Advice requested on 2 repairs (1983 Pinin in the UK)

[derekgale]

Hi,

My 1983 Pininfarina 2000i has developed a couple of problems that need sorting, and I would like some advice as to how to fix them, and any issues around fixing them.

The first is a "ticking"/blowing from the exhaust manifold - I think. It's about 1/4 engine speed, so sounds more like the manifold than a hole in the exhaust downpipe. I probably need to replace the exhaust manifold gasket - but it's hard to reach all the nuts – so my first question is: “What other engine parts do I need to take off first”. It looks to me as if I will need to split the manifold to downpipe joint as well, so my next question is, “what other parts will I need as well as the main exhaust manifold gasket to do a complete job?” For example, are the manifold to downpipe joint locknut tabs re-useable, or will I need a set of those as well? Mine do look a bit rusty.

The second problem is the heater control valve or the cable that moves it. I was adjusting the centre heater control lever (the one that switches the air temperature from Cold to Hot), and it went stiff to operate, then went loose. However you move now it no change in air temp happens. I assume that either the operating cable has failed, or that the heater valve has failed. How do I fix this? It looks as if I have to take out the centre console (and the seats as well?) to be able to access the heater box – and that looks like a complicated job. If someone has a list/sequence for this job it would help me a lot. The shop manual I have is rather vague as to how it’s done.

All advice welcome!

Derek (in *leafy Oxfordshire, UK)

* less leafy than it was as it's Fall/Autumn here now.

[rlux4]

I can address the 2nd issue.
If you remove the upper console it will expose the heater box. The heater core is relatively easy to replace if it comes to that, so if it does, let us know and we can help. However, before you get that far, get down where you can see the heater valve from the footwell on the passenger side (it's on the upper, rear side of the heater box), then move the heat control lever and see it operates the valve. It could be that the tab that screws down near the end of the cable has come loose and is allowing the cable sheath to move instead of just the inner cable.
Ron

[So Cal Mark]

the manifold job isn't difficult, unless of course everything goes wrong. Anytime you work with exhaust you stand the chance of broken bolts. You will have to separate the pipe to manifold flange. The heater pipe also has a bracket on the middle manifold bolt. If your bracket is welded solid to the pipe, you'll have to remove the pipe which means draining the cooling system. Also be aware the two upper manifold bolts go into the cylinder head cavity for the valve springs and can leak oil if they are not tight and sealed after installation.
Soak all of the exhaust bolts/nuts with penetrating oil before attempting removal

[Brian]

If it gave way that quickly and there is no coolant inside, you might want to check the cable carefully, it may be that the sleeve blew out. If you need to visit the heater valve, check some of these photos I took when I did mine (also an 83 Pinin).

http://www.bassler.us/spider/?fn=5