ll too too SHOP MANUAL FIAT - SERVICE DEPART MENT -i:0 worPASSENGER CARS 1100 - 11000 SHOP MANUAL SERVICE DEPARTMENT - TURIN SECTION INDEX GENERAL INFORMATION ENGINE LUBRICATION - COOLING FUEL SYSTEM ENGINE BRAKE TEST CLUTCH - TRANSMISSION DRIVE LINE REAR AXLE STEERING BRAKES - WHEELS AND TIRES ELECTRICAL BODY MAINTENANCE LUBRICANTS TOOL EQUIPMENTAl rights roserved. The total roproduction of 2 ‘text and illustrations in thie Manual, or any part thereof, Ie not permitted in any form. PRINTED IN ITALY Prati Nea Dae yaar AC at a era ose nao AasSection 1 GENERAL INFORMATION GENERAL DATA AND SPECIFICATIONS CAPACITIES IDENTIFICATION JACKING UP THE CAR ”FIAT - 1100-1100 PASSENGER CARSGENERAL INFORMATION 5 GENERAL INFORMATION The information contained in this book applies to the following versions of the « Elevenhundred »: — 1100/103 D Sedan (with engine 103 D.000) — 1100/103 D Family Car (with engine 103 D.000) — 1100103 H De Luxe Sedan (with engine 103 H.000) — 110/103 H Export Sedan (with engine 103 H.000) — 1100/103 G Special Sedan (with engine 103 H.000) — 1100/103 H Family Car (with engine 103 H.000) — 1100 D/103G 1 Sedan (with engine 103 6.005) — 1100 D/103 G 8 Family Car (with engine 103 6.005). Service procedures and data shown in this manual, whenever no mention of car model is made, are intended to cover all versions of Mod. 1100. Parts, data and operations particular to single versions are described separately and in each case applicable type or types are specified. Wear limit specifications, as mentioned in this book, are merely indicative and should not be intended as absolute values. Fig. 4 - 11000 Family Car,FIAT - 1100-1100 PASSENGER CARS GENERAL DATA AND SPECIFICATIONS Car Dimensions: Overall length (with bumpers) Overall width... 0... ‘Max. height (unladen) . . . . Front overhang Rear overhang... Wheelbase eter ‘Tread, front (on ground) Tread, rear... . Seeieeeaatt Road clearance (at silencer) Taming circle... .... Weights: Curb weight ©... 2... Useful load. Performances: ‘Maximum speeds, under full load, on level well kept roads, after running-in: Aiomiget: sao. oe abt. — second gear... 2... . .abt inirdl gears epic fob oo abt. — fourth gear 2.2... cab. etreversol ie fri Mes they abt. Climbable gradients, under full load, on well kept roads and after running-in: — first gear — second gear — third gear rt fourth geart dtl.) iNeed — reverse 1100/103 D 1100/103 D 1100/103 H 1100/103 H ‘Sedan. | Family Car [DeLuxe Sed|Export Sedan 103.000 | 108.000 | 108.000 | 109 1.000 in. | mm | in. | mm | in. | mm /| in. | mm 184.3 | 3920 | 149.1| 3788 | 186 3963 «154 3911 87.4| 1458 | 87.4| 1458 | 87.4 1488 | 67.4] 1458 88.7/ 1490 | 58.9] 1496 | 58.7| 1490 | 58.7} 1490 28.2) 640 | 26.2} 640 25.9| 688) 25.2! 640 37 940 | 31.8) 808 | 38 965 | 36.6) 931 92.1 | 2340 | 92.1| 2340 | 92,1] 2340 | 92.1| 2340 48.6| 1232 | 48.6/ 1232 | 48.6] 1232) 48.6 | 1232 az.9| ais | 47.9] 1218 | 47.9] 1218 | 47.9 | 1218 8.1| 130] 8.1] 130] 51 | 130| 8 128, last 10,8001841/,t.|10.500:341, 10.800 24" 10.500 esa | 20081» | 2017» | 2017 (690 kg) | (@10 kg) | (1S kg) | (18 kg) 4:passengers 4 passengers| 4 passengers 4 passengers plus 110 Ibs | plus 220 Ibs | plus 110 lbs | plus 110 Ibs (60 kg) 200 kg) (60 kg) (60 kg) | luggage | luggage | luggage | luggage mph | kmjh| mph | km/h | mph | km/h} mph ) kmjh we [oo [1m at as | ae | 35 31 50 31 50 37 60 ‘37 60, 47 | 75 41 18 86 90 56 90 18 |p 75 | 120 80 | 130 80 | 130 19 30 19 30 22, 35 22 35 | 30% 2% =| 30% 30% 12 14% 17% 17% w% | 8% | 10% | 10% 58% 45% | 88% 5.8% 30% 25% 30% 30%, (continued)ss % GENERAL INFORMATION: DATA AND SPECIFICATIONS 7 } GENERAL DATA AND SPECIFICATIONS 1100103 | 1100/103H | 11000 1100 D Sedan | Family Car Engine | | Type see see 103.000 | 103.000 | 103.008 | 103 6.005 Car Dimensions: in, | mm | in. | mm | in, | mm | in, | mm | | ) Overall length (with bumpers)... |164 | go1i | 149.1 9768 | 184.7, 9990 | 154.1 | so18 fOvernlhwidtisss dre scsi. dare 87.4| 1488 | 57.4) 1458 | 87.5 1480 | 87.5) 1460 Max. height (unladen) . eae 87.8 | 1468 | 58.9/ 1496 | 87.8 1408] 68.4) 1485 | Front overhang 2. 2... ee 28.2| 640 | 252 640| 26 | 660] 26 | 680 Rear overhang... . . . - ++ | 366| 931 31.8| 808) 36.6) 930] 36 918 2340 Whealbasal sii icc. usc yess 92.1| 2340 | 92.1 | 2940 | 92.1 | 2340 | 92.21 ‘Tread, front (on ground)... ‘Tread, rear . | 48.6| 1282 | 48.6| 1232) 48.6 | 1292 | 48.6 | 1292 seeeee sees | arg] tats | 47.9 1218 | 47.9 1215 #79 | 1218 Road clearance (at silencer)... . . s | 128] 8s| 10] 5 | 128 | 4.9) 125 Turning circle . veer + + + + [Bafeft.!10.800:34 Yate, 10.800138 4,8. 10.800)34'/,ft.| 10.800] Weights: | } Curb weight... ee | 2050Ib 2008 h «1978 Ih | 2080 Ib (930 kg) (810 kg) (895 kg) (880 kg) | | 4 passengers 4 passengers § passengers) § passengers| iGeohull loads eeeeers cers eee plus 110 Ibs plus 220 Ibs | plus 110 lbs | plus 110 lbs (60 kg) 00 kg) | (60 kg) (60 kg) luggage | luggage | luggage — luggage Performances: | Maximum speeds, under full load, on level | | | | well kept roads, after running-in: mph jaw | mph anh | mph | Xow) mph | koh \ — first gear 2.2... abt. | 22 | 35 | 22 | 38 | 22 | 38 | 22 | 38 i — second gear abt. | 37 | 60 | 37 | 0 | 37 | 60 | 37 | 60 = think gear... abt. | sa | 90 | ss | 90 | 86 | 90 | 86 | 90 —fourth gear... 0... + abt. | go | 190 | 80 |130 | 80 | 190 | 80 | 190 Se en oe tor | e's |e] | ele | a | Climbable gradients, under full oad, on well | | | kept roads and after rmning-in: | = first gear 2... 30% 21% 33% | 90% — second gear eats 17% | 18% =| 10% «=| «17% — third gear... 2... sas 10% 9% 11% 10% ereverselehs ceniete via hatesitie 30% 21% 33% 30%a FIAT - 1100-1100 PASSENGER CARS CAPACITIES QUANTITY ITEM a REFILL (oa | kg [us gats.limp.gats. feo] aie Fuel tank |S a ea { Gasoline (*) Radiator, cylinder jackets and eating system... ... | 6.000 - 83 | 44 | Water ( Engine sump 3.260 | 2.900 | 34 | 29 | FIAT Ol () ‘Transmission . 1.100 | 1.000 98 |) Rear axle casing . 0.650 | 0.600 56 || FIAT W 90 Oil (SAE 90 EP) Steering box... | 0.160 | 0.180 a4 |\ Hydraulic brake system 0.300 0.800 26 | Special FIAT Blue brake fluid or equivalent HD non-mi- neral type Hydraulic shock absorbers, | reach: front... | 0.165 0.180 au |) ~ Mod. 1100" | eer | | 090 | 0.170 a Se eter = Moa. troop | front... | 028s, | oa4o Hoel (san ee | rear 0.185 | 0.163 | 119 Windshield washer... 0 =) | water and FIAT DP.) quia (concentrated solution) or TRICO XAW 30 solution | 6 | | (¢) Premium (abt. 92 ON - Research Method) for 1100 D, (© Sedan, (© Pamily cat, (9) 018 kg pure water plus 0.017 kg (2.28% in weight) (Summer) or 0.094 kg (4.88% in weigh!) (Winter) of cleaner. () When temperature is close to 0° C (@2°F,) change to good commercial grado antitreeze mixtures. (9 See following table for grades: ENGINE OIL RECOMMENDATIONS The engine is lubricated with FIAT VS series oil. Tabulated below are the grades of oil to be used in relation to outdoor temporatures. VS 10 W, VS 20, VS 30 and VS 40 are detergent oils equivalent to the API service MS classification, which are recom- mended for engines operating under severe con- ditions (prevailingly intermittent duty, with frequent starts and short rans), The VS series oils are provided with good oxid- ation stability and afford remarkable corrosion resistance. Owing to their detergent properties, the oxidation products and sudge formed during com- bustion are kept in colloidal suspension and are not allowed to deposit on engine components. Detergent oils are apt to become darker than the common non-detergent oils (Regular and Pre~ mium), but their Iubricating properties are not im- paired. They should be changed with the same periodic frequency recommended for other engine oils. Detergent oils can be used without any precau- ieee eer fealoreal ey engines; old en- es (in which non-detergent oils have already Been used) should be flushed before filling in deter- gent oils. The above instructions hold also for FIAT Mult grado oils which, like the VS series, are detergent, Select the proper grade of oil as follows;GENERAL INFORMATION: DIMENSIONS 9 Lowest anticipated outdoor temperature FUNG anne MSC FIAT Multigrado oil (*) Below —18°C (10°F) (minimum) ‘VS 10 W (SAE 10 W) - Between 0° and —15° C (82° to 10°F) (minimum) VS 20 (SAE 20) Kbove 0° C (32°F) (minimum) ace ‘VS 30 (SAE 30) Kbove 30°C (90°F) (average)... | -VS 40 (SAE 40) (©) WARNING: Do not top up with ells of other grades or Mako. ‘The oil in crankcase should be changed at the _Oil changes, however, should be more frequent periodic intervals recommended in the Instruction when the vehicle is used extensively for short Book, when the car is generally operated under trips or for stop-and-go driving, as well as on normal conditions. dusty roads or in cold weather Fig. 5 1100/103 D Sedan dimensions. CAUTION Wheel screws are RH-threaded (right wheels) and LH-threaded (left wheels) up to chassis Nos. 1264627 (Sedan) and 1263330 (Family Car). On later cars all wheel screws are RH-threaded.GENERAL INFORMATION: DIMENSIONS 1 Fig, 9 - 1100 D Family Car dimensions.2 FIAT - 1100-1100 PASSENGER CARS IDENTIFICATION Serial Numbers. The engine number is stamped on a boss on lock right side, near the cylinder head gasket surface (fg. 10). ‘As shown in fig. 11, chassis number is stamped on the upper right side of engine compartment bulkhead. ‘The number for spares is stamped at centre on identification plate lower end (fig. 11). The identification plate, giving engine and chassis, numbers and number for spares, is located on engine compartment bulkhead right side (fig. 11). NOTE - A new type of identification plate, without ‘engine number, has been adopted from Septem- ber 1960. ‘When ordering spares specify: — Car Model; — Engine Number; — Chassis Number; — Number for Spares; — Part No. of the ordered spare. Fig, 10 - Location of engine number. Fig. 11 = Chassis number and unit Identification plate. JACKING UP THE CAR Either the hydraulic jack D. 10051 or the tool kit jack may be used to raise the car. To raise the car with the kit jack, insert the jack arm in one of the brackets provided beneath the body on either side of car. When jacking up the car: = apply the parking brake; = place the chock under one of the wheels resting on ground; — insert the jack arm in the bracket and tum the crank. When the car must be kept raisod for a period of time, as during servicing operations which call for the removal or disassembly of some under- floor components, use stands D. 15051, which shall be arranged as follows: — two under car front end; — two under rear axle casing, close to the wheels. In case the rear axle has to be removed, place the rear stands under the floor rails. NOTE Part numbers of most service tools have been changed in the latest edition of FIAT Too! Catalog. For all tools recommended in this book both the old and the new number, if any, are shown (the latter in brackets). The general tool list, at the end of this book, contains only the present numbers.Section 2 ENGINE DATA AND SPECIFICATIONS DIAGNOSIS GUIDE ENGINE REMOVAL - INSTALLATION - DISASSEMBY CYLINDER BLOCK PISTONS - PINS - RINGS CONNECTING RODS - BEARINGS - BUSHINGS CRANKSHAFT AND BEARINGS CYLINDER HEAD - VALVES - GUIDES + SPRINGS, CAMSHAFT AND BUSHINGS VALVE MECHANISM POWER PLANT TORQUE REFERENCE Page 8 1" 19 a 26 34 49 a 50 53ENGINE: DATA AND SPECIFICATIONS 15 DATA AND SPECIFICATIONS ee ee sees page 15 DIAGNOSIS GUIDE. . suis onthe « @ ceiaie csr a at 2 i, ENGINE REMOVAL AND INSTALLATION... 2.2.2.2... 0... cee eee » 19 ENGINE}DISASSEMBLY, yj «4 c when the engine is pulling hard during acceleration, or when a cold engine is started, Alternate short circuiting of each spark plug will determine the approximate location of a loose bearing. Excessive crankshaft end-play causes a sharp noise or rap, which occurs at irregular intervals and in bad cases generally it can be detected by the alternate release and engagement of the clutch. ‘Common causes of crankshaft knocks are a) excessive bearing clearance; 'b) excessive end play; ©) outof-round or eccentric journals; 4) unbalanced crankshaft; e) insufficient oil supply; £) low oil pressure: 9) loose flywheel. Connecting Rod Bearing Noises. Connecting rod bearing noises are usually a light yap or clatter, more audible than main bearings Knocks. The noise is most audible when the engine is idling with transmission in neutral and becomes louder as engine speed is increased. Connecting rod bearing noises can be located best by grounding out each of the spark plugs, fone at a time. These noises should not be con- fused with pistor or piston pin knocks, which are described in the following paragraphs. Possible causes of connecting rod bearing noises are: a) excessive bearing clearance: ‘b) insufficient oil supply; ©) low oil pressure; @) misaligned connecting rods; €) out-ofround crankpins, Piston Noises. ‘The most common piston noise is a slap, due to the rocking of the piston from side to side in the oylinder. Piston slap causes usually a hollow, muffled, bell- like sound. Slight piston noises, that ocour when the engine is cold and disappear after the engine is warm, do not ordinarily warrant correction. Piston slap is more audible at low speed under load. Piston xing noises generally cause a click, a snap or a sharp rattle on acceleration.FIAT + 1100-1100 D PASSENGER CARS Fig. 15 - Cross sectional view of engine type 105 D.000. ‘The section of 108 H.000 engine differs fom the oboxe for the carburetor (dual barrel).REMOVAL AND INSTALLATION 19 To diagnose the origin of piston and ring noi pour a spoonful of heavy engine oil (SAE 50) into each cylinder, through the spark plug hole. Crank the engine for several revolutions with the ignition, turned off, until the oil has worked down past the piston rings; then install the spark plugs and start the engine. If the noise still exists, check the pistons for faulty conditions. If the noise disappears, it is, probably due to defective rings or to an excessive side clearance of rings in grooves. Piston Pin Noises. Piston pin noises are detected as a sharp, metallic, double knock, generally audible with the engine idling, Causes can be: a) excessive piston pin clearance in piston boss; b) excessive piston pin clearance in connecting rod small end; ©) loose bushing in connecting rod small end. Valve Mechanism Noises. Noisy valves are revealed by a clicking noise ‘whose frequency is lower than that of other engine noises, because valves are operating at half crank- shaft speed. If only one or two valves are noisy, the sound will be intermittent, otherwise it may be continuous. Valve noise is generally due to an excessive valve clearance; other possible causes are: a) wom setscrews thread; ) broken valve springs; ©) excessive stem-to-guide clearance; @) excessive pushrod-to-guide bore clearance; @) excessive wear of one or more camshaft cams, Rough Running Engine. Possible causes: a) defective ignition; b) defective carburetion; ©) unbalanced cranksha! @) unbalanced clutch; ©) too great a variance in connecting rod and piston weights; £) incorrect valve adjustment; 4g) misaligned engine - transmission - propeller shafts 2) too stiff engine supports. Excessive Oil Consumption. When an excessive oil consumption is noticed, before attributing the trouble to piston and ring ‘wear, check for leaks, especially at gaskets and seals. Fouled spark plugs are a good indication that an excessive amount of oil seeps past the piston rings and valve guides. Another cause of spark plug fouling is a too high oil level, allowing crankshaft to dip into oil Low Oil Pressure. No pressure at all indicates a defective pump or oil leakage. Normal oil pressure, in a new or overhauled engine, should be 36.6 to 42.7 psi (2.6 to 3 kg/cm*). Possible causes of low oil pressure: a) unsuitable grade of oil; b) spoiled oil; ©) defective relief valve; @) worn or damaged oil pump gears; ©) excessive clearance in main and connecting rod bearings; 1) defective oil pressure gauge. Excessive Oil Pressure. Oil pressure should never exceed 42.7 psi (@ kgjem?), except during cold starts. A too high oil pressure should be avoided, as it causes an excessive oil consumption. Possible causes of too high oil pressure: a) too heavy oil grade; b) defective relief valve. ENGINE REMOVAL AND INSTALLATION Place the car on the pit or, if this is not available, on stands D. 15051, using garage jack D. 10051 to lift the car. Protect fenders with suitable coverings (fig. 18). Drain cooling system. Disconnect battery positive terminal, wires at coil, distributor, generator, starter and ‘oil pressure sending unit, and ground cable.