Ive just bought a dead copen. No compression whatsoever on cylinder no 4. Oil down the cylinder did nothing for the compression so maybe its a burnt or broken valve so first job is the head off for a look. Im reluctant to get started without a workshop manual - where can I get one? Any one else had the head off? or experienced zero compression ? What was it in your case? Could well be easier in the end just to put in a repacement engine altogether - anyone know of one available? (660) Thanks Simon
Hi Simon, you've come to the right place. Check the directory tab at the top of the forum to find the link to download the 659 service manual.
I once had a valve snap (it wasn't a Copen though) which dropped into the pot and pierced the piston crown. I got a new piston from a local engine remanufacturer but reused the con rod and big end shells etc. I did the job without removing the engine, just the head and sump pan to gain access to the crankshaft. Put it back together and it worked fine. Being as you have no compression at all you likely have a broken or badly burned valve. It might also be a broken valve spring stopping the valve from closing properly. You can check the spring without remving the head, just the rocker cover. If the spring looks ok why don't you remove the head then get a price from an engine builder to refurb the head. Do you have normal compression in the other pots and is your tester definitely ok?
Pots read 159/140/160/0 so tester is ok. Good idea on the valve spring - heres hoping! Ive got the manual now and have been reading up on it. seems a awful lot of work to get the head off - start by removing the wing!
If a spring s broken it is a good idea to replace all 16. It keeps everything even pressure and there is a chance if one has broken another could go. If the valve has broken it will have dropped into the cylinder and damaged the piston. Hopefully the cylinder bores will be ok and you could just replace the piston. If its a burnt out valve I would take the head to a specialist for them to rebuild it. In the old days you could lap in new valves but these days they have hardened seats because there is no lead in petrol. Keep us informed how you get on, it could be useful info for somebody else. Why did you buy a car with thIs problem? Was it a very good deal?
It was a very good deal and I fancied a challenge. Ive done valves / heads before but only 8 valve single cams in rear wheel drive cars where theres loads of space.
What an incredible pain in the arse job. After just 11 hours i got the head off. One of the ex valves on number four is missing a big piece so I need an new valve and possibly the seat re-cutting. Doesnt seem to be any damage to piston or bore so thats good news.
Did you find the valve piece that was missing or has it just burned away? Eleven hours to remove a head is an unbelievable time and is an endictment of how complicated todays cars are. Back in the early nineties I had a Maestro which blew head gaskets for fun. In the end I could take the head off! change the gasket and put it back in less than an hour. The beauty of having loads of under bonnet space and not having overhead camshafts and timing belts.
Well I'm sure it could be done in less time but not by me! And I didnt take the turbo, rad or front wing and headlamp off and a myriad of other stuff the manual advised. No sign of the missing piece - It may be that the vale simply burnt away. Will try post some photos
Back on this tonight but in the meantime got some prices for the bits needed: Exhaust Valve: £32.66 Head Gasket:£69.03 Inlet manifold gasket : £12.68 EXhaust manifold Gasket £20.61 All plus vat - scandalous!
A head gasket for the 1.3 engine is around twenty quid. The advantages of having a Toyota Yaris engine. Anyway, best of luck with the job and just think about how much money you've saved over buying a Copen that was a runner. Keep us updated with how it's going and don't forget Adam's pictures.
No news, The head gasket is coming from Japan, I think its swimming, not due til 10th December. Had the injector for no 4 tested and no faults so still no wiser as to what caused the failure. Will post photos if someone tells me how.
You need to create a photobucket account. Post the pictures there. You'll then be able to get shortcuts to post into your thread.
what happened to smac and his engine repair project. Seems he's not been on for a month. No photos either
He might not have his gasket from Japan yet. Japanese airmail is notoriously unreliable due to the kamikaze impulse.
I thought it was because they have Boeing Copen freight planes and only got enough room in the hold for a couple of small boxes with the canopy down!
If all else fails... http://www.ebay.co.uk/itm/DAIHATSU-...Make:Daihatsu|Model:Copen&hash=item27ca9a85cd
Is it possible to fit a 1.3 engine into a 700cc Copen? If it is Possible then that would be a canny mod for somebody who's turbo, or engine was kaput.
