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Old 10-12-2011   #1
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Unhappy Help! Dead cylinder, glowing exhaust manifold, hard to start

So here's the deal. I bought a 1980 Fiat Spider 2000 FI from a old mechanic last year. It was in pretty good shape, had a lot of new parts on it, the price was right, yada yada yada. Anyway, the engine was original, and so were all the gaskets, so naturally it was filthy and was leaking oil everywhere. I pulled the engine out and cleaned the engine bay, sprayed down the block and cleaned it off, then painted everything. In the process I replaced every top-end gasket I could think of, including the head gasket. I used the torque specs I found in the Fiat repair manual on mirafiori.com (very helpful site). Anyway, I got everything back together and set the inital timing with the two cam gears lined up to the raised notches on the cam housings, aux gear at 1 o clock, and the crank at 10 deg BTDC on the #4 cylinder. I tried firing it, it wouldn't start. I replaced the fuel filter and replaced the old rusty gas with new stuff, and replaced the fuel pressure regulator. It fired, but it's really hard to start and it has a really bad misfire. I've checked and re-checked the timing, and I've put a timing light on it to make sure it's at 10deg BTDC. Practically all the sensors are new, and so are the spark plugs, wires, cap, rotor, and pickup wire. I can start it and get it to run after a few tries, but it sputters and won't stay running below 1500rpm. I've also checked valve clearance, and each is at least .5mm when cold, so it's not a stuck valve. Any help would be appreciated... I'm running low on ideas and installation fluid.
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Old 10-12-2011   #2
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Re: Help! Dead cylinder, glowing exhaust manifold, hard to start

Crankshaft should be at TDC, not 10 BTDC.

Here's the relevant page from the original Fiat Spider manual and a general 2000cc Twink engine timing diagram.
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