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Punto (Mk2/2b) H2DaE's JTD Story

Introduction

It's been an up and down 19 months for me and the JTD, mostly because it's been off the road for 11 of them :p But decided to put together a short timeline of my time with the car that I can add to as time goes on :)

May 2006
Traded in my 1.2 Active for a ELX JTD with similar mileage. Well I say traded in, it was actually a straight swap! Which wasn't bad ;)

My Active
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And the JTD the day I got it (Don't worry I took the alloys off of the Active before I traded it ;))
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Mmmmmm sexy red interior :yuck:
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Decided the interior had to be changed, so when Jug had a Sporting/HGT one up for sale in the classifieds I was in there like swimwear!
Unfortunately things didn't go to plan, and I made a mess of the rear seat bolts that were rusted into place. So in this pic it was only the front seats that were fitted
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I also bought a red OMP strut brace, which there are pics of later in the post

June 2006
Booked my car in for a remap, as this was the whole reason I bought the car! Angel Tuning came out and mapped the car at my house, and suddenly my 80bhp Punto was ???bhp (Somewhere between 110 and 130bhp) :D
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July 2006
It's about time for a random shot of Whiley and Serin in my boot don't you think? :p
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I took my car down to Frensham Pond near to where I live for some photos as I hadn't taken any proper ones since I bought it. I think they turned out alright :)

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September 2006
While all the pissheads where at Skeggy; Me, Alex22, Bushboy and dannyhgt went to brooklands for an Italian day. I've got some videos of me, Alex and Chris doing the hillclimb. Chris had a standard JTD at the time (I think this one was a long stint, a 2 weeker iirc :p) but only one pic of mine and Danny's car :(

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Here you can see the difference between a standard JTD and a mapped one :) Bit of wheelspin in 2nd uphill ;)

https://www.fiatforum.com/gallery/data/1139/MOV00127.3GP
https://www.fiatforum.com/gallery/data/1139/MOV00129.3GP

And also a JTD very similar to my own and an HGT very similar to danny's racing on our private drag strip :)

https://www.fiatforum.com/gallery/data/500/MOV00019.3gp

It was at this show that I first spoke to Peter (Oldschool) about the new GSR kit he was developing for the JTD. Bushboy had tried it but had run into problems with the MAF sensor iirc so I offered to be the guinea pig and bought one. It wasn't until the Stanford hall show that it was ready, paid for and actually fitted but I was really impressed with the sound it made :D

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I now needed to have the car mapped again to take advantage of the GSR kit and Peter arranged for me to visit ChippedUK in the midlands. So I went over and had the car mapped, and here were the results:

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Now I mooched around for a few months after this, and if I'm being honest didn't treat the car well at all. It hadn't had any fluid changes for nearly 20,000 miles and was driven hard at all times, even when cold. I ended up paying the price for this...

January 2007
My car had been starting to run strange recently, when cold I had no power at all when off boost then as soon as I hit around 2200rpm it suddenly kicked in a flew off! Added to this when idling the whole car was shaking, at first it was only slightly but it then started to get worse. I put this down to an engine mount starting to go, but it turned out I was wrong.
At the end of the month I was taking my sister to work one morning when part of my modified wiper linkage came loose. So I pulled over to put it back together but when i put my foot on the clutch as I came to a stop, the pedal felt crunchy and there was a horrible rattly grindy noise coming from the engine bay. Managed to limp the car home and booked it in to a garage for them to inspect the damage and change the clutch and oil while they were there.

February 2007
The car went into the garage at the start of the month and had a clutch change, I also asked them to check the engine mounts while they were there. The car came back and the clutch was perfect, so it looks like the release bearing had given up. However on the receipt from the garage they had put that the engine was running poorly, which by then it really had started to. The cold problem was still there, also the shaking which wasn't the engine mounts as they were all in perfect condition.
So it was booked into Fiat to be put on examiner and also have the EGR valve replaced, as this is what I suspected was causing the problem.
When I went to collect the car from Fiat, the bloke who worked on the car came out and had a chat with me, he explained that they had changed the EGR valve and put the car on examiner, but that didn't turn up anything that could be causing my problems.
I was basically told that unless they stripped the engine they wouldn't be able to tell me what was wrong with my engine. My thoughts were "**** that am I paying Fiat hundreds of pounds to strip my engine when I can do it myself!" Finally decided that I was going to buy a replacement engine, fit that and then strip down my old engine to inspect what went wrong with it.

Coming soon, the engine swap :devil:
Cool thread Mark, I'm also looking forward to reading the engine swap update :D Although I remember part of it from first hand experience ;) lol

Is she all MOT'd up and what not now?
 
Nah not yet mate, got it booked in on the 2nd. Checked the car over and the only obvious fail would be the exhaust mounts, but getting the garage to replace them all before the mot.

Cheers for the replies guys, will write up the engine swap update asap :)
 
^^^that :p

nice, though, quite good power now! shame that it will need mapped again, etc when you put another engine in.

The map is still on the car, as the ECU is behind the dash and hasn't been changed. And it still has POWER :devil: Though I am going to the RR day at Red Dot in February to have the map looked at and tweaked for this engine ;)

And yes I have learned my lesson :eek: :p
 
The Engine Swap

April 2007

April seems to be a good month for buying engines, I'm not sure if that is down to people writing more cars off or that the people at the breakers have finally recovered from Christmas and are getting there arses into gear and clearing the backlog of scrapped cars out :p
I had a choice of about 5 Punto JTD engines over the course of a couple of weeks on ebay and the pick of the bunch for me was the one I ended up buying :D
It came off of a car with 45k on the clock (just over 5k less than the old engine), was from the same year as mine and included all the ancilliaries. I was the only bidder and managed to get it for the starting bid of £300, bargain ;)
I turned down the offer of getting it delivered for £70, which I kinda regret doing now. Me and my mate took a road trip from Hampshire to the South coast of Wales to collect it in his Citroen C4, not the best choice of car to transport an engine in retrospect :p It took us an hour just to lift the engine out of the car when we got back to mine, ended up having to tip it over the boot lip onto a big pile of old duvets (y) Made a bit of a mess of his bumper though, so if you ever read this Adam, sorry again :eek:
Anyway, enough going on. Here is the engine:

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Boost! :devil:
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After buying the engine, you'd have thought I would dive straight in and fit it! But no, I became a bit lazy as I had the use of my sisters Mk1 Punto to use so didn't especially need the JTD back on the road. So everything sort of just sat there...

August 2007

After loads of hassle from a few people :p I finally got my arse into gear and decided to crack on with the engine. I enlisted the help of a few forum members during the swap (Thanks to Whiley, bob_in_disguise, Si Punto, Jay, GhostWkd, Alex22 and dannyhgt for the use of his engine hoist) who where a great help and I couldn't have done it without them :)

PuntoMk2 is down atm so I'm unable to get hold of the pictures of the swap, will start writing again as soon as it's back :)
 
The Engine Swap Continued...

August 2007

So the first job was to get the old engine out, which was actually quite difficult as the car was on a stone driveway! So the engine hoist was an absolute bitch to move about, especially when the engine was dangling from it! Anyway, I didn't get any pictures of the process of removing the engine, but Jason got a few, here they are:

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Old engine on the left, new one on the right ;)

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Group photo in the empty engine bay lol! :D
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So, next job was removing the gearbox, 50 mile old clutch, alternator and the brand new EGR valve that had just been fitted to the car. My mate across the road kindly lent me the use of his garage to store the 'box in as you can see in these pics my garage is a little messy :eek: :p

Old Engine

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New Engine

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Gearbox

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Now I can't find the picture I have of the empty engine bay :mad: Think it's on a memory card somewhere that I can't find! :rolleyes:

Anyway, roll on September...

September 2007

OK so start of September we put the engine back in the car, and as is becoming a theme on this thread I don't have many pics of it in progress! I do have a pic of the new engine when it had just been put in the bay though:

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Turabooooo :D

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I managed to bend the bit of the gearbox remote that has the weight attached to it, and when we were refitting the weight it was catching on the chassis leg. One blowtorch, one hammer and a bit of swearing later it was straight again :devil:
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A couple of days later I thought I'd crack on stripping the old engine down to try and inspect what went wrong with it, I'll just post a quote from PuntoMk2 from the thread where I originally posted it :)

I've been doing a little stripping tonight ;)

Heres what the engine looked like when I got home from work
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Manifold off
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The head bolts were a ****ing **** to get off :( Fiat decided to use T60 Torx bolts for them, which meant having to borrow a Torx Socket and a huge breaker bar off someone down the road and cracking the ****ers off. Got them off in the end, and left my mate to take them out :)
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Front 5 bolts
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Front Left 3
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Front Right 2
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Back 5
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Back left 3
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Back Right 3
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The reason for all the pictures of the head bolts is that when they came out, the outer ones were clean but the ones nearer the middle were covered in oil. Was thinking this could have indicated head gasket problems but apparently not.

Anyway, off with it's head!
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Think I may have found the problem. Even though Fiat said that the timing was fine there seems to have been contact between one of the valves and the piston on cylinder 1, which would also explain the metallic clacking sound when I turned the engine off. Heres a closer look

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See where that circular mark is on the piston? It's the same size as the little gap on the valve, and isn't there on any other of the pistons. Looks a lot like there has been some contact between the 2. Other than that everything looks fine, which is confusing me more :( :hmmmm2:

So that didn't really turn up much as to what went wrong :( I then decided to carry on and strip down the head a bit to see if that turned up anything...

Here's what the head looked like when it came off the block:
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So first of all I had to remove the fuel rail which meant removing the fuel lines to each injector:
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The 2 injectors on the left have had their lines removed and the other 2 are still in place.
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After that undo the fixing bolts and the rail comes off (and pisses diesel all over my leg :()
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Next up was to remove the glow plug wiring so the inlet fannymold can come off
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Ta-da! One inlet manifold ready to be removed
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Thought I would unscrew the glow plugs to see what they look like
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And I managed to remove an injector! This one came out piece of **** and the others wouldn't budge, which is worrying. This is where all that diesel magic happens ;)
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It was an interesting exercise for me, and killed an afternoon doing nowt. Wonder why the one injector came out easily but the others are stuck fast. Might pop them over to Fiat and see if they can test them somehow.

Anyway, let me know what you think ;)

Cheers Lewis.

Got bored and been playing again :p

Inlet
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Next up is removing the thermostat, couple of bolts and a tap with a hammer and it's off!
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Looks spanking new inside!
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Next to be removed is the vacuum pump for supplying oil to the camshaft.
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Remove all the fixing bolts and then the bolts for the cover and you should see this
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A tap with a hammer and the insides pop out!
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You are left with this
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Again, knock the casing off with a hammer as it doesn't come off easily and this is the side that connects to the head/camshaft
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*INSERT REMOVING CAMSHAFT PULLEY HERE* I haven't been able to get it off yet, need something to grip the head while i remove the bolt


Unscrew the bolts holding the camshaft brackets in place and remove the camshaft oil pipe (Be careful as this bends very easily)
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Well after getting this far and not turning up anything obvious I thought it would probably be a better idea to concentrate on getting the new engine running again!

October 2007

Well one weekend at the start of the month me and Gareth got going with connecting everything back up! Again, not much in the way of pictures but I do have one! :p

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The engine started first time! :slayer: Ran for about a minute then all of a sudden started misfiring really badly! Looked/sounded like it was running on 2 cylinders, the engine looked like it was going to jump out of the bay lol :p Turned it off, restarted and it hasn't done it since! :)

Refitted the wheels and for the first time since February the car was back on 4 wheels with a running engine (y)

If there was one regret during all of this, it was that I didn't get more pictures :(

After this was all sorted, it was just a case of getting it ready for the MOT...
 
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Good post, made an interesting read. (y) Good to hear it's passed the MOT as well.

How well is the new engine running? Has it taken to your map ok or will you need to get it remapped?
 
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