Bella #4 - Abarth 500 Project

[texanbrit]

Today's fun was finding small differences between the 500L and 500 Abarth engines.

First I moved over the oil filter housing to replace the one that is damaged on the new engine. That was easy enough, but then I found that the oil return lines and one of the coolant lines didn't fit correctly. The 500L oil return line was a considerable distance off and is noticeably shaped differently under the turbo, and the coolant line is a different length.

Oil return

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Switched over the 500 Abarth lines and then things fit correctly. I think that means the oil filter housing is different but I don't see how it is that different.

With the oil housing buttoned up. I swapped in a new timing belt and water pump.

New timing belt

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Timing set

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Also a new MA filter, the old one was clean but while everything is exposed it makes sense.

New MA filter

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Went to install the 500 Abarth engine mount bracket and found it didn't fit because the 500L accessory bracket is different. All the same bolts and the accesory mounts are the same, but the casting is in the way by about an 1/8 of an inch. So swapped the accessory brackets over too.

500L accessory mount

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500 Abarth Accessory mount

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[texanbrit]

Didn’t get much done with the rebuild this weekend, still waiting on a new engine mount.

Spent a lot of time pulling the interior apart, but we’ll talk about that later.

Did install a new gasket in the oil cooler though and swapped over the less beaten of the coolers onto the unbroken assembly.

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[texanbrit]

Not much progress this weekend. Too many family obligations and still waiting on some key parts.

I did make sure I installed the correct underpulley and also put in some shiny new spark plugs that I got from Bookautowerks.

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Also installed the throttle body.

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[texanbrit]

So found that the new accessory drive belt tensioner I have is for the non-turbo engine, and they are different. Live and learn.

Tensioners, turbo to the left

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So I fitted the low milage one from the L back to the block. Also moved over the alternator and AC compressor and fitted a new accessory drive belt. Yes, I know.

That's not right

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I've got a special oil pan for this car, so decided to install that. It's not a real mod just looking after the engine....
Probably would have been smart to do this before adding any accessories to the engine, but that's how we roll

The old oil pan didn't want to come off, it was very thoroughly secured with silicone. I did finally get it off, but I don't want you to draw any conclusions by the proximity of the engine hoist. I certainly didn't lift the engine by the pan in the hope gravity would help, that would be crazy! Maybe it wasn't such a bad idea adding the extra weight though.

Cleaned up the mating surface on the block and laid out the RTV on the new pan. Don't think I'll be winning any cake decorating contests any time soon.

Cleaned up

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Permatex black RTV

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New pan installed, carefully torquing the bolts in order. it's certainly much easier doing this with the engine out of the car and upside down.

Promoteo pan installed

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While the RTV cures I went back to working on rebuilding the interior. Installed Ultimate pedal pedals and some fancy seatbelts so far. Not bad for a cheap daily but certainly not what you'd call modifications.....

Ultimate Pedals

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New front belts.

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Then I noticed that I'd goofed the accessory drive belt and fixed it.

Correctly routed accessory drive belt

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[texanbrit]

So this project stalled over the holidays. Couldn't seem to find the time or the motivation to get rolling again.

So the the Texas Spring Thing is coming up and I've set that as my goal to have this car ready. I've also named the car "Abby" as in "Abby Normal".

Abby Normal

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So with that goal I have 54 days to get this done!

Motivation

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Starting with the clutch. I have a choice between an OEM clutch and dual mass flywheel and a Clutchmasters FX350 with a light weight flywheel. Since this car is going to spend a lot of time in a school pickup line I decided the dual mass would be preferable, and hopefully will let me recover some cash selling the FX350.

Almost immediately regretted when positioning the flywheel. That dual mass setup has some heft to it!!!!

Chunky flywheel

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Brand new T50 flywheel bolts installed finger tight, and then locked the flywheel with the proper MOPAR tool (so fancy)

Flywheel locking tool

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Then tightened to 11ftlbs in a star pattern and then tightened an additional 40 degrees.

plus 40

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So those bolts are in now, and I can't change my mind

Had to borrow a clutch alignment tool from a friend, but clutch plate installed with 1,000 T30 bolts tightened to 12 ftlbs.

Clutch done

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Next will need to figure out where I put the transmission bolts and get the transmission reconnected.