My new 79...

[FiatBen]

FiatBen, Yeah, mine had around the same, and then felt like a grinder when it did turn... There was no way I could get the thing out without removing stuff.. Maybe you have a smaller starter? Or maybe an electric fuel pump (I have a mechanical one).
In any case, I'm going to try what Russ suggested, and straighten it out.. I'm just glad I noticed the leak before I got any further, and that it was obvious where it was coming from.

I was looking back over my notes. Had to pull the starter, which is never fun but doesn't seem to me to be the onerous task some would say. Also discovered that HF tool that made life so much simpler!! Will need to address shot boots on linkage at some point, but right now I'd be happy to just have a running car. Following this thread before attempting the 1800 head swap.

[garion]

Well, after bending and sanding, replacing bolts.... No luck. Still leaks... It did get further though.. This time I was able to fill the engine up first, then start topping it off with the rad in.. Only as it finished did it start leaking again... Argh..

[azruss]

Did you cut a new gasket for it, john, or try a metal to metal seal. Metal to metal wont work. you will need a paper gasket at minimum. Also the center clamp to the manifold bolt cant put any stress on the flange seal or else it will continue to leak.

[garion]

I made my own gasket from some gasket material (after using a purchased one first).. I learned that lesson a long time ago The center clamp might have been part of it, I tightened that after I tightened the hose... Anyways, I ordered a new part, new gaskets, and I'll also check the studs/nuts for that connection (I'm pulling off the water pump).. I went with the one without the T for the carb, I don't think that has the tab for mounting to the exhaust..

I also played around with the alignment a bit.. Found out that the tie rod adjustment toolkit from HF doesn't have one that works on our cars... Screwdriver in the opening seems to work, at least while everything is new.. I did an 'eyeball' alignment, since I still have everything in the air.. Once I get everything running again, I'll do the string alignment.

So close... I'll end up taking my first drive in 100 degree heat... Whee... At least I'll be set for next fall..

[garion]

I just can't win..

I got the new pipe today, much better than the old one. But... Apparently, its a different thickness of pipe, thinner than my original. Now it leaks at the other end, the hose connecting to it is too wide. At least those parts I can get locally.. *sigh*

[garion]

SHE RUNS! And no leaks from the cooling system.. .Though I have to bleed it, as the fan never came on, and my IR temp gun shows the thermostat didn't open (it worked before).. But it runs! The leak I had the other day was because the old heater pipe was a larger size than the one I ordered.. The old hose from the heater to the pipe, someone jammed on, and it expanded.. Trying to put it back on a smaller pipe just didn't work.. But when I pulled off the hose, measured both the pipe from the heater and the new pipe, they were the same... 6 inches of 5/8" coolant hose later....

I still need to set timing better, and I think the carb is running really rich.. I see gas squirting into the barrel at idle, and I don't think its supposed to do that..

Its runs!

[garion]

ITS ALIVE!

After getting the timing set, tweaking the throttle linkage, adjusting the carb, bleeding the cooling system, and doing a simple 'good enough' alignment, she's on the road!

The alignment is off, mostly because I used the string method and didn't have something for the tires to move on easily.. So turning the sleeves was difficult. Once I get a better setup, I'll tweak it in..

Went for a couple mile drive to the gas station and back...

- Brakes are sketchy... Pulls to one side..
- Steering is loose, could be tightened I think.. No where near as bad as the original steering box..
- I have a ticking noise related to engine rpm. I probably have to adjust the cam clearance or something.
- I have an exhaust leak somewhere. Noisier than it should be. But thats ok. Its not that bad right now.

[azruss]

congrats! you got it running in no time flat. drive it in reverse and slam on the brakes a couple of times and see if that gets rid of the pull. for alignment ease, roll the front tires on a plastic garbage bag.

[RRoller123]

You can put the front up on jack stands as long as you place them as far out on the control arms as possible, right under the ball joints. This is a good simulation of the geometry when the tires are on the ground. Then the string method is a lot easier, as you can get the tires off and on quickly to make the tie rod adjustments.

[garion]

RRoller for the win! Putting it up on jack stands made a world of difference.. I have the alignment dialed in now (at least toe)..

But now this is showing me that my driver's front brake is dragging... The next cool weekend I'll rip into that..

I love the sound of that second barrel on the DFEV opening up though! Much better than my old 1.8 and the adfa..

[garion]

So i decided to pull off that sticking brake and have a look... Once I got it off, take a look at the seal around the piston.... It just fell out..




Seriously, it just fell out.. So I remove the caliper from the, figuring I'll rebuild them, but I'm having no luck getting the piston out. Doesn't move at all... Time for some new ones....

[azruss]

the seal that fell out is just a dust seal. The actual piston seal is still in there. flood the gap between the piston and cylinder wall with PB blaster and let it set a few days. After that, you can pump it out of there with the brake pedal or use compressed air in the hose connection to the caliper. Careful, that piston can come out of there like a cannon ball.

[garion]

PB Soak started. I took the caliper out of the car, and blew air from my compressor into the that hose connection, but no movement.. I also don't have a perfect fit for getting air into that, but I was putting 80psi in there, and nothing.. Worse comes to worse, I'll put it back on the car and pump it out.

[majicwrench]

Put a C clamp on it and push the piston IN to get er moving. Then she will come out w air.

[spider2081]

Just a safety note
If blowing it out with air put something between the piston and the caliper I use a rolled rag. Then cover the whole thing with another rag. Keep you finger away from the piston as it will come out with a bang. The fluid in the caliper will spray all over if not covered.