101 1300 rebuild part 9: It’s in there.

Tonight on my way home from work I made a spur-of-the-moment decision. I decided the engine was going in the Sprint. I have spent 3 weeks talking about it, worrying over getting help, clearing the headers, centering the lot on the engine mounts and a thousand other things, it was time to put it in and tonight was the night.

The catalyst was Conrad telling me he usually put the engine and trans in Sprints separately, that it really ended up being about the same amount of work. I got to the shop, unbolted the transmission from the engine, hoisted it up and dropped it in. It took maybe 15 minutes and I had the motor mounts resting in their cut outs. The only hard part of putting the engine in was I had to remove and then reinstall the exhaust side motor mount to clear the headers.

img_7622Here it goes. A good quality hoist is key so you can lower it really slowly, allowing you to check clearances and guide it. Note the engine mount on the head.

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Original TI pictures found!

I was looking for a picture of Hans Mathon (sp?) I have at a CSRG event standing beside his Giulia SS that he recently sold via FJ when I came across the pictures below that the guy I bought my TI from sent me when I was on the fence about exercising the $3500 Buy It Now option. Really sad how busted up it is now. Oh well, have wrench , will fix.

mygiuliafrontA complete runner, very blue and pretty good looking. I was in my twenties and wanted a Giulia sedan in the worst way.
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Finally bought my first Alfa…

It’s not very often you get a chance to undo something you did that you regret. My first Alfa was a this 1964 1600TI and I sold it after about a year of ownership. It came up for sale last week on eBay and Craigslist for less than I sold it for. When I saw the pictures I understood why. The guy I sold it to had ground paint off in areas he suspected had rust under the paint, pulled the drive-train out and took the interior and front end trim apart. As sad as it was to see this car in this state and knowing full well it would be difficult to get it back to the state it was when I had it (which wasn’t all that great and to add insult to injury, it appears he lost some of the parts), I had to decide if it was worth it to buy it back and get it back on the road.

742947-r1-015-6_006Here it is being delivered to me when I bought it off eBay for $3500 in late 2002. Car looked great in the pictures and the plan was to fly to Atlanta and drive it home, but the seller changed his tune about it being capable of making the 3000 mile drive so I shipped it. That’s a younger version of me and my cousin Norm pushing it onto the loading deck. Car needed a clutch almost immediately and would likely have stranded me if I drove it home.

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SS Engine 00121 #1: Inspections

Drum roll please. The moment you’ve all been waiting for, I am back on the SS project. I know, I know, the 101 1300 I’ve been rebuilding for the last 4 months is not in the Sprint yet so why am I shifting gears and diving into this? Well, this engine rebuild is next on the list and I need to figure out what I need to replace (buy) and what performance modifications I am going to try and incorporate so cracking it open now will help my planning and give my wrench a smooth transition.

00121 veloce as found frontLooks like a greasy Alfa engine to me. Note early Marelli distributor, I think this may be destined for the 1300.

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101 1300 rebuild part 8: back on track

I mentioned in my last post in this series that I broke a motor mount boss stud off, well, it turned out to be a pretty involved process to get it repaired.  When I mentioned the problem to ‘expert’ friends they all said ‘Oh, those studs never want to come out’ well, I broke it off installing  a new one, not removing the old, bent stripped stud.  I’ve broken studs off before on other rebuilds and was ready with the usual arsenal of tricks.

First I tried simply grabbing the remaining piece with Vise-grips, no good.  Then I drilled it out and used an easy out seen below, I couldn’t get a grip on it so I welded a nut to the easy out, the easy out broke at the weld.  I got a bigger easy out and tried to turn it, it was resistant despite a lot of force.  I heated the boss and tried again, this time the corner of the boss cracked.

easy-out-stageHere I am at the first attempt, the easy out wasn’t so easy and even with a nut welded to the end it wouldn’t turn.

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101 1300 engine rebuild part 7: even closer

I had a lot of time this weekend to work on the Sprint engine rebuild and I got a lot done.  I had been stressing out about getting the cam timing set but it turned out to be an easy process.  I still need to get a dial indicator to find TDC perfectly, but it is very close right now.  All I did to set the cam timing is I pulled the adjustment lock bolts out, loosened the vernier adjusters, connected the timing chain and tensioned it, verified TDC and cam marks again then tightened the lot up and reinstalled the adjustment lock bolts.  I put a little red locktite on the big cam nuts and bent the lock tabs over.  I still need to install new cotter pins in the adjustment lock bolts.  Once that was done it was a downhill coast until I broke a stud off …

cam-timing-doneHere it is, cam timing adjusted, everything torqued and cam chain tensioned.  I plan on dousing this all with oil before the initial start-up, probably a few weeks away.

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101 1300 rebuild part 6: getting close

Here it is, probably my last post of 2008. I might have squeezed one more in and wrote about one of the Sprint Veloce Lightweights for sale in Europe right now but I have been busy keeping up the usual holiday schedule and another post doesn’t seem likely.

This post is mainly to catch up on two busy days at the shop trying to get as close as possible to having the Sprint on the road before the end of the year. The first picture in the series is a teaser and should be farther along in the series, but I like it since the Sprint can be seen watching my progress in the background.

img_7036I suppose the color of the turn signal lens could be called ‘impatient Orange’. When this was taken I had just made all the head nuts finger tight after fishing the timing chain up through the timing case.

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Berlina project 4: the dreaded waterpump replacement

Usually my bad karma manifests itself as a star chip in a windshield or a slipping clutch but lately it’s been all about the waterpump.  When I had the engine out of the Berlina I noticed a lot of play in the waterpump pulley but I thought that since the engine had worked so good for so long in the Sprint, I’d just roll with it. These things can take decades to tear themselves apart I thought.

Last week when I went to the local Mexican market a few blocks from my shop for some Tecate, chips and salsa and pineapple Fanta to restock the shop ‘fridge, I came out of the store and there was a puddle of pretty green antifreeze under my car. So much for a slow decline for the water pump.

part-1Is it just me or is coolant more viscous than it used to be? All this was apart a few weeks ago so since it’s fresh in my mind I suspect I can get through it pretty quick. I popped the hood at 5:30pm after picking up a set of sparkplugs, some carb cleaner and some ultra gray from my neighborhood chain auto parts store.  I had a date to keep at 7:30pm so I had to hurry.

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Giulietta Sprint 101 1300 engine rebuild part 5: Waterpump

Another pretty part ready for installation.  As with just about everything else relating to this 101 1300 rebuild, the waterpump is not just an off the shelf purchased part that gets to be bolted on.  Theoretically the waterpump is an owner servicable part and rebuild kits are available, but years in a hostile environment means the average, or even above average DIY Alfa owner is going to need help.

I pressed the impeller out of the bearings and found it to be in good shape with little corrosion or wear on the bearing and sealing surfaces.  Once the impeller was out I removed the snap ring that positioned the outer bearing and that is where I got hung up.  I wasn’t sure which way to try and press the bearings out and the special seal with the toleranced mounting flange and spring was all corroded.  At this point I decided I could irrepairably damage the pump if I wasn’t careful so I put all the parts in a plastic bag and delivered it, along with my rod bearings to John Norman Racing where Dan Marvin rebuilt it.

water-pump-rebuilt101 1300 waterpumps are no longer available, so if yours has a problem treat it gently, don’t assume you can buy a new one.

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Giulietta Sprint 101 1300 engine rebuild part 4: Head work

I am trying to figure out how it happened. It was supposed to be so easy, pull the 1750 out, put the 1300 in, scratch my head over some fit problems and voila! I’m back on the road. Okay, so I discovered the 1300 was stuck and suddenly I’m rebuilding it. Parts are bought and so on and then next thing I know I find myself at John Norman racing lugging in my cylinder head. Warped, cracked and 10 thousandths from being too short means I had to buy a different, rebuildable head.

new-valves-decked-headNew valves, guides with stem seals, lots of machine work and all set up and ready to go. I hope I can put the bottom end together to be worthy of this head.

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