Fiat Coupe Club UK

Green barn find resurrection - Discussion

Posted By: Mags

Green barn find resurrection - Discussion - 22/12/2022 12:24

Please hit me with questions and comments.

At the moment I'm researching exhausts. I want something that looks decent, isn't bothersome on highway cruise, and has reasonable cost. Please advice wink
Posted By: PaulL

Re: Green barn find resurrection - 22/12/2022 12:51

Good luck Mags !
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 28/12/2022 15:24

Mags, I'm keen to see your photos but am being asked to sign in to Google Drive.

It is possible to upload clickable pictures on here, although there is a limit to 5 photos per post and any photo should not exceed 2MB.

Here's the Howto

upload photos
Posted By: Mags

Re: Green barn find resurrection - Discussion - 28/12/2022 16:10

Try now wink
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 28/12/2022 16:15

Originally Posted by Mags
Try now wink


Yep just these two work smile

An advantage of the link I sent you is that you get continuity by scrolling from one pic to another wink
Posted By: Mags

Re: Green barn find resurrection - Discussion - 28/12/2022 16:37

Files attached using proper method

Attached picture 5A0D402F-F5CA-45B0-AF1F-10E5D82C5117.jpeg
Attached picture 9DD3195D-C3DE-4FB4-80D1-EAFDC07CF611.jpeg
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 28/12/2022 16:55

Speedy! Now looking foward to seeing the others, especially the interior...

I wish I could answer your question laugh
Posted By: Mags

Re: Green barn find resurrection - Discussion - 28/12/2022 21:31

Interior

Attached picture 9D8A1459-F7B5-4612-AC16-37899418EB92.jpeg
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Posted By: DaveG

Re: Green barn find resurrection - Discussion - 28/12/2022 23:49

Ooh that's an unusual interior, looks rather nice, even if the pics are upside down wink tongue

As for the "possibly bent" parts, I'm not sure, I'd have to take a look in the garage tomorrow...
Posted By: Mags

Re: Green barn find resurrection - Discussion - 29/12/2022 00:01

Haha, upside down, there’s a lot to learn for a newbie.

No matter what I do, they end up being upside down
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 29/12/2022 08:38

Originally Posted by Mags
Haha, upside down, there’s a lot to learn for a newbie.

No matter what I do, they end up being upside down


It's ok, they're rotatable smile

Yes the interior is great, how you keep it clean must be a nightmare!
Posted By: szkom

Re: Green barn find resurrection - Discussion - 29/12/2022 13:05

I love that interior for no other reason than it's a complete opposite to what we normally get over here!

I remember from several years ago now someone posting a dealer catalogue of options available on the continent. Quilted leather, different alloys, wood effect dash, etc. I'm tempted to get google translate on standby and see what goodies ebay has to offer
Posted By: Mags

Re: Green barn find resurrection - Discussion - 29/12/2022 16:47

From the accessories catalog

Attached File
Posted By: Mags

Re: Green barn find resurrection - Discussion - 29/12/2022 16:48

I’m struggling to find a replacement left hand side motor mount. The one under the transmission, looking like a tin can.

Also the upper radiator hose seems hard to find.
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 29/12/2022 17:27

Mags, would you like to do the magic photo trick on your first couple of posts in the Project thread proper?

Best place to put your search for the motor mount (engine mount) is in Parts Wanted smile

Remember to say what model of coupé you have, or you can put the appropriate avatar in your profile (click on your forum name top right-hand-side/Edit Profile.)
Posted By: Mags

Re: Green barn find resurrection - Discussion - 29/12/2022 20:00

Tricks done
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 29/12/2022 21:51

Originally Posted by Mags
Tricks done


thumb

Except "sitting" tongue

The bent part in "that" - it looks like the part the airbox bell fits through and I don't recall a kink there - it's an odd place to happen. The car itself looks terrific before storage and I'm wondering what would have caused that to bend.

Is the front bumper in good condition, no sign of damage?
Posted By: Mags

Re: Green barn find resurrection - Discussion - 30/12/2022 07:49

“Sitting” fixed.

Yeah, it is indeed around the air box. Probably comes from someone wrestling it to disassemble things
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 30/12/2022 08:34

Originally Posted by Mags


At the moment I'm researching exhausts. I want something that looks decent, isn't bothersome on highway cruise, and has reasonable cost. Please advice wink



I think Rosso on here is pleased with his recent fit of a Ragazzon exhaust....
Posted By: wink

Re: Green barn find resurrection - Discussion - 30/12/2022 09:56

Last exhaust I fitted was a German one that came via Joe at FCSS. Fits well and has been on for a few years with no problems.
Posted By: ePiFaNT

Re: Green barn find resurrection - Discussion - 01/01/2023 01:34

Originally Posted by Mags

At the moment I'm researching exhausts. I want something that looks decent, isn't bothersome on highway cruise, and has reasonable cost. Please advice wink


I’m well pleased with the Supersprint cat back exhaust on mine. 200cell cat from Biltema. Might be a bit on the pricy side though.

Pen fargekombo! Hilsen 20vt Plus i sør
Posted By: french_coupe

Re: Green barn find resurrection - 01/01/2023 12:59

You can try Joe in the UK for some new, but plenty of second hand parts.

He is contactable as Countrycrusing on here.
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 01/01/2023 19:51

Originally Posted by Mags
“Sitting” fixed.

Yeah, it is indeed around the air box. Probably comes from someone wrestling it to disassemble things


Have a look at french_coupe's project thread post today at 1323, I think you'll see how the bent part *should* look.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 02/01/2023 19:00

Great, thanks, found it. It shoud be bent, somewhat... I´ll try to get it back to its original position.

BTW I´m looking for the tool to lock the cams in position while doing the cam belt.

Is the one for the "20VT unique, or can I use the same as for ten n/a 20v? There are various descriptions out there, and some a bit unclear.
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 03/01/2023 15:39

I only know that Laser tool 3636 are the cam locking tools for the 20VT.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 04/01/2023 10:46

all right, found it on ebay smile
Posted By: Mags

Re: Green barn find resurrection - Discussion - 16/01/2023 16:47

Where can I source a radiator? I got one from AUTODOC, but it didn’t fit.
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 16/01/2023 17:20

Originally Posted by Mags
Where can I source a radiator? I got one from AUTODOC, but it didn’t fit.


You are probably better placing this in Parts Wanted, Coupé Related Chat or even General Maintenance tbh.

Autodoc have a reputation for saying they have the part then sending one of a different size.

Try Direnza rads.
Posted By: ScouseCoupe

Re: Green barn find resurrection - Discussion - 17/01/2023 22:24

Originally Posted by Mags
Where can I source a radiator? I got one from AUTODOC, but it didn’t fit.


Choose from here. All have a 5 year warranty now and not much money after all. AC condensers as well.

https://www.adrad.co.uk/car-radiator/catalogue.php?manu=FIAT&model=COUPE&engine=&year=
Posted By: 386ka

Re: Green barn find resurrection - Discussion - 18/01/2023 11:05

When you go to select the price - the 20VT version shows as unavailable. I'd recommend looking at the Direnza ones (since they're already UK based/built). If in the EU, then you can order alu radiator from Flexeo - and it's even cheaper than Direnza in my experience: https://motorstore.fr/shop/gb/radiateurs-aluminium/733-commande-decrouy-bernard.html
Posted By: clanger

Re: Green barn find resurrection - Discussion - 18/01/2023 11:43

When I bought the Direnza rad from a uk supplier back in late 2019 I am sure it was labelled as PRC manufacture. The Motorstore pictures whilst upside down, I am sure are the exact same product as Direnza.

Either way if you go alu be extremely careful on the installation, those fins are very delicate...! Don't ask.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 21/01/2023 21:18

Thanks, it’s on its way!
Posted By: Mags

Re: Green barn find resurrection - Discussion - 28/01/2023 12:02

Got the radiator, thanks guys!

I’ve got most of the parts needed under control now, but I’d really love a new coolant reservoir, mostly for aesthetic reasons….

Any leads?
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 28/01/2023 15:05

You could try cleaning your existing coolant reservoir?
Posted By: Mags

Re: Green barn find resurrection - Discussion - 28/01/2023 15:33

Yeah, I know. But the plastic is faded into this yellowish color, and on previous cars I’ve experienced that they get brittle and crumble when that happens.
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 28/01/2023 18:04

Originally Posted by Mags
Yeah, I know. But the plastic is faded into this yellowish color, and on previous cars I’ve experienced that they get brittle and crumble when that happens.


Ok, understood....bleach soaking not going to work do you think?
Posted By: Mags

Re: Green barn find resurrection - Discussion - 28/01/2023 18:34

Bleach soaking? Tell me more! How?
Posted By: szkom

Re: Green barn find resurrection - Discussion - 28/01/2023 20:43

Hydrogen peroxide is possibly the answer. If you take a look on YouTube you should find a few videos of people restoring older electronics by soaking the plastic in a solution
Posted By: clanger

Re: Green barn find resurrection - Discussion - 29/01/2023 10:58

It could be caused by iron staining - too infrequent coolant changes/flushes. I have used Oxalic acid in solution in the past, you don't need much say 1/2 teaspoon in 500ml water and it just disappears the staining. Its cheap and will not damage the plastic in anyway, its worth a try.
Posted By: ePiFaNT

Re: Green barn find resurrection - Discussion - 30/01/2023 12:04

click to enlarge
Posted By: Mags

Re: Green barn find resurrection - Discussion - 30/01/2023 18:34

Exactly laugh
Posted By: clanger

Re: Green barn find resurrection - Discussion - 30/01/2023 21:22

Best buy a new one laugh
Posted By: Mags

Re: Green barn find resurrection - Discussion - 31/01/2023 12:08

Yeah, but where?
Posted By: clanger

Re: Green barn find resurrection - Discussion - 31/01/2023 14:48

No idea, its not the path I would take
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 31/01/2023 14:54

Originally Posted by Mags
Bleach soaking? Tell me more! How?


Looking forward to the pics smile
Posted By: Mags

Re: Green barn find resurrection - Discussion - 09/02/2023 15:37

Are exhaust cams available? Mine has some pitting.

Attached picture B92DFA63-431E-45FE-8597-DFDE915F7E2E.jpeg
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 09/02/2023 16:28

maybe try Joe @ FCSS??
Posted By: Mags

Re: Green barn find resurrection - Discussion - 09/02/2023 20:44

are all cams with part # 46443933 correct? It appears to be the same part for both turbo and N/A applications
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 10/02/2023 08:21

Originally Posted by Mags
Are exhaust cams available? Mine has some pitting.


Suffered corrosion at some point in it's life, turbo and n/a cams are different, I hold stock if you're unable to find new.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 10/02/2023 09:20

If I Google the part nubber 46443933, I get some hits, and most of them are listed as cams that appear to suitable for a wide range of cars, such as this:
https://spareto.com/products/ajusa-camshaft/93074800



Attached picture cam.png
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 10/02/2023 10:00

Honestly I'd buy the known good used ones from Joe, I just wouldn't risk buying a 3rd party one in case the cam durations are simply not correct

Cheers Jamie
Posted By: Mags

Re: Green barn find resurrection - Discussion - 10/02/2023 12:00

I found some documentation, and the timing on the exhaust cam differs significantly between turbo and N/A.

So, all the cams offered for sale at generic websites claiming to be "one size fits all" are wrong.

Well, I gues they are correct in the sense that they can be installed, but the timing is significantly different.

Attached picture cam2.png
Posted By: DaveG

Re: Green barn find resurrection - Discussion - 10/02/2023 21:33

According to ePer all 20v inlet cams are the same (46443669) but different from 20vt (46414245) whilst for the exhaust cam the later 20v is the same as 20vt (both are 46443933) but different from the early 20v (46404716)
Posted By: Mags

Re: Green barn find resurrection - Discussion - 14/02/2023 09:47

Are there repair panels available, or do I have to make my own bits?

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Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 14/02/2023 10:35

You'll have to make bits as you go

Cheers Jamie
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 14/02/2023 10:45

Originally Posted by Jamiepm
You'll have to make bits as you go

Cheers Jamie


You beat me to it laugh
Posted By: Mags

Re: Green barn find resurrection - Discussion - 17/02/2023 20:16

I had these plated, and it turned out amazing!

The problem is that I don’t know where these go? !?!

Please advise.

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Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 17/02/2023 20:25

Is the large one top right the horn mount assembly?


Why am I thinking "radiator support bar" ends for the pair top centre... chinny
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 17/02/2023 20:27

But yes the plating does make it look that bit more special cool
Posted By: Mags

Re: Green barn find resurrection - Discussion - 17/02/2023 20:32

+1 on the horn mount. You could also be right about the radiator support bracket.
Posted By: Trappy

Re: Green barn find resurrection - Discussion - 17/02/2023 22:06

Originally Posted by Mags
I had these plated, and it turned out amazing!

The problem is that I don’t know where these go? !?!

Please advise.


Ask Joe, though he does get upset if it's 'too easy'...
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 17/02/2023 22:59

Originally Posted by Trappy
Originally Posted by Mags
I had these plated, and it turned out amazing!

The problem is that I don’t know where these go? !?!

Please advise.


Ask Joe, though he does get upset if it's 'too easy'...


Plating.....
banghead

..... but for the horn bracket it's so obvious when it's not correct, draws the eye.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 18/02/2023 08:53

Yeah, with the clamshell hood, way too many parts are exposed (and needs to be shiny).

But, you don’t approve of plating?
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 18/02/2023 11:10

Originally Posted by Mags
Yeah, with the clamshell hood, way too many parts are exposed (and needs to be shiny).

But, you don’t approve of plating?


I've always found it expensive and sometimes hit and miss for quality when you're trying to recycle rust to gold.
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 18/02/2023 12:29

Originally Posted by Countrycruising
recycle rust to gold.



What a business opportunity chinny
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 18/02/2023 12:36

Originally Posted by Edinburgh
Originally Posted by Countrycruising
recycle rust to gold.



What a business opportunity chinny


paper
Posted By: Mags

Re: Green barn find resurrection - Discussion - 18/02/2023 16:15

I had the parts sand blasted prior to plating. So they were perfectly clean. However, some of them were very rusted, so there is some pitting where the worst rust was. The pitted areas did not come out as shiny, but should still be adequately protected.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 25/02/2023 18:02

Where do I start?!? shocked

On a serious note, expect lots of questions as assembly is about to commence.

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Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 25/02/2023 18:24

Looks great, enjoy 😉

Cheers Jamie
Posted By: Mags

Re: Green barn find resurrection - Discussion - 06/03/2023 17:53

Oh no! A corner is broken off the valve cover, and was glued on by a previous owner.

Does anyone have one to spare?

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Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 06/03/2023 18:08

Originally Posted by Mags
Oh no! A corner is broken off the valve cover, and was glued on by a previous owner.

Does anyone have one to spare?



That's bad luck frown

Common occurence though due to incorrectly sequenced/over-tightening.

Incidentally, so that you don't get offers of the wrong model, it's useful to put your appropriate avatar under your name

Click on your forum name at top rhs, Edit Profile, scroll down, select avatar smile

Then post in Parts Wanted thumb
Posted By: Mags

Re: Green barn find resurrection - Discussion - 06/03/2023 19:05

All right, I did some forum housekeeping
Posted By: Mags

Re: Green barn find resurrection - Discussion - 06/03/2023 19:07

What’s this mysterious part on my thermostat?

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Posted By: szkom

Re: Green barn find resurrection - Discussion - 07/03/2023 08:15

Looks to be a random sensor that fits the thread which has been cut down
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 07/03/2023 15:49

Originally Posted by Mags
What’s this mysterious part on my thermostat?


As above, it was a coolant sensor fitted to block that port and mainly found on original thermostats fitted at the Pinifarina factory.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 07/03/2023 17:57

So I can replace it with the plug that came with the new t-stat?
Posted By: Mags

Re: Green barn find resurrection - Discussion - 09/03/2023 06:27

Well, another setback. Not a big deal, but still annoying:

I was gonna install the oil drain plug, only to discover that the threads were literally falling apart. Maybe it had some insert already, I didn’t notice anything when I took it out.

What’s the best way forward? Helicoil or the next size bigger?
Posted By: Just_Matthew

Re: Green barn find resurrection - Discussion - 09/03/2023 06:40

I need repair thread too. I think helicoil (V coil etc...) Is best solution because Coupé already have big thread and it is much stronger than aluminium. I'm going to do it next week, remove oil pan drill 18,5mm hole, make thread M20x1,5 and insert coil. And then apply new seal on pan and bolt it back.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 10/03/2023 06:21

All right, on to the next issue.

After replacing the cam belt, tightening the belt, rotating the engine over several times, re-checked the tension multiple times, I checked the timing again. It turns out that both cams are ever so slightly late. It makes sense really; the whole assembly settling in and the process of getting the tension right, has to affect timing.

How do I rectify this?

Ideally I would prefer to set the engine at perfect tdc, lock the cam gears, loosen the camshaft from the gear, and turn the camshaft forward until perfectly timed. Ideally I’d have the flywheel locked, too, and a place to put a spanner on the camshaft. Maybe I can use vice grips or fabricate a tool that fits over the end of the camshaft.

The other option would be to set the cams correctly, and turn the engine backwards. I’m not sure how well that’s gonna work. The belt pulling the wrong direction may mess up timing. I guess I could turn the engine beck too much, and then advance it to tdc, but there’s not that much wiggle room at the exhaust cam.

Maybe I should just leave it as it is. The timing is off by approximately the smallest amount I’m able to rotate the crankshaft.
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 10/03/2023 09:30

Are you using a TDC gauge and cam locks Mags?

It's important to have tension on the belt from the crank to the exhaust pulley, when that 18mm is loose you can turn the pulley slightly on the keyway which will take up the slack, I think this is the reason why it's timing up incorrectly.

Call me if it's easier: +44 1684 593187.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 10/03/2023 10:17

yeah, using a dial indicator on the #1 piston and cam locks.
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 10/03/2023 11:50

Originally Posted by Mags
yeah, using a dial indicator on the #1 piston and cam locks.


So it has to be that first step getting the belt tight over the idler and exhaust pulley,
Posted By: Mags

Re: Green barn find resurrection - Discussion - 11/03/2023 12:30

Om my first attempt I got the timing a bit late, after getting some great advice from Joe Countrycruising a was able to time it better. Now it’s just a fraction early (see photo) . I’ll settle for this, since it’s better to be early than late laugh ( as the belt settles in, it’ll make the cams time later.)

I suspect I’m more anal about the details than most.

Attached picture 01F60E0C-D5EA-47B0-9232-91B1D3EA2AA9.jpeg
Posted By: Gripped

Re: Green barn find resurrection - 15/03/2023 15:51

Fantastic. My kind of rebuild.

What sort of plating did you get? Looks like a couple of different types. Zinc, Nickel / chrome Passivation.. .?
smile
Posted By: Mags

Re: Green barn find resurrection - 16/03/2023 10:06

Honestly, I don't know. The nuts and bolts I sent off to a company that put them in a drum, that can do all at once. The larger bits I had yellow chrome plated at a different company, and they were hung individually. They came out way more yellow. The nuts and bolts are very original looking.
Posted By: Mags

Re: Green barn find resurrection - 16/03/2023 10:53

Well, I checked, and it is zink plating.
Posted By: Gripped

Re: Green barn find resurrection - 17/03/2023 08:51

Nice. Looks great..
Posted By: Edinburgh

Green barn find resurrection - 17/03/2023 08:55

Folks - a gentle reminder that comments should go into the discussion thread please...
Posted By: Mags

Re: Green barn find resurrection - 27/03/2023 08:03

Another small set back: when installing the sump drain plug, the threads literally started falling apart. I suspect there was an old Timesert in there.

I'm considering (drilling) tapping it to M20, any better suggestions?
Posted By: Mags

Re: Green barn find resurrection - Discussion - 03/04/2023 10:51

well, now I'm stuck on this ridiculous problem. I can't seem to drop the sump without disassembling basically the whole car.

And I got an M20x1.5mm sump plug kit, but for the life of me I'm not able to get the threading tap going - catching - so to speak.

So no I'm stuck with the sump half way off, and a big useless hole where the drain plug used to go. And possibly shavings - swarf - left in the sump.

Please give me some encouragement tongue
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 03/04/2023 11:14

from memory, and I may be wrong, I think in order to remove the sump you have to undo the bolts for the oil pick up pipe and then pop the pipe out the fitting is in, as otherwise the baffle plate stops you removing the sump..

Maybe drop Joe @ FCSS a message as he will know for sure how to proceed

Cheers Jamie
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 03/04/2023 11:42

Originally Posted by Jamiepm
from memory, and I may be wrong, I think in order to remove the sump you have to undo the bolts for the oil pick up pipe and then pop the pipe out the fitting is in, as otherwise the baffle plate stops you removing the sump..

Maybe drop Joe @ FCSS a message as he will know for sure how to proceed

Cheers Jamie


Yes two ways to drop the sump, one is removing the pickup strainer, 2x 6mm that hold the pipe to the pump and a 3rd bolt holding it to the mains cap on number 3, drop that off and you might be able to wiggle the sump past the subframe.
The other method is lowering the subframe down at the front, for this you might need to remove the o/s drive shaft and the alloy support bracket, either way it's a pig of as job on axle stands.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 03/04/2023 12:53

Thanks guys, a couple of things to try 😊
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 03/04/2023 12:59

Originally Posted by Mags
Thanks guys, a couple of things to try 😊


Hope the rest goes smoothly Mags thumb
Posted By: Mags

Re: Green barn find resurrection - Discussion - 03/04/2023 14:06

Sitting on my workbench wink

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Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 04/04/2023 06:13

thumb thumb
Posted By: french_coupe

Re: Green barn find resurrection - Discussion - 23/04/2023 11:36

Your disks came out well after an acid bath. Not seen that before.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 24/04/2023 12:47

One of them has some pitting, although not very deep. I’m curious to how it’s going to turn out.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 22/05/2023 19:35

Where do these go?

I don’t remember, and the other side is taken apart as well…

Attached picture IMG_4465.jpeg
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Posted By: skinflint

Re: Green barn find resurrection - Discussion - 22/05/2023 21:09

The square holes have white clips that push into them for self tapping screws to go into.
The 2 lower clip things on the right slot into the slot on the brake hose to secure it where it passes through a hole - possibly in the strut?
Not sure about the upper thing on the right.
Posted By: french_coupe

Re: Green barn find resurrection - Discussion - 23/05/2023 05:50

The clip in the top right screws to to body using the square hole and the u shape section is where the ABS wire clips on.
I think the rubber grommet is for the wires to the brake pads but the wires have probably been cut off many years ago.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 03/06/2023 20:20

What 17” wheels will clear the Brembo calipers? The ones I got, definitely don’t….

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Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 03/06/2023 20:56

I'd need to get Countrycruising to remind me of the details but I'm sure the solution to my own 17s involved spacers.

The Brembos had just been refurbed and 'someone' had refitted the wheel without the spacer, scoring lines all over the freshly-done caliper frown
Posted By: DaveG

Re: Green barn find resurrection - Discussion - 03/06/2023 22:03

These 17" Momo Sports clear with no spacers required (but wobble bolts are)

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Posted By: Mags

Re: Green barn find resurrection - Discussion - 30/09/2023 11:12

I got a set of Alfa Mito wheels that need 2-3mm spacer only, so I’ll settle for that.

Next issue: it’s been six months since I took the oil pan off. Now I’m struggling to figure out how to put it back together..

The tube for the dip stick sits loose, and the o ring is doing nothing. And what’s the threaded fitting on the right for?

Does this look right?

Attached picture IMG_4944.jpeg
Posted By: Mags

Re: Green barn find resurrection - Discussion - 30/09/2023 11:32

Here’s the full overview

Attached picture IMG_4948.jpeg
Posted By: Mags

Re: Green barn find resurrection - Discussion - 01/10/2023 21:32

Well, after giving it some thought, I figured it out.

The sump pan is installed, but it was quite an ordeal, just to fix the broken sump plug. I still have to install the drive shaft.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 03/10/2023 20:12

Identify this part please, I’m pretty sure it’s something I took off when dropping the sump pan, but it’s been six months so I can’t remember …

Also, this rubber knob thing goes somewhere around the oil cooler I think.

Attached picture IMG_4952.jpeg
Attached picture IMG_4953.jpeg
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 03/10/2023 21:48

The bracket piece is off the sump, but I forget it’s exact location

The rubber item fits on the Eiffel tower and cushions the rear of the oil cooler

Cheers Jamie
Posted By: Mags

Re: Green barn find resurrection - Discussion - 04/10/2023 07:12

Thanks, Jamie. The bracket piece is probably used to mount something else to it, maybe it will become obvious further down the road.
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 04/10/2023 09:11

Originally Posted by Mags
Identify this part please, I’m pretty sure it’s something I took off when dropping the sump pan, but it’s been six months so I can’t remember …

Also, this rubber knob thing goes somewhere around the oil cooler I think.


The bracket is a support bar belt side of the sump to the cast alloy half shaft support bracket.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 04/10/2023 17:22

Got it, thanks!
Posted By: Mags

Re: Green barn find resurrection - Discussion - 04/10/2023 19:07

New topic:

The o-ring for the visco drive; is it supposed to sit flush like this, or be buried deep inside the housing?

Attached picture IMG_4955.jpeg
Posted By: Mags

Re: Green barn find resurrection - Discussion - 04/10/2023 19:08

Close up

And, what are the correct dimensions for the visco o-ring?

Attached picture IMG_4955.jpeg
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 05/10/2023 09:17

I'm unsure about the O'ring without checking but Steve sells these at Alternative Autos, it needs to be the right material otherwise the gearbox oil destroys the rubber.

Link here.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 05/10/2023 11:35

Thanks, I just ordered one from him smile
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 05/10/2023 15:29

Originally Posted by Mags
Thanks, I just ordered one from him smile


thumb
Posted By: Mags

Re: Green barn find resurrection - Discussion - 06/10/2023 19:57

Is it possible to remove and replace just the lower (black) part of the rear bumper? Mine has melted around the exhaust tip.

Attached picture IMG_4963.jpeg
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 07/10/2023 09:36

Originally Posted by Mags
Is it possible to remove and replace just the lower (black) part of the rear bumper? Mine has melted around the exhaust tip.


Unfortunately not, the black valance is all part of the bumper so it can't be replaced but it can be repaired or at least trimmed to suit if it's not melted too bad.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 07/10/2023 10:42

This is the damage

Attached picture IMG_4965.jpeg
Attached picture IMG_4966.jpeg
Posted By: Mags

Re: Green barn find resurrection - Discussion - 07/10/2023 15:43

Rear caliper pistons: do they screw or push in?

Attached picture IMG_4967.jpeg
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 07/10/2023 16:13

Right hand screws them in on both sides, the wind back action for R/H and L/H are not handed like some other cars and if you need to wind the piston out operate the hand brake arm and it will screw them out.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 07/10/2023 21:13

Thanks again!
Posted By: Mags

Re: Green barn find resurrection - Discussion - 09/10/2023 08:25

Are heated seats a rare option? Mine has that, but the switch is broken on one of the seats.

Attached picture IMG_4968.jpeg
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 09/10/2023 15:02

Heated seats were never an option in the UK.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 09/10/2023 17:47

I found a new one at alternative autos !
Posted By: Mags

Re: Green barn find resurrection - Discussion - 15/10/2023 14:32

I’m on to the rear brakes. I’ll send them off to be sand blasted, and rebuild them with new parts myself.

I can’t figure out how to remove the piston, turning them doesn’t really seem to make any difference.

Is there a guide somewhere, to rebuilding the rear calipers?

Attached picture IMG_4975.jpeg
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 15/10/2023 17:15

This guide in the How-to section is probably the closest to what you're looking for, not sure if it is quite what you need.
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 15/10/2023 17:51


I use compressed air to pop them out

As a word of caution,getting the piston back in with new seals is tricky. I found lubing the seal and piston with silicone grease made it less painful

Cheers Jamie
Posted By: DaveG

Re: Green barn find resurrection - Discussion - 16/10/2023 12:14

I thought the rear pistons needed to be unscrewed, but as Joe says you can operate the handbrake mechanism to "pump" the pistons out.

But in my experience it's almost impossible to remove the internal handbrake mechanism from inside the piston once removed, some very specialised narrow circlip pliers are need. If your pistons are OK and if the seal at the rear (around the shaft that pushes onto the piston from behind) is not leaking, then just remove them and the seals before sending them off, but TBH it's a lot less hassle just to buy some new (reconditioned) exchange calipers, making sure to get the exact design you want (if that is important to you) and then get them painted if you want another colour.
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 16/10/2023 13:34

you can do either Dave, or at least that's how mine came out.

Regarding the internal bits, I agree it looked fiddly and was working so I didn't touch the mechanism.

Cheers Jamie
Posted By: Mags

Re: Green barn find resurrection - Discussion - 23/10/2023 17:11

Stupidly enough, I’ve managed to misplace the bolts for the front struts. They appear to be M12x70mm. Does anyone know the exact specs, or a good place to source replacements?

I’d like to replace the nuts for the tie rods, and lower ball joint pinch bolts. Maybe replace them as well…
Posted By: Mags

Re: Green barn find resurrection - Discussion - 25/10/2023 11:48

82439066 Is the correct part number, I finally found the answer to my own question.

It is indeed M12x70mm with a 1.25 thread. Available from multiple sources once you figure out the correct part number
Posted By: Mags

Re: Green barn find resurrection - Discussion - 26/10/2023 20:03

Back to the rear brakes. I’ve popped the pistons and installed new seals. But I can’t get the new pistons more than half way in, before they start spinning without moving.

The handbrake level is attached to a screw, that screws into the piston. But the threaded insert in the piston rotates freely. So when the friction of the screwing action reaches a certain level, the insert in the piston starts spinning, and consequently no further movement.

Help! I can’t imagine how to get the piston all the way in…
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 26/10/2023 20:17

Are you spinning the pistons clockwise?
Posted By: Mags

Re: Green barn find resurrection - Discussion - 26/10/2023 20:51

Yes. I can wind them all the way in without the seals installed
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 27/10/2023 13:39

mmmm, strange, without being there and trying for myself I can't think what's wrong. drop Joe a message (Countrycruising) as he may have a solution

Cheers Jamie
Posted By: Mags

Re: Green barn find resurrection - Discussion - 08/11/2023 19:53

All right, I ordered a special tool for the brakes, so I’ve put that off for now.

So I’ve moved on to engine bay assembly. First I hooked the turbo up. What would be the next natural step? Is there a preferred way of assembly from here?

Attached picture IMG_5072 – middels.jpeg
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 09/11/2023 18:42

The bit to pay attention to is the turbo heat shield and the radiator and fans, as it’s all a tight fit

Cheers Jamie
Posted By: clanger

Re: Green barn find resurrection - Discussion - 10/11/2023 14:58

Agree with Jamie - just to add, I found it useful adding a sheet of 3 or 4mm plywood behind the radiator fins upon assembly, fitting the fans then gently pulling the plywood out and screwing the fans on. Removes all risk of nicking the radiator with the fan frame especially if you are using the replacement Direnza type alu rad
Posted By: Mags

Re: Green barn find resurrection - Discussion - 10/11/2023 19:53

Yeah, got the direnza. I planned to fix the fan shroud to the radiator prior to installation. Isn’t that possible?
Posted By: clanger

Re: Green barn find resurrection - Discussion - 11/11/2023 09:19

Give it a go, it might be. There have been times when I needed to remove the fans for better access to the manifold and heat shield but not need to remove the radiator, I forget. Either way what I describe does help reassembly if you need to replace seperately.
Posted By: Mags

Re: Green barn find resurrection - 18/11/2023 14:30

Installed a bung for an extra O2 sensor today. Meaning to add some pictures, but can’t find the option to shrink them to the appropriate size.
Posted By: Edinburgh

Re: Green barn find resurrection - 18/11/2023 15:04

Are you PC or Mac?
Posted By: Mags

Re: Green barn find resurrection - 18/11/2023 15:35

iPhone
Posted By: Edinburgh

Re: Green barn find resurrection - 18/11/2023 16:12

If it's a matter of dimensions, presumably you've tried this (if your model provides this function)

Open the Photos app on your iPhone and the picture that you want to resize.
Tap Edit in the top right corner of the screen. ...
A new menu will open up, with a variety of editing tools. ...
Tap the gray square icon in the top right part of the screen. ...
You're now in the dimension editing menu.


If it's file size you want to reduce, try emailing the photo to yourself from your iPhone, and after hitting "Send" you should get a dialogue box:- choose the file size from the options within.

Otherwise on a Macbook, open the photo in Preview and you can alter the file size under Tools/Adjust size
Posted By: Mags

Re: Green barn find resurrection - Discussion - 23/11/2023 19:36

This is the hard pipe, running over from the inter cooler, towards the intake. I guess this bracket is broken?

Attached picture IMG_5104.jpeg
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 24/11/2023 11:06

Yes, the bracket isn't the best design if I'm honest, and should be an easy fix
Posted By: Mags

Re: Green barn find resurrection - Discussion - 28/11/2023 08:11

I just realized that I've replaced my brake master cylinder (just for preventive maintenance) with a new, 22.2mm one, and thrown the old one away. I didn't know it was supposed to be a bigger bore.
Now what? I guess the bigger one has to go with the Brembos?
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 28/11/2023 08:13

If you're a LHD?
Posted By: Mags

Re: Green barn find resurrection - Discussion - 28/11/2023 08:50

Yes, I'm LHD



Attached picture IMG_0550.jpeg
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 28/11/2023 09:26

The brake assist unit and master are different to the RHD models, LHD are way easier to work on as both units are in the engine bay and the master is from memory the same size as the 16v models so the 22mm where as the Bosch RHD is 23.8, short and stubby.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 28/11/2023 10:46

Great News!
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 28/11/2023 12:36

Originally Posted by Mags
Great News!


I'd offer up the new master just to be sure you've got the right part.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 29/11/2023 09:01

what do you mean by offer up? I'm sorry - English is not my first language.
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 29/11/2023 09:58

Fit the part on to the vacuum assist unit.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 01/12/2023 20:32

I’m about to prepare the radiator shroud. There are some flappy tin work on it, and some rubber flaps to rivet on, I think. At least I have a bag of rubber pieces…. Does anyone have a picture of how it all goes together?
Posted By: Mags

Re: Green barn find resurrection - Discussion - 06/12/2023 12:41

Does this go here?

Attached picture IMG_5125.jpeg
Posted By: Edinburgh

Re: Green barn find resurrection - Discussion - 06/12/2023 13:07

Originally Posted by Mags
I’m about to prepare the radiator shroud. There are some flappy tin work on it, and some rubber flaps to rivet on, I think. At least I have a bag of rubber pieces…. Does anyone have a picture of how it all goes together?


Perhaps these photos will help give you a guide - forgive my first attempts at peening rivets...

Attached picture IMG_20200607_1833548.jpg
Attached picture IMG_20200607_1808586.jpg
Attached picture IMG_20200607_1748087.jpg
Attached picture IMG_20200607_1720486.jpg
Attached picture IMG_20200607_1719495.jpg
Posted By: Mags

Re: Green barn find resurrection - Discussion - 06/12/2023 22:16

Thanks, now on to something new:

This doesn’t look right? The pipe is pointing upwards where the angle hose to the block goes. And the bracket is pinched against the radiator.

Attached picture IMG_5135.jpeg
Attached picture IMG_5134.jpeg
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 06/12/2023 23:35

You've basically got it bolted to the upper ac mounting bolts

It needs bolting to the 2 lower ac securing bolts
Posted By: Mags

Re: Green barn find resurrection - Discussion - 09/12/2023 23:00

The upper bolts have loose nuts that need to be held in place while threading the bolts.

The lower however, are apparently impossible to get started on the thread. I hope there are no loose nuts behind there…
Posted By: Mags

Re: Green barn find resurrection - Discussion - 11/12/2023 21:08

Finally got the bolts on, but now I can’t get the belt back on. Is it possible to reach the tensioner with the engine in place?

Attached picture IMG_5151.jpeg
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 12/12/2023 15:26

Originally Posted by Mags
Finally got the bolts on, but now I can’t get the belt back on. Is it possible to reach the tensioner with the engine in place?


You'll need to make a special tool to reach the 8mm bolt in the centre of the pulley, mine is a cut down 8mm allen tool 10mm long welded to a flat bar which is perfect to slide down the side of the a/c compressor, slacked off the 6mm adjuster so you can refit the belt and then tension and lock off the 8mm.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 12/12/2023 19:57

Cool! I’ll get the welder fired up and get on with it!
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 13/12/2023 12:57

thumb
Posted By: Mags

Re: Green barn find resurrection - Discussion - 14/12/2023 08:48

Got the tool made. On the first attempt my tool broke, so I had to add som welds for strength. Finally I got the tensioner loose and the belt installed.

Attached picture IMG_5163.jpeg
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 14/12/2023 10:22

Yes it's needs to be strong, especially when owners use thread lock rolleyes
Posted By: Mags

Re: Green barn find resurrection - Discussion - 25/12/2023 18:00

I’m down to this selection of brackets, does anyone recognize any of them?

Attached picture IMG_5177.jpeg
Posted By: french_coupe

Re: Green barn find resurrection - Discussion - 26/12/2023 10:16

The black one on the left is attached to the back of the battery tray. The other black one next to it is to hold the battery in place.
Posted By: french_coupe

Re: Green barn find resurrection - Discussion - 26/12/2023 10:19

The black one in the center is from one of the front struts and holds the brake lines / ABS sensor cable in place.
The black one on the right attaches under the car to the gearbox to cover the bottom of the flywheel.
Posted By: french_coupe

Re: Green barn find resurrection - Discussion - 26/12/2023 10:22

Not sure but the one in the bottom left looks like it either holds the horns in place or is next to the power steering fluid container and bolts to the chassis.
Posted By: french_coupe

Re: Green barn find resurrection - Discussion - 26/12/2023 10:23

The others are familiar but I don’t remember where they go.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 26/12/2023 12:43

Brilliant, thanks!
Posted By: Mags

Re: Green barn find resurrection - Discussion - 01/02/2024 19:26

Yo friends! I was told this bracket goes on the back of the battery tray, but obviously not like this?

Attached picture IMG_5285.jpeg
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 01/02/2024 20:02

Originally Posted by Mags
Yo friends! I was told this bracket goes on the back of the battery tray, but obviously not like this?


Correct thumb
Posted By: Mags

Re: Green barn find resurrection - Discussion - 02/02/2024 20:27

I’m correct in my assumption that this is wrong? In that case, what is the correct way?
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 03/02/2024 01:14

Originally Posted by Mags
I’m correct in my assumption that this is wrong? In that case, what is the correct way?

As you've got it, nuts from the front with the plate at the rear.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 14/02/2024 20:40

I’m having trouble making ends meet

Attached picture IMG_5322.jpeg
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 14/02/2024 22:47

This breather needs to run close to the block under the thermostat.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 04/03/2024 12:02

I’m working on the sticky dash at the moment. I’m slowly cleaning the stuff up, but is there a way to restore the original finish?

Attached picture IMG_5387.jpeg
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 04/03/2024 14:07

My method is using isopropanol to remove all the sticky mess, wipe with panel wipes and a couple of coats of satin black rattle can to give it that OE soft touch look.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 04/03/2024 14:11

I understand. The soft touch look. Has anyone attempted achieve the actual soft touch?
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 04/03/2024 15:27

Yes owners have also applied Plastidip paint.

https://www.plastidip.co.uk/product/aerosol-spray
Posted By: Mags

Re: Green barn find resurrection - Discussion - 06/03/2024 15:33

Moving on… does anyone have this? To spare?

Attached picture IMG_5390.jpeg
Posted By: Jamiepm

Re: Green barn find resurrection - Discussion - 06/03/2024 20:22

Worse case, just buy some hose from a local auto factors and thread it over the ac pipe
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 07/03/2024 05:58

Originally Posted by Mags
Moving on… does anyone have this? To spare?


I'm sure I've got a clamp somewhere.
Posted By: Mags

Re: Green barn find resurrection - Discussion - 07/03/2024 13:41

Originally Posted by Countrycruising
Originally Posted by Mags
Moving on… does anyone have this? To spare?


I'm sure I've got a clamp somewhere.


Fantastic! Let me know if you stumble across any
Posted By: Countrycruising

Re: Green barn find resurrection - Discussion - 07/03/2024 17:03

Originally Posted by Mags
Originally Posted by Countrycruising
Originally Posted by Mags
Moving on… does anyone have this? To spare?


I'm sure I've got a clamp somewhere.


Fantastic! Let me know if you stumble across any


Yes I've found one thumb

I have your address so I'll pop it in the post.
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