Page 1
Fiat & ABARTH
tricks
by GREG SCHMIDT
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FIAT and ABARTH TRICKS
by Greg Schmidt
Copyright 1984 Greg Schmidt
Revised 5th
produced by Greg Schmidt with thanks to: Adrienne, Trudi, June, and Roy for
production support; to Maurice Dhoore for "investigation"; to Chris Butler for the cover
page; and Doc Sekito for "Good vibrations".
Revised second printing October 1984 with updated pages reformated and printed on a
daisywheel printer by Kennerley C. Ashley, D.D.S and bis Radio Shack Model Four
computer.
Enthusiasts will also want a copy of ABARTH
pages, with 220 illustrations, Osprey Publishing Ltd., England 1983. ABARTH
distributed in the USA by Classic Motorbooks (see above & use order #F770A). ABARTH
was reviewed in the September 184 issue of Road & Track Magazine on page 28. Note
that about 80% of engine rebuilding, conversions & part numbers are contained in
ABARTH
From time to time, new/revised materials are produced for this book. If you would like
updated pages forwarded to you, please send a pest card with your name, address, and
the number of the book that you have (noted in red on page 1) to: FlAT and ABARTH
TRlCKS 1512 E. 5th Street #94 Ontario, Calif. 91764 USA
(There is no charge for this service)
.
by Pat Braden and Greg .Schmidt, 160
is
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FIAT & ABARTH Tricks
l hope the information contained in this book will prove valuable to you. New material, corrections and
comments are always welcome. Questions and new materials will be accepted when accompanied by a
self-addressed and stamped return envelope. "MORE ABARTH TRICKS"
82).
With the Sporting intent,
PURPOSE
may be forthcoming (see page
The purpose of this book is to provide a comprehensible source of technical information for owners and
enthusiasts of Fiat-Abarth and other make sport cars which were derived from the Fiat 600 and Fiat 850.
Special emphasis is placed on returning more of these vehicles to every day use and maintaining them
with reasonable efficiency and a minimum of misspent time or frustration. So it. is hoped that a few
owners who have heretofore Dot had the opportunity and pleasure of experiencing their neat little cars in
action (or on a regular basis) will be provided with enough "first-hand experienced" information (which
with time might otherwise have been lost) and provided the incentive to restore them to original or
updated "drivers car" condition. Because, when these cars work right
production sports car yet offered to the driving public. And that full song high-reving engine and cat-like
agility (from a vehicle of such humble specifications yet) is usually more than enough to quickly remind
the owner that this is "his kind of automotive plaything"..!
The best use of F.I.A.T. and ABARTH
For conveyance and protection, it is recommended that the pages of this booklet be put in a hard cover
loose-leaf binder. For heavy workshop use, clear plastic sleeve page covers can be used to protect those
pages removed as reference for the job at hand. Both ABARTH
ABARTH TRlCKS
hand -ln -hand. Best results will be obtained by first reading (or rereading) chapters: 3, 6, 7, 11, 12, 13, and
skimming the appendix of ABARTH.
Make reference notations in the margins of_ABARTH
information in FlAT and
with the best of intentions, one-of-a-kind publications like this one are frequently Dot returned to the
lender. Protect your copy and encourage your friend to purchase his own copy by giving him the ordering
information on the facing page. That way I can continue to make FlAT and ABARTH TRICKS
available to those who really
are designed to complement each other. You should have both so they can be used
Then read all of FlAT and ABARTH TRlCKS.
about the loctions of updated, new and related
ABARTH TRICKS. Lastly, l suggest that you Dot loan this book to anyone, as even
enjoy these purposeful, efficient, and fulfilling conveyance devices.
(see bottom of facing page) and FlAT and
they can be as entertaining as any
and ABARTH
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ILLUSTRATIONS--starting on page 84
Figure 1: Fiat and Abarth Pushrod-engine Pistons......................................................................84
Figure 2: Timing Gear and Ignition Timing Marks ........................................................................84
Figure 3: 600/750 Oil Filter Assembly ............................................................................................84
Figure 4: 600/750 Distributor and Abarth Tachometer Drive ... 85 Figure 5: 850/0TI000 Weber 30 DIC
Carburetor.........................................................................................................................................86
Figure 6: Induction Systems and Hardware ..................................................................................87
Figure 7:Cooling System Parts..........................................................88
Figure 8:Exhaust Systems and 850/0T1000 Mounting .................... 88
Figure 9: Clutches 89
Figure 10: 600/750 Clutch Actuation and Cable Support .............................................................89
Figure Il: 600/750 Mounts and Engine Compartment Panels ......................................................90
Figure 12: 850/0TlOOO Mounts and Modifications.......................................................................90
Figure 13: Drive-Train Movement Bar ............................................................................................90
Figure 14: 600/750 Transaxle, Axles and Gear Change ...............................................................91
Figure 15: 850/0T1000 Gear Change and Drive axels...................................................................92
Figure 16: 600/750 Handbrake ........................................................................................................92
Figure 17: Drum Brakes and Automatic Adjusters.......................................................................93
Figure 18: Hydraulic Brake Cylinders ............................................................................................93
Figure 19: 850/0T1000 Spider Covered Headlights....................................................................... 93
Figure 20: Suspension and Steering(a. Fiat b. Special Abarth). 94
Figure 21: l27/Al12 Conversion engine...........................................................................................96
Figure 22: Abarth 750 DORC Engine...............................................................................................97
Figure 23: Berlina Corsa TC and TCR Hardware ...........................................................................98
Figure 24: Fiat-Abarth Trim and Emblems .....................................................................................99
Figure 25: Currently Available Abarth products ..........................................................................100
Note: Part numbers net found in these illustrations are located in “Abarth” parts interchange, or drawings
in chapters 12 & 13.
Cover page:
Berlina Corsa TC OT1000 Spider
750 Double Bubble 1300/124- OT
850 Scorpione Scorpione 1300 SS
750 Record Monza 1000" Bialbero
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CONTENTS
Chapter 1: OLD BUSINESS FROM "ABARTH" " ,
Missing Photos and Flat-Abarth Desirability ......................................................................4
Corrected Copy .....................................................................................................................5
Corrections and Supplements to Technical Chapters 7 ...........................Fiat-Abarth Bialbero Engine Details 12
Chapter 2: POWER UNIT REMOVAL AND REPLACEMENT
Power Unit Removal 13
Installation Procedures and Checks 18
Starting, Adjustments and Break-in ..................................................................................26
Chapter 3: MAINTENANCE AND REPAIR
Maintenance Checklist........................................................................................................32
Tune-Ups..............................................................................................................................33
V-Belt Adjustment ...............................................................................................................35
oil Filter.................................................................... _..............................................36
Oil Changes and Leaks ...........................................................................37
Head Gasket and Cooling System .....................................................................................40
Head Retorque and Valve Adjustment ..............................................................................41
Timing Chain and Gears .....................................................................................................41
Clutch Replacement............................................................................................................42
Distributor, Generator and Starter .....................................................................................42
Carburation and Fuel System.............................................................................................43
Exhaust System...................................................................................................................46
Cables and Controls ...........................................................................................................46
Drive Axles...........................................................................................................................49
Transaxle and Gearlube......................................................................................................52
Brake System, Adjustent and Handbrake 53
Wheels and Tires..........................................................................................................55
Suspension and Steering ...................................................................................................55
Battery and Cables..............................................................................................................56
Electrical System, Gauges, and Lights .............................................................................57
Chapter 4:"DRIVERS CAR" CONVERSIONS AND IMPROVMENTS
Late Model European Engine Conversions.......................................................................59
High Fuel Economy Preparations......................................................................................62
124 Engine Conversion for the 850....................................................................................63
Front Radiators....................................................................................................................66
Diaphrgam Clutch Conversion and Cab1e Support ... 66
Mounts Strengthening ........................................................................................................67
Drive Train Movement Bar..................................................................................................68
Shifter Modification .'.................................. _ ...........................................68
6000 Transaxle Conversion................................................................................................68
Brake System Improvements.............................................................................................68
Suspension Set-Up and Improvements.............................................................................69
Battery Conversion .............................................................................................................70
Chapter 5: BODY, TRIM AND REPLICA CARS
Body, Trim and Accessories Notes ...................................................................................71
Berlina Corsa Replicas .......................................................................................................74
Berlinetta Bertone, OT1600/2000. . . . . . . . . . . . . .. 77
Chapter 6: COMPETITION EVENTS AND PREPARATION
Individualized Specifies,..................................................................., Carburetor Jetting 79
High Performance Engine Lubrication System ................................................................80
Chapter 7: PARTS, SERVICE WORK AND A LITTLE EXTRA _
Availability of Parts & Service............................................................................................81
"Getting Mead", "Your short Pump" . .'. ..............................................................................83
Machine Works, future. Booklet.127 Water Pump.............................................................82
Appendix : Specifications
Yearly Changes, Gearing Jetting, Engine Specs Misc ..... 101
New Materials as ol 1/1/85, 3/85, 7/85
How About Trying a Complete Drive-Line Conversion? 106
Ashley Clutch Linkage Fix for 850/OTIOOO ....................................................................107
Drawings : Pedal Linkage, 750 Muffler strap ...... 108
Fuel Recommendations) Windshield Repair, ..................................................................109
Abarth Scorpione vs OTAS Grand. Prix...........................................................................110
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CHAPTER 1: OLD BUISINESS FROM "ABARTH"
MISSING PHOTO
We were unable to locate representative photos of: the Spider sinle headlight Fiat-Abarth 210A which was
the first special- bodied 600-based Abarth (See page 50 of "ABARTH"), the "ugly ducking" Allanano 750
Spider in street configuration (pages 55-56), and the handsome Allanano 850 Spider "Riviera" which was
an Allemano coupe with the roof chopped off (pages 56, 58) . Below are drawings of these models. Photos
and information on the or 2000 coupe (850 coupe body and 2000cc Abarth twin cam with modified chassis
similar to the or 1600 Sedan) should have appeared on page 84 of "ABARTH" and can be found on page
77 of this booklet.
"The Duck" 210A Riviera
Why Are FIAT-ABARTH Cars Desirable?
What is an everyday road-going "sports car?" Perhaps a vehicle that possesses everything
the sporting
driver could wish for. Like: responsive performance from the engine, suspension, steering, and brakes
plus lightweight, aerodynamic good looks, reasonable driver confort and a certain "aggressive emotional
flavor". Along with these forms of efficiency, l am going to add fuel economy, ease of maintenance and
repair, and simplicity of design for a given purpose. Brute power (and attendant bulk) may have its place
for racing or "weekend fun" but as everyday sporting transportation it leans heavily into the areas of ego
gratification and over-use/abuse of resources necessary for the desired result. A true sports car qets the
most it can from what it needs. Fiat-Abarths embody aIl of these qualities. Add to all this the fact that
these cars are for the most part quite inexpensive to purchase (as classic sports cars go no,.; days), and
there is not a lot more an enthusiast could ask for in sporting transportation....
ln the case of the Fiat and Abarth sports cars, which this booklet is about, the only real issues that might
be considered "flaws in the mold" would be: (1) noise and vibration levels for extended highway use, (2)
relatively short-lived and fragile power unit components and accessories, and (3) poor braking efficiency
on early 600-based cars. ln the first case, other than using a quieter muffler, more sound insulation and
higher final drive gearing, there is not much that can be done about it. The second is rea1ly net an issue
(especially if you are a mechanical hobbyist) in that hardly a car in existence bas an engine or related
hardware easier to remove and simpler to rework. And on the third point ; it is a small matter to convert
to the front disk brakes from a later model Fiat.
Page 7
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"ABARTH"
CORRECTIONS ( Sure, we made mistakes) Listed by page and location, corrected copy
underlined
page
##
26 Right
27 Middle of left column : a modern Fiat 127 cam can be used in the 850 block to change
column middle first paragraph: described in detail in Chapter 11.
engine rotation
for use in 600-00.500 Abarth conversions ( see Chapter 13).
27 Second paragraph: complete cylinder head with side draft Weber two barrel carburetor, or 850 style
downdraft Weber and special valves and springs for the standard head, olus high-performance camshaft
and _exhaust_ Systems.
27 Last paragraph : As to 127 aftermarket engine
parts appropriate to Fiat 850 and Abarth OT1000. there is
only a set of heavy-duty valve springs (There is a cog-belt camshaft drive conversion kit suitable for
600/850 based motors but it is different from a 127 kit) . The high performance 127 camshafts, while good
for 850/903 conversion engines going into a 600-based car, are of no use in an 850-based car unless you
have the direct drive camshaft gears to overcome reverse rotation. Likewise, the special 127 combination
valve cover and intake manifold with 32/32 Weber barrel carburetor may be unusable as delivered
because the float bowl will sit sideways in 600 and 850 based cars (also at a 5 degree angle in the 850based cars). ln addition, the ail filler cap is on the opposite end of the valve cover which makes adding oil
difficult.
48 The last paragraph in the left column was insert here by mistake (it also appears in the right column).
The following text should have been in its place: The Fiat 600 handling and heatinq sins proved negligible
for the stock car, but critical for the Abarth-modified cars. The tendencies to roll over or over-heat were
magnified when the available power was increased. They were characteristics of the Fiat 600 which
Abarth never completely conquered. In view of the unqualified success of his cars as racers, he obviously
solved then well enough to suit his purposes. One other design limitation that nagged Abarth was the
marginal brakes of the 600. This was finally dealt with by fitting disk brakes up front on the street cars and
disk all around on the racinq oriented machinery.
50 Middle of the left column: Outer springs were strengths(measured at 1.25"
compressed. length) or inner sprinqs of 29 kg. could be used with
available in 34, 43 or 50 kg.
the standard 24 kg. 600/750 outer spring giving a total spring pressure of 53 kg.
53 Photo caption and "Spider. Zagato" paragraph: The Zagato brothers cut off the roof and
redesigned the rear body sections of their coupes to create two Fiat-Abarth spiders. The upper photo
shows a 56 “topless Double Bubble”, and below it a '58 "topless Record Monza”. Both models used
pushrod engines (no rear-engine DOHC spider street cars were made).
58 Photo caption: Perhaps the most pleasantly proportioned, available, 600-based road-going Abarth
and
certainly the most conformable tourer, the Allemano-bodied Scorpione Coupe came with an 850 cc., or on
rare occasions, the one liter pushrod engine.
59 First paragraph: Brakes were improved by increasing the wheel cylinder
diameter and replacing_the
hinged brake shoes with self-centering type.
60 Bottom of the third paragraph: The engine-driven fan
(not the rear radiator) was removed on this
model, and a short water pump was used
60 Replace the last sentence before "850 Sports Prototype" with: This car has the non-covered headlights
and non-removable rear body/motor mount panel and no starter motor access panel. Front disk brakes
were fitted, but nearly all other details remained identical to the original Record Monza 750 twin cam
model.
63 Middle of the last paragraph: The cars which came before were simply unknown and most
which came
after were either too mundane (warmed over Fiat look-alikes) or too exotic and expensive.
Page 8
pp.72 The third and fourth sentences should read: The 817cc U.S. smog exempt version of the 850 engine
that Fiat Obtained by decreasing the cy1inder bore by one millemeter (to 64mn) in 1968 to 1971 sedan
models was used along with a 32mm one-barrel Weber and special : intake manifold, exhaust system,
cam and finned alloy five quart sump by Giannini .
pp. 106 #8 should read: 17mm heads on high-tensile steel cylinder head bolts marked _ABARTH & C"
(Fiat 600 has 13mm bolt heads & Fiat 850 bas 14 or 17 mm heads on semi-hardened iron bolts which are
labeled “Fiat”)
pp. 107-110 regarding the current value of the various Fiat-Abarth models : The prices listed are now quite
low especially with the recent upsurge in classic car collecting & racing. Also, when "Abarth" was being
written (1981-2), my experience had been more with the "low dollar fixer" type of car & this was reflected
in my value estimates along with the fact that "being in the business" allowed me to meet many.
enthusiasts & hear of the base deals. Keep in mind though chat a nice complete & running car can Cake
as much time & money to restore to original as “rough basket-case” because a "nice" car will still require
stripping totally to make it 100%. The only Car worth a lot of money is one that's nearly perfect....
6
Page 9
Corrections & Supplemental. Materials for "Abarth" Technical Chapters
7
pp. 109 Fiat-Abarth 1300/124 OT item #3. : Reclined to 3/4 upright
front radiator ; mounted & shrouded on
left side of original spare tire well with Abarth grille & electric fan etc...
pp. 109 regarding engine number on cylinder block: 1300/12h number is located on right sida of block
near fuel pump.
PP. 109 info regarding Fiat-Abarth Scorpione 1300 S/SS :
with pop-up head lights and a 1300cc pushrod
version of the Fiat 124 engine. Top of pp.
110 : Was modified
and 4-wheel disc brakes (the Scorpione S and the
by Lombardi to fit the Fiat 850 chassis. The true Scorpione SS has special suspension
1300/124 previously listed has 850-type......
pp.l07, 113, 120, 122 aIl these pages mention a non existsant Chapter 14. You probably realized wo meant
to say chapter 13
On pp.135 at end of first paragraph we meant to say: refer to chapter 12 (pp 120).
pp 113 regardin, those "Larger engines for Early Abarths”, GOOD NEWS : Maurice Dhoore in Belgium has
investigated for me the possibilities of using currently produced readily available fiat 127/Autobianchi
A112 engines of tram 903 to 1050cc in early Abarths.
These engines are closely related to the Fiat 850 but rotate in the desired clockwise direction. There are
some outer accessories that need to be replaced or modified ("see pp. 59-61 of this booklet), but the
engine itself would Ot require disassembly or internal modification as with the conversion outlined in
chapter 13 of "Abarth”. Of particular interest is the Autobianchi A.112 Abarth 1050cc engine which
produces around 70 horsepower (compared to about 42 hp for Abarth 750)
pp. 113 right column 5th line should read : cylinder boring and an oversize
head gasket are required for
sizes over about 67mm.
pp. 114:special 9.8 to 1 pistons (altered piston pin height with full floating pin design)
and rings (thin
width)
pp. 114 add to bottom of page : Special Abarth Muffler - with chrome tipped twin large diameter outlet
pipes p. 116 add to the list of “Updating for Daily Use”
x « Available battery » conversion
x Drive-line movement bar
x Clutch cable locator/center support strengthening bracket
x 850/OT 1000 diaphram clutch conversion
x 850/OT1000 stvle cooling system thermostat conversion
pp. 118 just above “Condition of the Crankshaft”, should have appeared the paragraph in the middle of
the right column of page 133 ( Henceforth. When referring ... etc)
which is also applicable for this booklet
too.
Then the following additional information : Engine rebuilding and assembly procedures are easier to
accomplish if you mount front (flywheel end) of cylinder bIock to an engine stand that allows motor to be
rotated to varying positions (especially to flip_ block over and back during piston insertion and rod-cap
installation). Take care_ when mounting block to leave enough room for front crankshaft seal-housing
installation.
Pp 118 and of first paragraph under “condition of the Crankshaft” : Note also that oversize Abarth
bearings do not come in standard U.S. sizes (.010", .020" etc)" So double check Abarth bearings before
crankshaft grinding. Finally as a general rule, most Abarth 850, 1000 and OT1000 engines use special
Abarth large main bearings while nearly all pushrod motors use standard Fiat rod bearings.
pp. 119 under "The Cylinder Block" at end of first paragraph : Fiat no-longer supplies late 903 center main
bearings with oil delivery hale and grooves. Therefore using Fiat bearings will negate the desirable
pressurized center main bearing; so bearings made by other suppliers (like A.E.) should be used in this
situation.
Note also that bearings for pressurized center mains can be used on aIl other 850 engines even though oil
holes will ho of no functional value.
Page 10
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While on the subject of 903 cylinder blocks (identified by 4 boIt water pump mounting flange) note that
they are about 5mm taller than 843/OT1000 blocks to compensate for increased crankshaft stroke and
longer connecting rods (which allow s same pistons
to be used in both 843 and 903 motors). ln addition 903 cylinder head thickness is different and pushrod
and distributor drive shaft lengths are longer than 843 /OT1000 pieces. Note also that 843's can be made
into “903's by substituting 903 crank with 843 rods special made pistons. 817's can be bored out 1mm (or
larger if desired) to make an 843 as well.
pp. 119 and 120 regarding align-honing block main-bearing 8addles and connecting rod. big-ends : ln this
process, a very small amount of metal is ground away from mating surface of bearing cap and block or
rod saddle resulting in a smaller diameter hole which is then honed or bored-out to original size
specifications after cap is torqued in place.
pp. 119 just before lest paragraph in left column : After good “dry” measurements are obtained remove
crankshaft and lubricate bearings/thrust washers before refitting and torquing main caps. Now “flip”
crank over using only your fingers on the counterweights. If it won't "spin" freely at least one-haIf turn,
something is wrong. Loosen one main cap at a time to Iocate a "tight” bearing and determine the problem.
pp. 119 regarding crankshaft and end-play at bottom of left column : Proper procedure for measuring is 1.
insert large screwdriver tip at one side of center main-cap and lever crankshaft away from center bearing.
2. Measure clearance at one of the end main-bearings (between main-cap end machined edge of crank
journal). 3. Move screwdriver to other side of center main and lever crank in opposite direction. Take
second measurement at same end main-bearing as before. 4. subtract smaller figure from larger. End-play
should be .010" maximum.
pp. 119 right column 2nd paragraph 2nd sentence, (600/750 camshaft bearings are not pressed into block
but held by locator bolts like the rear cam bearings).
pp. 119 middle of right column : After boring/honing cylinder, do not use solvent to clean them. Use water
and detergent and then clean, oiled rags.
pp. 120 under “Pistons and connecting Rods”, after first sentence : when rebuilding, .6mm (about .024")
"over" your bore-diameter is usually a good safe piston size to order as it leaves room to bore again but
is normally sufficient to remove grooves in cylinders caused by broken piston rings. Remember that size
stated on piston box and stamped on piston crown is not piston diameter but rather the appropriate
finished bore diameter.
pp. 120 figure-A should have looked more like figure-1 of this booklet (pp.84)
pp. 120 bottom of left column end top of right column OT/1000 piston pins are "full floating” and not press
fit into connecting-rod as stated.
pp.120 right. Column starting at 13th line clown should read: Most original
stepped top- except 600, 600D, and OTl000
pistons must face when taking note of combustion chamber shape in cylinder head.
(sec figure-1 of this booklet) making it obvious which direction
pistons have at least a slightly
Note: piston or rod weights should not vary more than 1 gram.
Page 11
9
pp 121 the end of first paragraph : If you find that piston and rod assemblies are quite difficult to install in
block because piston ring installation chamber at too of cylinder bore is not exaggerated enough, use a
self round-file to accomplish the desired effect your self (rather than returning to machine shop again.) Be
sure to stuff rags in cylinder bores to catch motel dust. Light tapping with a hammer handle on piston
crown ( and some patience) is aIl that should be required to insert piston in bore. Incidentally, if you
should ever hear a definite “snap” when installing a piston, always remove ring compressor and purchase
a new ring to replace the one you just broke... As a precaution, crankshaft should be turned so that rod
journal for cylinder you ere working on is in the down
position. This helps avoid contact between
connecting rod and freshly machined crank journal during installation. Use cheap and simple flat-castiron piston rings. Exotic design or alloys may break or fail to seat thus spoiling Your engine job. Ring
end-gap should be . 0081” to .012”.
pp.121 right column, at end of 1 st paragraph : Keep in mind that using a high performance reground cam
sometimes necessitates machining off material (maybe .045" or so) from the undersides of rocker arm
stands to cancel side-effects (geometry and adjustment problem). Also note that Abarth racing cams with
rear roller- bearing can be installed in any block.
pp.124 the end of 1st paragraph: (600 20mm/..80"and 850 25”/1” pump gears). 600D/850 style pumps
require oil-delivery tube blanking-plate to be fitted over hole in pump cover-lid/pickup when used in a
600/750 motor.
pp.124 under : "Timing Chain and Gears” see additional timing gear installation and alignment details on
pp. 41 and figure 2 of this booklet.
pp.128 first paragraph: same style keepers : springs, & locator/retainer
CupS
pp. 128 Second paragraph see new info pp. 6 of. this booklet regarding pp.106 #8 of "Abarth" for
information about Fiat 600 and Abarth 750/OT1000headbolts. Note that 850/903 bolts are 9mm fine tread,
750/OT1000 are 100mm course thread and 600/600D use smaller 8mm bolts. Also it should be mentioned,
that Fiat made special offset “crows foot” wrenches in both 14mm and 17mm sizes, thus negating the
need for one oddsize (14mm) bolt head to fitted behind thermostat housing on 903 engines. Finally, when
Abarth bolts are fitted with two washers, the thin brass one goes against the cylinder head surface and
thick hardened steel type between bolt head and brass washer. Don' t use oil on head-bolt threads or
washers as torque values will be effected.
pp.128 right column, middle of paragraph just before “The distributor should read (especially the left
cover).
front
Figure 7 will side in identifying and dealing with cooling system parts as described on pp 130, pp.132#11,
and pp.155-136 of “ABARTH” as well as its parts interchange (pp.149,) and new materials in this booklet.
pp.131 #8 1 Note that cylinder head locator dowels are only fitted to 850/903/OT1000 engines.
pp.132 first two paragraphs Note that valve adjustment, distributor installation and timing adjustment
procedures are explained in detail on pp:29 #3 and 42 of this booklet. Also note that about two three
healthy squirts of motor oil from a lever-operated oil can is sufficient to aid piston ring lubrication with
tight new engines.
pp.132 #10 regarding installation and adjustment of carburettor linkage : On 850/OT1000 models and
conversion engines, grease linkage pivot pin on top of valve cover and install pivot arm (with cable
attaching-sleeve or stud fitted), spacer/retainer washer, and clip or cotter. Fit return spring to arm and
valve cover bracket. Grease linkage pivot ball on carburettor and snap on plastic socket with threaded rod
and (loose) jam nut fitted. Adjust length of treated rod so that when inserted in arm hole, stop "foot" on
valve cover 1/8” from touching pivot arm. Install rod retainer clip. Rock plastic socket back and forth on
linkage baIl and hold in position at center of travel while tightening jam nut (8mm open-end wrench).
Original 600/750 engines have similar but non-adjustable throttle control linkage (see figure F pp. 138 for
parts identification).
Page 12
10
pp.134 end of #3 should read: Maybe
noisy for a street car.
pp.134 middle of right column regarding distributor/oil pump shaft length headaches : lts possible to cure
shaft length problems without disassembly of engine if motor has been put together with the wrong shaft
length. If shaft is too long
for your block, you can fit brass spacer washers between head and distributor
housing. If your engine should ever "jump" distributor timing when you bit a pronounced clip or bump in
the road, you knew shaft length is too short.
Machining the base of distributor housing or making a
“splined adapter” from an old distributor shaft-end end drive-shaft-end brazed together) to fit between
drive shaft and distributor shaft can help take care of this Iittle inequity,
pp.135 first sentence of "Cooling System" has two comma's missing : three-boIt water pump ,
fan , and
shroud.
pp.136 10th line clown misspelling : or utilize a small filler/
pp.136 second paragraph 7th line: will require a 1" section
header tank.
of the 600/750 hose .
pp.136 regarding thermostat housing and fittings for conversion engines:
see figure 7 of this booklet.
pp.137 “Exhaust System” : See figure 8, pp, 108 drawinng, & pp. 46 of this booklet for more details.
pp. 139 after third sentence in 2nd paragraph: see figure 5 of this booklet .
pp.141 right column should be all-one-paragraph.
pp.142 right column end of 1st paragraph : see pp 22. of this booklet for cable-adjustment and adaptersleeve info .
pp.142 right column 2nd paragraph, end of first sentence add: (note that 850 disk is a slightly larger
outside diameter but will usually clear inside of 600/750 pressure pIate mounting flange.)
pp 142 1st paragraph of "Clutch" : see pp 66 and figure 9 of this booklet for diaphragm clutch conversion .
"ABARTH" Interchangeable Parts Lists : Corrections & Updates
"ABARTH"
Page Part Description Columns Correction/Update
146 .. Carburetor Base Gasket ..................................600 Notes for Weber 26 IM
146 .. Engine Gasket Set...........................................Fiat 600........................... 907945 $5.80
148 .. Tappet-std........................................................Fiat 850........................... SAME(8req)
*149 .. Thermostat .......................................................A750/F600 ...................... 4045626 $16.30
149 .. Thermostat.......................................................OT1000/F850.................. 4154313 $3.30
149 .. Fan & Pu11ey Key ...........................................750&600 Notes... delete-NLA
149 .. Hub for Plastic Fans .......................................600 Notes ... late 600D same as 850
149 .. Fan Cooling Shroud........................................750&600 Notes .. delete information
151 .. Input/Clutch-Pilot Shaft .. 750&600 Notes..late type(early NLA)
151 .. 3rd Gear............................................................A750/F600 ...................... NLA(old# 875487)
151 .. seal for Inner Boot ..........................................750&600 Notes..600D seal-40001150
*152 .. Axle Shaft ...........................................................A750/F600 .......................early 23mm axle-NLA
*152 .. Axle Shaft .........................................................A750/F600 ... 24.34m axle-4009303
*152 .. Axle Shaft .........................................................750&600 Notes.. 600D axle-4061138
*152 .. Sp1ined Ax1e-Attaehing Sleeve..A.750/F600........................................... for 23mm-878272
*152 .. Sp1ined Ax1e-Attaehing Sleeve..A750/F600.. for 24.34mm-4095427
152 .. Snap Ring to Retain Axle .. 750&600 Notes..for 24.34:mn axle only
152 .. Tie Rod Ends ...................................................750&600 Notes..early type(late NLA)
152 .. King Pin Set .............................................................750/600/OT1000/850..1900637 $16.60
Page 13
*152 .. Leaf Spring (Lower)Bushing..A750/F600.............................................. 4007967 $3.50
152 .. Leaf Spring (Lower)Bushi_g..0T1000/F850 ......................................... 4140008 $6.20
152 .. Inner Front Bearing Seal ...OT1000/F850............................................. SAME(2req.)
*153 .. Collapsible Bearing Spacer..A750/F600 ............................................... 986842 $1.55
153 .. Wheel Cy1inder- Front ..................................750&600 Notes..600D-4394465 $18.20
153 .. Wheel Cylinder- Front.0T1000/850 Notes.850 Sedan-4379471 $11.00
155 .. Fuse Box.........................................................F600 ............................... SAME
155 .. Wiper Rheostst .......................................OTIOOo/850 Notes ..67-72 Spyder
156 Revised Spark Plug Recommendation Chart:
11
Brand Name Abarth 750
Pushrod
Fiat 600/600D Abarth OT/OTS
1000,1300/124
Fiat 850 Sport
A112Abarth
Fiat 127
A112
Champion L-5, L-4J L-7J N-6Y N-7Y N-9Y
NGK B-7HS B-6HS BP -8ES BP-7ES BP-6ES
Lodge 2HN HN 3HLNY 25HUIT HLNY
Bosch W225T1 W175T1 W260T30 W200T30 W175T30
Marelli CW-7N CW-6N CW-8LP CW-78LP CW-7LP
Abarth AB200 AB175 AB260LY AB230LY AB200LY
158 .. Fiat 600 Front Grille with Emblem .. 889868 $4.55, Upper & Lower Grille Whiskers .. 884321(4req.)
$2..90, Center Wiskers .. NLA(2req.) 158 .. Fiat 600D Hubcap. .411722?(4req#) $12.90 159 .. Motorsport
Imports .. Note: 600/850 & 127 cog-belt kits differ.
. Denotes a major
error :in. "ABARTH" Interchangeable Parts List.
New Listings for "ABARTH" Parts Interchange
Page # Part Description A750/F600 OT1000/F850 Notes
147 .. Connecting Rod... 88822(4req.) $7.25 425683 $13.5 843
427731 $23.5 903
147 .. Conn Rod Bolt...........................................884067(8req) $.30 .... 4187674 $1.45
147 .. Rod Bolt Nut...........................................12566220(8req) $.55 . . ----------------- .............
148 .. Replacement Pistons. 66-5765 Borgo-600D.. 66-6210 Borgo-817cc
(62mm ... oversize) ... (64mm + oversize)
148 .. Exhaust Valve ................................. 4064702(4req) 54.15-600D(23.5mm) may
fit 750
148 .. Valve Spring ..............................................................898327(8req) $1.20..use A12/127 Abarth
to OTI000(16req)
148 .. Valve Spring- Outer.. ..................................................................................4208869(8req) $2.15
148 .. Valve Spr_- Inner.. ...........................................................................4183703(8req) $.95
148 .. Rocker Arm ........................................................... 991327( 4req) $5.90. .4189130(.4req) $4.30
99l328(4req) $3.65..4189131(4req) $4.30
148 .. Push Rod ..................................................................... 880904(8req) $2.00..4130697 $7.00 843
4109429 $2.10..903
149 .. Fan Shroud Clamp Ring.................................................................................4109842 $1.65 .....
149 .. T .Stat. Housing Lid/Water Outlet ............................................. 4100580 $9.05 . to mid 68
4187098 $6.55 .. 69-73
150 .. Intake Manifold... _. NLA( use aftermarket) ... 4226436. $28.00
150 .. Flywheel Ring Gear .. NLA(use 4113558 fly- ..4109024 $15.55
wheel complete $86.75)
151 .. Speedometer Cable ... see.pp.91. of FAT ................................................4136084 $9.40
155 .. Combination Light/Wiper Switches(3-inch)..4204126 $13.00-coupe
155 .. Heater Fan Switch ... .................................................................................4294181 $2.75
160 Vandervell, Clevite, AE, Repco, & Glacier are good alternate sources .to try for Fiat
engine bearings.
- 160 other Abarth clubs are located in : England, Germany, France, Sweden, Japan.
159-160 ADS & PES are out of the Fiat business and most of the other
listed sources no longer supply much for the early cars. See pp. 81-82 of this booklet for good new
sources....
Page 14
12
Fiat-Abarth “Bialbero” Engine
"Bee al bier o" Means 'two shaft'
In the beginning there was a dual over-head-cam Fiat-Abarth engine which utilized the basic Fiat 600
cylinder block and very few other original Fiat pieces (see figure 22 and photograph on page 12 of
ABARTH).
dual two-barrel downdraft Weber carburettor cocked half - sideways atop short manifolds between
the cams. It used the standard Fiat" long water-pump" and engine-driven fan. Next came the
cross-ram manifolds, still feeding between the cams, but using dual twin choke sidedraft racing style
Webers (see photographs on pages 56 and 57 of ABARTH).
manifolds on the right side of the head to achieve a more conventional "cross-flw' style intake/exhaust
tract. This engine looks quite similar in layout to an Abarth Simca 1300 (see page 80 of ABARTH).
Wate-rpump without an engine driven fan was fitted for use with a front mounted radiator and electric fan.
Along the way, 700 and 1000 cc displacements were adopted to suit various racing classes. Fiat cast
special books for for the twin-cam and push-rod 1000 cc engines which would allow a larger cylinder
bore of 65 mm. Early-on, these exotic "mini-rotors" cane in the Zagato bodied Record Monza and later
they were fitted to the front radiator equipped Abarth-made Bialberos and a group of small bore "sports
racers"*.
Twin earn engine parts are very difficult t to get. I don't think any DOHC pieces have been made for about
fifteen years. Some early motors use standard 600 : train and rod bearings, connecting rods, piston pins,
timing chain and gears for the jack earn, water-pump and pulley, fan and shroud, generator, oil pump,
front crankshaft seal rousing, oil filter canister, rotor mount, and Sate of the nuts, bolts, washers,
bushings, gaskets and seals. A 600 cylinder block, flywheel, clutch, fuel pump, and oil pan could
probably be made to work on the early twin cams with slight modifications. Late "cammers" use nothing
that would qualify as a standard Fiat part except perhaps the oil pan gasket. Unless you can get parts
"special made" (see page 82), you nay have to settle for a pushrod engine conversion....
Bore and stroke specifications were altered to produce either 750 or 850 cc. This engine had
Finally, the side drafts were attached to short
A short
* 1960 750 Tubolare
1962 1000 Tubolare
1965 1000SP Barchet ta
1969 1000'Millino
750 rev limit: 7000rpm
1000 rev limit: 7800rpm
750 DOHCMotor
Page 15
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CHAPTER 2
POWER UNIT REMOVAL, INSTALLATION, STARTING, ADJUSTMENTS, AND BREAK-IN
PROCEDURES
Power Unit Removal
One of the nicest features of most rear engine Fiat and Abarth models is the ease with which
the motor can be removed and handled. The removable rear body/engine mount panel allows
the job to be accomplished by one person with the aid of only a small floor jack. In addition, the
number one cylinder exhaust header pipe and water pump housing serve as a perfect set of
handles to jocky the lightweight engine around making these vehicles ideal "hobby cars."
Allemano Coupe and some Record Monza/Bialbero Models though, have a non-removable rear
panel thus requiring that the motor be dropped out the bottom like a Volkswagen Bug or 356
Porsche (have you noticed that the Record Monza is almost a 3/4 scale look-alike for the old
Porsche coupes) or lifted out the top. The late model Monza also has a one piece nonremovable firewall panel which requires removal of bellhousing-to-engine and starter motor
colts from under the car.
For all models I recommend placing the car on a level cement surface to allow the floor jack
wheels to move better when the engine is rolled out the back. Also, it is an excellent idea to
remove the engine compartment lid (or at least insert a safety prop). Besides providing
improved access, you eliminate the change of a poorly supported lid falling on your head. The
parking brake (if operational) should also be securely set.
The following sequences are designed to be quicker and more precise than repair manual
procedures ; especially if a friend reads the steps as the mechanic works.
For Pushrod Engined Fiat 600-Based Vehicles with Removable Rear Body Panels:
.*Under Front Hood:
1. Remove battery cover thumb screws. t cover (if cover is still in place). Disconnect and isolate
negative cable and from battery. Remove fuel line hose (will stop tank from siphoning later)
from gas tank outlet pipe and plug (a wooden golf 'T' works well) pipe and hose to avoid
contamination.
*At Sides of Car:
2. Place blocks in front of and behind left front tire. Jack car up from a point beneath right door
sill and just in front of right rear tire and support chassis with a safety stand.
*From Beneath Car:
Remove flywheel and clutch lower dust shield (10mm heads on 3 Bolts) and lower cooling
/engine compartment shroud (see Figure-11, or for cars with auxiliary or front radiators, FigureD. Page 136 of "Abarth" book),
if these tin pieces are not already missing (7mm head sheet metal screws).
Loosen oil drain plug a little (17mm socket and large breaker bar) but do not remove at this
time. Disconnect bottom hose at radiator and drain engine coolant into a large pan. If an
auxiliary or front radiator is fitted, remove water pump hose from car.
Page 16
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*From Above and Behind Car:
On Berlina models, remove rear bumper and support brackets and/or deck lid props when fitted.
Remove one lower bolt/nut/washer and then two upper attaching nuts and special serrated flat
washers from studs on right side rear body/engine mount panel (power unit ground strap
should be fitted to top stud as well). Unbolt muffler unit at exhaust header flange(s) and sump
support bracket(s). After unscrewing exhaust trim panels (see Figure- 11), muffler is withdrawn
from beneath (many muffler shroud panels have been cut away to facilitate installation of a nonstandard exhaust system). After stuffing a rag in water pump inlet, removing pan & lowering car
may be necessary to momentarily jack up left side of car if muffler could not be jockeyed out
with right side raised. Remove sheet metal screws (7mm heads) which attach lower rear portion
of muffler shroud panel (if intact) to left side of removable rear body panel. Reach under sump
and remove plug to drain engine oil into a pan. Replace plug hand tight.
*In Engine Compartment:
3. Detach distributor vacuum, crankcase breather hoses, air cleaner support strap(s) and loosen
clamp ring before removing cleaner assembly from carburettor intake. Loosen both top water
hose clamps and slide hose back off radiator inlet pipe. Remove large rear motor mount nut
(17mm socket), washers, and upper rubber doughnut. Support engine from center of oil sump
with floor jack. Remove two attaching nuts and washers and one lower bolt/nut/washer from left
side of removable rear body panel. Disconnect license plate light wire (except some Berlina).
Jack engine up until contact is made with body (at transaxle bellhousing) and maneuver rear
body panel out of car. Immediately wrap rear panel with a blanket and store it in a safe place so
it's not damaged. Lower engine to normal position, place a small jack beneath rear portion of
transaxle and raise it slightly to relieve some
weight from floor jack (this is important:
*Continuing in Engine Compartment:
4. Disconnect fuel supply hose as it enters fuel pump and
allow to drain into small can. Plug hose (wooden golf 'T’) to avoid contamination. Detach
accelerator and choke control cables, temperature sensor wire, two generator wires, distributor
primary wire and high tension cable and tuck them out-of-the-way to avoid entanglement.
Disconnect low oil pressure wire at sensor (600) or oil pressure gauge supply hose fitting
(Abarth) at steel tubing.
Some Berlina Corsa competition models have a half dozen or so oil lines relating to remote oil
filter/ cooler/pressure regulator and crankcase breathers to disconnect and plug.
*Within Passenger Compartment:
5. Tilt rear seat forward (Berlina) or remove rear cargo area trim panels (Coupe and Spider) and
then remove floor mats, carpet, and insulation padding from behind. Remove five sheet metal
screws (7mm heads) securing transaxle/starter cover and carefully pry off cover (frequently
stuck to body). Remove two starter attaching nuts and pull starter forward (wiring. and
operating cable can remain attached if starter requires no attention) and wrap a rag around it
before locating it in a secure position atop transaxle case. Remove four large (19mm heads)
engine-to-bellhousing attaching
bolts with lock washers.
*4-At Rear Again:
6. Using gloves or rags to protect your hands, grasp exhaust header with left hand (palm up)
and underside of water pump housing with right. Lift slightly and pull toward rear while rolling
engine backwards on floor jack. Balance engine on jack before lowering and removing from
jack. Run a piece of mechanics wire through an upper bellhousing-to-engine mounting hole and
an available hole in firewall to hold up rear
of transaxle before removing small support jack (letting transaxle hang unsupported will ruin
shift linkage coupler and transmission mounts).
Page 17
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For Fiat 850 Spider and Coupé Based Vehicles with 850-Based
Engines (Sedan models and 'radiale' engined cars differ slightly) :
*Under Front Hood :
1. Remove battery cover plate (two plastic thumb nuts) and disconnect and isolate negative
cable from battery. If optional large capacity Abarth fuel tank is mounted in front, fuel outlet
pipe/hose should be disconnected and plugged.
*At Sides of Car:
2. Place blocks in front of and behind left front tire.
Place floor jack in front of right rear tire (under suspension mounting bracket), lift car until tire
is almost ready to loose contact with ground, and support , chassis with safety stand.
*From Beneath Car:
Use 10mm socket with long extension to remove flywheel and clutch lower dust shield bolts (3
bolts, if intact. Note that right bolt also attaches power unit ground strap).
Remove lower cooling/engine compartment shroud (7mm head sheet metal screws) if intact.
Loosen oil drain plug (17mm) a little but do not remove at this time.
Drain coolant into a pan by disconnecting bottom hose at radiator. Radiator cap should be
removed after most of the coolant has drained
out. Leave the drain pan in' place for now. Water
pump drain plug can removed to evacuate trapped fluid.
*At Sides of Car:
On pre-1972 Spider based models, remove bumper tip securing bolt located inside right rear
wheel well (13mm socket). Remove safety stand, lower car, switch blocks to right front tire, jack
up left side of car in front of rear tire and support with safety stand. Remove left bumper tip bolt.
*From Beneath:
Remove muffler heat shield bolts (7mm head sheet metal screws) if intact. Some jockeying
around may be necessary to remove heat shield from car as muffler and body interfere. Lower
car.
*From Rear (or sides) of Car:
On 72-73 Spider based models access to bumper tip bolts is provided within engine
compartment by removing coolant recovery tank on right and access plate/windshield washer
bag-holder bracket on left. With a Coupe simply loosen
bumper tip retainer bolts a couple of
turns with 13mm open- end wrench from within bumper tip bracket itself.
3. Detach small direct-crankcase-vent hose and larger valve cover vent tube from underside of
air cleaner. Remove air cleaner lid, 3 (10mm socket) lock nuts with retainer plate, and then air
cleaner housing from carburetor intake (Sedan differs). Loosen top hose end slide it back off of
radiator inlet tube. Carefully remove fragile heater hose from thermostat housing tube (two very
large well-placed screwdrivers will help to lever it off a-little-at-a-time). Remove fan shroud
clamp ring (10mm socket & 10mm wrench) & peel back rubber bellows. Use white adhesive tape
(especially on 70-73 Spiders and all Racers) to label wires for: stop, tail, turn, license, and
backup (early 68-on) lights before detaching. Remove bumper mounting strap bolts (straps
Page 18
16
project forward through rear body panel and are attached to sides of rear engine compartment
by two special serrated locking type bolts on each side). A Coupe or Sedan bumper may now be
removed by merely sliding it rearward. On Spiders, remove large nut, bolt, washers and upper
rubber doughnut from rear motor mount (lower bolt head must be held with a vice grip pliers or
17mm box-end wrench to facilitate removal of top nut with. half-inch drive 17mm socket
/extension/ ratchet. With a Coupe or Sedan* first detach engine mount torque strut (see Figure-
12) from left side of rear body panel and then remove 17mm lower
spring mount retainer nut (do
not remove top spring mount nut unless you plan to replace inner rubber doughnuts, spring or
center stand parts). Now with all cars, support engine lightly from center of oil sump with floor
jack. Remove six rear body panel attaching nuts, and special serrated flat washers (on Spiders a
special ratcheting 13mm box-end wrench works well on the top nut on either side, while others
can be removed with thin-wall 3/8" drive deep socket and ratchet). Jack engine up just enough
for motor mount to clear rear body panel mount perch. On Spiders, wrap rags around bumper
tips at sides of both rear fenders to keep from scratching paint.
* Sedans have a removable upper-rear-access-panel to unbolt first (10mm socket for 2 nuts & 2
bolts).
Now pull body panel rearward with your hands (tap with rubber mallet if necessary) and remove
from car. Cover it with a blanket and store in a safe location.
*From Within Engine Compartment:
4.Disconnect fuel pump inlet hose and insert a wooden golf 'T' in hose to stop leakage. 1970 and
later models with closed fuel vapor system should have gas cap removed momentarily to relieve
pressure before removing fuel line. Also, fuel line usually needs to be tied or wired to left side of
inner body to preclude interference on engine removal. Disconnect accelerator and choke
control cables and tuck them out of the way. Drain motor oil into a pan & replace plug hand
tight.
Detach two generator wires (cars equipped with alternators have 3 connections). Remove two
nuts (17mm socket) and four large flat washers and pull generator or alternator rearward while
slipping belts from crankshaft and water pump pulleys. Now
use a 3/8" ratchet, deep 13mm socket and long extension to detach one heavy black cable and
one or two heavy brown or grey wires from starter solenoid post. Use same setup (about 24" of
extensions J, to remove three starter mounting nuts (a flashlight may be helpful to locate nuts).
Unplug push on connector to remove red wire from s tarter solenoid. Three lock washers will fall
on ground as you pull starter out of car. Detach tempeature sensor and oil sensor(s) (Spider = 2,
Coupe/Sedan = 1) wires, distributor primary wire and high tension cable (at the coil). Pull
generator and temperature sensor (coil wire from ignition switch also Before 90) wiring harness
forward and to the right to locate it behind radiator filler neck so that it's out-of-the-way.
5.Lower engine as far as. floor jack will allow. Use 19mm box end wrench with suitable length of
pipe slid onto end to increase leverage while removing two upper engine-to-bellhousing
mounting bolts. Jack engine back up near its normal installed position. stuff a rag into water
pump inlet & remove coolant drain pan.
*From Beneath Car:
Use 1/2" drive ratchet and leverage pipe, 19mm socket, and short extension to remove
remaining two (lower) engine mounting bolts. On right side you will need just the right length
extension and proper leverage to remove bolt as radiator cowling is in your way. Now support
transaxle at rear with small jack and lift slightly to remove some
of weight from floor jack
(important).
Page 19
17
*At rear:
6.Using gloves or rags to protect your hands, grasp number one cylinder header Pipe with left
hand (palm up) and underside of water pump housing with your right. Lift slightly and pull
rearward as you roll the power unit backwards out of the engine compartment. Balance engine
on jack before lowering and removing motor. Tie a piece of mechanics wire through upper left
bellhousing bolt hole and fuel sensor access hole to support transaxle before removing support
jack.
Next time try it for speed. About 30 minutes is an excellent time. . .
Page 20
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Power Unit Installation
These procedures are suitable for a fully assembled and "prepared" rebuilt (original or
conversion) engine (see Chapter 12 or 13 or "Abarth" book). The preceding engine removal
sequence should be consulted if uncertainty regarding installation steps is encountered.
When the motor is being installed there is a natural excitement about getting the car running for
the first test drive. For this reason and as a matter of convenience, I recommend checking
several items before
starting the installation. In this way, you will not become rushed near the
end and overlook details which might spoil or delay your job......
Check brake fluid level, and if low, the presence of fluid leakage at master or wheel cylinders.
Pump brake pedal a few times to make sure the system is holding pressure. Check battery
condition (water level, charge, clean battery posts and cable connections. See pp. 56 ).
Especially on 600-based models, use a flashlight to check inside of gas tank for rust, excessive
sediment, or water. You might want to remove fuel gauge sensor, float and fuel pickup
pipe/screen assembly which is sometimes clogged with rust and debris. Be very careful with
fragile sensor attaching studs which are easy to snap off (use penetrating oil on them before
removing nuts). If rust is apparent, it will be necessary to remove tank and have it filled .with an
acid bath solution to remove scale that might later clog fuel lines and carburetor jets. (Note:
Some radiator repair shops have facilities to clean fuel tanks). Sometimes a rust clogged fuel
pickup screen will need to be replaced or discarded and an inline fuel filter installed to take its
place. 850 based cars do not suffer these maladies as often, but it's still a good idea to check
because gas tank access on these models requires that power unit and transaxle be removed
first. Also make sure that you have at least 3 or 4 gallons of fresh
premium fuel in the tank for
initial starting and test drives (you might want to drain tank first if car has been setting a long
time and fuel has "gone bad"). Radiators should nearly always have their tanks. removed and
cores rodded out*
at a radiator shop. Check throw-out-bearing condition by applying forward
pressure while rotating bearing. Dry, rough, or sloppy bearings will require replacement. As a
matter of fact, it is a good policy to always replace this inexpensive piece as a noisy bearing will
require engine removal later. Grease should be applied to the surface that bearing collar slides
on when in use. Check to see that operating fork-to-collar retainer clip is in good condition and
properly
fitted & greased. This is good time to add or change transaxle gearlube (gearbox must
be level). Axles, sleeves, couplings, and axle boots should also be checked and if necessary
replaced now.
(See pp. 49 for axle checking and replacement procedures). Check that two
transaxle-to-engine locator dowels are in place in lower engine block mounting bolt holes and
use duct tape to hold upper flywheel dust shield (see Figure M, pp. 143 of "Abarth") to rear of
block during engine installation.
* Note. Some radiators came from the factory with excessive amounts of solder present within
their cores which restricts flow & later hastens premature clogging. "Boiling out" doesn't
disolve it!
Also: External fins are often packed With grease which blocks air flow.
Page 21
19
If you haven't already, now is the time to fill the engine with motor oil (see pp. 37 for
recommendations and procedure), Unscrew carburetor lid and lift it high enough to allow float
bowl to be 1/2 filled with fuel (unnecessary if electric fuel pump is being used). Replace lid,
tighten screws and wipe away any spillage. Slide new top water hose and clamps onto cylinder
head outlet pipe (or thermostat housing lid) but do not tighten.
Remember that car should be on a level cement surface. '
Installation Procedures for 600 Based Cars with Pushrod Engines and Removable Rear Body
Panels:
1.Block front wheels and set handbrake.
*At rear:
Support transaxle in level position with a small jack and remove your bellhousing support wire.
Place engine on floor jack and balance it with middle of its sump resting on jack. Roll engine
into back of car jacking it up as necessary for clearance and finally reaching a height and level
position that will allow transaxle input shaft, to enter greased crankshaft pilot bushing. Using
gloves or rags for your hands, lift motor slightly by exhaust header and water pump while
pushing forward and rocking engine side to side as input shaft and then locator dowels enter
their final positions. (Hopefully, if taped-on, flywheel dust shield will not falloff a few times while
trying to accomplish this). Frequently, input shaft splines will' not be in alignment (especially
course-spline Models) with clutch disc splines which causes engine to stop moving forward
before locator dowels are engaged. Either moving input shaft just slightly or rocking engine
from side to side while pushing forward (with transmission in gear) should solve this little
problem. Care should be taken not to "hang" or rest engine heavily on pilot shaft and throw-outbearing contact-ring (held onto clutch pressure-plate) during installation. Contact ring
attachment is somewhat delicate.
*From Inside Car:
2. Install and tighten four large bellhousing-to-engine attachment bolts (19mm) with lock
washers (2 longer bolts go in bottom holes). Replace starter motor dust shield plate and then
starter itself (2 nuts and lock washers). If starter was removed completely you will need to attach
two electrical cables (large black battery cable and heavy brown wire: also rubber protector
boot) to threaded brass post near starter control lever arm. Also control cable must be attached
to the arm. Select adjustment hole in cable bracket that allows starter lever a small
amount of
play before starter engagement. On those cars that have been converted to a 600D starter, a
conventional solenoid has replaced mechanical lever arm and an electrical wire with plug-in
"bullet" connector replaces control cable and is run from a late model combination ignition, and
starter switch. Lever on floor is then relegated to the role of "a trim item."
600D starter
Also from inside car, check visible condition of clutch cable (broken inner cable strands or
damaged outer cable housing) and watch for smoothness of operation and flexing of center
support/locator plate (see Figure-10) as someone operates clutch pedal for you (initial cable
adjustment may be necessary for checking purposes).
Page 22
20
I nearly always replace old clutch cable with latest 600D improved type and beef up center
support/locator plate (see Figure.10 and pp.66 ). Check that clutch return spring is properly
fitted and in good condition. You cannot get along without this .spring because it also helps to
hold special cable-attachment-pin and retainer bracket (see Figure-10).
Install transaxle/starter motor access-cover-panel(five-7mm head sheet metal screws and
special serrated flat washers. Larger screws necessary If Clips are stripped out). Perfect contact
of cover panel rubber-sealing-gasket is essential if engine heat, fumes, and noise are kept from
entering the passenger compartment. Replace all insulation padding, floor mats, and rear cargo
area trim panels (4 Pivot rear seat-back into normal position on a Berlina).
* From Beneath:
Remove jack from beneath transaxle, leaving floor jack under engine.
*In Engine Compartment:
3. Although on 600-based cars, generator and drive belts could
have been fitted before engine
installation, now is also a convenient time to do this job. When you are seated on a suitable
stool, motor if located in perfect position while rear panel is not yet in place. Fit water pump belt
into forward-most generator pulley groove and crankshaft pulley belt in rear-most generator
pulley groove. With belts "hanging" in pulley grooves, slide assembled generator and mount
bracket in position to rest upon water pump housing. Tilt pulley end of generator down to allow
belts to be slipped over crankshaft and water pump pulleys. Now slide generator forward and
onto bracket mounting studs. If you already have correct belts for your setup this is an easy job.
See pp. 35 for proper belt adjustment procedures. Attach two generator wires (posts end
connectors ere different sizes to assure correct connection.) with protector boots, distributor
primary wire (from D, CB, or negative post on' ignition coil to distributor plastic terminal with
threaded stud), and coolant temperature sensor _ire with protector boot. Install new
fuel pump
supply hose between delivery pipe (exiting firewall) and engine. Allow enough slack in hose to
accomre0date engine movement. Plug-in coil high-tension wire and use tie-wraps or plastic wire
loom clips to neatly route and retain spark plug wires in a manner that will avoid fouling or
chafing against other components. With 600's, attach low oil pressure sensor 'wire with
protector boot. On original Abarth, connect a new oil pressure gauge supply hose, and on
conversion engines (see pp. 141 and Figure I of "Abarth") attach appropriate wires or high
pressure hoses as necessary.
4. Jack engine up until bellhousing contacts body at firewall. Slide engine mount stand and
large lower rubber doughnut onto rear body panel stud (see figure K, PP.141 and 143 or
,"Abarth") and manoeuvre panel and mount into installed position.
Fit four special serrated flat washers onto panel mounting studs, taking care not to forget
ground strap attachment between top right stud and upper fan shroud mounting bolt on water
pump, and pull up and tighten nuts a little at a time. How install two lower bolts/nuts/washers
attaching panel and body at each bottom corner. Lower engine and remove floor jack. Install
upper rubber doughnut, large flat washer, lock-washer, end tighten nut with 17mm socket. You
may Want to touch up any scratches that occurred on bottom of a tin oil pan with some black
spray paint.
*Note: never allow generator wires (#67 & #51) to reversed. Immediate damage will occur....
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Make sure
for 9.bottom pp(carburetor linkage rod length is properly adjusted based-850
procedure). Remembering that, depending on valve cover style, some conversion engines will
require shortening of throttle cable steel tube as it exits the firewall and a longer inner cable
wire (see pp. 138-139 of "Abarth"). Check, straighten, or replace and lubricate accelerator cable
wire (for 850-based cars see procedure.-PP.47). With rubber dust boot fitted to cable wire, slide
outer cable housing-end into retainer bracket register on valve cover while threading inner wire
through hole in pivot stud or sleeve (see. pp. 139 of "Abarth"). Secure outer housing-end by
metal screw and plate clip (750/600) or snap ring clip (850-based and conversion). Force rubber
dust boot over end of outer cable housing. When tightening pinch bolt, see that there is at least
1/8" of slack in wire between pivot stud or sleeve and pinch bolt (wire must be pulled to rear and
then released to remove excess slack in cable and associated linkage). This is necessary to
allow for engine movement during acceleration and shifting. As an added touch, I like to remove
about 3/4" of insulation from a piece of 16 gauge electrical wire and slide it over bare cable wire
end (saves you from being stabbed when working in engine compartment. Check, straighten, or
replace and lubricate choke control wire keeping in mind that cable will be too short on
conversion engines (see pp. 139 and Figure G of "Abartht”). Also, lubricate all carburetor
mounted linkages, and inside the car; choke and throttle control pedal/pivot housings. Now
slide outer choke cable into register or bracket attached to carburetor assembly while threading
inner wire through cloke pivot arm pinch bolt hole. After tightening outer cable retainer bolt,
provide "pre-load" by lifting driver operated handle about 1/4" off of its stop. Now while holding
arm in fully -mounted choke pivot-carburetor
ou can be sure that when you In this way y). mm wrench7and
pliers (position, tighten choke wire pinch bolt open
Test .the choke off it is offwant
the operation to see that it works fully and smoothly (see pp. 130 of "Abarth" for linkage &
spring details).
Attach license plate light wire (except some Berlina models). Then slide top hose onto radiator
inlet pipe (for conversion engines see pp. 136 of "Abarth" regarding top hose to radiator inlet
reducer sleeve) and tighten clamps. On motors with vacuum distributor advance, install a new
hose between carburetor and distributor fittings.
5.Jack car up from in front of right rear tire and support with a safety stand.
* From Beneath:
Check condition of rubber shift linkage coupler (see Figure.14 and pp. 48) and transaxle mounts
(Figure-11), Watch coupler and mounts along with clutch cable center support/ locator(fig.10)as
someone operates shift lever and clutch pedal from inside car. Oil soaked, softened, cracking,
or split rubber parts, damaged mount brackets/crossmember, or excessive movement of driveline(pp.68&Fig13) or cable support(pp.66)should be attended to now
. Also, it's a good time to
adjust handbrake (see pp. 54 and Figure-16) if driver operated control lever moves more than 5
or 6 clicks before locking rear wheels, adjustment is not optimum.
Install new lower and front or auxiliary radiator (if fitted) hoses and while you're at it check
condition of water pipe hangers (if fitted). Fit lower flywheel/clutch dust shield (3 bolts with
10mm heads - frequently necessary to retap stripped threads and install 1/4"x20 American
bolts). Install sheet metal screws that hold muffler heat shroud panel (if intact) to rear body
panel.
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*In and Beneath Engine Compartment:
Using new exhaust flange gasket(s) and bolts with brass nuts and lock washers, attach muffler
to exhaust header (may
be necessary to raise left side of car to position muffler properly). ,Fit
muffler support strap to rear bracket on original tin oil pan(or on conversions with cast sumps,
attach to special made bracket - see pp. 137 and Figure E of "Abarth") and then to attachment
ear at right rear corner of muffler. Install exhaust trim panels with sheet metal screws where
exhaust pipes poke through the muffler shroud panel (see Figure- 11). I'd think twice about
using the asbestos trim plate gaskets, as asbestos could conceivably flake off and be
transmitted by original 600 style heater ducts into passenger compartment. Remove support
stand and lower car (except for cars with front radiator). Make sure water pump and radiator
drain taps are closed before filling cooling system with plain water
(temporary). If your car has a
front radiator it will necessary to either open the bleeder fitting (if provided) at top surface of
front radiator or jack rear end of car up high to facilitate partial
release of air bubbles from
system. Do not fit radiator cap or lower cooling and engine compartment shroud (see Figure- 11)
as yet.
*In Front:
6.Connect fuel supply hose to gas tank (if removed). Check to see that all electrical switches are
in 'off' position and attach ground cable to "prepared" battery (see pp. 56 and 70 regarding
battery preparation and conversion). Now in engine compartment, remove distributor cap and
with ignition points closed and ignition switch 'on' flip points open a few times with small
screwdriver tip while watching to be sure that you have “fire” to the points.
* In Front:
Jack up car from center of front leaf spring and place safety stands under chassis behind each
front wheel. Remove suspension splash shield (if intact) and adjust clutch pedal free-play by
loosening jam nut and turning adjuster sleeve-nut until about 1 inch (or to suit your driving
preference) of free pedal movement before clutch starts to disengage. If you have used a
particularly thick clutch disc lining material, it may be necessary to fit a spacer sleeve onto
cable-end before installing adjuster sleeve-nut and jam-nut (see Figure-10 for parts
identification). Look for brake master cylinder leakage before refitting suspension splash shield
and lowering car.
Installation Procedure for Fiat 850 Spider and Coupe Based Cars with 850-Based Pushrod
Engines( Radiale engines differ in some details).
First read introductory installation paragraphs on pages 18-19. Then check condition of: 3
starter Mounting studs on transaxle bellhousing, clutch cable and return spring, transmission
mount brackets (I recommend strengthening modifications - see pp. 67 and Figure-12), and
engine mount perch on rear body panel (frequently Spider models will require rear panel/mount
perch repair. See pp. 67 and Figure-12). Remove throw-out-bearing pivot arm and grease pivotball and arm socket. Late U.S. models ('70-'73) with pollution control equipment can
conveniently have all smog hardware removed if a '68 or '69 model engine has been fitted to the
car ....... (see details on pp44
). Fit all new fuel line (6mm fabric-braided hose) and clamps
between gas tank and fuel pump supply pipe as it exits left firewall. These seldom-replaced
hoses are frequently rotten and can be difficult to change with engine installed.
Page 25
23
Installation Step #1 is same as for 600 based cars (See pp. 19 ).
*Reaching Forward From Behind and Below Engine:
2.Install two (long). lower engine-to-bellhousing mounting bolts (19mm socket and extension)
with lockwashers. Then remove transaxle support jack.
*From Behind and Above:
Lower engine as far as floor jack will allow and install upper (short) mounting bolts (19mm box
or open-end wrench). This is a very good time to check or replace clutch cable and/or return
spring and to pre-loosen cable jam nut for later adjusting (10mm open-end wrenches) as poor
access will make these jobs more difficult later. Also, cable-end threads can be sprayed with
WD-40 to aid in adjustment sleeve movement. Raise engine back to level position. Install starter
being sure
to fit lockwashers. 13mm deep socket and very long extension(s) can be used to
insert, start, and tighten the three nuts. Plug in red solenoid wire and then attach large black
cable and large brown wire (or 2 grey or brown wires with an alternator) with protector boot to
threaded post on solonoid.
3.Follow Step #3 - pp. 20 of procedure for 600-based cars as well as the following supplementary
information. For late model cars with alternators there are four wires to attach rather than two (2
thick grey wires fitted to threaded post-also with radio suppression condenser ,wire-and
protector boot j yellow w/ plastic covered female connector plugged into plastic male socket;
small grey w/ bare female connector pushed onto remaining bare spade connection). Early ('66'69 cars have ignition coil attached to rear body panel and, therefore, it's wiring must be
attached later. Late ('70-'73) models also use an external ignition coil ballast resistor. See #5, pp.
35. if you have any doubts
about the more complicated coil wiring on these models. (You may
melt points or be unable to start car if wiring is wrong). Long coolant temperature sensor wire
with protector boot is green in color and plugs into top of water pump by-pass banjo fitting
retainer bolt on cylinder head. On late cars, coil high tension and primary wires should be
routed through retainer/insulator gromet fitted to bracket atop fan shroud housing (these
relocated ignition coils require long wires). Spiders have two oil pressure sensors (see Figure I,
pp. 140 of "Abarth”) and Coupes one.
To test if you have Spider sensor wires fitted correctly, turn on ignition key and if oil pressure
gauge immediately pegs itself to right, you have wires switched. (Usually the wire that is slightly
shorter and has a large rubber protector boot fitted to it, is the one that goes to low-pressure
warning Iight sensor) .
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4.With Spider-based models, jack up engine until transaxle bell housing makes contact with
firewall. With rags wrapped around bumper tips and plastic mounting gaskets in place and
located by rear body panel attaching studs, start to insert body panel/ motor mount perch into
position (sometimes jack must be lowered just slightly for panel to clear muffler tail pipes».
As panel is moved into place, insert mount stand sleeve and large lower rubber doughnut
between panel mount perch and engine mounting bracket. (see Figure K, pp. 141 of "Abartht”).
Take care not to pinch any electrical wires while pulling up and tightening 6 nuts and special
serrated flat washers that attach rear panel to body. Lower engine until contact with mount
perch is made and insert large mounting bolt and flat washer from beneath mounting perch. Fit
small upper rubber doughnut, large washer and nut. Lower engine and remove jack. Hold bolt
head from beneath with a 17mm box-end wrench or vise grip pliers and pull-down and tighten
locking nut from top using a 1/2" drive ratchet, 6" extension and l7mm socket. Install bumper
mounting strap bolts (special serrated locking type) loosely and jack car up one-side-at-a-time
to install bumper tip attaching bolts from within the rear wheel wells ('72 and '73 models access
is through inner fender panels). While right side of car is jacked up and supported with a stand,
install lower flywheel dust cover with power unit ground strap attached to right side bolt (l0mm
socket and long extension for 3 bolts. If threads are stripped use a 1/4X20 tap and fit u.s. bolts).
Then fit a new lower radiator-to-water pump hose and clamps. On '67-'69 models attach stop/
tail/turn wiring by plugging in plastic sockets on either side of the engine compartment. License
plate and backup light wires (brown and yellow) should have their individual spade connectors
pushed together and rubber insulator sleeves forced over them (it is easiest to slide insulator
sleeve over "male" end and pull it back before pushing connectors together. Then lubricate
connectors and sleeve with WD-40 to allow sleeve to slide over connector. If you have a '70-'73
Spider) and you marked lighting wires with tape on disassembly you ere in good shape when
refitting them. If not, see pp. 58 for hookup diagram and don't forget to replace six square
protector boots while you' re at it.
On Coupe models, mount bracket, spring assembly, and engine torque strut should be fitted to
engine in one piece (see Figure- 12). With engine jacked up, slide rear panel (with body gaskets
fitted) into body and draw up and tighten nuts with special washers. Lower engine, remove jack,
install lower flat and lockwasher and tighten nuts. Attach torque strut to left inner rear body
panel using 2 rubber gromets, steel spacer sleeve, through-bolt, lockwasher, and nut (see
Figure- 12). Install rear bumper (4 special bolts at sides of engine compartment and 2 pinchbolts for outer tips) and attach license plate and backup light wires. Jack up right side of the car
and fit flywheel dust cover, ground strap, and lower hose as noted for Spiders.
*Within Engine Compartment (and if necessary, Within Passenger Compartment):
'66-'69 Coupe and Spider Models can have ignition coil/distributor wiring attached now (see #5,
pp. 35 for coil wiring detail.
Follow carburetor and choke control cable attachment directions detailed in Step #4 of 600based installation procedures. (pp.21), noting that 850-based throttle pedals often develop a lot
of play in them before carburetor actuation is accomplished. The lever arm is staked onto the
end of throttle pedal pivot shaft where it pokes through center (shifter) tunnel near driver's right
foot. It needs to be removed (see pp. i7 ) and welded without getting it hot enough to melt the
plastic pivot bush/ bracket. Carefully inspect heater hose where it slides onto thermostat
housing tube. Often, end of this hose is split
from impatient removal, crystallised from heat, or smashed by original wire-type clamp. Pull
hose a little further out of firewall and carefully trim off about the last 5/8" of damaged end. Now
slide hose onto thermostat housing tube and fit new American style clamp. Install a new top
radiator hose and clamps. Force rubber fan bellows over lip on radiator shroud and install large
wire 01amp. Fill cooling system with normal tap water
but do not fit lower cooling shroud and
muffler heat shield or radiator cap yet. If you are retaining pollution control equipment on '70-'73
Page 27
25
model cars, hose attachment details are provided on pp. 45 .
5.Jack car up in front of left rear tire and support with safety stand.
*From Beneath :
Inspect transmission mount brackets for splitting or spot-weld failure (see pp. 67 and Figure -12.
for repair and strengthening modifications). Shift linkage rubber coupler should be watched as
shift lever is moved slightly
forward and back. If coupler moves more than transmission shaft,
check for worn pivot sleeve or attachment hole in coupler (see Figure-I5).
Now see that shift lever is in a perfect perpendicular position when car is in neutral. If not, 2
coupler clamp-bolts can be loosened and shifter moved to perpendicular before retightening.
Watch for excessive drive train movement as clutch and shifter are operated and check rear
body panel/engine mount perch for spot weld failure and torn sheet metal (see pp. 67 and
Figure-12 for repair and modification details). Lying on your back in front of rear tire, use 13mm
ratcheting box-end wrench to adjust handbrake (long threaded rod at rear of shifter tunnel) so
that rear wheels lock at about five clicks of lever movement. Still on your back but now beneath
muffler, use two l0mm open-end wrenches to adjust clutch pedal free play. Move threaded
adjuster sleeve on cable-end (attached to operating fork in bellhousing) until adjustment is
achieved (1 inch pedal free-play or to suit driver). Note also as pedal is operated, if left side of
center tunnel (near driver's right foot) moves or groans. This problem can be cured by
strengthening the area where cable pivot pin attaches to inner tunnel (see pp. 67).
* At Front :
Check that all electrical switches are in 'off'" position and attach ground cable to "prepared"
battery (see pp. 56).
Make sure to fit positive cable-end insulator boot and install battery cover plate (2 plastic thumb
nuts and rubber washers). Check to see that you have "fire" to ignition points (see #6 - pp. 22 of
procedure for 600-based models).
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26
Starting, Adjustments, and Break-In Procedures
Quite frequently, with a freshly rebuilt "tight", engine, nothing short of a brand new starter and
battery will turn things over fast enough (or at ail) for these motors to start. It's not that the
engine is too tight but that this starter is just not a very strong unit even though it may have
started a previous "loose" motor just fine. It is normally necessary to tow the vehicle with
another car or hand
push it down a moderately steep incline. If your car has external oil lines
and remote filter end/or oil cooler, it is highly recommended to crank or tow the car with spark
plugs removed until oil pressure shows on the gauge. On engines without external lines, it's up
to the individual whether to develop oil pressure before attempting to start. If you have a 600/750
motor with paper element oil filter, be sure to fill the canister with oil before fitting the lid (see
Figure 3) for filter parts-breakdown). Pump brake pedal again a few times to make sure
everything is still in order. An operational handbrake is a big plus during pull/push starts. A
horn and stop lights might come in handy too.
“Starting Drill” for All 600 and 850 Based Cars
1.If you are going to pull it, tie a fairly long rope around front leaf spring-to-chassis attaching
brackets. Don't even think about “pushing
it with another car” and with an aluminium bodied
model, caution your helpers to be very careful where they apply pressure if hand-pushing.
2.With a screwdriver, scratch a reference mark across joining point of cylinder head and
distributor housing (if not done earlier). Adjust idle mixture needle screw out
seat. Adjust carburetor idle stop screw in
about 2 1/2 turns after it starts to make contact. Place
1 1/2 turns off its
screwdriver (for idle and mixture adjustments), open/box wrench (to move distributor for timing
adjustment), a glove or small rag for your left hand (to rotate distributor by its cap), and a jug of
water next to you on passenger seat. Full choke fully out and make sure it is opening and
closing properly. Turn on ignition switch and see that generator and oil lights (if fitted) are on.
Place car in third gear and push clutch in.
3. After slack in rope is taken up, have driver of tow car pull away slowly and wait until he has
reached about 10 miles per hour. Let clutch out and give a small pump or two to accelerator
pedal.
4.If everything is right the fact that you have "primed" carburetor float bowl beforehand should
allow car to fire immediately.
As soon as it does catch and start to run, shove in clutch while operating throttle. At same time,
honk horn or stick your left arm out of open window to signal driver ahead that car is running
and start to brake in relation to how quickly the tow car is stopping. If you are having trouble
keeping it running with throttle pedal, a handbrake stop will make things a little easier (you
won't have to move your foot from throttle to brake pedal). If you didn't use handbrake to stop,
apply it not and shift gearbox into neutral. Engine should be idling very fast and no doubt
misfiring considerably. Look at oil pressure gauge or tight to be sure you have pressure (cold
starts should show at least 50 Ibs. with a new engine).
If no oil pressure is indicated, shut off engine immediately and investigate. Don't be alarmed
about all the smoke coming from rear of car. It is only the oil you squirted into cylinders being
burned and paint/oil residue smoke off of exhaust headers. If someone is available, have them
operate throttle linkage in engine compartment (if necessary to keep engine running) .
Page 29
27
5.Grab your screwdriver, wrench, and glove/rag and run to back of car. Adjust idle speed down a
little as engine allows and if possible try to open choke linkage a-little-at-a-time conditions
permitting. If you are able to open choke fully and lower idle speed to around 1500 RPM within a
minute or so, you are in position to make some preliminary adjustments by turning idle mixture
needle screw in and out and loosening and rotating distributor back and forth (use glove when
moving distributor by grasping cap) a little to eliminate misfiring. Keep adjusting idle so that it
stays around 1500 RPM.
Optional
If you cannot open choke without engine immediately wanting to stall or can barely even keep it
running with choke fully on, try slowly loosening idle-jet retainer brass screw (see Figure 5 for
30 DIC 2-barrel carb models) off its seated position anywhere from 1/32 to 1/3 of a turn. If idle
speed goes up immediately at any particular position, idle jet is,. either plugged, a larger jet is
required, or you have a vacuum leak (see pp. 129-130 of "Abarth" and pp. 43 of this booklet for
details).
6.Look under car for signs of oil, fuel, or water leaks (stop engine to investigate if leaks are
noted remembering that any water pump seal leakage may
cure itself in a day or two). Be
especially careful that cars with front or auxiliary radiator have run long enough to open their
thermostat (if fitted) and/or purge themself of air bubbles. If motor seems to be running well
enough, try driving car around the block (don't get too far from home yet) 4 or 5 times while
keeping an eye on water temperature and oil pressure gauges. Don't let water temperature get
above 200°F or do any hard acceleration. Whiile driving, note any irregularities regarding driver
controls (shifter, clutch, throttle, brakes, steering, etc.) that should be attended to when you
return (see Chapter Three). Back car up to your work area, recheck water level, check condition
of radiator cap before fitting, adjust idle down to around 1200 RPM (if possible) and play with
fine idle mixture needle screw, stopping just before idle speed shows any sign of faltering or
slowing down while turning screw in. Remember to keep a close eye
on water temperature
(200°Fmaximum) while completing final tuning adjustments.
Final Adjustments
1. With the possible exception of primary-side idle jet on 2-barrel Weber 30 DIC carburetors,
standard jetting should be just right as fitted for any stock Fiat or Abarth engine/carburetor
setup. If you have modified the engine (cam, compression, head work, or alternate carburetion)
see Race Preparation, Chapter 6 (pp. 19) for rejetting guidelines. If you have a good
distributor, I
have found that the best way to set final ignition timing is "by ear." With glove on your left hand,
grasp top of distributor cap as you start to loosen distributor housing clamp nut.
As you slowly rotate distributor counter-clockwise (more advance), engine speed will increase
until a very definite misfiring occurs. Now slowly rotate distributor clockwise (retard) until
engine almost stalls. Final timing point will be found when distributor is rotated from retard
(stall) position 1/4 of the way back (counter-clockwise) towards where misfiring is pronounced.
Sit on a stool and play with timing for a few minutes until you are satisfied that you have found
the spot to lock distributor housing in place. You will realise that the point at which engine runs
best and idles fastest is not the proper place to set timing as engine will b_ slowed down
considerably from fastest idle when properly positioned. Look at reference mark you scratched
on cylinder head/distributor housing base and don't be, surprised if these "static timing" marks
are now 1/8" or less from each other if you used the recommended setup procedure (see pp.42).
Page 30
28
Now drive car around the block another half dozen times. As a quick double check of timing, try
going around, end accelerating lightly out of a fairly slow (900) corner in third
gear. If engine "pings" badly (fresh premium fuel is a must for this test), it is a sign that you
have too much advance. Although excessive retard may spoil best acceleration, idle, and
starting performance, too much advance can really be detrih1ental to engine life (especially if
you lug the car up hills without enough momentum (see pp. 118 of "Abarth").
2. When you return to work area, place a large piece of cardboard on ground under engine
(extending from crankshaft pulley to beyond flywheell. Try some additional adjustment of fine
idle mixture and idle speed screws. A good idle speed is 1050 to 1150 RPM (never mind that the
Fiat manual says). Below 1000 RPM, idle may be irregular and prone to stalling whi19 over 1200
RPM you frequently encounter detonation or “running-on” after ignition is shut off. Not gauge
readings for oil and water and turn off ignition key. Remove cardboard and inspect for signs of
oil leakage. A fine spray of droplets on pulley end is normally from timing cover oil seal or
centrifuge (if fitted), and on flywheel end it denotes front seal problems. Now is the time to find
and stop leaks, as later-on after more driving, oil will be blown around making location of the
source more difficult (see pp. 37 for common oil leaks).
3. If your starter and battery are decent, you should now be able to restart car and put 15 or 20
miles on it (no dusty conditions without air cleaner though). A good break-in procedure is to
drive car at about 35 miles per hour and then accelerate relatively hard (not full throttle though)
to 55 miles per hour before backing off to-aIIow deceleration to 35 miles per hour again. Do this
about 10 times during Jour drive. Remember to monitor temperature and oil gauges carefully
(see pp. 126, last paragraph of "Abarth" for acceptable oil pressure readings). Park car for the
rest of the day. Cover carburetor air intake and set engine lid (if removed) in place.
Page 31
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Cylinder Head Retorquing and Valve Adjustment
I have found that, despite the extra work, retorquing the head after
the first time the engine has
been brought up to operating temperature is a really good idea.
1. With engine cold, check oil and water levels before draining cooling system (drain top or plug
fitted to bottom or front of lower radiator tank or detach lower hose at radiator).
Unclip cap from distributor and set it off to right side of cylinder head. Disconnect fuel and
emission line(s) at carburetor and plug hose(s) with a golf 'T'. Detach throttle cable linkage rod
at carburetor. Be very careful on 850-based cars while using a screwdriver to lever delicate
plastic ball-socket off (keep screwdriver tip as close to socket as possible to avoid breakage).
Then remove linkage pivot arm cotter pin (600-based) or retainer clip (850-based) and upper
spacer washer. Pull off outer cable housing dust boot (if fitted) and remove retainer plate (600)
or clip (850). Lift pivot arm off valve cover pivot pin while detaching throttle return spring and
pushing outer cable forward and out of holder bracket on valve cover. (When done in suggested
manner, cable adjustment will not be lost). Tuck cable with attached linkage out-of-the-way. On
some cars, _ou will need to detach choke cable before removing carburetor and drip tray (if
fitted). On other models} carburetor can be unbolted (600-based= 2 studs, 850-based=4 studs)
without cable detachment and moved to an out-of-the-way position thus avoiding readjustment
of choke control cable as well. 600 or 750 cylinder head water outlet and hose may be
left intact, but 850 and OT1000 style thermostat housing (2 or 3 hoses connected) will
need to be removed (unless you have the special "crow's-foot" off-set wrench
formerly sold by Fiat in 14mm and 17mm sizes) to gain access to headbolt behind it.
Use speed wrench to remove valve cover hold-down nuts and then carefully lift
cover(large screwdriver tip sometimes helpful to lever it off when stuck to gasket)
just enough to facilitate removal of washers from 4 studs (magnet probe may help;
600/750=4 lock washers, late 600D/850/0T10000=4 lock and 4 hold down plate
washers). Use socket to remove 4 rocker stand hold down nuts and washers a-fewturns-at-a -time and pull off rocker assembly.
2. Starting in center of head and progressing outward in a spiral pattern, torque ten head bolts
(one is inside intake manifold port) to 38 to 40 ft. Ibs. (600/600D engines only=22 ft. lbs.). Then
torque a second time, as center bolts frequently loosen up when outer ones are tightened.
Replace rocker assembly, flat washers, and lock nuts, pulling down nuts a few turns at a time
while making sure that all adjuster studs stay properly located in push-rod sockets. Torque
locking nuts (600/750/ early 850 sedan with 8mm studs using 14mm socket=15 ft. lbs.
850/0T1000 with 10mm studs using 17mm socket=25 ft. lbs.)
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30
3. Valves must now be readjusted (see specifications on pp. 132 of
"Abarth"). I like to loosen all
jam/locking nuts with a socket wrench before
beginning valve adjustments. It saves time, and also when job is finished, if
you have any doubt that all valves have been adjusted, simply attempt to
rotate each jam
nut with your fingers as a final check. To obtain proper
adjustment, loosen jam nut 1/2 turn, unscrew adjusting stud 1/4 turn, insert
feeler gauge, turn adjusting stud back until nearly as tight as your fingers
can accomplish, spin jam nut down with fingers and tighten with open end
wrench. Frequently, adjusting studs will not even need to be held with tools to stop them from
moving as jam nut is tightened. A small- adjustable (crescent) wrench or pliers can be used to
hold>-studs if your fingers are not enough though (special Fiat adjusting tool was formerly
available). If gauge is too 10088 or tight now, try again. I find it easier to provide a relatively
heavy drag on gauge when finished. Each adjustment should naturally have about the same
amount of drag on gauge as the others.
Adjustment Sequence:
With transmission in neutral, use a ratchet and socket on generator pulley nut to turn engine
over in direction of ,engine rotation (some people will find this job easier if spark plugs are
removed). You will need to apply finger pressure to belt on right side and beneath generator
pulley to stop belt slippage on clockwise motors (600-based cars) or from left side of pulley and
on top of belt for counter-clockwise units (850-based). Turn pulley until #4 cylinder valves are
rocking (exhaust just
finishing closing and intake, just beginning to open) and adjust both
valves of cylinder 1. Continue in sequence with: #2 rocking, adjust #3; #1 rocking, adjust #4; #3
rocking, adjust #2.
4. Replace thermostat housing and hoses (if removed), valve cover, carburetor drip tray (if fitted)
and gaskets, carburetor, distributor vacuum hose (if fitted), throttle cable with linkage and
spring, choke cable (if removed), fuel line(s), distributor cap. Test for proper choke operation.
5. To install 850/0T1000 Coupe or Spider air cleaner, first slide a piece of new fuel line hose onto
intake manifold fitting for direct crankcase breather valve leaving the other end uncut to length
for now. Slip valve cover breather hose (with internal flame-trap screen fitted) onto large tube
fitting on underside of air cleaner assembly. Drop 3 spacer sleeves onto carburetor lid studs
(retap stripped stud threads and use 1/4X20' U.S. studs or bolts) before lowering air cleaner
body with rubber gasket fitted, onto studs as breather hose is pushed over tube on valve cover
filler neck. Fit large retainer plate (sometimes necessary to straighten plate with hammer on a
flat surface) and then install three locking nuts (10mm socket) being careful to not over-tighten
and strip threads. Bend three retainer tabs on air cleaner lid inward, hold new filter element in
place, and bend tabs back to hold filter in place. Place lid on air cleaner assembly and attach3
hold down clips. Carefully route direct-crankcase-breather valve hose around throttle linkage
and cut to length before fitting to remaining (small) tube on underside of air cleaner assembly.
Snap carburetor fuel line into clip on right underside of cleaner assembly (see Figure 6 for parts
identification).
600/750 & 850-Sedan air cleaners slide over a round rubber seal that sits on top of carburetor
intake/air horn. 600-based types have a clamp-bolt to be tightened and attachments for two
small crankcase breather hoses (one from valve cover, one from cylinder block). 600, 600D, and
750 all use different filter elements. 850 Sedans use same style valve cover breather tube (with
flame-trap screen inside), direct-crankcase-breather hose, and filter element as 850 Coupe and
Spider (see paragraph above). All types attach support strap(s) to (longer) exhaust header
mounting stud(s) and 850 Sedan has an additional mounting bracket that attaches to a stud
"ear" cast onto side of carburetor assembly. (Again, see Figure 6).
Page 33
31
6. Check belt tensions and readjust if necessary. Close radiator drain top or refit bottom hose,
and if there are no water leaks, fill cooling system with a mixture of 50% permanent type
coolant and the rest distilled water. Start engine (If engine doesn't turn over fast enough to start
now, you probably have a bad starter motor and/or battery.) noting any obvious/excessive valve
noise and add coolant as necessary to compensate for air bubble evacuation during warm-up
(take special care for cars with front or auxiliary radiators) before replacing radiator pressure
cap. On 850/0T1000 models (not OTS or OTR) fill plastic coolant recovery tank about 1/2 full of
coolant. While on the subject, you can clean inside of plastic tank by tossing a handful of nuts
add some solvent into tank and shaking vigorously while covering filler/outlet holes with your
palms. Step Two is to replace solvent with soap and water..
7. Finally, if no fluid leaks are apparent) install engine compartment and cooling system shroud
(see Figure 11" and Figure D pp. 136 of "Abarth") on right side and with 850-based models, also
muffler heat shield on left using 7mm-head sheet metal screw with special serrated flat washers.
You can drive car normally now, but do not maintain any given speed on the highway for more
than 4 or 5 miles at a time and refrain from drag-race starts or full throttle acceleration for about
five hundred miles ; at which time you should change the motor oil (with engine hot). Some
people like to retorque cylinder head and adjust valves at this time also, but those who
recommend this, have normally not done these jobs just after the first time car was driven. If
you don't mind the extra work though (and it will help you sleep better), go ahead and da it a
second time.. As motor continues to loosen up during break-in period. idle speed should be
adjusted back down to around 1100 RPM.
Fiat-Abarth 850 TC Power Unit
Page 34
32
CHAPTER 3
MAINTENANCE. ADJUSTMENT, AND REPAIR PROCEDURES
Fiat and Abarth Routine Maintenance Checklist
Suitable after engine break-in is completed (at 500 miles, vehicle is in
good condition, and being used as regular transportation. If maintenance history is unknown
and restoration not planned, do complete checklist when you obtain the car.
Daily:
Check operation of dashboard warnings lights and gauges (especially oil pressure, coolant
temperature and charging system).
Weekly
Check coolant and oil levels with engine cold and watch for signs of fluid leakage beneath car.
Coolant recovery tanks on 850-based cars should remain
about half full. If the tank is near
empty just a few days after refilling several times, look for blown head gasket or defective or
incorrect radiator cap.
Monthly :
Check battery water (especially in hot weather) and brake fluid (if low check for signs of master
or wheel cylinder leakage) levels, tire inflation pressures (see PP.55 ) and wear characteristics
(uneven wear could mean wheel alignment is out of adjustment), condition of wiper blades (you
sure
wouldn't want to scratch that expensive windshield because of defective wipers), generator
and water pump belt tension (see pp. 35 ), and windshield washer fluid level (always keep
reservoir filled on late cars with rear mounted washer bags as empty plastic bags are easily
melted due to close proximity of exhaust headers). If heater (850-based cars) has not been used
this month, drive carfor a few minutes with heater water-valve open. Change DOHC engine oil
filter every 1500mi.
When Evident:
Adjust (or repair) brakes (600/750 front and rear, 850/0T1000 to mid-1968 rear only) when too
much pedal movement or poor braking efficiency are noted. Adjust handbrake (5 clicks
optimum). clutch:" throttle, choke, or shifter controls when effectiveness is reduced. Investigate
steering and suspension noise, play or stiffness of operation and brake noise or spongy pedal
on application. Keep engine clean by utilising coin-operated car wash to spray hot soapy water
throughout engine compartment from above and below. Plastic bags should be tied over
distributor and air filter intake. After rinsing, drive car home and wipe everything with clean, dry
cloth. This keeps things nice, aids in repair work, and allows source of an oil leak to be spotted
immediately.
Every 2500 to 3000 Miles:
Change engine oil and filter element (if fitted) (centrifugal filter should be cleaned about every
two years or 25,000 miles). Grease two front suspension king pins, 6 steering tie-rod-ends (600based only). Adjust greaser cap on distributor in
2 or 3 turns (600 based). Check air filter
element if conditions are dusty and replace when necessary.
Every 5000 or 6000 Miles or as Required: .
Do a tune-up (see pp.33 ). (Poor performance, starting, idling and fuel economy are signs that
it's time to check things out). Retorque cylinder head and adjust valves (see
pp. 29&30).
Page 35
33
* see pp.22 for 600/750 & pp. 25 for 850/0T1000 clutch adjustment.
Every 10 000 to 12,000 Miles or Yearly: Retorque head and adjust valves with engine cold:
Replace in-line fuel filter (if fitted), check fuel and emission lines and if necessary replace with
new 6 or 8mm fabric-braided neoprene hose and new clamps. Check freeze. plugs/water hoses
and drain coolant. If radiator interior shows debris lodged in ends of tubes (seen through filler
hole) remove radiator and have it rodded out. If exterior fins are plugged with dirt and grease
pull radiator to carefully scrape/brush solvent/steam clean away blockage noting that
disintegrating fins are cause to replace radiator core itself. Allow engine to run with drain plugs
removed, and heater valve (if fitted) on, and a water hose inserted in filler neck to replenish fluid
loss until drain water is totally clear before shutting off engine and water hose. When system is
empty, replace plugs and fill radiator with 50/50 coolant and distilled water. Rotate radial
_ tires
front to back on the same side of car noting irregular wear (alignment problems, etc.) and check
air in spare tire. Check generator/alternator brushes and replace if necessary. 600/750
generators should have their external oiler fitting (on commutator-end) filled with 50 wt. oil.
Change transaxle gearlube(90 wt.) and check steering box adjustment & lube level. Check for
excessive play in axles, sleeves, and couplings (see pp.49 ) and condition of axle boots, shock
absorbers, and engine/transmission mounts including excessive drive line movement (see pp.
be. ). Check floor, under-body, and spare tire well for formation of rust and lubricate
door/hood/engine lid hinges and locks plus seat slider rails & adjusters.
Every 25,000 Miles or 2 Years:
Clean oil centrifuge (see pp. 36 if fitted) .
Remove and clean fuel pump and carburetor filter screens. On older 600-based cars that are not
driven regularly, remove and clean fuel tank pick-up screen and check for rust inside tank.
Disassemble and inspect brakes for lining wear or fluid seepage. Check rubber brake hoses for
cracks or deterioration. Bleed brakes until replacement of all fluid is accomplished. Disassemble
generator to repack bearing(s) (switch to sealed bearings when replacing) and on 600/750
models check commutatorend bushing play. Repack front and rear (crush spacer required)
wheel bearings. Change steering gearlube (90 wt -1/2pt).
Tune-Ups
1. First check for excessive oil buildup within air cleaner housing. Normally there is almost no
sign of oil when your engine is "tight”. A lot of oil film probably means broken piston rings and
excessive compression blow-by from crankcase breather tube.
2. Compression Test: Four readings that are close to each other is much more important than
high readings in some
cylinders. Warm motors throttle held open and all spark plugs removed a
strong engine might register say 180 lbs. per sq. inch after about four to six engine rotations. All
the way down to about 120 lbs. per sq. inch is good as long as all readings are within about 10%
of each other. To determine if a low reading is caused by a ring or valve problem, use a lever
operated oil can to deliver about 3 or 4 squirts of engine oil into a low cylinder and try the test
again. If your reading shoots up from 60 Ibs. to say 190 Ibs. you would know that rings are the
problem (oil temporarily “sealed” rings). If there was little or no change from 60 lb. reading you
might be able to cure the problem with just a valve job. A cylinder with excessive blow-by also
frequently fouls its spark plug with oil.
Page 36
34
3. While spark plugs are out, check plug color and gap. Color of center insulator should be light
brown or grey and gap .022"-.025". When center electrode tip is significantly rounded off or
plugs are fouled, replace spark plugs. As a temporary
emergency fix, an "oiling" cylinder can
have one
hot plug (ie : F.850=N13Y ,BP4ES...) installed to burn away oil fouling. Don't take a chance trying
this with irreplaceable Abarth motors.
4. Pull off distributor cap and use a socket wrench to rotate generator pulley (apply finger
pressure to crankshaft belt to stop belt slippage) until ignition points are fully
open. (Rock
advance mechanism forward and back to be sure of full point gap). Point gap should be about
.018" with no pronounced tit on one point and a depression in the other. Mildly burned points
without tits showing can be saved by filing with an abrasive stick as long 8S care is taken to
clean away all signs of grit when finished. While points are open, grab hold of rotor and try to
wobble distributor shaft side to side. If more than about .002" of change in point gap is seen,
distributor should be replaced as there are no service parts available for this condition (worn
cam/advance bushing). A small amount of grease should be applied to rubbing cams where they
contact point rubbing block and a drop or two of engine oil given to the felt wick within cam
spindle and under rotor (except for early Marelli 850/OT1000 distributors with large round rotor
and advance on top). Now grasp rotor again and rotate the advance clockwise to check free
movement. When you release rotor, advance should snap back immediately. If it doesn't, worn
advance mechanisms and/or loose springs are probably the cause. Springs are still available
but some advance mechanism parts are not. If your advance works good, lightly
parts, if not obtain a new
distributor. Check all distributors to see that primary wire plastic
oil moving
insulator block is in good condition so as not to allow electrical shorts. Tip of rotor can be very
lightly filed and distributor cap electrodes scraped with a pocket knife to improve contact
surfaces. Be sure rotor is not a sloppy fit on distributor shaft. Early large round Marelli
850/OT1000 rotors come in two different styles. One is notched on bottom to allow advance
weight movement and other one is not. When replacing, use notched type which fjts both
distributors. Plug wire sockets, carbon brush, & terminals should be checked carefully
for
arcing/erosion*/damage. 600/750 vacuum advance units should be checked with a special
tester/pump tool and external grease cap fitting filled with grease. Side-entry distributor caps
are a little more expensive but fit all models whereas top-entry plug wire type will only fit
850/0TIOOO Coupes and Sedans. Side-entry style also offers a more compact plug-wiring
arrangement regardless of car model. .Check high tension wires for cut, chafed, hard or oil
softened insulation and damaged boots and replace when indicated. Cars without radios can
use solid copper-core wires with silicone covering.
* especially with Ducielier (black) caps fitted to 70-71 Spiders
Page 37
35
With a radio, supression wire should be used. Shop around for high quality plug wires and use
retainer guides and wire holders to route and support them. Late 850 (903 engine with right side
of engine compartment coil mounting) has long coil-wire supported by rubber gromet held in
bracket atop fan-shroud housing. NOTE : late long wire' Marelli points also fit early distributors.
5. Check ignition coil polarity noting that all models have a negative ground electrical system.
Before 1970, coils with internal ballast resistor were used. To check polarity, remove wire from
SW, BAT, B, or positive terminal of coil, turn ignition switch on, and momentarily brush wire
connector across any bare metal ground. You should see a small spark. On CB, D, or negative
coil terminal there should be a wire going directly to distributor-terminal stud.. .Other wire for
tachometer (usually brown) is also attached to negative coil terminal.
1970 and on Spiders and Coupes have external
ballast resistors (white or brown ceramic block
with two terminals and attached to coil mounting bracket). The problem here occurs when coil is
replaced. Many auto parts store catalogs are confusing or in error on this subject. So If you are
given a coil with internal resistor for a late car, you now have two resistors and maybe not
enough juice to start the car. On the other hand, if you are given a coil without an internal
resistor for an early car, you will have no resistor at all and stand a good chance of melting
point rubbing-block
or eventually"
frying the points themselves. The same thing will happen if you get the wiring wrong and bypass the resistor on a late car.
Use same procedure as described with early coil to determine which is hot wire from ignition
switch (usually blue and white wire). Attach it to SW, BAT, B or positive side of coil.
The other coil terminal should have a stiff red wire attached between it and ballast resistor.
Remaining D, CB or negative terminal on ballast resistor should have one wire going directly to
distributor terminal stud (routed through holder gromet on fan shroud along with high tension
wire) and tachometer wire (usually brown) attached to it. It is a good idea to have your coil
tested at an auto electric repair shop to ensure that it is not weak. For replacement purposes, I
recommend using earlier (internal resistor) coil on all models and tossing external resistor
away.
6. Check ignition timing (see pp. 28 ), carburetor adjustments (mixture, idle speed - 1100 RPM,
throttle. and choke operation and full movement pp.21 ) and lubricate all carburetor linkages.
Check or replace air filter. If necessary clean carburetor
7. Check belt condition and adjustment (see pp.35 ). Check exhaust system (holes, broken
welds, mountings, flanges, pipes, muffler) and quick check cooling, fuel, and emission hoses.
8 . Clean and test battery (see pp.56).
9. Check operation of all electrical equipment including: lights (stop, tail, turn, headlight-aiming.,
instrument, interior, backup, side markers, engine compartment, etc.) horn, wipers, electric
washer (if fitted), and fuse connections.
Belt Condition and Adjustment
Belts should not be cracking, fraying, or oil-soaked. About ¾” of back-and-forth belt deflection
should be noted when pressure is applied. Spare belts should always be carried in the car.
Page 38
Fiat and Abarth Specifications
Fiat 600 Major Changes & Improvements :
APPENDIX
Fiat 600 in 1959
*handbrake moved from transaxle to rear wheels
*fine spline transaxle input shaft and stub axles adopted
*starter solenoid with switch incorporated in ignition switch replaces pull-cable starting system
*self-centering steel brake shoes replace hinged aluminum type
*carburetor size increased from 22 to 26mm':
Fiat 600D From Mid-1960
*increased engine displacement 767cc vs 633cc (new crankshaft, block, pistons, connecting rods.
etc.)
*larger valves, improved cylinder head * and rocker arm assembly
*larger carburetor 28mm vs 26mrn
*larger water pump
*oil filtering via centrifuge instead of paper element
*higher ring and pinion ratio 4.86 vs 5.36 - (Sedan)
*larger wheel cylinders (7/8" vs 3/4" on 600 Sedans)
*movable vent windows in front doors
Fiat 600D From 1965
*rear opening doors (hinged in front) with movable vent wing windows
Fiat 850 Spider Improvements and U.S.A. Required Changes:
Fiat 850 Spyder U.S.A. very early 1968
*decreased engine displacement 817cc (engine # 100GS3 040) vs 843cc (# 100GS 000) via 64 mm bore
rather than 65mm.
*improved radiator, water pump. and hoses
*improved design of front disc brakes
*self-adjusting (friction type) rear drum brakes
*dual master cylinder with tandem reservoirs
*coarse thread front wheel lug-bolts (to match rear wheels)
*non-recessed uncovered headlights
*small round side marker lights added
*backup light added to rear bumper (switch on transaxle)
*high-back bucket seats
*passenger-side sun visor added (early cars had only one)
*passenger grab handle deleted from dashboard
*new design outside mirror and relocated from fender to door *safety break-away interior mirror
*'Windshield washer bag moved from luggage compartment to engine bay *minor changes to gauge
faces and trim rings (black instead of gold)
Fiat 850 Sport Spyder U.S.A. 1970-on
*increased engine displacement 903cc(#100GBS040) vs 817cc (new crankshaft. block, 65mm pistons
from 843 engine, connecting rods, cylinder head, valves, pushrods, head bolts, distributor/oil pump
drive shaft. finned alloy sump - 4.5 qt. capacity vs 3 qt.)
*larger primary carburetor Venturi 23mm vs 21mm with pollution control devices added to fuel and
exhaust systems plus transaxle switches
*larger water pump with 4 bolt mounting (vs 3 bolt) and improved fan cooling-shroud
*alternator charging system with regulator, 2 relays, and one in-line fuse replaces generator system
*600 combustion chamber volume in head is 24.3cc.600D is 29.5cc
Page 39
*i
g
,
)
I I
(Ap
nition coil with external balast resistor
*new design ignition distributor manufactured by Ducillier (French) *wider wheels - 5" vs 4 1/2"
*redesigned rear body panel and tail lights with backup lights incorporated and separate
rectangular rear reflectors fitted
*larger front turn signals
*larger rectangular shaped side marker lights
FIAT 850 Sport Spyder U.S.A. '72-'73
*engine lubrication modified to include pressurized center main bearing
*larger water pump pulley (6-bolt)
*new design ignition distributor manufactured by Marelli
*redesigned steering wheel, dashboard, hand throttle, heater box, switches, and electrical accessory
equipment. Rocker switches '73 only
*redesigned bumpers, and license lights moved from bumper tips to rear body panel
Popular* final Drive (Ring &: Pinion) Uses
Tooth ~ '
Count Ratio Common Use ~ ,
7/45...................... 6.43.....................600 Multipla
8/43...................... 5.38.....................600, 600D MU1tipla, 5iata 750
8/39...................... 4.88.....................600D,F-A 750 pushrod, Fiat 850w/13"wheels
8/38......................4.75.....................F-A Monomille, 750 DOHCRecord Monza
8/37...................... 4.63.....................OT/OTS/OTR 1000, 850 Sedan w/12" wheels
9/41...................... 4.56.....................F-A 750/850 pushrod (DB,Berlina,Allemano)
9/39...................... 4.33................... 750/850/1000 pushrod (Allemano,Berlina,Zagato,
Monomille), 700/850/1000 DOHC (Bialbero TCR
8/35....................... 4..38....................Simca 1000(for conversions---see pp.63)
9/37...................... 4.11.....................OTR 1000,A-S 1150,1000TC
10/39........................3.90 1300/l24,scarpione,1.3-Z.
9/35...................... 3.89................., A-S 1300/1600, 1000SP
10/37........................3.70.....................F-A 1300/124,Scorpione
10/35........................3.50.....................A-S 1.3/1.6/2.0,2.0/3.0 SP
Many other ratios were available for racing.
Note that 600/7 5 0, 600D/F-A 1000, &: Fiat 850/OT 1000/Simca
1000/A-S 1150 belong to 3 different gearbox families; so pinion
shafts do not interchange. ...600/750 pinion shim are NLA.
* Many models were commonly fitted with several different ratios
as standard equipment.
Transmission
Ratios( approximate
600/D 600 DOHC Close- fiat-Abarth 850/ Abarth-Simca
Gear 750 Mult Ratio'-4sp 5-sp OT1000 6-sp
1st 3 -38 3-38 3.33 3-38 3.32 3.64 3.17.2.57
2nd 2.06 2.06 2.06,1.75
2.4,2.1,1.9,1.8,
1.6.1.4 1.3 1.2
2.06 2.00.1.89
3nd 1.33 1.28 1.33 1.20 1.6.1.4,1.3.1.2 1.41. 1.52.1.48
4th .89 0.84
0.96 0.83
1.04 0.90 0.86
1.5, 1.2, 1.00, 0.90 0.96 1.30 1.25
5th 1.2, 1.0, 0.90, 0.80 (0.87) 1.17 1.12
6th 1.08.1.00
** see Lou Canut article ::m making your own close-ratio transmission in Abarth Register
Newsletter #23
ri.l '82) pp.6 and also #40 (Dec. 85) for Glenn Sipe article on pp. 27-30
-
Page 40
Carburetor Jetting
Fiat 600-Based Cars
Application 55-59 Fiat 600 59-61 F 600 61-69 F
F-A 750 ohv F-A 850 ohv 1000ohv 750dohc 1000dohc
600D
Carb model Weber 22IM Weber 26IM Weber
Weber 32IMP/E Solex 32PBIC 34PBIC 2W.36DCL 2W.40DCDE
28ICP
Throttle .87” 1.02” 1.10” 1.26” 1.26” 1.34” 2-1.40” 2-1.57”
Main venturi 16mm(.63”) 19mm(.75”) 19mm(.75”) 22mm(.87”) 24mm(.94”) 25mm 3 3mm
Main Jet .80 1.00 1.00 1.25, 1.30 1.30 .90 1.30
Air Jet 2.00 or 2.15 1.90 1.90 1.90,1.75,
2.25 2.50
1.80,2.00
Emulsion F2 F3 F1 F4, F9, F1 T2
Idle Jet .45 .45 .45 .45, .50 .45 .45 .45
Needle & Seat 1.50 1.5 1.25 1.75
Starting jet F6 120 F5100 ---- F5 150 110
Float level 5mm (.197”)*
7mm 7mm 9mm(.354”)
7mm(.275”)**
Flop Drop 7mm 7mm 7mm
* plastic float ** brass float Pump jet .45 .45 .45
Fiat 850-Based Cars
Application Fiat 850
Sedan
127/A112 850 Coupé & Spider
OT(OTS)1000 A112 Abarth 1050 (1000) 1300/124
Carb model Weber 30ICF Weber 32IBA Weber 30DIC(A) 2-bl Weber 30DIC 2-bl Weber 32DMTR 2-bl Weber 32DCOF
Throttle 1.18” 1.26” P-1.18” S-1.18” P-1.18” S-1.18” P-1.26” S-1.26” 2-1.26”
Main venturi 21 or 22 24 22 21 21(23 23 21 23 22 22 23
1.38,
1.20
Main Jet 1.15 or 1.20
Air Jet 1.45
Emulsion
Idle Jet .40
Idle Air Jet 2.00
Aux. Venturi
Pump Jet .45 or .50
Needle &
1.50
1.35
- -
-,
F52
.45 .45 .47,
1.70 1.70
5,
3.5
.40 .40 .40
1.50 1.50 1.5
.10,
.12
.40,
.90
F52,
52,
F50
50
.45
.70,
.40
4 3.5,
4
1.15(1.17) 1.15(1.17) 1.10, 1.15 1.20 1.00 1.15 1.10
1.85 1.85(1.70) 1.85 1.85 1.65 2.00 1.65
F15 F15 .45 F30 F30 F30
.40, .42(.45) .45(.50) .50 .45(.50) .70 .45
4.5 4.5 4.0 4.0
.40(.50) --- .40 --- .40(.45) ---
1.5 1.50 1.50
Seat
Float level 7mm(.275) 6mm(.235)
Mealsure float level with drill-bit as bowl lid is held verticle with gasket fitted & float arm tang just touching the spring-loaded ball at tip of needle
valve
Main venturi diameter is often cast onto rear of carb body above throttle linkage.
Page 41
Fiat
600 & 850 Engine Rebuilding
Clearances g. Specifications
Main Journals: 1.9996 to 2..0002"
Main Brg. Clear: .001 to .0025
Rod Journals: 1.5742 to 1.5750"
Rod Brg. Clear.. - .001 to .002511
Crank End.-Play - .0025 to .010"
600 Piston @ Sk1.rt - .0015 to .0020"
850 Piston @ Sk1.rt - .0025 to .003"
600 Pin in Piston - .0001 to .0005"
6850 Pin in Piston - .0003 to .0006”00
Pin in Rod - .0002 to .0005"
Ring End-Gap - .008 to .014"
Top Ring to Groove - .002 to .0025"
2nd Ring to Groove - .001 to .002”
850 Inner Spring -39.7 lb. @.815"
Oil Ring to Groove - .001. to .0015"
Cam Brg. Clear. - .001 to .003"
Oil Pump Gear to Housi.ng -.0004 to .004"
(replace -.006" )
O.P. End-Play -.0004 to .002"
(replace -..004")
O.P. Gear Lash -.003 (repl -.006”)
O.P./Dist.Shaft Bush -.001 to .0025”
600 Fuel Pump Rod Project.
850 F.P. Rod Project. -.040 to .060”
Tappet Clear - .0005 to .0015"
Valve Stem to Guide -.001 to .0025"
850 Stem Diameter - .275 to .2755
600 Valve Spring -33.4kg @.24.5cm
850 Outer Spring -10 2.5 Ib. @.972"
850 Cam Timing-25/51/64/12(sport)
16/50/56/16( sedan)
Abarth OT 1000 Characteristics & Engine Rebuilding Clearances
1000 type 202: 65x74-. 982cc, 9.5 compression (OTS 11.5), 26/75/67/30
valve timing, 8° in1tial adv., .016 paint gap, 29/26mm valves, .008"adj.
1000 type 200(Radiale) 10.5 compression, 27/65/67/25 v.timing, .010"adj.
Main Journals: 2.1228 to 2.1232". Ma i n C l ear .: .0 02 to .00 24"
Rod Journals: 1.5734 to 1.5742". Rod Clear.: .0018 to .0022"
Piston Skirt Clear: .0035 to .0045”,. Cam Brg. Clear.:.0016 to .0028"
Abarth 750 & 1000 Bialbero (DORC) Characteristics
& Engine Rebuiling Tolerances (courtesy of Lou Canut)
750 t.1pe 221: 61x64m.m, 747cc, 9.7 compression, 52/68/73/25 valve timing,
8° initial advance, .48m.m. pout gap, I-.28 E-.43mm valve adj.,33/29dia.
1000 type 229: 65x74mm, 982cc, 10.5 compression,52/75/62/34 valve timing,
15° initial. advance(Bosch), .33mm point gap. I-.23 E-.43 valve adj.
Main Journals: 750 center-50.76 to .5O.77mm, 750 ends-50.79 to 50.80mm.
1000 all-53.92 to 53.93mm
Main Clearance: 750 center-.045 to .080mm. 750 ends..025 to .060mm,
1000 all-.051 to .087mmI .Crank End Play: all-.06 to .08mm
Rod Journals: 750-35.988 to 35.998mm, 1000-39.964 to 39.985mm
Rod Clearance: 750-.22Z to .057, 1000-.040 to .062mm.
Piston Skirt Clear.(90° from pin axis): 750-.09 to .1, 1000-.105 to.115mm
Pin in Piston: all- .002 to .013mm .Pin in Rod Bush: all- .001 to .013mm
Piston Ring to Groove: all top-.045 to .072, 2nd-.025 to .0;2, oil-.020 to .061mm .Ring End Gap: all-.1mm
Cam Follower Clear.: all-.005 to .037 . Valve Stems: I-7.97 to 7.96,
E-7.96 to 7.95 .Stem Clear.:I-.03 to .05,E-.04 to .06
Valve Spring& Ten s i o n: 750 In-14.8kg @ 21mmI. Out-24.7 @ 22.5mm, 1000 In -22.5 @ 22mm,
Out-30.6kg @ 23.5mm.
Cam Journal to Head. Clear.: all-.020 to .062mm . T.Chain Deflect.:8-10mm
Notes:
1. When rebuiding engine, it is desirable to obtain clearance. As close as possible to the
minimum( smaller) figure.
2. See pp.132 of "Abarth." for tune-up & torque wrench specifications.
3. To convert troll inches to millimeters divide by .03937 To convert from mm to inches multiply
by .03937
4 Optimum clearances are listed. Wear limits for replacement sometimes
exceed then figures by
several tenths of a mm..
Page 42
Fiat 127, Autobianchi Al12, & Al12 Abarth
specifications & Engine Rebuilding Tolerances
127 type 100GL & A112 type A0 or A5: 65x68m.m, 903cc, 9.0 compression, 25/51/64/12 or 17/43/57/3 or
11/43/43/11 valve timing, 10° initial advance, .016” point gap, 29/26mm valve dia., I-.006 E-.008" adj.
A112 Abarth 1000 type A1: 65x74mm, 982cc, 10.0, 20/46/60/6, 10° adv., .016", 29/26mm, .008 & .01011 adj.
A112 Abarth 1050 type A2: 67.2x74mm, l050cc, 10.4, 16/56/56/16, 10° adv., .016", 29/26m.m, .010 & .012" adj.
Main Journals 903: 1.9994-2.0002"
Abarth: 2.1224-2.1232"
Mains Clear. 903: .0011- .0029”
Abarth: .0013- .0025”
Rod Journals 903 : 1.5741-1.5750"
Abarth: 1.5733-1.5743"
Rods Clear. 903: .001 - .0083"
Abarth: .0017- .0032"
Crank End-Play: .002 - .010 "
Piston @ Skirt 903: .002 - .0027"
Abarth: .0027- .0035"
Pin in Piston 903: .0003- .0004"
1000: .00008- .0003"
1050: .00016- .0004"
Pin in Rod 903: interference
Abarth: .0003 - .0006"
Ring End-Gap: .009 - .015 "
Top Ring Clear. : .0016- .0028"
2nd Ring Clear. : .0009- .0020"
Oil Ring Clear. : .000b- .0019"
End Cam Brgs.Clear: .0010- .0030"
Center C.Brg.Clear: .0018- .0036"
Oil Pump Gear-Housing: .002-.0055"
Oil Pump End-Play: .0008- .0041"
Oil Pump Gear Lash: .006”
Oil Pres.Releif Spring:9.5 Ib.@.89"
Fuel Pump Rod Project.: .039-.059"
Tappet Clearance: .0004- .0018"
Valve Stem-Guide: .0009- .0023"
V.Stem Diameter: .2748- .2756"
Outer Valve Spring: 54 1b.@ 1.437'1
Inner Valve Spring: 12 Ib.@ 1.279"
Rocker Arm Clear.: .0005- .0018"
Oil Pressure (hot): 43-57 lbs
Fiat/Fiat- Abarth Quick Reference Engine Chart
Use Fiat
CC 633 695 747 767 817 833 843 847 903 903 982 982 982 1050
Bore 60 61 61 62 64 62 65 62.5 65 65 65 65 65 67.2
Stroke 56 59.5 64 63.5 63.5 69 63.5 69 68 68 74 74 74 74
on
Based on 600 600 600 600D 850 600 850 600 850 127 600 850 127 127
Rotation Cw Cw Cw Cw Ccw Cw Ccw Cw Ccw Cw Cw Ccw Cw Cw
Engine
number
Years
Produced
600
Ohv Ohv Ohv Ohv Ohv Ohv Ohv Ohv Ohv Ohv Ohv Ohv Ohv Configurati
Dohc Dohc Dohv,
100 222 215,
55-61 60-66 56-61 61-71 68-71 58-60 64- 60-71
F-A
700
F-A
750
219,
221
Fiat
600D
100-D 100-
F 850 F-A
G3
F/OT
850
217 100G,
850
203
F-A
850
hemi
214,
220,
214G
60-61
69
F850 127, *
A112
Fohc,
100-
100G
GB
L,
A112A0
70- 69-on 60-71,
F-A
1000
hemi
210/2
08,
229,
210G
60-66,
66-71
OT
1000
Hemi
202,
200
64-70 71-75 76-on
A112
abarth
A112A1
A112
abarth
A112A2
600 & 850 Drum Brakes
600 600D Multipla 850
Cp/Sp
Master cylinder 3/4" 3/4" 1" 3/4"
Front wheel Cyl. 3/4" 7/8" 1 1/8" Disc
Rear Wheel Cyl. 3/4" 7/8" 3/4" 3/4"
Drum Diameter
(Original)
7.293-7.304 8.672-
8.683
7.292-
7.303
Max Oversize .040" .040" .040"
Lining Width 1.18"
New Lining Thickness : all models .16"
Replace Linings: .040”
Note: Use Lubriplate #110 Brake lube at all points of metal-tometal effort (from G. Mortensen)
Group 22N/32amp.hr. Battery
Conversion(see pp. 70)
Lenght - 9 ¼”
Width - 5 ¼”
Height - 8”
Marelli Generator
R90-180/12- 2500
(600/750-180watt)
Bosch generator
D90/12/16/3
(600/750-230watt)
600 Starter- B76-0.5/12S
600D Starter- E76-0.5/12S
600/750 Electrical
Regulator
A/4-180/12
(14.5volt)
Regulator
GN 1/12/16
(14.2volt)
*also:
Panda & Uno
“45” models
Page 43
How About Installing The Complete Fiat 850 Drive-Line In A 600-Based Car?
At first glance, it seems highly desirable to use the nice all-syncro 850 transaxle and also not be
required to reverse the 850 engine rotation....
As you might expect though; if this was a "clean & simple conversion”, I wouldn't have spent all of
chapter 13 in “ABARTH" talking about the reverse rotation 850 conversion (as well as pages 59-6 1 at
this book regarding the 127/A112 engines which don't
require a rotation change).
Here are some of the details of the Compl ete Dr iv e-Li ne Conversion:
A) Major Fabrication & Welding
The rear suspension arms must be cut and the inboard pivot points relocated to allow room for the wider
850 transaxle. Needless to say, this is a precision job and it forever alters the or iginality of the Car Next,
the left engine compartment firewall will need to be trimmed about 3 or 4 inches to accomodate the off-set
850 bellhousing. Some cutting under the rear seat area to allow linkage clearance will be necessary as well.
With the gearbox in position and 850 axles. 600 splined-sleeves fiti.ad,.aeaB1lre 850 motor mount off-set so
that the 600 mount perch on the rear body panel can be cut oft and moved to the left the correct amount.
You'll want to beef-up the perch supports quite a bit as the rear panel was not meant to carry the motor offto-one-side(as with 850s), not to mention the fact that the panel will be weakened even further when you
trim away some of the surounding sheet metal tor crankshaft pulley clearance. With engine and rear panel
fitted.. a new motor mounting bracket can be made. 850 trans mount brackets are retained and mounting
holes drilled in body/frame channels for use with long bolts and rubber pads when mounting gearbox.
Complete 850 shifter and all related hardware must be installed about one inch further to the rear than the
600 lever was positioned.
Careful alignment of everything is critical if you expect the wheels to rotate freely(without axle
bind)when you're done.....
B) Minor Details?
A special speedometer cable will need to be made-up. 850 radiator can be used but mounting holes on the
firewall must be moved, and you may have some trouble making the tan and radiator shrouds line-up
properly. The 600 radiator air-exit door must be permanently located in the open
position.. Heater tube on lower radiator tank must he plugged. Heater tube on thermostat housing can be
used for Jaeger water temp. sensor or plugged. Some 850 water pump pulleys may be too large to clear
right inner tender.
600 valve cover with a special longer linkage rod Can be used. Choke cable will be too short. Air cleaner
intake tube must be cut off to clear deck lid. Mufr1er heat- shield panel must be cut away to fit 850 exhaust
system. 850 voltage regulator must be substituted. Some body styles will require deck lid modification to
clear distributer. Oil gauge connection may necessitate minor alterations.
As you can see, the above conversion extensivly and permanently
up 600 might be OK, but don't even consider
MUTILATING an Abarth in this way (and to little or no real
butchers the car. Doing it to a beat-
advantage)....
And by-the-way, there is a company who will. sell you (for $10.00) a four page set of instructions which
talks about suspension, mounting, shifter and clearance modifications but does not mention the Minor
Details as listed in item B above ... The rest is up to you.
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