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Abarth 500 Workshop Manual

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TECHNICAL HANDBOOK
ABARTH 500
ASSETTO CORSE
AND
LIMITED EDITION
Versione 2011
Approvata CSAI in data xx-xx-2011
Approved of CSAI in date xx-xx-2011
Release 7.0 – 1/1/2011
TECHNICAL HANDBOOK
ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
Pagina 2 di 56
Release 6.0 16-06-2010
1 INDEX
1
INDEX .......................................................................................................... 2
2
CONCTACTS .................................................................................................. 4
2.1
Commercial Office (abroad): .................................................................... 4
2.2
Commercial Contacts (Italy): ................................................................... 4
3
DOCUMENTATION .......................................................................................... 5
1.
Trofeo Abarth 500 Sporting regulations ............................................................ 5
2.
Trofeo Abarth 500 Technical regulations ........................................................... 5
3.
“Scheda Tecnica” (Technical Form) for Abarth 500 Assetto Corse & Limited Edition 5
4.
This manual of use and maintenance ................................................................ 5
5.
The Abarth 500 Assetto Corse & Limited Edition Spare parts list .......................... 5
4
CONFIDENTIALITY ......................................................................................... 5
5
LIMITED EDITION MODEL ............................................................................... 6
6
TECHNICAL DATA .......................................................................................... 7
7
BINDING EQUIPMENTS ................................................................................... 8
7.1
Tyres .................................................................................................... 8
7.2
Wheel rims ............................................................................................ 8
8
BASIC SET-UP ............................................................................................... 9
9
SCHEDULED MAINTENANCE .......................................................................... 10
9.1
Engine & turbocharger inspection / rebuild ............................................... 10
9.2
Contacts .............................................................................................. 10
9.3
Costs .................................................................................................. 10
10
ENGINE USE ............................................................................................... 11
10.1
Forewords ............................................................................................ 11
10.2
Operating temperatures ........................................................................ 11
10.3
Operating revs ..................................................................................... 11
10.4
Lubrication ........................................................................................... 11
10.5
Correct engine oil level .......................................................................... 11
10.6
Engine cooling ...................................................................................... 12
11
FLUIDS AND LUBRICANTS ............................................................................. 13
11.1
Quantity and specs ............................................................................... 13
11.2
Gearbox oil change ............................................................................... 13
12
REAR WING................................................................................................. 14
12.1
Settings ............................................................................................... 14
12.2
Aero characteristics ............................................................................... 15
13
CONTROLS .................................................................................................. 16
13.1
Dashboard description ........................................................................... 16
13.2
Multifunctional display ........................................................................... 17
13.3
Warning messages ................................................................................ 17
13.4
Warning lights ...................................................................................... 17
13.5
Ambient light sensor ............................................................................. 18
13.6
Examiner ............................................................................................. 18
14
IMMOBILIZER .............................................................................................. 19
15
FUEL SAMPLING .......................................................................................... 20
15.1
Item list .............................................................................................. 20
15.2
Functional scheme ................................................................................ 20
15.3
Fuel pump activation switch installation ................................................... 21
16
WELDING PRECAUTIONS .............................................................................. 23
17
CLUTCH PEDAL TRAVEL ................................................................................ 25
TECHNICAL HANDBOOK
ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
Pagina 3 di 56
Release 6.0 16-06-2010
18
GEARBOX SPARES ....................................................................................... 27
18.1
External control mechanism ................................................................... 27
18.2
Internal control mechanism .................................................................... 27
18.3
Main shaft ............................................................................................ 28
18.4
Lay shaft ............................................................................................. 29
19
TIMING BELT TENSIONER CHANGE ................................................................ 31
20
TIMING BELT COVER INSTALLATION .............................................................. 37
21
REAR AXLE – CENTERING BUSHINGS ............................................................. 41
22
FRONT SUSPENSION SUBFRAME CENTERING BUSHINGS .................................. 43
23
OIL BREATHER TUBE REMOVAL PROCEDURE ................................................... 45
24
REAR AXLE OPTIONAL BALL JOINT INSTALLATION ........................................... 45
25
OPTIONAL AIR MANIFOLD INSTALLATION (TURBOCHARGER OUTLET) ................ 47
26
FRONT SUSPENSION MODIFICATION ............................................................. 49
27
REAR BRAKE LIMITER VALVE “BERINGER” ...................................................... 50
28
GEARCHANGE LEVER MODIFICATION ............................................................. 52
29
REAR TORSION BEAM AXLE – BRACKET REMOVAL ........................................... 54
30
RECOMMENDED TORQUE SETTING ................................................................. 54
31
UPDATES .................................................................................................... 55
TECHNICAL HANDBOOK
ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
Pagina 4 di 56
Release 6.0 16-06-2010
2 CONCTACTS
ABARTH & C S.P.A.
Address Via Plava 80 – 10135 – Torino
Tel +39 011 0044871
Fax +39 011 0044858
2.1 Commercial Office (abroad):
Reali Susanna
Tel +39 011 0044856
Fax +39 011 0044858
e-mail susa[email protected]t
2.2 Commercial Contacts (Italy):
Autoalberta by Uboldi Corse – Lomazzo - CO
Tel 02 96248837
duboldi@autoalberta.it
Campana Onorio – Modena - MO
Tel 059 828079
campana@campanacarrozzeria.it
Forza Service – Torino - TO
Tel 011 2203312
aldo@forzaservice.it
Romeo Ferraris – Opera - MI
Tel 02 57610636
mario@romeoferraris.it
Garage Diffusion – Alessandria - AL
Tel 0131 443191
mario.viotti@garagediffusion.it
Zatti – Parma - PR
Tel 0521 949711
pierbelli@autozatti.com
TECHNICAL HANDBOOK
ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
Pagina 5 di 56
Release 6.0 16-06-2010
3 DOCUMENTATION
For the preparation, use and maintenance of the cars it is necessary to refer and
adhere to the following documents:
1. Trofeo Abarth 500 Sporting regulations
2. Trofeo Abarth 500 Technical regulations
3. “Scheda Tecnica” (Technical Form) for Abarth 500 Assetto Corse & Limited Edition
4. This manual of use and maintenance
5. The Abarth 500 Assetto Corse & Limited Edition Spare parts list
The Entrants should supply the event’s Scrutineers with the following documents:
1. “Scheda Tecnica” (Technical Form) for Abarth 500 Assetto Corse & Limited Edition
2. CSAI Roll bar homologation form 91CS (copy on page 45 of the “Scheda Tecnica” –
only accepted if printed on watermarked or stamped paper)
3. Body chassis modification numbered certificate released by Abarth and referring to the
specific chassis number
4. CSAI catalytic converter homologation form CAT 022-CSAI (copy on page 9 of the
“Scheda Tecnica” – only accepted if printed on watermarked or stamped paper)
5. Technical Passport (according to the relevant National Sport Authority rules)
4 CONFIDENTIALITY
All technical or commercial information distributed from Abarth and/or from Abarth
consultants / partner / organiser / CTC must be treated as confidential and not
circulated.
TECHNICAL HANDBOOK
ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
Pagina 6 di 56
Release 6.0 16-06-2010
5 LIMITED EDITION MODEL
Before being entered for the first time to an event belonging to any Trofeo Abarth 500,
the Abarth 500 Limited Edition have to be delivered back to Abarth for being inspected
and for having engine, turbocharger, engine loom and ECU sealed.
Abarth will not charge Customers with costs for these activities (except transportation
costs).
Abarth will provide customers with the quotation of additional costs to restore cars to
their original conditions: these restore activities have to be mandatory done before the
first event, upon acceptance of the quotation.
Cars have to be delivered to Abarth a fortnight before the intended Trofeo event, and
standard inspection and sealing operation take few days.
Contacts:
Abarth & C spa
Via Plava 80
10135 Torino, Italia
To the attention of Mr. Antonio Santarella
Tel. 011 0044895
e-mail
antonio.santarell[email protected]
Mr. Santarella must be informed and agree on the delivery date.
TECHNICAL HANDBOOK
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ASSETTO CORSE AND LIMITED EDITION
Pagina 7 di 56
Release 6.0 16-06-2010
6 TECHNICAL DATA
Engine • Turbocharged 4 cylinders in line with 4 valves per cylinder,
1368 cm
3
• Power output: 190 CV (140 kW) at 6500 rpm
• Maximum torque: 300 Nm at 3000 rpm
• Garrett GT 1446 fixed geometry turbocharger
• Special reinforced water and air hoses
Electronics • Bosch series ECU racing optimized
Transmission • M32 6-speed gearbox
• Limited slip differential
• Specific drive-shafts
Suspensions • Front: Mc Pherson, racing adjustable dampers with coaxial spring
and nut ring for adjustable ride height. Adjustable camber by plates
• Rear: twist beam axle, racing adjustable dampers with spring
and nut ring for adjustable ride height
Steering • Rack and pinion, electric power steering with racing setting
Brakes • Brembo radial front calipers with four pistons ø 40 mm
• ø 305 mm x 28 mm ventilated front brake disc
• Rear calipers with single piston ø 36 mm
• ø 240 mm x 11 mm rear brake discs
• High performance racing brake pads
• Rear pressure regulator to optimize car handling
Body • Rear spoiler and front bumper splitter
Chassis • Welded steel multipoint rollcage
• Lightened interior
• FIA homologated seats with 6 straps seat belts
Wheels • 7 x 17” painted cast aluminium rims
• 205/50 ZR17 tyres
Weight • 970 Kg
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ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
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7 BINDING EQUIPMENTS
7.1 Tyres
- Dry weather Slick 20/61x17 branded Abarth supplied by Michelin
- Wet weather moulded 20/61x17 branded Abarth supplied by Michelin
Michelin official Distributor committed for the Trofeo Abarth:
Bellotto spa
Via Ateste 8
35042 Padova
Tel +39 0429 1906001
Fax +39 0429 4941
info@bellottoracing.it
The price is fixed to 224,00 € + taxes each.
The Michelin distributor will provide tyre servicing by each circuit.
7.2 Wheel rims
OZ aluminium wheels, 7”x17” ET37, design 5740949 branded Abarth
Directly distributed by:
OZ spa
Via Monte Bianco 10
35018 San Martino di Lupari PD
Tel +39 049 9423806
Fax +39 049 9469176
Sig Rita Cento
Rita.cent[email protected]
or
Sig Emile Willaerts
Emile.willaerts@ozracing.com
The price is fixed to 238,00 € + taxes each (198,00 € + taxes each for 6 pcs batches).
Just for contingent emergency recovery, a limited stock of spare rims will be available at
the circuit service facility.
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ASSETTO CORSE AND LIMITED EDITION
Pagina 9 di 56
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8 BASIC SET-UP
TECHNICAL HANDBOOK
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ASSETTO CORSE AND LIMITED EDITION
Pagina 10 di 56
Release 6.0 16-06-2010
9 SCHEDULED MAINTENANCE
After the first 200 km a complete first engine oil change requires to be done
(wear-in oil).
Replacement engine oil: Selenia Abarth 10W50.
Further to the usual maintenance routines, it is suggested to adhere to the following
mileage scheme:
After each
400 Km
Front wheel hub replacement
600 Km
with new
synchromesh
1.500 Km
Turbocharger inspection / rebuild (exclusively at Abarth)
3.000 Km
Engine inspection / rebuild (exclusively at Abarth)
9.1 Engine & turbocharger inspection / rebuild
At due mileage, used engines must be delivered back for service to Abarth.
All the mandatory seals must not be damaged/removed, and the engine must include its
turbocharger, the electric loom and its Electronic Control Unit.
For each used engine and/or turbochargers, Customers will receive a rebuilt engine
and/or turbocharger in return.
Used turbochargers alone may be delivered back for service to Abarth, clearly specifying
their corresponding engines.
9.2 Contacts
Used engines and/or turbochargers have to be delivered to:
Abarth & C spa
Via Plava 80
10135 Torino, Italia
To the attention of Mr. Claudio Pettigiani
Tel. 011 0044909
e-mail claudio.pettigiani@abarth.it
Shipment costs as well as custom duties and import/export taxes are Customer’s
charges.
9.3 Costs
Engine + turbocharger basic rebuild cost is 3.700,00 + taxes.
Turbocharger basic rebuild cost is 1.330,00 + taxes.
TECHNICAL HANDBOOK
ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
Pagina 11 di 56
Release 6.0 16-06-2010
10 ENGINE USE
10.1 Forewords
Engines will always have to be carefully and properly used, duly warmed up (minimum
water temperature 60°C, roughly corresponding to the III position of the thermometer of
the display) before every use.
Engines should not be used outside the purposes and missions described in the
Regulations.
Without express permission of Abarth, none of the engine components may be removed,
changed or modified.
At any time, only the exhaust system described in the “Scheda Tecnica” and required by
the Technical Regulations can be used.
At any time, only the fuel required by the Technical Regulation can be used; equivalent
fuels may be used upon express Abarth permission only.
10.2 Operating temperatures
The best operating conditions for the engine are water temperature 70-80°C
(corresponding to the IV position of the thermometer on the display), ranging to a
maximum of 90-95°C (corresponding to the V position of the thermometer on the
display).
Air bubbles in the coolant may affect the temperature measurement, thus the above
values are significant on condition not to have leakages from the circuit.
In the case of a liquid leakage (after a crash or other accident), immediately stop the
engine to prevent serious mechanical damages.
10.3 Operating revs
The engine management system has an in built rev limiter set to 6000 rpm in neutral
gear and 6500 rpm with the car moving.
Over-revs, although caused by driver’s errors or negligence, do shorten the normal
service intervals.
10.4 Lubrication
Mandatory use of:
Oil filter cartridge: Fiat genuine spare part n° 73500049
Lubricant: Selenia Abarth 10w50
Neither engine oil nor filter need to be changed in the engine life recommended above.
It is however necessary to check the engine oil level and top up if necessary.
10.5 Correct engine oil level
The engine oil intake is 2.95kg. The right level of oil can be checked from the oil stick.
The correct level is 2-3 mm below the max.
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ASSETTO CORSE AND LIMITED EDITION
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Release 6.0 16-06-2010
2 - 3 mmMAX
MIN
In order to check the correct level it is necessary to follow this procedure:
Let the engine run at idle for about 1 minute with the engine warmed up to at
least 40°C – 2
nd
level in the dashboard.
Switch off the engine, wait one minute and check that the level on the stick.
Top up to the correct level.
When the engine is cold, and in the case you are not confident on the actual initial oil
quantity, fist top up to a level intermediate between the minimum and the maximum,
then proceed as above.
The use of the engine with an engine oil level different than the recommended can
cause severe damages to the engine itself.
Quantities lower than recommended because of lateral acceleration can cause
starvation of the system and the pump.
Quantities above recommended can cause lower engine performance and can
result in oil going into the catch tank.
10.6 Engine cooling
After warming the engine in (water temperature 70°/80°C, corresponding to the 4
th
position of the thermometer on the display), the coolant do not have to overstep the
“Maximum” level limit market on the water reservoir.
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ASSETTO CORSE AND LIMITED EDITION
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11 FLUIDS AND LUBRICANTS
11.1 Quantity and specs
Engine cooling system Coolant PARAFLU UP
CUNA NC 956
-
16
ASTM D 3306
Gearbox Oil SAE 90W – API GL6
2,584
litres
2,158 Kg
Brake and Clutch fluid Oil TUTELA TOP 4
FMVSS n° 116
DOT 4
Engine Oil Oil
SELENIA
ABARTH
SAE 10W-50 2,950 Kg
Driveshaft joint, diff side,
rubber boot volume
Grease
TUTELA
STAR 325
NLGI 2 75+/-8 gr
Driveshaft joint, diff side,
tripod flange volume
Grease
TUTELA
STAR 325
NLGI 2 75+/-8 gr
11.2 Gearbox oil change
For the gearbox lubricant change, follow the procedure below:
1. Unscrew A
2. Unscrew B and empty all the oil
3. Clean A and B, taking care of any previous sealant product
4. Refit B, using Loctite 510 or similar sealant product
5. Fill from A recommended oil quantity and refit A
IMPORTANT
C is not the oil level checking point and C must left tight at all times.
N.B. to be sure that the oil is at the correct level, it is necessary to drain all the oil and
fill it with the recommended quantity.
A
B
C
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ASSETTO CORSE AND LIMITED EDITION
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12 REAR WING
12.1 Settings
The rear wing inclination may be adjusted to get three levels of downforce, just
repositioning the fixing screws on the wing support:
Standard pitch (α medium)
Minimum pitch (α min)
Maximum pitch (α max)
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ASSETTO CORSE AND LIMITED EDITION
Pagina 15 di 56
Release 6.0 16-06-2010
12.2 Aero characteristics
Here are the aero characteristic relative to the rear wing changes:
Rear wing setting
Cx
Cz
f
Cz
r
Cz
α
min
0,423
-
0,105
0,091
-
0,014
α
medi
um
0,433
-
0,101
0,067
-
0,034
α
max
0,438
-
0,100
0,060
-
0,040
Aero coefficient (front section area 2.09 m
2
, chassis pitch H
front
/H
rear
298/319)
Polare vettura
-0,045
-0,04
-0,035
-0,03
-0,025
-0,02
-0,015
-0,01
-0,005
0
0,42 0,425 0,43 0,435 0,44
Cx
Czt
Polare Czp
0
0,01
0,02
0,03
0,04
0,05
0,06
0,07
0,08
0,09
0,1
0,42 0,425 0,43 0,435 0,44
Cx
Czp
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ASSETTO CORSE AND LIMITED EDITION
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13 CONTROLS
1 = Dashboard
2 = Starter button
3 = Ignition switch
4 = Left side window
5 = Right side window
6 = NOT operative
7 = Hazard lights
8 = Rear fog/rain light
13.1 Dashboard description
The dashboard is divided in 4 functional areas:
1. Warning lights
2. Electric speedometer
3. Electric rev counter
4. Multifunctional display
2
3
1
4
5
6
7
8
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ASSETTO CORSE AND LIMITED EDITION
Pagina 17 di 56
Release 6.0 16-06-2010
13.2 Multifunctional display
A = Sport mode, it is always on, even when the light is off
B = Service light, to be ignored, it comes on at 30,000km!
C = Fuel Level
D = External temperature
E = Light settings (only when the dip beam is on)
F = Engine coolant temperature
G = Odometer (in km)
H = Date
I = Possible icy road – less than 3
o
C!
J = Time
13.3 Warning messages
Warning messages are shown in the central display.
When starting the engine up, a warning message for the inertial cut off switch is shown
(to be ignored).
Whatever other possible warnings have to seriously be taken in consideration.
13.4 Warning lights
TECHNICAL HANDBOOK
ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
Pagina 18 di 56
Release 6.0 16-06-2010
No
Description
Colour
1
General warning
-
disregard always on
Amber
2
Not active
3
Rear fog/rain lights
Amber
4
Main b
eam of headlights
Blue
5
Lights are on
Green
6
Left indicator
Green
7
Fuel level low
Amber
8
Not Active
9
Not Active
10
Not Active
11
Alternator warning
Red
12
Power steering problem
Red
13
Low engine oil pressure
Red
14
Amber
15
High engine coolant temperature
Red
16
Right indicator
Green
17
Low brake fluid level
Red
18
Not Active
19
Not Active
20
Not Active
21
Not Active
13.5 Ambient light sensor
The dashboard has an in built light sensor. This measures the light in order to adapt the
dashboard contrast during day or night.
13.6 Examiner
The engine diagnostics (EOBD) can be checked with an Examiner Smart HD which is
distributed by: Actia Italia srl Via Europa, 31 Preganana Milan
All Fiat Group Dealers have Examiners.
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ASSETTO CORSE AND LIMITED EDITION
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14 IMMOBILIZER
Underneath the dash, as shown in the picture below, there is the immobiliser box; this is
required for the engine to start.
Moving, removing or electrically disconnect the immobiliser box is absolutely forbidden.
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ASSETTO CORSE AND LIMITED EDITION
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15 FUEL SAMPLING
15.1 Item list
Rif. Number Description Quantity
1 5742010 Fuel sampling diagram 1
2 5739437 Switch cover 1
3 5737224 Switch 1
4 5740616 Rivet circular head 3 x 12 1
4 EST 3710 Rivet circular head 3 x12 Alt
5 7031597 Support 1
6 10185 Cable tie 1
7 5742175 “T” coupling 9/16" 1
8 5735479 Coupling 9/16" for fuel sampling 1
15.2 Functional scheme
Hole
φ
12 on
the main fuse
box
/