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Old 20-11-2016   #16
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Re: Fiat 500D Engine 1962

don't drop the front pulley....
I have one with a piece out...
my mate said he will weld it but will be a bugger to do
then spin it on the lathe to make sure it's true
they are very hard to come by.....

the back part can be spun from a later one..
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Old 20-11-2016   #17
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Re: Fiat 500D Engine 1962

Quote Originally Posted by Alfons1972 View Post
@Franko500: your pistons seem to be early tuning pistons to rise the compression ratio...
Did you check the diameter of those pistons? are they for 540ccm or even more??
I checked the size they are 67.4mm diameter, so standard size but yes they look like the early tuning ones that I think The hobbler mentioned a while ago. So really hope I can save them. Only problem being if I can reuse the cylinders as the later cylinders have the recess and use a different gasket so not sure if they are interchangeable.
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Old 20-11-2016   #18
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Re: Fiat 500D Engine 1962

Looks to me like the bearing damage, and possibly the piston seizure, was the result of catastrophic oil preasure failure due to the broken oil pickup pipe rather than a lack of, or simply bad, maintenance?
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Old 20-11-2016   #19
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Re: Fiat 500D Engine 1962

Quote Originally Posted by Franko500 View Post
I checked the size they are 67.4mm diameter, so standard size but yes they look like the early tuning ones that I think The hobbler mentioned a while ago. So really hope I can save them. Only problem being if I can reuse the cylinders as the later cylinders have the recess and use a different gasket so not sure if they are interchangeable.
I hope you can reuse them too. They are an interesting part of 500-history
What recess do you mean that later cylinders should have? What later cylinders do you mean?
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Old 20-11-2016   #20
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Re: Fiat 500D Engine 1962

The 500D cylinders have a flat face on top.
The F/L cylinders have a recess - see image.
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Old 20-11-2016   #21
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Re: Fiat 500D Engine 1962

Quote Originally Posted by Franko500 View Post
I checked the size they are 67.4mm diameter, so standard size but yes they look like the early tuning ones that I think The hobbler mentioned a while ago. So really hope I can save them. Only problem being if I can reuse the cylinders as the later cylinders have the recess and use a different gasket so not sure if they are interchangeable.
Actually it was #Toshi975 who posted the modified pistons
http://www.fiatforum.om/500-classic/...barrels-2.html
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Old 20-11-2016   #22
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Re: Fiat 500D Engine 1962

Quote Originally Posted by Franko500 View Post
I checked the size they are 67.4mm diameter, so standard size but yes they look like the early tuning ones that I think The hobbler mentioned a while ago. So really hope I can save them. Only problem being if I can reuse the cylinders as the later cylinders have the recess and use a different gasket so not sure if they are interchangeable.
hello Franko500,

now I know what you mean with "recess" (my english is not so good).

ok: the gaskets are interchangeable, there are no differences beween gaskets of D- and F-type engines.
As you absolutely correctly mentioned that recess was later added for leading exhaust gas to that hollow screw if the head gasket was broken. The D-type engine didn't have that. No problem for the gasket.
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Old 20-11-2016   #23
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Re: Fiat 500D Engine 1962

So if I can save the Pistons but need new cylinders, I could use the cylinders from my L & use the original D head?
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Old 20-11-2016   #24
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Re: Fiat 500D Engine 1962

Quote Originally Posted by Franko500 View Post
Ian, when I get a minute I will remove my L clutch plate and take a photo of the flywheels and differences.
From what I can see the D has a lighter flywheel and is thinner.
The L looks to be a different profile and heavier than the D but looks lighter than the 126.
The 500D flywheel has different teeth (less than the 500F and 500L) and even less than the 500R/126.
So for a D flywheel you need a 500D starter.


Quote Originally Posted by Franko500 View Post
So if I can save the Pistons but need new cylinders, I could use the cylinders from my L & use the original D head?
yes, of course. 500D and 500F/L have 499ccm and absolutely the same bore diameter. I hope you can safe those pistons. But you first should try new piston rings if they fit.

But tell me: why would you use new cylinders? are they damaged?
Thanks Franko500 thanked for this post
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Last edited by Alfons1972; 20-11-2016 at 20:30.
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Old 20-11-2016   #25
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Re: Fiat 500D Engine 1962

I have only managed to remove one piston as there is corrosion in the cylinder and the other one won't move. So they may need machining to remove the damage to the bore wall. This will mean the Pistons will be too small. So I will need to fit different Pistons or fit different cylinders so I can use the original Pistons.
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Old 20-11-2016   #26
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Re: Fiat 500D Engine 1962

I have a pair of 500 barrels if they are required (came plonked on top of the pistons on the 595 engine I have). they will need a good honeing, or possibly a bore-out to the next piston size.
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Old 21-11-2016   #27
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Re: Fiat 500D Engine 1962

Sean, I have been known to have a leaning towards retaining old bits of a car. But I would cut my losses on that one and just get a new set of matched pistons and barrels, possibly even a cheeky set of those 540cc ones.
From my experience with the corrosion-seized ones on my 500, yours will need boring. So the pistons won't fit even in the unlikely event of them being OK. Mind you, I also decided the original Fiat quality was likely to better so in my case I had the barrels rebored to fit the next sized but one pistons. It cost me nearly as much in the end.
KNO_6358 by Peter Thompson, on Flickr
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Last edited by fiat500; 21-11-2016 at 00:18.
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Old 22-11-2016   #28
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Re: Fiat 500D Engine 1962

Quote Originally Posted by the hobbler View Post
I have a pair of 500 barrels if they are required (came plonked on top of the pistons on the 595 engine I have). they will need a good honeing, or possibly a bore-out to the next piston size.
Thanks for the offer. Hopefully I will be ok.
I have got one piston out and the bore looks to be ok and should just need a hone.
The other one is causing a few problems and wont budge. So its in soak at the moment. Then I might try the ATF, petrol and rag in the bore, set it alight and see if that does it. Otherwise I will take it to the machine shop and they will put it in their hot acid to see if it moves. Going by the other one I think the engine had been sitting for a long while and the rings had just dried up with a funny old gundge around them.
Alternatively I may try my 500L pistons & pots. I need to strip that engine as I will probably be using the crankshaft if its the same.
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Old 25-11-2016   #29
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Re: Fiat 500D Engine 1962

So anyone got any bright ideas how to get this piston out?
Tried hitting with a block of wood and hammer.
Difficult with the cylinder off the block! but cant run the risk of damaging a D block. Also with the unusual shaped crown I'm concerned on hitting it too hard as I don't want to damage it.
Tried soaking in penetration oil.
Placed penetrating oil and petrol in bore, set fire, heated cylinder still no movement.
Turned it upside down and left with oil and petrol in the inside of the piston to hopefully penetrate the rings via the oil holes in the piston ring slots.
Nothing come out the other side.
I have now left it to soak with white vinegar as that usually helps break down all sorts of stuff.
I really want to get this piston out!
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Old 25-11-2016   #30
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Re: Fiat 500D Engine 1962

Stick it in the oven......?
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