate 6 Snap ring NOTE The synchromesh device shown in figs 166 and 167 appli...

Page 106: ...t plate 3 fig 168 of the 1st gear synchronizer has an end lug jutting in into a slit in the gear An end of the synchromesh ring 2 abuts against the thrust plate while the plate lug sets in touch with...

Page 107: ...in splines or breakage of synchronizer springs 7 Improper quality of transmission lubricant 8 Misadjusted clutch linkage and clutch make de clutching impouible REMEDIES 1 Rebuild transmission and repl...

Page 108: ...the transmission and differential assembly by means of the hydraulic jack with adapter A 70516 REMEDIES 1 Be sure the gears are completely engaged before releasing the clutch pedal 2 Adjust as outlin...

Page 109: ...6 Countershaft to input shaft sleeve 7 Input shaft B Input shaft bushing 9 Oil seal 10 Differential carrier cap 11 Ring gear 12 Drive pinion output shaft 13 Drive pinion rear ball bear iog 14 First d...

Page 110: ...r seats Ball bearings should be in top condition and show no axial play in excess of 02 0 5 rnm maximum limit radial play of bearings must not be greater than 002 0 05 mm Check that the inner race rev...

Page 111: ...k that the overall diameter of the new ring when seated in the gear corresponds to specifications All gaskets and seals must be in top condition renew if there is the slightest doubt as to their effic...

Page 112: ...drive pinion nut the double race ball bearing has been pre as sembled insert all gears into shaft fig 179 fit the front ball bearing into its bore secure the drive pinion bearing with screws and lock...

Page 113: ...s follows affix tool A 70099 on cover assembly making sure that rails are disengaged from forks fig 182 locate the tool with the dowel pin arrange shifter forks 4 and 5 fig 182 at their location marks...

Page 114: ...gears are neither chipped nor damaged in any other way Check to make sure that the wear of side gears and thrust washers is not excessive Noisiness on pull Check adjustment of differential cage beari...

Page 115: ...ved renew bearings if necessary If light marks or imprints are detected at contact face of pinion gear thrust washers smooth them out if possible otherwise renew thrust washers Thrust washers come for...

Page 116: ...0 95 1 1 05 1 10 1 15 1 20 mm Some tools have been designed to help the operator determine the thickness of pinion washer fig 194 Also the following formula should be used Proceed as outlined hereafte...

Page 117: ...in which case it is preceded by the sign minus If the number stamped on pinion stern is preceded by the plus sign the thickness of the shim is obtained by subtracting this figure from the indicator r...

Page 118: ...s are permitted to take a snug seat With the ring gear bearings under the correct preload check the ring gear to pinion backlash which should range between 004 0 10 mm and 006 0 15 mm Hold the drive p...

Page 119: ...1 15 1 20 m m The replacement of pinion shim involves the disassembly of differential unit of course Consequently on subsequent assembly all adjust ing and preloading steps as already outlined should...

Page 120: ...thrust washer thick ness Fig 203 Incorrect contact Pull side heavy contact on toe al looth flank bollom Coast side heavy conlact on heel at tooth nank bottom Move pinion away from ring gear by reduci...

Page 121: ...er support 3 Gearshift lever 4 Gearshift lever pin fastener 5 Gearshift lever pin Disassembly Inspection and Repair Disassemble the gearshift mechanism as follows remove the passenger s side front sea...

Page 122: ...HEELS 123 SPECIFICATIONS AND DATA 123 TROUBLE DIAGNOSIS AND CORRECTIONS 125 SEMI ELLIPTIC SPRING 128 CONTROL ARMS 130 KINGPIN HOUSINGS 130 STEERING KNUCKLES AND WHEEL HUBS 131 CHECKING AND ADJUSTING F...

Page 123: ...122 FIAT 850 PASSENGER CARS I r _ no I l 1 1 Fig 209 Sectional view of left side front suspension and whe 1 ass3mbly...

Page 124: ...brication Directions Adjustment Directions SPECIFICATIONS AND DATA page 123 125 127 128 130 130 131 133 135 136 137 137 137 137 137 138 Semi elliptic spring Leaves Camber Bushings to kingpin housing C...

Page 125: ...ge 131 2 10 15 1 15 472 to 512 12 to 13 mrn shims 0197 0 5 mrn thick 079 to 157 2 to 4 mrn 236 to 315 6 to 8 mrn sleeve adjusters at tie rod ends F T 3 grease Shock absorbers Type Working cylinder bor...

Page 126: ...rrectly 3 Proceed as recommended under Wheels and Tires 4 Replace mounting and rubber pad 5 Check shock absorber on test equipment and overhaul it 6 Proceed as recommended under Wheels and Tires II RE...

Page 127: ...BLE CAUSES 1 Uneven tire pressure 2 Loose or worn wheel bearings 3 Inoperative shock absorbers 4 Loose steering knuckle or kingpin housing 5 Incorrect front wheel alignment 6 Control arm resilient bus...

Page 128: ...spension assembly with the hydrau lic jack and slide off the semi elliptic spring pin fig 211 Remove the screws holding the semi elliptic spring at center and take out the spring Remove upper control...

Page 129: ...2 load P 353 Ibs 160 kg 3 load P 573 Ibs 260 kg A 6 378 162 mm B 1 319 118 33 5 3 mm C 1 516 118 38 5 3 mm o 4 547 354 115 5 9 mm Fig 215 Checking data of semi elliptic spring as fitted on car 0 0 1 p...

Page 130: ...1 319 118 Specifications refer to ing deflection rate 110 kg 33 S 3 rom a spring in the same 1 374 109 conditions as on car or anchored at cen 2nd Static load 353 lbs 1 516 1I8 in IOO lbs ter Camber...

Page 131: ...0 016 to 0 054 mm Should clearance be beyond wear limit replace bushings and the kingpin too if necessary Use driver A 74016 to remove and install bushings Inspection and Repair 9 10 r 14 1 13 J 1 I...

Page 132: ...r thrust washers for service come in the thicknesses tabulated on foot of page No appreciable clearance should be felt on installation between steering knuckle and kingpin housing after upper and lowe...

Page 133: ...arm to kingpin housing pin E Nuts pivot bar to control arm F G Screws and nuts pivot bar to body shell H Pin semi elliptic spring to kingpin housing I Nuts and pins sway bar shackle S Shims camber an...

Page 134: ...to take up any appreciable play between Fig 225 Inserting estendblock bushing in kingpin housing upper eye 1 Driver A 74042 2 Eslendblock bushing Fig 226 Installing kingpin 1 Driver A 74014 2 Kingpin...

Page 135: ...g 230 Installing wheel hub cap 1 Driver A 74088 2 Wheel hub cap fit the hub drum to the steering knuckle fit the nut and washer securing the wheel hub to the steering knuckle fit the hub cap to the hu...

Page 136: ...he control arm pivot bar and insert the spacers and shims on studs fig 233 in the same nwnber as counted on disassembly Fit the control ann pin and tighten the pin nuts to 32 5 to 36 2 It lbs 4 5 to 5...

Page 137: ...ce with the steering wheel at mid travel and road wheels for straight ahead drive Raise front wheels and arrange turntables of fixture Ap 5106 thereunder Set the sector scale 0 Ii on turntable top at...

Page 138: ...ally on turns No particular directions are required for service of the bar as a matter of fact the only parts subject to wear are rubber cushions and bushings which are situated at the clamping points...

Page 139: ...out the nut 30 To do so punch a mark B fig 238 on the nut washer at a point cor responding to the center of one of the six flats of the nut then unscrew the nut until the adjacent corner A fig 238 co...

Page 140: ...m CHECK WITH WHEEL ON After removing the wheel cover and hub cap undo a wheel screw then affix bracket A 74029 to rim by said screw Push the wheel straight on towards car then apply on bracket the dia...

Page 141: ...IAT 850 PASSENGER CARS Fig 241 Side sectional view of car rear end across wheel hub drum wheel cylinder axle shaft oil boot and right side ear wheel slip joint pin Up to car with spare parts number 18...

Page 142: ...AR SUSPENSION AND WHEELS SPECIFICATIONS AND DATA TROUBLE DIAGNOSIS AND CORRECTIONS CONTROL ARMS COIL SPRINGS INSTALLATION REPLACING FLEXIBLE JOINT CHECKING AND ADJUSTING REAR WHEEL TOE IN Page 143 143...

Page 143: ...50 PASSENGER CARS o Fig 242 Side sectional view of car rear end across wheel hub drum wheel cylinder axle shaft all boot and right side rear wheel slip joint pin Starting from car with spare parts num...

Page 144: ...ontrol arms Connection to underbody Adjustment Position for tightening underbody bracket screws arm pin nuts at underbody silentblock bushings shims wheels toed in by 00 12 6 car loaded Up to car with...

Page 145: ...236 4 to 6 rom 000 to 079 0 to 2 rom FlAT MR 3 grease two hydraulic telescopic double acting 1 063 27 rom 9 921 252 rom 14 803 376 rom 15 197 386 rom 4 882 124 rom 059 to 157 1 5 to 4 rom 512 to 669...

Page 146: ...as directed under Wheels and Tires 3 Inspect and fix as directed under I Wheels and Tires 4 Adjust brakes as outlined under Brakes II 5 Check camber of loaded spring and replace spring if not within s...

Page 147: ...146 FIAT 850 PASSENGER CARS v o _ L I Rear suspension sectional views across control arm and shock absorber mounting bushings and brake backing plate I I I J I I Fig 243...

Page 148: ...and then the coil spring Repeat above procedure at the other arm and remove it CONTROL ARMS Disassembly Inspection and Repair Fig 245 Pulling rear wheel hub 1 Brake backing plate 2 Wheel hub 3 Ram pul...

Page 149: ...ntrol arm 3 Resilient bushing Fig 249 Checking control arm and drum assembly 1 Fixture A 74142 2 Fixture dowel 3 Shims arm to fixture 4 Control arm Adj ustment Place the control arm complete with bush...

Page 150: ...ter 3 976 101 mml active turns 4 total turns 6 direction of winding clockwise Fig 252 Installing roller bearing snap ring 1 Bearing cup 2 Bearing snap ring 3 Rear wheel hub Coil springs are graded int...

Page 151: ...shell 1 Control arm rear lock pin 2 Control arm 3 Shims 4 Tool A 74143 Slide the rear end of arm into body bracket Set the coil spring with rubber seats Secure the axle shaft to flexible joint and th...

Page 152: ...t sleeve screws move back the sleeve on axle shaft and remove the inner spring remove cotter pin and screw out the nut four complete lurns fig 258 2 Fig 259 Taking wheel shaft part way Qut 1 Ram pulle...

Page 153: ...1 I I I i III I I I I I I I I I J II I I S E MI CA R R EG G IA TA ____ _ Fig 263 Diagram for setting rear end geom etry A Screws front bracket to underbody recommended torque 28 9 to 36 2 ft Ibs 4 to...

Page 154: ...n angle fig 263 use the clearance which is left between holes and screws A fig 263 securing bracket B to body Recall that a linear movement of some 177 3 5 mm measured at a distance of some 6 8 2 03 m...

Page 155: ...m of torque repeat above procedure at the other wheel recalling that wheels should be toed in by the same angle NOTE ON SELF LOCKING NUTS When the threads on which self locking nuts of the nylon ring...

Page 156: ...pts 317 U S pts 0 17 It 0 15 It Fluid grade FIAT S A With the inner pad being crushed under an axial load of some 331 lbs ISO kg Operation A shock absorber may be theoretically divided into three sect...

Page 157: ...t adjustment washer 20 Valve star shaped spring 21 Inlet valve 22 Piston snap ring 23 Piston 24 Inlet valve holes In piston 25 Rebound valve hotes in piston 26 Rebound valve 27 Valve guide cup 28 Rebo...

Page 158: ...Section 7 STEERING SYSTEM SPECIFICATIONS ANO OATA TROUBLE DIAGNOSIS AND CORRECTIONS STEERING WHEEL STEERING GEAR IDLER ARM AND SUPPORT STEERING RODS FRONT WHEEL TOE IN Page 159 160 163 163 167 167 168...

Page 159: ...158 FIAT 850 PASSENGER CARS STEERING SYSTEM Fig 210 Steering system and front running gear units...

Page 160: ...DATA Steering gear type Gear ratio Worm bearings Sector shaft bushing Bearing adjustment Wonn to sector tooth lash adjustment Sector shaft bushing bore Sector shaft diameter Sector shaft ta bushing fi...

Page 161: ...nce 4 Loose steering linkage connections 5 Loose or incorrect fitting of worm to sector Hard Steering POSSIBLE CAUSES 1 Incorrect tire pressure 2 Incorrect front wheel alignment 3 Incorrect adjustment...

Page 162: ...ues 2 Inspect and correct front wheel alignment as outlined on page 135 J Adjust bearings as outlined on page 138 Inspect and correct as outlined on page 184 5 Inspect replace damaged parts if any and...

Page 163: ...nnections 3 Incorrect adjustment of steering worm to sector Hard Turning when Stationary POSSIBLE CAUSES 1 Incorrect tire pressure 2 Incorrect adjustment of steering worm to sector 4 Check all mountin...

Page 164: ...nting nut 1 Ratchet wrench A 89854 2 Horn bulton wire REMEDIES 1 Inspect and innate tires to recommended pressures 2 Inspect and adjust front wheel alignment as specified on page 135 3 Adjust bearings...

Page 165: ...properly and fix it if necessary Fig 274 _ Removing steering rods 1 Tool A 47035 2 link rod 3 Pitman arm 4 Rod end ball stud 5 Track rod Fig 275 Steering gear on service fixture I Steering gear 2 Ada...

Page 166: ...sting nut 5 fig 280 Slide off the worm I fig 280 complete with roller bearing cones 3 Tap out roller bearing cups with driver A 74046 and the oil seal 2 fig 280 with driver A 74017 Inspection and Adju...

Page 167: ...bly and adjust ment all components are thorougWy washed and lubricated For correct position of pitman arm on assembly a tooth is omitted in the sector toothing while the pitman arm shows a double toot...

Page 168: ...the more worn part or both Fig 282 Installing steering worm and bearings 1 Roller bearing cones 2 Worm Fig 2al Installing pitman arm 1 Torqua wrench 2 Pitman lrm Renew pin bushings if they show signs...

Page 169: ...rs against the outer edge of wheel rims at rear zero the gauge and mark the points measured with chalk Jack up the car at front and rotate the wheels half a turn Lower the car and set the gauge plunge...

Page 170: ...KES SPECIFICATIONS AND DATA TROUBLE DIAGNOSIS AND CORRECTIONS Page 171 171 172 SERVICE BRAKES 175 EMERGENCY AND PARKING BRAKE 180 WHEELS AND TIRES 182 SPECIFICATIONS AND DATA 182 TROUBLE DIAGNOSIS AND...

Page 171: ...rake types I expansion shoes I mechanical hand controlled acting on rear wheel shoes 17 2915 to 7 3032 185 24 to 185 53mm Drum diameter Skimming drums maximum allowable oversize I 315 0 8 mm bonding P...

Page 172: ...iltrations of water through rear end because boot has failed or seats are no longer tight 6 Seized pedal shaft this is also the cause for hard pedal or locked brakes REMEDIES 1 Flush the system replac...

Page 173: ...ring sealing surfaces 3 Fluid leaks through connections 4 Fluid leaks at wheel cylinders 5 Fluid leaks through hoses Excessive Effort Required on Pedal POSSIBLE CAUSES 1 Swollen rubber seals because t...

Page 174: ...no free travel 4 Seized maste cylinder piston 5 Master cylinder flooded because compensating hole is clogged REMEDIES 1 Adjust the rod to piston clearance and set to OtI8 0 3 mm 2 Clean and bleed the...

Page 175: ...the master cylinder Also valve ring rotates in so doing thus equalizing wear over the whole surface and reducing it to a negligible fraction Rubber valve ring and seal ring 8 and 3 develop a marked to...

Page 176: ...linder 1 Rubber boots 2 Pistons with stems 3 Fluid inlet port 4 Cylinder bOd 5 Seal rings 6 Spring backing washers and piston reaction spring 1 The edges of valve and seal rings 8 and 3 facing respect...

Page 177: ...ling the master cylinder thoroughly wash all components in clean brake fluid For wheel cylinders follow the same inspection and repair procedure as for the master cyl irider BRAKE SHOES AND LININGS Ch...

Page 178: ...be impaired Adjusting Shoe to Drum Clearance Brake shoes are of the self centering type and therefore no alignment problem is met with them As a matter of fact I brake shoes are setting automatically...

Page 179: ...operation is prolonged check all connections for air leaks If no leaks are found check master cylinder and wheel cylinder seals for perfect tightness WARNING To prevent air from being drawn in by mast...

Page 180: ...ed manually through a ratchet lever and actuates rear wheel shoes The handbrake does not call for any special care for service Just check the wear condition of control cable should any plait wire be t...

Page 181: ...tions work on cable stretcher 4 fig 302 so that wheels cannot be turned manually cable should be well taut lock the stretcher in position by tightening down nut and counternut NOTE Special care should...

Page 182: ...ge front 17 1 psi 1 2 kg em rear 28 4 psi 2 kg em TROUBLE DIAGNOSIS AND CORRECTIONS Excessive Tire Wear POSSIBLE CAUSES 1 High speed on very rough terrain 2 Sudden variations of speed due to rapid acc...

Page 183: ...ven tire pressure on each pair of wheels 12 Incorrect camber wear only on one side of front tire tread REMEDIES 1 Repair or replace wheel rim as required should tire be exceedingly damaged replace it...

Page 184: ...following a wheel run out from warpage or impact b wheel out of round caused by irregularities in the rim or tire c static unbalance or uneven distribution of the weight around the axis of rotation Co...

Page 185: ...Section 9 AIR CONDITIONING SYSTEM WINDSHIELD WASHER TIGHTENING REFERENCE AIR CONDITIONING SYSTEM WINDSHIELD WASHER CHASSIS TIGHTENING REFERENCE Page 187 189 191...

Page 186: ...tor 9 Air delivery shutter to feaf compartment 10 Air delivery shutters to front compartment 11 Heater electro Ian switch 12 Heater radiator air scoop control lever 13 Excessive coolant temperature In...

Page 187: ...by turning on the electro fan switch 8 This switch is energized only with the ignition on To convey cool air straight toward passengers besides pulling lever A shut off heater shutters D aItd E and p...

Page 188: ...mpartment c open the shutter E if heating of the rear compartment too is desired In case of very cold climate conditions move the lever A part way up only in order to reduce the quantity of incoming a...

Page 189: ...At last bleed the heater radiator through the proper screw I fig 311 NOTE In the event that pure water has been added in the cooling system check the rate of Paraflu fluid in coolant mixture as outlin...

Page 190: ...190 FIAT 850 PASSENGER CARS c c II N...

Page 191: ...8 to 2 2 0 25 to 0 30 screw R 50 Znt R 80 Znt Axle shaft oil boot te transmission 1 38258 21 M 8 x 1 25 R 50 Znt 14 5 to 18 1 2 to 2 5 screws and nuts 1 61008 11 Stud R 80 Znt Drive pinion bearing re...

Page 192: ...5 body screw nut Screw R 80 Semi elliptic spring to cross rail R 50 Znt 735802 M 10 x 1 25 Screw 43 4 6 screw nut R 100 Fosl Semi ellipticspring to kingpinhous R 50 Znt 1 61050 11 M 12 x 1 25 Screw 6...

Page 193: ...screw Wheel hub and brake backing plate 4108912 M 10 x 1 25 R 80 Znt 43 4 6 to control arm screw Wheel hub inner bearing plate 4108912 MID x 1 25 R 80 Znt 43 4 6 screw R 80 Znt 101 3 14 Flexible joint...

Page 194: ...1 25 Screw R 50 14 5 2 Sd Stab Idler arm mounting ta body screw R 50 Znt nut 1 61041 11 M8x 1 25 Screw R 50 14 5 2 Sd Stab R 50 Znt Tie rod end ball stud nut 1 25756 11 M 10 x 1 25 Stud C 21 21 7 to...

Page 195: ...Section 10 ELECTRICAL BATTERY GENERATOR GENERATOR REGULATOR STARTING MOTOR IGNITION SYSTEM LIGHTING SYSTEM INSTRUMENTS AND CONTROLS RADIO RECEIVER Page 196 199 205 217 223 232 237 242 10...

Page 196: ...ecess cover hold down nuts fig 314 Fig 313 Side sectional view of battery at filler neck with electrolyte level sight 1 Battery case 2 Sealant 3 Cover 4 Filler neck with vent slots 5 Terminal post 6 E...

Page 197: ...A 95852 Readings should be taken at eye level on float graduated stem the float being free and tube vertical Once reading has been taken I return the elec trolyte to the cell from which it was sucked...

Page 198: ...round all users totally excluded Even in the worst test conditions wet car etc an insulating resistance reading of less than 10 000 Ohms should not be recorded A quick check can be carried out using a...

Page 199: ...s Field winding Regulator separate Engine to generator drive ratio new belt Pole shoe inner diameter Brush Part No Bench Testing Data Testing generator as a motor at 680 F 200 C Feed voltage Current d...

Page 200: ...3 CS GENERATOR ASSEMBLY Fig 315 Side sectional view of generator Fig 316 End sectional view of generator across field frame pole shoes and windings Fig 317 End sectional view of generator across ar m...

Page 201: ...ts according to the following directions Fig 319 Wiring diagram for motoring tes1 G Generator V Voltmeter 15 V scale A Ammeter 10 A scale B Battery capable of supplying a voltage slightly above 12 V d...

Page 202: ...in dif ferent increments adjust load rheostat to ensure a constant 12 V output at each given r p m rate at the same time read the value of current supplied Each reading will give a point of the output...

Page 203: ...lly Field winding inspection may be carried out using the bench for current feed and instrument reading Fig 323 Undercutting mica between commutator bars using fixture Ap 5015 1 Armature 2 Culter 3 Cu...

Page 204: ...ccelerated wear rate of commutator segments and brushes remarkable voltage drops between commutator and brushes and a marked excitation current increase Overhaul Irrespective of the repair or replacem...

Page 205: ...5 _20 C 16 5 68 95 F 20 35 C 15 Closing voltage 12 4 to 12 8 Voltage contact stroke variation I below I V rom Reverse current not above 16 Amps Air gap closed contacts 0138 0 35 rom Point gap 0154 to...

Page 206: ...tion start the generator increase its speed gradually and check on voltmeter the value of cutout contact closing voltage Take reading at the instant at which test lamp glows Closing contact voltage sh...

Page 207: ...l remain constant The voltage instead with the decrease in resistance should drop to as low as 12 V Checking Current Regulator CURRENT REGULATOR VOLTAGE REGULATOR CUTOUT RELAY l 5c 51 6 c _6 I I I I I...

Page 208: ...ct welding in voltage regulator and cur rent regulator short circuited coils burnt windings are often due to causes not ascribable to regulator and which generally originate from troubles in the TO US...

Page 209: ...ues Inspect the resistor and make sure that the wire is not broken at some point and that no coils aYe shorted In doubtful cases remove the resistor and test at 68 F 200 C resistance must be 80 to 90...

Page 210: ...t 4 0 12 A R Voltage drop rheostat suitable to allow turning on of 5 with T open and cutout contacts open Selting of instruments before inserting the unit P At minimum voltmeter reads zero T Open R Al...

Page 211: ...nts except ammeter which should have a 40 A scale a With the regulator in thermostat oven at 1170 to 1270 F 470 to 530 C close I start the gener ator and set its speed and rheostat R for a 13 Volt ten...

Page 212: ...y 12 Voltage regulator adjusted low REMEDIES 1 Check regulator clean points with a proper file replace unit If points cannot be reconditioned 2 Cheek and replace regulator by a new one 3 Check and rep...

Page 213: ...pen l engine cannot be started renew wire or recondition insert or clamp No Charge Indicator Goes out but then Glows Feebly POSSIBLE CAUSES 1 Indicator lamp faulty from low lighting voltage 2 Voltage...

Page 214: ...ension adjust or renew belt as required No Charge Indicator Lights up and Goes out Regularly LOW CHARGING RATE WITH DISCHARGED BATTERY POSSIBLE CAUSES 1 Loose terminals faulty wires 2 Faulty battery 3...

Page 215: ...ulator if not clean there Is a short renew regulator unit if output 15 high fault lies in generator from con dition 5b check for undue contacts between ter minal 51 and terminal 6111 or between plus b...

Page 216: ...hes with generator operating regularly should range between 25 000 and 37 000 miles 40 000 and 60 000 km IMPORTANT Never insert radio interference suppression condensers of any capacity between termin...

Page 217: ...oes I D Armature diameter Part No of brushes Drive control Bench Test Data Operation test at 680 F 200 C Amperage Torque developed Speed Voltage Stall torque at 680 F 200 C Amperage Voltage Torque dev...

Page 218: ...0 5 12 S VAR 9 Fig 339 Side section view of starting motor Fig 340 End section view of starting motor across pinion drive Fig 341 End section view across commutator end head and view of brushes Fig 34...

Page 219: ...rter switch or battery loose 3 Battery thoroughly flat 4 No contact on commutator from worn brushes 5 Starter switch points pitted worn or insulated from foreign matter 6 Armature or field winding gro...

Page 220: ...ammed lever weak springs dragging hub sleeve or solenoid core Disassemble motor and renew defective parts TESTING Wire up as per diagram fig 343 Install starter on a bench provided with a ring gear wh...

Page 221: ...livered a 258 A current at 7 4 to 8 V lock the ring gear and actuate the starter control lever to stroke end The delivered torque should be 4 92 to 5 64 ft lbs 0 68 to 0 78 kgm 3 No load test room tem...

Page 222: ...e Mechanism Take down armature assembly slide off drive end head and remove drive mechanism Prior to replacing or fitting drive mechanism lubricate inner splined face with FlAT VS 10 W oil and contact...

Page 223: ...trifugal advance to engine Static advance lengine lOOG OOO engine IOOG 002 engine lOOG OOO engine IOOG 002 26 to 30 230 to 270 Breaker point pressure Point gap Insulating resistance between terminals...

Page 224: ...e system is subdivided into two circuits fig 348 namely the low tension circuit or primary circuit which includes the power supply breaker con denser and ignition coil primary winding the high tension...

Page 225: ...compare it with figs 349 350 351 The automatic advance range of distributor to engine is as wide as 30 Checking the vacuum operated advance device Check that distributor is free to rotate in its suppo...

Page 226: ...indicates the clos ing angle NOTE Starling from engine 100 G OOO No 573196 and 100 G 002 No 515049 the ignition distributor is no longer fitted with vacuum advance To check the new design distributor...

Page 227: ...ust be greater than 50 MD at 500 V d c This can be measured with a megohm meter Measuring spark length Run the ignition coil with the distributor without using H T distribution and send all sparks to...

Page 228: ...htness is assured by the connector seal on seat Adjust the tester spark meter point gap at 315 8 nun then operate the manual pump lever Take care to push the lever all the way down each time so that t...

Page 229: ...e crankshaft until ignition timing mark on 1111IIII Iltllll TIMING fig 358 Ignition timing Arrows show the position of timing marks for correct setting of ignition distributor The mark on centrifugal...

Page 230: ...m of tester 1 on the chalk mark drawn on pulley U ignition is timed correctly at idling speed the mark on pulley must be aligned with the white line 100 or 11 0 on plate Ap 5030 9 IGNITION SYSTEM TROU...

Page 231: ...ht springs weakened Ignition Coil Unserviceable POSSIBLE CAUSES 1 Connections loose or soiled ELECTRICAL REMEDIES 1 Replace springs by genuine ones REMEDIES 1 Clean connections and tighten down 231 An...

Page 232: ...5 235 235 236 236 Headlamps Double filament bulb high beam low beam Front parking and direction signal lamps Double filament bulb parking direction signal Side direction signal lamps Tubular bulb Rear...

Page 233: ...lE 5 10 Q l 0 t l L VE OI NEfIQ 7 i liH 0 0 cr 1 0 Q 0 03 115 iii I 0 I I ii I 0 I lat 1 iJ l1 IiS6 b11 lD Jllt 1 p in san J S l S bl 1 0 i 1 ij ij 0 rUcr h 3 8 cr O N 6 0 51 61 6 b JD l g 1i i l I I...

Page 234: ...g warning lights and starting circuits 26 Electro fan motor switch 27 Jam switches on door pillars for courtesy light 28 Fuel gauge tank unit 29 Rear view mirror map light with toggle switch 30 Starti...

Page 235: ...1 Depress clips 1 so that the lamp unit will come out To replace the bulb snap out spring retainers and remove the bulb which is fitted with a flange coupling to lamp unit NOTE Bulbs must not be repla...

Page 236: ...icles B C 1 u 40 mm settled vehicles C Ground clearance of headlight center the upward slanting some 150 separation lines should start from the meeting points P of vertical lines a a with the horizont...

Page 237: ...se plate lamp 1 Lllmp frame 2 Bulb 3 Bulb holder Fig 367 Removing instrument cluster for replacement of bulbs 1 Six insert insulated junction block white 2 Six insert insulated junction block red 3 Sp...

Page 238: ...blown fuse by a new one locate and remove the source of the trouble which brought about the blowing to avoid any recurrence Fig Fuses PROTECTED CIRCUITS 369 Low oil pressure indicator Coolant tempera...

Page 239: ...when coolant temperature exceeds Low oil pressure indicator Indicator lighting pressure Na charge indicator Initial speed for battery charge Fuel reserve supply indicator Fuel reserve supply engine ca...

Page 240: ...at 12 Volts and 77 F 250 C Stall torque draw I 77 to 93 120 60 crank gear type 52 to 66 14 43 It lbs 6 kgcrn 140 F 60 C 52 to 66 r p m 2 1 Amps S It lbs 70 kgcm 10 6 to 14 1 oz 300 to 400 gr 100 2 600...

Page 241: ...r light switch 3 Windshield wiper switch with blades park ing off automatically 4 Horn button 6 Adjustable outlets for air admission into car see page 187 for use 7 Rear view mirror with courtesy ligh...

Page 242: ...ators are wired Coolant Temperature Warning Light The glowing of the warning light indicates irregulo r operation of engine Possible causes thermal switch points bound incorrect tension of generatorI...

Page 243: ...e check the motor on bench against data tabulated on page 238 and renew the unit if some specifications are not met Removal and Installation Take down the windshield wiper assembly as follows remove i...

Page 244: ...lwne control knob works also as on off power switch Depressing this double purpose knob energizes the receiver turning the knob counterclockwise adjusts the volume The anterma trimmer is located on th...

Page 245: ...ssage opemng 1 Drilling point 2 Templet on fender top corner Fig 380 Fitting the templet for cutting out the instrument panel lining and fashioning the panel holes preparatory to the radio set install...

Page 246: ...ody b the plastic panel c the spring washers and nuts tighten the nuts on set shanks secure the set at the rear using a self thread ing screw and a special retainer plate wire up as follows a the loud...

Page 247: ...Section 11 BODY GENERAL DDORS FRONT COMPARTMENT LID ENGINE COMPARTMENT LID GLAZING BUMPERS SEATS REPAIRING ACCIDENTED CARS BODY UPKEEP Page 247 249 252 253 253 254 254 255 257...

Page 248: ...ss rail mounting _ C D Rear control arm joint centers E Rear spring center F Sway bar mounting G Power plant mounting points Measured aHer control arm turning axis Centro rUOla _ Wheel Center Asse uoi...

Page 249: ...ODY UPKEEP GENERAL 247 page 247 249 249 250 251 252 253 253 253 254 254 254 254 255 255 255 257 Sedan integral construction four five seater Two doors front hinged each with two window glasses the fro...

Page 250: ...folding are made with cloth and imitation leather lining or all imitation leather lining Rear seat of the bench type with reclining back Additional luggage room behind the rear seat back Fig 387 Fron...

Page 251: ...rtnight 01 April 1966 the ventilator window stop handle Is fitted with a safety push button DOORS 249 Disassembly To disassemble the door proceed as follows Remove the arm rest the window regulator cr...

Page 252: ...y 2 Regulator control cable 3 Cable sheave 4 Cable dip 5 Drop glass run channel 6 Window regulator cable tensioner screw Fig 393 Removing drop glass 1 Glass pane 2 Glass bottom channel 3 Regulator cab...

Page 253: ...r lock link 6 Remote control link Fig 391 _ Door and window conlrols 1 Regulator 2 Regulator cable sheave 3 Regulator cable 4 Remote control 5 Door check strap Adjustment After the door has been assem...

Page 254: ...ering colwnn U the lid must be replaced just back out relevant hinge stud nuts 1 fig 401 Fig 400 Front compartment lid catch 1 Catch mounting nuts 2 Catch hook return spring 3 Catch hook Fig 401 Repos...

Page 255: ...d glass 1 Rubber weatherstrip 2 Weatherstrip draw cord 3 Wind shield glass Fig 405 Removing windshield glass GLAZING Removing and Installing Windshield Glass To remove the windshield glass proceed as...

Page 256: ...glass out from window opening pressure must be exercised at the base rather than at top comers of pane Rear Quarter Window Glasses For removal and installation of these glasses too refer to above par...

Page 257: ...t may be different in nature and severity For this reason it is rather difficult to give specific and detailed instructions on body repair covering the many possible cases as each blow and or bump may...

Page 258: ...anged as shown in figures 412 413 and 414 Fig 413 _ Detail showing use of gauge A 74141 for checking underbody rear A Gauge dowel pins to be engaged into control arm mounting brackets B Gauge feel Lea...

Page 259: ...kerosene dry and rub with a cloth moistened in fluid oil Next remove any trace of oil using a clean woolen cloth This procedure will not alter the brilliancy of chromium plated parts and will preserv...

Page 260: ...Section 12 MAINTENANCE TOOL EQUIPMENT MAINTENANCE LUBRICANT SPECIFICATIONS SERVICE TOOLS Page 260 261 262...

Page 261: ...es 2 500 Ian Inject grease in lubricators Every 6 000 miles 10 000 krn Replace oil in s p CHECKS AND INSPECTIONS I Replace air cleaner element 2 Check ignition distributor breaker contacts 3 Clean spa...

Page 262: ...in open cup not below 404 F 200 C Pour point not above _13 0 F 250 C FlAT VS 10 W Oil for engine Viscosity at 122 0F 500 C I Engler units 2 7 to 3 3 below 5 F 160 C minimum Kinematic cSt 18 5 to 23 7...

Page 263: ...iate bushing Refacer camshaft bushing Installer crankshaft rear gasket and cover Set of installers I piston Sector scale engine timing CrankI engine timing Master gauge indicator A 95687 Reamers tappe...

Page 264: ...ly support use with service stand Arr 22204 Tool shifter fork adjusting Dial indicator with base to be used with drive pinion shim thickness gauges Gauge drive pinion shim thickness use with A 95690 A...

Page 265: ...check and adjustment Pilot pin control arm shim installation PullerI ram wheel hub Pair of tools coil spring compression Gauge and clamp rear wheel toe in check STEERING Puller tie rod end ball stud P...

Page 266: ...AL 289 BODY 294 ROADSTER 297 ENGINE 300 CHASSIS 300 ELECTRICAL 304 BODY 309 FAMILY 312 CHASSIS 315 ELECTRICAL 334 BODY 340 IDROCONVERT TRANSMISSION 343 CONSTRUCTION AND OPERATION 343 DRIVING THE CAR 3...

Page 267: ...266 FIAT 850 PASSENGER CARS c c c E c u...

Page 268: ...with damper ring double tracked chain Carburetor Weber type 30 DIC I dual throat with super feeder device Air cleaner warmed air scoop has been elimi nated cleaner redesigned to suit new carburetor I...

Page 269: ...ring gear 0 211 0 254 0 12 0 11 Braking system 0 493 0 592 0 28 0 28 FlA T special blue label fluid Front shock absorbers each 0 299 0 359 0 170 0 155 IFIAT S A 1 fluid Rear shock absorbers each 0 264...

Page 270: ...s two seater two door Rear side windows part way swiveling outward Bright metal outer trim mouldings around side windows windshield and rear window Engine compartment lid with inner water shields and...

Page 271: ...tribution of loaded weight front axle rear axle Performance Speeds maximum on fiat road run in and fully loaded first gear second gear third gear fourth gear over reverse Gradients maximum climbable r...

Page 272: ...7 E 64 98 64 99 A 6UJ 6l 94 C 64 95 64 96 E 64 97 6U8 20 Fig 421 Skirt diameter metric of 100GC OOO C ngine measured at class grading points 5 197 20 787 MAIN SPECIFICATIONS OF ENGINE Engine type Cycl...

Page 273: ...ifications Up to engine No 425696 37 3 1 468 30 1 181 20 7 815 kg 8 O 4 17 6 9Ibs kg 18 1 39 7 2 2 Ibs VALVE SPRING SPECIFICATIONS A Free length 8 C Length and load Cor spnng check Up 10 engine N 4256...

Page 274: ...Valve timing diagram at increased tappet clearance of 0148 0 375 mm loizia searico EJilhaust opens Fine aspirazione Intake closes Fine scarico Exhaust closes P M T D C Inizia aspirazione Intake opens...

Page 275: ...t compression ring clearance of new parts second step cut oil ring clearance of new parts third radial slotted oil ring clearance of new parts in 2 5563 to 2 5567 2 5571 to 2 5575 2 5579 to 2 5583 2 5...

Page 276: ...led choke type easy starl ing device super feeder device accelerator pump From the diagram in figure 431 it will be seen that the fuel flows past the needle valve l into the bowl 17 where the float co...

Page 277: ...eas the secondary throttle working on shaft 27 remains closed Subsequently the lug 29 abuts against the lug 28 of the idler lever 25 which will cause the lever 26 to rotate the secondary shaft 27 unti...

Page 278: ...5 Carburetor viewed from the volume control screw end 18 Main jets 22 Throttle stop screw 31 Idle jet 33 Volume control screw 58 Strainer inspection plug cam 42 and lever 43 urges the diaphragm 44 to...

Page 279: ...ll the easy starting knob on floor tunnel all the way out to throw in the choke device position A fig 433 WARMING UP ENGINE During this period whether the vehicle is station ary or moving the knob sho...

Page 280: ...screw 33 to obtain the mixture which gives the highest regular engine speed at the selected degree of throttle restriction Finally further narrow the throttle opening to the best idle speed and contro...

Page 281: ...PASSENGER CARS Fig 440 Sectional view of left side front suspension and wheel assembly Front wheel camber is 2 10 20 with fully loaded car and 10 15 with unloaded car The kingpin angle is 4OZ0 20 and...

Page 282: ...sition 1st I Initial load for checking 441 lbs 1 063 1l8 deflection rate 200 kg 27 3 rom 2nd Static load 661 lbs 2 008 157 910 071 infl00 lbs 3rd I 300 kg 51 4 rom 51 4 100 kg Settled load 1 036 lbs 4...

Page 283: ...SUSPENSION COIL SPRINGS Coil spring specifications Free height Heigh under 1 135 lbs 515 kg of load Height under 1 695 lbs 769 kg of load _ Deflection rate between 705 and 1 499 lbs 320 and 680 kg 9...

Page 284: ...e moved from column see covering procedure on page 301 for the Roadster Version fia 445 Rcmovin steNb coium join shield 1 St Cr 19 cotU l nc ibtc joint 2 Joirt shield 3 Upper slrcr mg shaft Fig 446 Re...

Page 285: ...rcuit bleeder connection 4 Front brake calipers 5 Slop lights jam switch 6 Brake fluid reservoir 7 Rear brake drum 8 Nuts 2 of the campins 13 9 REar brakes circuit bleeder connection 10 Rear brake sho...

Page 286: ...pressure is established by depressing the brake pedal the wheel cylinder piston moves on and causes the adjacent lining to come in contact with the disc Simultaneously with the above described functi...

Page 287: ...e greater than the clearance between the friction ring 9 and washers Under this condition the friction ring 9 is stop ped by the washer l0 while the piston continues to move Fig 450 Tipping caliper mo...

Page 288: ...both wheel hub screws from brake disc remove the staked nut the backing washer and slide off the wheel hub assembly withdraw the brake disc as shown in fig 454 at last back out caliper bracket to dis...

Page 289: ...er screw and the gap between opposite lining pads is not lesser than 429 10 9 rom Fig 456 Detail showing caliper mounting bracket and disc splash shield 1 Brake disc splash shield 2 Caliper bracket cl...

Page 290: ...rrier plate to R 50 Znt steering knuckle screw 1 610008 11 M8 x 1 25 Screw R 80 14 5 to 18 1 2 to 2 5 Screw brake caliper ta caliper 1 59703 21 M 10 x 1 25 R 80 Znt 39 8 5 5 carrier plate Stud road wh...

Page 291: ...to the headlight center to center distance Draw a horizontal line b b on the screen at the following distance from ground B C 25 32 20 mm where C corresponds to the ground clearance of headlight cent...

Page 292: ...t 20 Parking light Indicator green light 21 Low oil pressure indicator red light 22 No charge indicator red light 23 Direction signal indicator green light 24 Instrument cluster lights 25 Reserve supp...

Page 293: ...g 2 8 8 2 6 b 6 II AllUIl AZlUFII lQ NERO 2 0_ 0 0 No MAMONE 10 Q mf O iii o z I NUl Gl O I tAllROtoIE Gl Ll 34...

Page 294: ...r extra 29 Key type ignition switch also energizing warning lights and starting circuits 30 Map light with toggle swItch incorporated 31 Electro fan motor switch 32 Fuel gauge tank unit 33 Spark plugs...

Page 295: ...stal lation of receiver fig 465 should be made using templets included in the radio kit Fig 465 Fitting templet to drill radio receiver mounting holes 1 Templet 2 Radio receiver mounting holes on inst...

Page 296: ...rument Cluster Remove the instrument cluster as follows disconnect the steering column mounting from instrument panel and lay the wheel on seat I Fig 469 Removing instrument cluster 1 Instrument clust...

Page 297: ...e over switch with master switch 2 on 6 Direction signal light switch 7 Adjustable air out lets ventilation and healing 8 Map light with toggle switch incor porated 9 Clutch pedal 10 Brake pedal 11 Ac...

Page 298: ...spring and slide off seats at front Fig 414 Removing rear seat cushion Fig 415 Removing rear seat back rest Arrows point to back rest holding screws Fig 476 Removing rear seat back rest 1 BacK rest 2...

Page 299: ...partment lid is fitted with a catch device operated through a push button fig 479 To adjust the catch for correct opening and closing of lid just reposition the striker 1 to the catch hook 3 as requir...

Page 300: ...296 FIAT 850 PASSENGER CARS o...

Page 301: ...etting strokes of wiper arms and one double for adjusting glow of panel light and outer light indicator Set of dashboard instruments with five separate dials tachometer and oil gauge added Control swi...

Page 302: ...rall height applies to an unloaded car Overall height for cars fitted with hard top is 47 44 1 205 mm Instrument panel of new design Grab handle on instrument panel passenger s side Utility compartmen...

Page 303: ...el tool kit and accessories _ _ Carrying capacity Payload two people plus 132 lbs 60 kg luggage Loaded weight passengers plus luggage Distribution of loaded weight front axle rear axle Performance wit...

Page 304: ...arings REAR SUSPENSION r page 300 300 301 302 302 Rear coil spring specifications Free height Height under 1 003 51 lbs 455 23 kg of load Height under 1 563 lbs 709 kg of load Deflection rate between...

Page 305: ...Next work on the steering wheel so to set the joint yoke into the lower groove Secure the yoke and the bracket in place tight ening down on the screws and nut Pulling Wheel In case the steering wheel...

Page 306: ...ig 489 Removing steering wheel on work bench 1 Ratchet wrench and extension for steering wheel nut 2 Ouler light and direction signal selector switch 3 Steering column mounting bracket Fig 490 Removin...

Page 307: ...wn from the bracket without use of tools renew parts as required and reverse the above outlined procedure to reassemble check ball bearings for perfect efficiency and replace one or both if showing si...

Page 308: ...Nuts and studs reflector support rings 7 lamp unit spring fasteners 8 Corner direction signal lamp shell Aiming Headlights Set the car in conditions outlined on page 233 for aiming operation and proc...

Page 309: ...ws which secure the lens 2 fig 496 and the lamp shell I to the body Bulbs 3 are inserted by bayonet coupling Fig 497 Disassembling rear parking stop and direction signal lamp 1 lamp lens 2 Partition p...

Page 310: ...s also as a bulb holder The cylindrical bulb is held by means of spring fasteners FUSES Oil pressure gauge Low oil pressure indicator Temperature gauge Fuel gauge 15 54 and reserve supply indicator Wi...

Page 311: ...I n f i i 47 T 1J L rII ss os...

Page 312: ...tion ignal light tell tale green 32 High beam Indicator blue 33 Low oil pressure indicator red 34 Oil gauge light 35 Oil gauge 36 No charge indicator red 37 Engine tachometer 38 Engine tachometer ligh...

Page 313: ...a assembly to rear wheel housing remove the lid from engine compartment interior and work through the opening in the wall Fig 503 Instrument panel with location marks for drilling radio receiver mount...

Page 314: ...column mounting bracket and lower the wheel as outlined on page 302 Remove lock nuts from dashboard control switches and the trip odometer zero setting knob Disconnect the speedo drive cable from spee...

Page 315: ...s side 1 Windshield washer foot control 2 Steering column 3 Clutch pedal 4 Brake pedal with master cylinder control rod 5 Ac celerator pedal 6 Air intake water drain hose 1 Horn relay BODY Removing I...

Page 316: ...partment in instrument panel 1 Release pushbutton with key Jock 2 Grab handle 3 Utility drawer 4 Interior light Utility compartment and articulation system shown In figure are the ea ly design Fig 514...

Page 317: ...at front 1 Top front cross rail 2 Top front catch 3 Top front catch clamp and lever Insert side nap lock pins into lock plates fig 517 Secure the top to windshield frame by actuating catch levers fig...

Page 318: ...nd tires tire type and pressure location of spare wheel Air conditioning conditioner design Chassis tightening torques ELECTRICAL Battery 48 A h capacity Generator type D 100 12 25 4 SB Regulator 360...

Page 319: ...37 0 37 FLAT special blue label I fluid Front shock absorbers each 0 290 0 349 0 165 0 150 Rear shock absorbers each 0 264 0 317 0 150 0 135 FIATS A 1 fluid Windshield washer bag Water and FIAT D P I...

Page 320: ...on and run in engine first gear second gear third gear _ fourth gear over reverse Gradeability at full load with level road in good condition and run in engine first gear second gear third gear fourth...

Page 321: ...ifications and Data Adjusting Shoe lo Drum Clearance AIR CONDITIONING TIGHTENING REFERENCE TRANSMISSION DIFFERENTIAL page 315 315 317 318 318 319 321 322 322 322 322 323 323 324 324 325 326 326 327 32...

Page 322: ...316 FIAT 850 PASSENGER CARS FRONT SUSPENSION ASSEMBLY I Fig 522 Sectional view of left side froht suspension and wheel assembly...

Page 323: ...4 Ibs 079 to 157 70 kg Toe out 2 to 4 rom Tread front on ground 45 031 1 224 rom Wheelbase 78 739 2 000 rom Shock absorbers 2 Type hydraulic telescoping double acting Working cylinder bore 1 26 32 rom...

Page 324: ...ring Affix tool A 74083 fig 526 and actuate it to compress the coil spring Disconnect the hydraulic brake fluid hose Untie lower control arm from underbody observ ing the number of shims set between a...

Page 325: ...kness Thrust washers for service come in the following thicknesses 1555 1575 1594 1614 3 95 4 00 4 05 4 10 rom The same procedure must be performed at lower control arm fig 528 Fig 527 Tightening uppe...

Page 326: ...eet ing at angle O e Lower control arm plane meeting at angle Y with centerline of screws F G NOTE Nub A should be tightened down when angle I some 2QO Nut D should be tightened down when angle I ome...

Page 327: ...ed car seven people plus 154 lbs 70 kg are the follow ing camber 0 30 20 caster 4 55 30 For front wheel toe out see covering specifica tions on page 326 To adjust camber fig 530 and caster P fig 530 s...

Page 328: ...63 recalling that with car at load COl L 7 people plus 154 lb 70 kg angle must be 10 30 angle 0 must be 00 12 12 wheels toeing in by 079 to 091 2 to 2 3 rom SPRINGS SPECIFICATIONS Wire diameter 7283 0...

Page 329: ...shaft diameter 1 1295 to 1 1287 28 690 to 28 669 rom Fitting clearance roller shaft to bushing 0003 to 0020 0 008 to 0 051 rom Fitting clearance idler arm pin te bracket bushing 0005 to 0021 0 012 to...

Page 330: ...bout with the adjustment of the steering gear check to see whether the trouble must be traced to the linkage being at fault in the affirmative fix the steering linkage Inspection and Repair Carefully...

Page 331: ...ent the worm out ot true limit is 002 0 05 rom Both roller bearings should not feel rough on spinning or show play at races Examine gaskets at worm and roller shaft for first class condition Renew any...

Page 332: ...ey have been press fitted in place bush ings must be reamed to the specified bore of 8666 to 8614 22 012 to 22 033 rom Bushing insertion is not a difficult matter do not forget however that the idler...

Page 333: ...e travel 1 4 6 rom Hydraulic circuit fluid I grade FIAT special blue label capacity 651 G B pts 782 U S pts 0 37 It Adjusting Shoe to Drum Clearance The brake shoes should be adjusted for the fol lowi...

Page 334: ...control ratchet lever 3 Brake fluid reservoir 4 Parking brake ratchet lever stretch er 5 Hydraulic circuit bleeder connector 6 Rear brake shoe actuating levers controlled by ralchet lever 7 Rear slop...

Page 335: ...plate and replace the carnpin one or two serrations on so to approach the shoe to the drum for a clearance of 004 0 10 rom Fig 542 loosening lower anchor campin nuts 1 Campin nuts 2 Brake drum Fig 543...

Page 336: ...on lank 9 Healer radiator coolant delivery line 10 Heater radiator coolant outlet line 11 Radialor coolant drain cock 12 Heal lndleator 13 Windshield air outlets 14 Shifter lever for air delivery towa...

Page 337: ...coolant drain plug 6 Ther mostat 7 Radiator 8 Expansion tank 9 Heater radiator coolant delivery line 10 Healer radiator coolant outlet line 11 Heat indicator 12 Wind shield air outlets 13 Electrofan...

Page 338: ...Lower control arm pivot bar to 1 25749 11 I M 16 x 1 5 R 50 Znt 130 2 ta 144 7 18 ta 20 arm mounting bracket nut Bar R 80 Znt Kingpin mounting nut to control R 50 Znt 1 25748 11 M 14 x 1 5 Kingpin 38...

Page 339: ...late screw 1 Steering R 50 Znt Steering wheel la column nut 743601 M 18 x 1 5 Column C 12 28 9 to 36 2 4 10 5 Tube Steering column to instrument 1 61096 11 M 8 x 1 25 R 50 Znt 10 8 1 5 panel screw nut...

Page 340: ...8 Arnp hr 10 236 260 rom 6 772 172 rom 8 8SS 225 rom 40 8 lbs 18 5 kg 29 8lbs 13 5 kg with electrolyte without electrolyte Weight GENERATOR REGULATOR SERVICE DATA Type Marelli ffi50H Cutout Relay Feed...

Page 341: ...g z z J jLj AlZURR T AZZURRO AZZURRO 12 13 AZZURRG NER ROSSO ROSSO r MARRONE MARRONE L f I 67S130D 31 0 31 32 t L 11 t RI 1ID g VERDE...

Page 342: ...rge indicator 18 Instrument cluster light 19 Low oil pressure indicator 20 Fuel gauge with reserve supply indicator 21 Instrument cluster light switch 22 Rear view mirror map light with toggle switch...

Page 343: ...the amperage at every generator speed increment each reading will represent a point of the output curve of the generator as shown in fig 55 Heating test Speed for abt 1 hour and 45 min Current delive...

Page 344: ...t1 Fig 549 Side sectional view of generator 4000 R P M JOOO ol l L L_ L _ 1000 1000 A JO I r t I 1 I t 10 rI t _ I J 10 Fig 550 End sectional view of generator across commutator end head Fig 551 Outp...

Page 345: ...t the car in the following conditions at nO load with tires inflated to recommended pressure on a level surface 16 5 5 m apart from an opaque white screen make sure that car centerline is square to sc...

Page 346: ...fig 553 Fig 554 Removing dome light 1 Cylindrical bulb 2 Lens 3 Lamp shield To aim the high beam of inner headlamps turn on the high beam and work on screw 2 fig 552 for vertical adjustments and on s...

Page 347: ...tor Wiper motor 1 with ignition on Instrwnent cluster light Electrofan motor Direction signal lights and indicator Stop lights Dome lights 2 30 Rear view mirror map light Horn 3 56 bl Left side low be...

Page 348: ...er BODY Integral construction seven seater four door Body shell with inner framework longitudinal ribbed roof panel air intake louvers at rear of side panels for engine cooling Sheet metal body floor...

Page 349: ...etal framed Bench type seat is divided into two sections each reclinable forward Bench type rear seat accomodating three is imitation leather lined and metal framed Seat can be collapsed on floor abov...

Page 350: ...342 FIAT 850 PASSENGER CARS Fig 559 Side view of 850 Family...

Page 351: ...t synchronised DESCRIPTION The use of a hydrokinetic torque converter cou pled to the input shaft of a conventional gearbox gives exceptionally smooth and progressive vehicle operation In fact because...

Page 352: ...solenoid which is in turn controlled by the knob switch in selector lever signalling the driver s intention to change gear as well as by the neutral switch situated in the gearbox cover and operated v...

Page 353: ...bine vanes then back to the impeller via the stator vanes Turbine vanes are concave to absorb the maximum amount of energy Such a profile however results in the inversion of the oil flow Consequently...

Page 354: ...o l m Z Gl m ll o l ll Fig 563 Exploded view of torque converter 1 Impeller 2 Specer ring 3 Stator 4 Turbine 5 Spacer ring 6 Driven plate 1 Driven plate hub 8 Spacer ring 9 Pressure plate oil seal 10...

Page 355: ...r the thrust exerted by the oil tends to rotate in the opposite direction to that of the impeller IT such a tendency were not controlled the torque mul tiplication effect would be destroyed with ensui...

Page 356: ...diagram of Idroconvert transmission with clutch engaged 1 Release mechanism clutch 2 Turbine 3 Impeller 4 Stator 5 Oil pump 6 Oil pressure regulating valve 7 Valve solenoid 8 Plunger valvo 9 Main oil...

Page 357: ...fice the oil pump suc ceeds in compensating this loss to prevent any pressure drop within the bell housing OPERATION OF RELEASE MECHANISM CLUTCH The release mechanism situated between torque converter...

Page 358: ...m of Idroconvert transmission with clutch disengaged 1 Release mechanism clutch 2 Turbine 3 Impeller 4 Stator 5 Oil pump 6 Oil pressure regulating valve 7 Plunger valve solenoid _ 8 Plunger valve 9 Ma...

Page 359: ...other hand the engagement phase must adjust itseU to the speed of bell housing pressure plate assembly turbine speed and that of the driven plate gearbox input speed as it is these factors which deter...

Page 360: ...r change down has occur red causes the valve on the driven plate to move thereby uncovering the partialiser orifice and at the same time reducing or eliminating the speed differential between bell hou...

Page 361: ...road profile and conditions During traditional driving the Idroconvert transmis sion enables the driver to obtain the same perfor mance as with a conventional gearbox The one difference is that gear c...

Page 362: ...cle parked up hill with stationary engine and gear inserted it will be necessary to close the starter motor inhibitor switch circuit i e move selector lever to neutral position As gear disengagement m...

Page 363: ...lerating slightly engine speed increases as soon as selector lever knob is touched Le knob switch closes the electrical circuit causing clutch disengagement 2 Checking the Starter Inhibitor Circuit Wi...

Page 364: ...elay Starter motor will not Faulty neutral switch no connection to earth in this case engine starting operate may be obtained by depressing selector lever knob Faulty starter inhibitor switch current...

Page 365: ...ion carry out the following operations in the order given Fit Idroconvert assembly to gearbox in the fol lowing manner apply a film of sealing compound on contact faces of both Idroconvert unit and ge...

Page 366: ...c o 0 e c c o o 2 o c o ii c Z D C o IAT 850 PASSENGER CARS...

Page 367: ...ling torque converter support remove solenoid I fig 585 and if neces sary the plug covering pressure point 2 slide out plWlger valve 2 fig 583 together with its return spring remove dustcover 2 fig 58...

Page 368: ...ump as described below Fig 580 Fitting pump oil seal 1 Service tool A 70142 for pump seal fitting 2 Pump body place transmission casing with torque converter side facing upwards thoroughly clean pump...

Page 369: ...r A 70146 2 for plunger valve assembly Fig 58S Checking solenoid operation 1 Solenoid 2 Pressure point plug 3 Solenoid lead connec tor 4 Retaining plate for torque converter output shaft 5 Torque conv...

Page 370: ...er gasket 3 to cover recess 2 to prevent the pressure regulating valve from damaging the gasket during assembly of cover fit the cover making sure that the valve does act on the feeler gauge also ensu...

Page 371: ...urrounding area remove solenoid and ensure that it is work ing properly by wiring connector 3 fig 685 to the terminal of a 12 V battery check that the plunger moves freely and that the plunger stroke...

Page 372: ...facing upwards remove dust cover 2 fig 582 remove seal using service tool A 45023 lubricate a replacement seal with GI M oil exercising the utmost care to avoid damaging the sealing lips offer the se...

Page 373: ...as de scribed on page 354 To Remove and Refit Valve Cover Removal of valve cover entails the removal of the transmission from the vehicle therefore remove gearbox from the vehicle and separate Idrocon...

Page 374: ...357 to page 362 Torque Converter The torque converter cannot be interfered with as it consists of an enclosed welded unit If the engine runs efficiently but performance is poorI the transmission overh...

Page 375: ...ve assembly to be stuck in one position Consequently the transmission remains constantly engaged or disengaged according to the position of the valve plunger However this defect may also be due to plu...

Page 376: ...f1 1 PRINTED IN ITALY SERVICE DEPARTMENT Reprint No SAT 2271 Norm No 502 236 1500 Xll l968 Poligrafic o ROGGERQ TORTIA Torino Via Marochetti 8 Tel 69 05 77 69 77 54 67 70 90...

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Fiat 850 Coupe 1968, Shop Manual

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