it looks very daunting. But dont give up. Go watch some videos of these cars actually running. I find that spurs me on to make some progress. That or buy some new tools.

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http://uploads.tapatalk-cdn.com/2016...3be4f19ab4.jpg

Progress


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I think there is a locator pin preventing perfect mating. I guess there are several differences between the early and late series engines. Next week I'll torque things down to specs.


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Got a lot done today. Engine wiring harness, most of the coolant lines, rear prop shaft, exhaust downpipe, sway bar, seal the engine, transmissions, transfer case.. Next sort out the coolant and oil breather pipes.

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Got the spark plug holes dried, cleaned out and replaced the plugs. The wells were almost half full of water. Forgot how the coolant and oil breather hoses go. Had to removed a half shaft to refit the front suspension. Ran out of daylight.


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Glad to see this saga is finally coming to an end for you.

No update because the owner hasn't paid me for February. I even ordered the coil for him. He has been dodging me for 2 weeks so money...no love.


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Got paid so I'm back into the dogs breakfast the people at Lancia call their vacuum and intake piping. The PO did some mods so.... The original diagrams almost uselesshttp://uploads.tapatalk-cdn.com/2016...206f592d8b.jpg
On another front got the half shafts regreased and reassembled, front suspension done (under some tension) and coolant piping.


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Checked the wiring, connected all the hoses, flushed the cooling system, removed the valve cover and spark plugs, lubed the cams and pistons. Cranked the engine over until it got oil pressure and gas cleaning the combustion chambers. In the home stretch. http://uploads.tapatalk-cdn.com/2016...a8708e88a0.jpghttp://uploads.tapatalk-cdn.com/2016...87d96b3743.jpg


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What is up with that cam lobe rust???

The engine has been sitting for god knows how long. The oil cap was a bottle cap.


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You REALLY need to get the rust off those cam lobes...

If you can clean and polish it off they may be just fine. If you don't, the engine will run but will have a shortened life on the cams. If you find pitting, then you'll have engage a machine shop or maybe replace the cams.

Should be pretty easy to get this cleaned/polished/sorted now rather than later.

angela

Classic stuff, rufrob .. good luck with your repairs

Baby stepshttp://uploads.tapatalk-cdn.com/2016...b7070b7154.jpg


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Got a few loose connections. At the coil, possibly air flow meter but I don't think so.
http://uploads.tapatalk-cdn.com/2016...13206bbcab.jpg
Possible cold stare valve,
http://uploads.tapatalk-cdn.com/2016...74f01e2555.jpg
Now I'm not getting spark nor fuel.
http://uploads.tapatalk-cdn.com/2016...c76d62af1a.jpghttp://uploads.tapatalk-cdn.com/2016...60693b203c.jpg


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I know nothing about the mechanical workings of the Integrale but loving your updates.

Take this as a cautionary tale.
I just discovered this car came with 3 different coils. Since the original coil was missing I bought the wrong one. Just found a used proper one in the UK. In the meantime fuel system clean, fuel pump check and general clean up.


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Tidied up some stuff. Just waiting for the coil to arrivehttp://uploads.tapatalk-cdn.com/2016...cb1d08eccf.jpg


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What is the car to the right?

So, taking bets on it firing up with the new coil? I am impressed by your patience. I would have long ago suggested an LS engine transplant to the owner! :)

G

What did you do on the cam? Tell us you didn't just slap the valve cover back on!!??

I used a 1000 then 2000 grit sand paper on the cam. The worst of the rust came off with my finger nails. I then soaked the top end with fresh 10/30 oil.


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It's some weird French plastic thing. It runs!!
http://uploads.tapatalk-cdn.com/2016...3132c4ea43.jpghttp://uploads.tapatalk-cdn.com/2016...e912259aa4.jpg


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That is so ugly that it's interesting....

http://uploads.tapatalk-cdn.com/2016...75b9ce8837.jpghttp://uploads.tapatalk-cdn.com/2016...f8253df67a.jpg
And now this.


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Been there before...

ouch

good luck, last time I found something similar the lines.took.forever. to clean up.

Hehe....dad had Lancia Kappa with basically the same engine (2L 16v turbo). It was a disposable car. He even had it converted to run on LPG at some point.

Funny how Delta with same "throwaway" underpinnings is now a collectors item.

Thank the Gods it has a plastic tank and hoses. There should be plastic tank conversions for all steel tanks.


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Got a used Nissan intank pump from the owner. With some mods I got it in. It took a lot of cranking before it fired albeit on 2 then 3 cylinders. The gas is half rotten so I had to hand pump it out and clean the tank as best I could. http://uploads.tapatalk-cdn.com/2016...537c73007f.jpg


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https://vimeo.com/169931402


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replaced broken cap and rotor, which helped but on condition persists. When I first start the car after letting it sit for a week. It starts right up, but wont rev easily. It fast idles but increasingly wont take throttle. If I turn the engine off, restart is almost impossible. I need to floor it and crank for a long time. I will try the fuel filter next. Any suggestions?

What's the fuel pressure doing? IT sounds like it's loading up with fuel.

Edit: Vacuum leak could cause this...

You know, I don't mean to sound negative, but I'm really not comfortable with the way that engine sounds...

There's a pretty distinct metallic sound. I mean it could be anything - even a bit errant trim work tapping about furiously, or something very noisy in the injection system. Can a few others on this site listen to the video and comment as to whether this is normal for this engine?

angela

It's either a vacuum leak or fuel delivery. When I get it closer to idle it doesn't sound that bad. I plan to put heavier oil in later. I'm not happy with the sound either but I'm only doing what the owner wants. In that video the spark plug cover was rattling too.


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New problem.
Was running up until replaced cap and rotor and filling with coolant. Now no start. Cranks freely with WOT but tightens and floods with the throttle left alone.
Check the timing is good. http://uploads.tapatalk-cdn.com/2016...534eaa5010.jpg


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Anything fuel-related needs to be looked at after sitting this long. I would start with changing fuel filter then checking fuel pressure at fuel rail.

If fuel pressure is still too low, you have pump issue or FPR is stuck. If too high, the return hose is blocked (or FPR is stuck).

Once fuel pressure at injector rail is correct (should be 3 bar minus whatever intake vacuum is) , you should test injectors for spray pattern. Chances are they are severely clogged.


Also, any air leak between turbo and intake will add another layer of variables. Check it by pressurizing everything south of turbo intake to roughly 0.5 bar and listen for leaks (some air might escape via valves, that is OK).

So:

1. make sure there are no air leaks
2. make sure fuel pressure is within spec
3. make sure injectors actually inject

That kind of reminds me of something my father once said:

"Never buy a weird car, 'specially one of them furrin jobs".

Thank you so much beepbeep. Hence begins another billing cycle.


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