Yet another: 82 FI Won't Start

[Arod2051]

In the video you posted at the beginning, the starter sounded as though it might be a bit weak.
I have a couple of starters sitting in my garage that work better that that.
I will be in San Ramon on Friday. Would you like to try one of them?

Roy, Thanks for the kind offer. I used to drive to San Ramon every two weeks for school. Unfortunately, I have four really important meetings on Friday.

I am still going through to clean connections from battery to starter.

I have not turned the crank after cleaning the ground connection to the bell housing, but I want to clean off the connectors to the starter relay, and whatever I can get to. I also didn't let all the oil drain out of the cylinders so I am worried that it was hydrolocked.

Someone is selling '70-'78 starters in San Jose for $40. That sounds more convenient to pick up than have you lug one around and then wait for me in San Ramon. FWIW, I appreciate the guidance and the offer.

[majicwrench]

Rolling over engine w plugs out will quickly remove any oil that may be in cylinders. IF it hydrolocks, it is POSSIBLE it is filling a cylinder w fuel. Not likely.
Cleaning connections is not likely to make a diff. Sandpaper is not required. You DO need a good ground, and you should try to find ground strap on drivers side of trans bellhousing to body. Just for shits and giggles, next time you try to crank it, take some jumper cables and hook one neg clamp to battery neg and other neg clamp to engine and see if it improves cranking.

Oh, and changing starter is famously difficult if you are not equipped. I wouldn't try to swap starter till you are darn sure that is issue.

[RoyBatty]

Just going off my past experiences in dealing with my own starter issues. Mine sounded like yours does when the brushes wore out on mine. In any event I'll be in San Ramon all day friday. Weather should be nice so the spiders making the trip. Let me know if you change your mind.

[Arod2051]

Keith,

The ground from the bell housing to the body looks pretty solid. I'll give the ground (-) terminal to engine jumper a try when I next try to fire it up. I like that idea. Work around the possible source of the problem to see if it is the root-cause.

Roy,

I went ahead and bought a Marelli starter from another fiat owner a couple miles away. I'll get it tested tomorrow. But for $40 and a new friend, it was a great deal, I thought. I wish I can come see your spider tomorrow, but my electric car won't get me to San Ramon and back to Morgan Hill in one charge. Have a fun ride!

[Arod2051]

Thanks Roy, Keith, et al;

Success! It is starting up. I believe soaking the cylinders and ensuring proper connections did the trick. I bought a used Marelli starter. I now have a Bosch and Marelli version. It is now idling really rough with a lot of vibration, but it is idling!!!

http://youtu.be/D61IEJYEwOk

To summarize:

From advice from this forum, I performed the following:

1) Pulled the plugs and soaked cylinders in Marvel Mystery Oil (MMO) (ATF can be used) for 24 hours with plugs still out.
2) Put the car in 4th gear, jacked up the right passenger tire, and used right rear wheel to turn the crank. It turned stiffly at first then started to break a little loose.
3) MMO leaked through, so added a little more and let it soak for the next 48 hours. Then repeated step 2.
3) Cleaned the ground connection from the transmission bell housing. The crimp connector on the chassis seemed intact.
4) Installed new plugs and wires, gapped to 0.027" (Manuals states 0.024" - 0.027" for non-resistor plugs).
5) Measured 12.93V at the battery terminal and 12.93V at the starter solenoid. I did it blind because I did not know what I was touching, but the DMM showed 12.93V.

[bradartigue]

2nd the weak starter and/or terrible lead to the battery or chassis. Plugs out offers almost no resistance, plugs in the resistance is actually tremendous

[RoyBatty]

Well done!
Depending on the previous owner and the condition of things, you may find the need to change out some vacuum lines and such.
Also the lubricants you used to free up the engine may have fouled the plugs. Either remove and clean them or change them out.

[Arod2051]

Thanks again, Roy and Brad.

Brad's write-ups and his advice to use my rear-wheel as a crank 'wrench' were awesome.

Roy, I have timing belt, air leaks, and now vacuum line checks on my list. Can I assume air leaks and vacuum lines are one in the same? When that is all done, I'll flush radiator fluid.

I am sure I will have more questions and will start a new thread with my newbie question when I cross that bridge.