Engine and power unit
- Make
- Fiat
- Model
- 500 Factory Service Manual
- Year
- 2007–2024
- Section
- Engine › Engine and power unit
Manufacturing data and tolerancesEngine and power unit
ENGINE AND POWER UNIT
| Measurement | Value | Validity |
|---|---|---|
| Crankshaft endfloat (mm) | 0.055 ÷ 0.265 | 1.2 8V 1.3 Mjet |
| Cylinder head support surface flatness (mm) | < 0.1 | 1.2 8V 1.4 16V |
| Cylinder liner diameter - Grade A (mm) | 70.800 ÷ 70.810 | 1.2 8V |
| Cylinder liner diameter - Grade B (mm) | 70.810 ÷ 70.820 | 1.2 8V |
| Cylinder liner diameter - Grade C (mm) | 70.820 ÷ 70.830 | 1.2 8V |
| Cylinder liner ovality (mm) | ± 0.05 | 1.2 8V 1.4 16V |
| Cylinder liner taper (mm) | ± 0.005 | 1.2 8V 1.4 16V |
| Cylinder liner diameter oversize (mm) | 0.1 | all versions |
| Main journal diameter - Category A (mm) | 47.994 ÷ 48.000 | 1.2 8V |
| Main journal diameter - Category B (mm) | 47.988 ÷ 47.994 | 1.2 8V |
| Main journal diameter - Category C (mm) | 47.982 ÷ 47.988 | 1.2 8V |
| Main journal diameter undersize (mm) | 0.127 | 1.2 8V 1.4 16V |
| Crankpin diameter (mm) | 41.990 ÷ 42.008 | 1.2 8V 1.4 16V |
| Crankpin diameter undersize (mm) | 0.127 | 1.2 8V 1.4 16V |
| Main journal seat diameter - Category 1 (mm) | 51.705 ÷ 51.709 | 1.2 8V |
| Main journal seat diameter - Category 2 (mm) | 51.709 ÷ 51.713 | 1.2 8V |
| Main journal seat diameter - Category 3 (mm) | 51.713 ÷ 51.717 | 1.2 8V |
| Main half-bearings - Category 1 (red) (mm) | 1.836 ÷ 1.840 | 1.2 8V 1.4 16V |
| Main half-bearings thickness - Category 2 (blue) (mm) | 1.843 ÷ 1.847 | 1.2 8V 1.4 16V |
| Main half-bearings thickness - Category 3 (yellow) (mm) | 1.848 ÷ 1.852 | 1.2 8V 1.4 16V |
| Main journal half-bearing thickness oversize (mm) | 0.254 ÷ 0.508 | 1.2 8V |
| Clearance between main bearings - crankshaft main journals (mm) | 0.025 ÷ 0.040 | 1.2 8V 1.4 16V |
| Piston outer diameter -Grade A (mm) | 70.760 ÷ 70.770 | 1.2 8V |
| Piston outer diameter - Grade B (mm) | 70.770 ÷ 70.780 | 1.2 8V |
| Piston outer diameter - Grade C (mm) | 70.780 ÷ 70.790 | 1.2 8V |
| Piston pin housing diameter in pistons (mm) | 17.982 ÷ 17.986 | 1.2 8V |
| Piston gudgeon pin diameter oversize (mm) | 1.2 8V | |
| Gudgeon pin outer diameter (mm) | 17.970 ÷ 17.974 | 1.2 8V 1.4 16V |
| Sealing ring seat in piston - 1st groove (mm) | 1.230 ÷ 1.250 | 1.2 8V |
| Sealing ring seat in piston - 2nd groove (mm) | 1.210 ÷ 1.230 | 1.2 8V |
| Sealing ring seat in piston - 3rd groove (mm) | 2.510 ÷ 2.530 | 1.2 8V |
| Cylinder compression 1st sealing ring thickness (mm) | 1.175 ÷ 1.190 | 1.2 8V |
| Cylinder compression 2nd sealing ring thickness (mm) | 1.170 ÷ 1.190 | 1.2 8V |
| Cylinder compression 3rd sealing ring thickness (mm) | 2.475 ÷ 2.490 | 1.2 8V |
| Sealing ring oversize (mm) | 0.1 | 1.2 8V 1.4 16V |
| Cylinder compression 1st sealing ring gap (mm) | 0.20 ÷ 0.40 | 1.2 8V |
| Cylinder compression 2nd sealing ring gap (mm) | 0.25 ÷ 0.70 | 1.2 8V |
| Cylinder compression 3rd sealing ring gap (mm) | 0.20 ÷ 0.45 | 1.2 8V |
| Cylinder compression 1st sealing ring endfloat (mm) | 0.020 ÷ 0.060 | 1.2 8V |
| Cylinder compression 2nd sealing ring endfloat (mm) | 0.020 ÷ 0.060 | 1.2 8V |
| Cylinder compression 3rd sealing ring endfloat (mm) | 0.020 ÷ 0.055 | 1.2 8V |
| Crankpin seat diameter (mm) | 45.128 ÷ 45.138 | 1.2 8V |
| Connecting rod half-bearing thickness (mm) | 1.544 ÷ 1.548 | 1.2 8V 1.4 16V |
| Connecting rod half-bearing thickness oversize (mm) | 0.254 ÷ 0.508 | 1.2 8V |
| Clearance between connecting rod bearings - crankpin bearings (mm) | 0.021 ÷ 0.060 | 1.2 8V |
| Cylinder liner diameter - Grade A (mm) | 69.600 ÷ 69.610 | 1.3 Mjet |
| Cylinder liner diameter - Grade B (mm) | 69.610 ÷ 69.620 | 1.3 Mjet |
| Cylinder liner diameter - Grade C (mm) | 69.6200 ÷ 69.630 | 1.3 Mjet |
| Cylinder liner taper (mm) | ± 0.010 | 1.3 Mjet |
| Cylinder liner ovality (mm) | ± 0.005 | 1.3 Mjet |
| Main journal seat diameter - Category A (mm) | 54.710 ÷ 54.714 | 1.3 Mjet |
| Main journal seat diameter - Category B (mm) | 54.714 ÷ 54.718 | 1.3 Mjet |
| Main journal seat diameter - Category C (mm) | 54.718 ÷ 54.722 | 1.3 Mjet |
| Main journal diameter - Category A (mm) | 50.994 ÷ 51.000 | 1.3 Mjet |
| Main journal diameter - Category B (mm) | 50.988 ÷ 50.994 | 1.3 Mjet |
| Main journal diameter - Category C (mm) | 50.982 ÷ 50.988 | 1.3 Mjet |
| Crankpin diameter - Category A (mm) | 42.591 ÷ 42.600 | 1.3 Mjet |
| Crankpin diameter - Category B (mm) | 42.582 ÷ 42.591 | 1.3 Mjet |
| Main half-bearings - Category 1 (red) (mm) | 1.836 ÷ 1.841 | 1.3 Mjet |
| Main half-bearings thickness - Category 2 (blue) (mm) | 1.841 ÷ 1.846 | 1.3 Mjet |
| Main half-bearings thickness - Category 3 (yellow) (mm) | 1.846 ÷ 1.851 | 1.3 Mjet |
| Main journal half-bearing thickness oversize (mm) | 0.127 | 1.3 Mjet |
| Crankpin half-bearings - Category A (red) (mm) | 1.546 ÷ 1.552 | 1.3 Mjet |
| Crankpin half-bearings - Category B (blue) (mm) | 1.550 ÷ 1.556 | 1.3 Mjet |
| Main journal half bearing oversize (mm) | 0.127 | 1.3 Mjet |
| Thrust half-washer thickness (mm) | 2.310 ÷ 2.360 | 1.3 Mjet |
| Clearance between main bearings - crankshaft main journals (mm) | 0.028 ÷ 0.048 | 1.3 Mjet |
| Small end bush inner diameter (mm) | 23.006 ÷ 23.012 | 1.3 Mjet |
| Piston pin housing diameter (mm) | 22.990 ÷ 22.996 | 1.3 Mjet |
| Piston pin outer diameter (mm) | 22.892 ÷ 22.987 | 1.3 Mjet |
| Cylinder compression 1st sealing ring gap (mm) | 0.20 ÷ 0.30 | 1.3 Mjet |
| Cylinder compression 2nd sealing ring gap (mm) | 1.0 ÷ 1.5 | 1.3 Mjet |
| Cylinder compression 3rd sealing ring gap (mm) | 0.25 ÷ 0.50 | 1.3 Mjet |
| Cylinder compression 1st sealing ring thickness (mm) | 1.970 ÷ 1.995 | 1.3 Mjet |
| Cylinder compression 2nd sealing ring thickness (mm) | 1.470 ÷ 1.490 | 1.3 Mjet |
| Cylinder compression 3rd sealing ring thickness (mm) | 1.970 ÷ 1.990 | 1.3 Mjet |
| Sealing ring seat in piston - 1st groove (mm) | 2.08 ÷ 2.10 | 1.3 Mjet |
| Sealing ring seat in piston - 2nd groove (mm) | 1.53 ÷ 1.55 | 1.3 Mjet |
| Sealing ring seat in piston - 3rd groove (mm) | 2.02 ÷ 2.04 | 1.3 Mjet |
| Piston outer diameter -Grade A (mm) | 69.520 ÷ 69.530 | 1.3 Mjet |
| Piston outer diameter - Grade B (mm) | 69.530 ÷ 69.540 | 1.3 Mjet |
| Piston outer diameter - Grade C (mm) | 69.540 ÷ 69.550 | 1.3 Mjet |
| Cylinder compression 1st sealing ring endfloat (mm) | 0.09 ÷ 0.13 | 1.3 Mjet |
| Cylinder compression 2nd sealing ring endfloat (mm) | 0.04 ÷ 0.08 | 1.3 Mjet |
| Oil scraper ring endfloat (mm) | 0.030 ÷ 0.070 | 1.3 Mjet |
| Big end diameter (mm) | 45.734 ÷ 45.774 | 1.3 Mjet |
| Clearance between connecting rod bearings - crankpin bearings (mm) | 0.030 ÷ 0.062 | 1.3 Mjet |
| Cylinder head gasket size with average maximum piston projection (mm) | projection 0.028 - 0.127 thickness (no opening) 0.67 - 0.77 | 1.3 Mjet |
| Cylinder head gasket size with average maximum piston projection (mm) | projection 0.128 - 0.227 thickness (no opening) 0.77- 0.87 | 1.3 Mjet |
| Cylinder head gasket size with average maximum piston projection (mm) | projection 0.228 - 0.327 thickness (no opening) 0.87 - 0.97 | 1.3 Mjet |
| Crankshaft endfloat (mm) | 0.155 ÷ 0.355 | 1.4 16V |
| Cylinder liner diameter - Grade A (mm) | 72.000 ÷ 72.010 | 1.4 16V |
| Cylinder liner diameter - Grade B (mm) | 72.010 ÷ 72.020 | 1.4 16V |
| Cylinder liner diameter - Grade C (mm) | 72.020 ÷ 72.030 | 1.4 16V |
| Main journal diameter - Category A (mm) | 47.997 ÷ 48.003 | 1.4 16V |
| Main journal diameter - Category B (mm) | 47.988 ÷ 47.994 | 1.4 16V |
| Main journal diameter - Category C (mm) | 47.982 ÷ 47.988 | 1.4 16V |
| Main bearing half undersize (mm) | 0.127 | 1.4 16V |
| Piston outer diameter -Grade A (mm) | 71.960 ÷ 71.970 | 1.4 16V |
| Piston outer diameter - Grade B (mm) | 71.970 ÷ 71.980 | 1.4 16V |
| Piston outer diameter - Grade C (mm) | 71.980 ÷ 71.990 | 1.4 16V |
| Clearance between piston - cylinder liner (mm) | 0.030 ÷ 0.050 | 1.4 16V |
| Piston pin housing diameter (mm) | 17.982 ÷ 17.986 | 1.4 16V |
| Cylinder compression 1st sealing ring thickness (mm) | 0.970 ÷ 0.990 | 1.4 16V |
| Cylinder compression 2nd sealing ring thickness (mm) | 1.170 ÷ 1.190 | 1.4 16V |
| Cylinder compression 3rd sealing ring thickness (mm) | 1.975 ÷ 1.990 | 1.4 16V |
| Cylinder compression 1st sealing ring gap (mm) | 0.20 ÷ 0.40 | 1.4 16V |
| Cylinder compression 2nd sealing ring gap (mm) | 0.25 ÷ 0.45 | 1.4 16V |
| Cylinder compression 3rd sealing ring gap (mm) | 0.20 ÷ 0.40 | 1.4 16V |
| Sealing ring seat in piston - 1st groove (mm) | 1.020 ÷ 1.040 | 1.4 16V |
| Sealing ring seat in piston - 2nd groove (mm) | 1.210 ÷ 1.230 | 1.4 16V |
| Sealing ring seat in piston - 3rd groove (mm) | 2.010 ÷ 2.030 | 1.4 16V |
| Cylinder compression 1st sealing ring endfloat (mm) | 0.030 ÷ 0.070 | 1.4 16V |
| Cylinder compression 2nd sealing ring endfloat (mm) | 0.020 ÷ 0.060 | 1.4 16V |
| Cylinder compression 3rd sealing ring endfloat (mm) | 0.020 ÷ 0.055 | 1.4 16V |
| Big end diameter (mm) | 45.128 ÷ 45.138 | 1.4 16V |
| Small end diameter (mm) | 17.939 ÷17.956 | 1.4 16V |
| Clearance between connecting rod bearings - crankpin bearings (mm) | 0.023 ÷ 0.060 | 1.4 16V |
Parts & tools for this job For 2007 Fiat 500
- PARTEngine gasket setSearch: Fiat 500 2007 engine gasket set
- TOOLTorque wrenchSearch: 3/8 inch torque wrench
- TOOLFeeler gauge setSearch: feeler gauge set
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