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
1

INDEX

INDEX .......................................................................................................... 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
1
2

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ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
GEARBOX SPARES .......................................................................................
18.1
External control mechanism ...................................................................
18.2
Internal control mechanism....................................................................
18.3
Main shaft ............................................................................................
18.4
Lay shaft .............................................................................................
19 TIMING BELT TENSIONER CHANGE ................................................................
20 TIMING BELT COVER INSTALLATION ..............................................................
21 REAR AXLE CENTERING BUSHINGS .............................................................
22 FRONT SUSPENSION SUBFRAME CENTERING BUSHINGS ..................................
23 OIL BREATHER TUBE REMOVAL PROCEDURE ...................................................
24 REAR AXLE OPTIONAL BALL JOINT INSTALLATION ...........................................
25 OPTIONAL AIR MANIFOLD INSTALLATION (TURBOCHARGER OUTLET) ................
26 FRONT SUSPENSION MODIFICATION .............................................................
27 REAR BRAKE LIMITER VALVE BERINGER ......................................................
28 GEARCHANGE LEVER MODIFICATION .............................................................
29 REAR TORSION BEAM AXLE BRACKET REMOVAL ...........................................
30 RECOMMENDED TORQUE SETTING.................................................................
31 UPDATES ....................................................................................................
18

27
27
27
28
29
31
37
41
43
45
45
47
49
50
52
54
54
55

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TECHNICAL HANDBOOK
ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
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 susanna.reali@abarth.it

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

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TECHNICAL HANDBOOK
ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
3

DOCUMENTATION

For the preparation, use and maintenance of the cars it is necessary to refer and
adhere to the following documents:
1.
2.
3.
4.
5.

Trofeo Abarth 500 Sporting regulations

Trofeo Abarth 500 Technical regulations
Scheda Tecnica (Technical Form) for Abarth 500 Assetto Corse & Limited Edition
This manual of use and maintenance
The Abarth 500 Assetto Corse & Limited Edition Spare parts list

The Entrants should supply the events 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)

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.

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TECHNICAL HANDBOOK
ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
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.santarella@abarth.it
Mr. Santarella must be informed and agree on the delivery date.

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ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
6

TECHNICAL DATA

Engine

Turbocharged 4 cylinders in line with 4 valves per cylinder,

3

1368 cm

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 40 mm

305 mm x 28 mm ventilated front brake disc
Rear calipers with single piston 36 mm
240 mm x 11 mm rear brake discs
High performance racing brake pads
Rear pressure regulator to optimize car handling

Body
Chassis

Rear spoiler and front bumper splitter

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
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, 7x17 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.cento@ozracing.com
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
8

BASIC SET-UP

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ASSETTO CORSE AND LIMITED EDITION
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
600 Km
1.500 Km
3.000 Km

Front wheel hub replacement

Gearbox inspection / rebuild with new synchromesh
Turbocharger inspection / rebuild (exclusively at Abarth)
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 Customers
charges.
9.3 Costs
Engine + turbocharger basic rebuild cost is 3.700,00 + taxes.
Turbocharger basic rebuild cost is 1.330,00 + taxes.

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TECHNICAL HANDBOOK
ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
10 ENGINE USE
10.1 Forewords
Engines will always have to be carefully and properly used, duly warmed up (minimum
water temperature 60C, 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 70-80C
(corresponding to the IV position of the thermometer on the display), ranging to a
maximum of 90-95C (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 drivers 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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ABARTH 500
ASSETTO CORSE AND LIMITED EDITION

MAX

2 - 3 mm

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
nd

least 40C 2 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 70/80C, corresponding to the 4th
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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ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
11 FLUIDS AND LUBRICANTS
11.1 Quantity and specs
Engine cooling system

Coolant

Gearbox

Oil

Brake and Clutch fluid

Oil

Engine Oil

Oil

Driveshaft joint, diff side,

rubber boot volume
Driveshaft joint, diff side,
tripod flange volume

Grease
Grease

CUNA NC 956-16
ASTM D 3306

PARAFLU UP

SAE 90W API GL6

TUTELA TOP 4
SELENIA
ABARTH
TUTELA
STAR 325
TUTELA
STAR 325

2,584
litres
2,158 Kg

FMVSS n 116
DOT 4
SAE 10W-50

2,950 Kg

NLGI 2

75+/-8 gr

NLGI 2

75+/-8 gr

11.2 Gearbox oil change

A
B
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.
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ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
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 ( medium)

Minimum pitch ( min)

Maximum pitch ( max)

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12.2 Aero characteristics
Here are the aero characteristic relative to the rear wing changes:
Rear wing setting
min
medium
max

Cx
0,423
0,433
0,438

Czf
-0,105
-0,101
-0,100

Czr
0,091
0,067
0,060

Cz
-0,014
-0,034
-0,040

Aero coefficient (front section area 2.09 m2, chassis pitch Hfront/Hrear 298/319)
Polare vettura
0
0,42

0,425

0,43

0,435

0,44

-0,005
-0,01
-0,015

Czt

-0,02
-0,025
-0,03
-0,035
-0,04
-0,045
Cx

Polare Czp
0,1
0,09
0,08
0,07

Czp

0,06
0,05
0,04
0,03
0,02
0,01
0
0,42

0,425

0,43

0,435

0,44

Cx

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ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
13 CONTROLS
1

1
2
3
4
5
6
7
8

=
=
=
=
=
=
=
=

Dashboard
Starter button
Ignition switch
Left side window
Right side window
NOT operative
Hazard lights
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

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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
o

I = Possible icy road less than 3 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

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ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

Description
Colour
General warning- disregard always on Amber
Not active
Rear fog/rain lights
Amber
Main beam of headlights
Blue
Lights are on
Green
Left indicator
Green
Fuel level low
Amber
Not Active
Not Active
Not Active
Alternator warning
Red
Power steering problem
Red
Low engine oil pressure
Red
ECU problem, look at EOBD
Amber
High engine coolant temperature
Red
Right indicator
Green
Low brake fluid level
Red
Not Active
Not Active
Not Active
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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ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
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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ABARTH 500
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15 FUEL SAMPLING
15.1 Item list
Rif.

Number

Description

Quantity

5742010

Fuel sampling diagram

5739437

Switch cover

5737224

Switch

5740616

Rivet circular head 3 x 12

EST 3710

Rivet circular head 3 x12

Alt

7031597

Support

10185

Cable tie

5742175

T coupling 9/16"

5735479

Coupling 9/16" for fuel sampling

15.2 Functional scheme

Hole 12 on
the main fuse
box

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15.3 Fuel pump activation switch installation

The T17 relay, circled red in the main fuse box, activates the fuel pump. This triggers
the fuel pump only after having received a go ahead from the ECU. The Fuse F21
protects the system. To use the fuel sampling system it is necessary to bypass the ECU.
The external switch, marked in green, actuates the fuel sampling system. It is therefore
necessary to plug the switch with the pin 48 purple/yellow and 49 green/orange. This
has already been done on all the Trofeo cars, but the following wiring diagram is
included for your information.
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16 WELDING PRECAUTIONS

To protect it from irreparably damages, before any welding operation on the car it is
necessary to unplug the ECU as described below.
1. Disconnect the earth wire from the battery

2. Disconnect the ECU earth wire from the chassis

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3. Remove the 4 screws fixing the ECU and leave the ECU on the engine without placing
it in touch with any metallic part of the car.

In order to complete this procedure it is not necessary to remove the seals from the ECU
and its wiring.
We would like to remind you that any broken/suspect sealing is an infringement of the
Regulations of the Trofeo Abarth, and will require the ECU to be inspected by Abarth
(costs to be charged to the entrant), whose corresponding punishment is to be decided
by the National Sporting Authority.

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17 CLUTCH PEDAL TRAVEL
Brackets manufactured and assembled according to the following drawings may be
installed to reinforce the clutch master cylinder.

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Adjust the clutch pedal stop to limit the pedal travel in such a way its length to be 60
mm.

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18 GEARBOX SPARES
The car is equipped by a standard M32 gearbox manufactured by Fiat, whose spare parts
are available through the Ricambi Originali Fiat network.
Spare part list is hereinafter.
18.1 External control mechanism

18.2 Internal control mechanism

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18.3 Main shaft

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18.4 Lay shaft

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19 TIMING BELT TENSIONER CHANGE

It is possible to upgrade the automatic timing belt tensioner with a fixed unit.
1 - Take the engine fittings apart in the following order::
-

Airbox pipe
Water tank
Oil breather pipe
Timing belt upper cover
Engine mount chassis side
Engine mount engine side
Timing belt lower cover
Coils and spark plugs
Plug for timing setting

2. Insert in the first and second cylinder the specific tool (part code: 1860992000) to
check the piston position and in the plug for the timing check on the inlet cam the
specific tool (part code: 1860985000) to fix the camshaft.

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3. Use cable ties to ease the removal of the spring loaded belt tensioner.

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4. Unscrew the bolt on the belt tensoner, remove the belt tensioner and unscrew the M8
stud from the engine head.

5. Screw the new stud (part number 5742363) with a torque of 25 Nm into the head.

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6. Insert the new fixed belt tensioner (Part number 5742362) and fix with a new M10
nut (Part number 7055942).

7. Remove the cable ties (see point 3).

8. Slacken the camshaft pulley bolt.

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ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
9. Turn the belt tensioner anticlockwise, until contact is made with the belt.

10. Find the right belt tension by turning the belt tensioner anticlockwise until a tension
of 98Hz is reached.

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11. Tighten the belt tensioner bolt with a torque of 25 Nm.

12. Tighten the camshaft pulley bolt, previously slackened, with 120 Nm of torque
(it is recommended to use the specific tool: spare code 2000015800)
13. Remove the timing tools.
14. Turn crankshaft clockwise at least for two complete revolutions.
15. Check the correct belt tension (98Hz).
16. Check the engine timing again with the specific tools.
17. Remove the timing tools.
18. Rebuild all items previously removed.

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ABARTH 500
ASSETTO CORSE AND LIMITED EDITION
20 TIMING BELT COVER INSTALLATION
To avoid from gravel and stones to intrude among timing belt and pulleys, it is possible
to install the covers as described below, built and fixed as follows:

Timing pulley cover plate 5743271

Timing belt protection 5743272

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1. Loosen the generator and remove its driving belt.
2. Remove the crankshaft service pulley by unfastening the three screws.

3. On the standard timing belt cover, mark no.2 holes (4,2 mm) for fixing the ABS
timing belt protection (drw 5743272) by using the protection itself as a template and the
cover plate (drw 5743271) for lateral reference, so to duly close the open slot (see
picture below) but keeping a controlled gap of 5 mm from the rib in the casting to avoid
future removal complexities.

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ASSETTO CORSE AND LIMITED EDITION
4. Remove the plastic standard cover, drill the no.2 4,2mm holes and fix the ABS
protection by using no.2 M4x14 screws, no.4 elastic washers 4 mm and no.2 M4 self
locking nuts (nuts to finally result outside of the cover).

5. Reassemble the standard plastic cover on the engine, locate the cover plate (dwg
5743271) on the timing pulley, duly centered on the 9,1 mm holes and the 3 mm
hole for the timing pulley pin; to properly center the service pulley, first fasten it by
using tapered head screws to tighten as far as possible. Then, change each taper screw,
one by one, with the standard ones (see point 2), with a setting torque of 25 Nm.

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6. Reinstall the service belt, duly tensioned by blocking the generator in position.

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ASSETTO CORSE AND LIMITED EDITION
21 REAR AXLE CENTERING BUSHINGS
A total of no.6 centering bushings (dwg 5743148) are required for each car.
The centering bushings wont be supplied as spares by Abarth. They may be
manufactured according the attached drawing.

Place the no.3 bushings (per side) in the existing holes of the standard support, and
fasten the axle assembly by using the standard screws.

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ASSETTO CORSE AND LIMITED EDITION
22 FRONT SUSPENSION SUBFRAME CENTERING BUSHINGS
A total of no.2 centering bushings (dwg 5743061) are required for each car.
The centering bushings wont be supplied as spares by Abarth. They may be
manufactured according the attached drawing.

Completely insert the centering bushings 5743061 into each side rear fixing holes of the
standard subframe.

Use the standard screws to fasten the subframe.

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ASSETTO CORSE AND LIMITED EDITION

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ASSETTO CORSE AND LIMITED EDITION
23 OIL BREATHER TUBE REMOVAL PROCEDURE
Suppressed.

24 REAR AXLE OPTIONAL BALL JOINT INSTALLATION

1. With the aid of an hydraulic press, remove the standard rubber joints from the rear
axle (push outbound).

2. Insert the NMB ABYT10 ball joint (cod. Abarth 7064574) into the adaptor (cod. Abarth
5743021) and locate it with the 5716489 snap ring.

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3. Press fit the adaptors 5743022 into the ball joint, one for each side.
4. With the aid of an hydraulic press, install the complete ball joint adaptor into its
housing in the rear torsion beam axle, moving inbound from outside, and locate it with
the 1/10694/76 snap ring. Thermal dilatations may help the job.

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ASSETTO CORSE AND LIMITED EDITION
25 OPTIONAL AIR MANIFOLD INSTALLATION (TURBOCHARGER OUTLET)

Start from standard piping FIAT 51819199; remove the rubber Garrett plug and reduce
the standard fixing racket.

Plug the standard rubber manifold FIAT 50902212 and lock it with the collar 1/30007/90

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ASSETTO CORSE AND LIMITED EDITION

With a further collar 1/30007/90, lock the rubber manifold to the Garret outlet port. The
lower end is to be connected to the following standard pipings via a quick release plug.
NOTE: change the standard gasket of the quick release plug with a O-Ring 1/44640/81

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ASSETTO CORSE AND LIMITED EDITION
26 FRONT SUSPENSION MODIFICATION
To ease the front suspension arms removal and installation, it is allowed to
modify the front subframe as shown in the following images:

Right

Trim on the existing

buttonhole

Cut out

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Left

Trim on the existing

buttonhole

Cut out

27 REAR BRAKE LIMITER VALVE BERINGER

The optional KIT 5743623 is available for the installation of the S1 Beringer rear brake
pressure limiter valve.
This Kit is composed by:

1
2
3
4
5
6
7
8

Abarth p/n
Description
Quantity
5743146
Beringer brake limiter
1
5743615
Brake limiter support
1
5743450
Metal hose
1
5706151
M/F M10x1 fitting
2
7058070 Rectangular section seal
2
7043346
TBE M6x1 screw
4
12601277 6x12x0.5 elastic washer
4
7043850
M6x1 self locking nut
2

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