Project Money Pit

Dogbreath

Dogbreath

Dogbreath

Soldato
Joined
18 Oct 2002
Posts
16,661
Location
Devon
After commuting to work at 8000RPM in my VTEC* equipped Rover 400 for the last 2 years, I began to realise that I was missing the MR2, or at least the power delivery. Something with forced induction was needed. Something with a decent bit of power, reasonable handling, and preferably 4 seats now I'm a parent. Enter the Fiat Coupe.

I know the looks are very marmite, many people think they are vile, but I like them, and the performance of the 20VT was very temping. Looking around, I could either splash out 4-5k on a really nice one, or about 2-3k on a fairly rough one.

Then I discovered a local car being sold due to some engine problems e.g. a misfire at idle and occaissional smoke as described by the owner. I knew I'd I'd be stupid to even consider it, but it had to be worth a look.

In fact, "occaissional" smoke meant it actualy obliterated the road once boost went over 0.5bar, and it would only start to run on 5 after the turbo had started spooling up. The exhaust manifold was also obvioulsy cracked. Basicaly, a sick Italian car, normaly the very last thing anyone with an ounce of sense should consider buying. Unfortunately, it was me looking at the car. In my defence it was fairly low mileage, had quite a bit of service history and the rest of the car was in very good condition. And it was very cheap. Cheap enough in fact for a project car (even though I already have several on the go).

Thus begins project Money Pit.
coop_drive_side.jpg

It's an 'S' plate :D
coop_drive_rear.jpg

Interiot shot. Please forgive the poxy Ripspeed gearknob and handbrake. They will be going ASAP.
coop_interior.jpg



*VTEC 'Virtualy Torqueless Engine Control.' :D Then again the fact that it weighs as much as a Mondeo probably has something to do with it...
 
So having purchased the beast, I decide to do a bit of research. Hmm, probably not the correct order to do things in. A few lunchtimes spent perusing the Owners club forums showed that not only were parts expensive, but the car was not the easiest thing to work on.
Countless people advised me that should the cambelt need to be replaced then the car would be a write off. Stories of hideous unreliability, bankrupt owners lying destitute in the gutters etc.

So I might be needing a workshop manual then, no probs, get a dodgy one off Ebay. Only after getting one did I relalise they aren't worth the price of the cheap blank CD they are burnt on. Just a more or less random collection of extracts from the service manual coupled with a few DIY how to guides. But crucialy almost no useful information on the 20V engine.

So, after checking the simple stuff: coil packs, injectors, spark plugs, the misfire seemed to be a bit deeper routed. Whip out the compression tester and get around 170 PSI from 1,3,4 and 5, and just 35 PSI from No.2 :(

Oh well, time to wade in the with spanners. Excuse the lack of pictures here, I was keen to get stuck in before the predcited monsoon started.

In order to remove the head the following jobs need to be done:
Remove undertray and front bumper (very easy)
Drain coolant, and remove radiator and header tank. Discover radiator is rotten and will need re-coring.
Remove widscreen washer reservoir and O/S inner wheel arch
Remove manifold heatshield and discover the large crack, which will be welded at some stage.
Disconnect the following from turbo: downpipe, inlet trunking, outlet hose, oil lines, coolant lines.
Unbolt manifold and remove manifold and turbo from engine.
Unbolt O/S engine mount and upper engine steady, supporting engine on trolley jack.
Move engine up/down/back/forward to gain access to cambelt cover bolts, and undo a cut down Torx bit.
Remove cam belt.
Remove coil packs, and cam cover
Remove fuel rail and injectors
Unbolt the plenum from the inlet manifold (tricky)
Remove thermostat housing (easier than leaving it on head and removing numerous pipes).
Unbolt head and remove.

Car now looks like this:
coop_in_drive.jpg


Head looks like this
coop_head.jpg


Block looks like this
coop_bores.jpg


Bores are actualy in good condition, even No.2 with the original honing marks still visible
coop_bore_close.jpg
 
So at this stage there was still no evidence of the cause of the low compression, but the finger of suspicion now pointed to the rings on No.2 piston. The piston has to be removed to check them, and this means dropping the sump.

Removing the sump on the coupe is a swine of a job, it's hed in place with dozens of torx bolts, many of which are hidden from view. Once removed, the powersteering pump and exhaust get in the way, and just as you think you are clear, you realise the oil pickup pipe is preventing you removing the sump, so you have to get a spanner into the inch or so gap you have created and unbolt the pipe.
Easily the worst job so far, and I'm dreading putting it back together.

Anyway, with the sump off, the big ends can be removed and the pistons pushed up and out of the block. The cause of the engines problems was then quite clear!
coop_piston.jpg


This chunk of ring land was floating about in the gap, held in by the remains of the oil ring.
coop_ring_land.jpg


So not much to be done until I get a big pile of replacement bits. I'm waiting for a price on pistons, as I'm tempted to renew all 5, but I'll just put new rings on of they are silly money.
Currently I need:
1 Piston (maybe 5)
Set of piston rings
Head gasket set
Radiator
Cambelt
Auxiliary belts
Tensioners, Idlers etc.
Water pump (another silly manufacturer that used plastic impellers)
Maybe a set of big end and main bearings.

Undecided whether to remove the engine and box to do the clutch at this stage. It's a lot of extra work, especialy in a driveway, so I'm tempted to leave it for now. The turbo is a little worn, but serviceable, so that will also be left for another day as it's pretty easy to replace.
 
Nice project mate, the Coupe is a nice car (for a fiat anyway;))

Respect on the gamble and having the balls to wade in feet first.

I look forward to the next instalment :)
 
Nice project and Good luck. Should be a very interesting thread to keep an eye on.

Modern cars suck for space to work in. How many knuckles you got left?
 
Nice project, my dad use to have one. Always turned heads around town but that may be the fact that it was yellow and as you say not to peoples taste :p Re-mapped and upping the boost gave him 260 at the fly.
 
I forgot to post that during disassembly I discovered the probable cause of the meltdown. A Grainger valve plumbed into the actuator, and the original electric boost control valve was disconnected. This will all be put back to standard for now. I will be getting the injectors cleaned and tested as well, just to make sure.
 
That interior looks gorgeous. Shame the outside of the car is a little... quirky ;).

Respect for taking on what looks like a very tricky project. Good luck with it :).
 
I've just took the cylinder head off my 8000rpm screamer today (civic vti).

Was only running on 3 cylinders.

Looked like someone had took a bite out of one of the exhaust valves.

Not looking forward to putting it back together one little bit!

And I thought I had it tough!
 
They're very frantic when they work properly, a lot more throw-you-back-in-the-seat than Kate's 200SX for certain. My mate has a Portofino (?) Blue one, it's absolutely lovely but he blew it up the other day and replaced it with an MGF.
 
Adz said:
That interior looks gorgeous. Shame the outside of the car is a little... quirky ;).
Click to expand...

Blame Chris Bangle for that :D

Thanks for the comments chaps. Head is currently at a local engine rebuilders to have a light skim, and I'm waiting for some prices on bits from them which I should get tommorow, and will then empty the bank account. Planning on taking some time off work once I have them so I can get it back on the road ASAP.
 
Respect for the project - but I would'nt have gone for one of those personally - good luck & happy pocket digging. :eek:
 
Is it wrong that in my eyes the koop's best styling cue is the body-coloured band that runs from the door across the dash and to the opposite door?

*n
 
Lopéz said:
They're very frantic when they work properly, a lot more throw-you-back-in-the-seat than Kate's 200SX for certain. My mate has a Portofino (?) Blue one, it's absolutely lovely but he blew it up the other day and replaced it with an MGF.
Click to expand...

Done anythig more to the Supra recently or are you still infatuated with your new Swedish plaything? :D

Talking of Sweden, one thing that I'm really trying to get out of my head is the idea of an engine transplant. The coupe's weakest link is the engine, though when it's running it's a great unit. Let's see, we want 5 cylinders, turbocharged, bombproof, very, very tuneable. Any ideas? ;)
 
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