Sprint Update: Engine compartment refresher part 1.

You may remember I made a plan to detail the engine compartment of the Sprint as part of the engine rebuild. While waiting for the Piston and liner set to arrive, for the head and water pump to be rebuilt and other things I have no control over to get done I tackled the engine compartment. The firewall and inner fenders etc had silver rattle can spray paint over green car paint over the original red. On top of the paint was a lot of gooey oily debris from the last 20,000 miles of commuting and events this car has done.

The first step was to take a picture to see where everything should go when the paint is dry. Next I used Simple green and scrubbed the engine compartment then followed that up with power washing. Once it was dry I removed all the firewall grommets and associated brackets and wet sanded the old paint to make it smooth. I had delusions about going down to the bare metal but this car is sort of an original scruffy car so I decided a quick go over followed by some matched car paint put in a rattle can would be ‘good enough’.

engine-compartment-doneI got your attention with the nice done detail shot of the drivers corner. The brake fluid can leaks so I had bare metal to work with in this area. The smaller grommet brackets are just polished up with mag polish, the larger steering column bracket was bead blasted and painted ‘dull aluminum’ silver. The new rubber grommet for the steering column was $50 AND it required extensive shaping with a razor blade to get it to fit. The throttle linkage was blasted and painted and installed through a new rubber piece.

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Giulietta Sprint 101 1300 engine rebuild part 3: more bottom end work

If you’re not into reading about engine rebuilds the next few posts will probably bore you… I woke up early Sunday and set out for the shop determined to figure out the oil pan set up on the engine I’m building. I bought a 101 1300 Normale oil pan for pretty cheap that was dirty and the windage tray had a lot of surface rust, but I figured I could clean it up and if I got the rust off it would stay off since it will be in an oil bath. I had to look at the parts book illustrations several times before I figured out how the windage tray brackets get installed. The brackets themselves were bent up but I aligned everything with some pliers and I’m now confident I know how it goes together.

1300 windage tray bracketThe brackets are taller on one side than the other, probably to put the windage tray at an angle to direct the oil to the pick up as it drops out of the crank. The ‘cigarette’ seals can be seen here sticking out of the end main cap. These will have to be trimmed before the final assembly.

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Giulietta Sprint 101 1300 Engine rebuild part 2: depths have been plumbed and the ascent begins.

I have a good honest tired accomplished feeling tonight. I spent about 5 hours on the bottom end of the 101 1300 engine that is going back in the Sprint and I got a lot done.

I brought the 1400 kit I bought along with the head to Glenn Oliveria, local Alfa engineer par excellence and driver of a neat column shift 750 series Giulietta Sprint race car, to get some advise. He measured a few things, thought about it and decided the head had been milled .040″ already and would require a .010″ skim, in addition to a valve job, to be ready for action. He explained what was involved to use the 1400 kit, chamfering the head, measuring valve to piston top clearance, measuring tdc combustion chamber volumes to calculate compression and balance the compression across all 4 cylinders. Oh, and peening the rods might not be a bad idea. Long story short, a $1000+ machining bill would be paid to make the 1400 kit work so I am going to go stock 1300cc 9.1 to 1 compression ratio piston liner set for the Giulietta Sprint.

1300 crud trapThese holes are about 2 inches deep. When I first started cleaning this up they were barely visible. Lots of crud had gotten in here over the years. I used a drill bit to help auger it out then washed them out. Nice and clean now.
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Berlina Project part 5: Road report and teething

When I started this project I had one goal: to make an economical, mechanically simple yet comfortable commuter to try and keep my BMW 3 series wagon from reaching the end of its warranty miles (100K) a year before the warranty termination date (3/10).  I think I have achieved my goal but I have had some small teething problems in addition to the long list of perceived problems I made before I started driving the Berlina daily.

At 83961 miles I put in 10.7 gallons in to fill it up.  This morning at 84,300 miles I put 10.17 gallons in.  339 miles on 10.17 gallons of gas equals 33.3 mpg.  Amazing for a 1750 with dual Dellortos and 10548 cams being driven ‘spiritedly’ as the Brit’s like to say!  Even if my odometer is off by 10% I’m doing good.  I guess the economical part of my goal is currently exceeding expectations.  It can also be said that when the fuel gauge starts looking low I still have about 5 gallons of gas.  I will take a few more MPG readings over the next few weeks and report.  I will also try and check how many miles my car thinks a mile is.

Leaky Axle seal?  Probably.  Squeek from a loose sway bar mount?  Maybe.  Worn out trunion bushes?  I hope not.  In addition to the obvious leak I get a little more wiggle in the rear end in cornering than I am used to in an Alfa and some squeeks.  I’ll probably have to stick my head under here this weekend.

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Something about the devil and idle hands…

You know the beginning of Magnolia when the lady shoots a shotgun at her husband and misses him but hits her son who just jumped off the roof as he falls by the window? Well the pile of circumstances today wasn’t quite that profound but the result was pretty good. The story is something like this…

Possibly the most absurdly cute car ever. Don’t you just want to pinch its cheek?

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Berlina project part 3: success!

My dad was in town and to keep him busy I brought him to the shop with me on Saturday afternoon a couple of weeks ago. We spent most of the time talking about the best approach and after one false start got the engine and transmission to mate up. Not an easy job when you leave the transmission in the car. Dropping the front swaybar turned out to be the trick to make two faces parallel. Once it was in I probably spent more time trying to find the correct bolts to bolt the motor mounts down than I did installing the engine.

Two successive afternoons the following week I put all the pieces together and to my amazement it fired right up. I didn’t want to try and retrofit the early 60’s 1600 Veloce airbox (though it probably would have looked very cool) so I traded it for the Euro airbox seen here. I spent $11 more than I paid for the car on a bag of parts from a local dealer including a new oil pressure send unit to put the finishing touches on the assembly part of the project.

Here it is in all its glory. I traded a late ‘scalloped with tabs’ valve cover for the smooth unit seen here with the 90 degree breather to match the airbox. Note the high out-put alternator from a late 80’s spider.

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101 1300 rebuild for Giulietta Sprint part 1: Out with the new, in with the old

If you have followed the Berlina recommission posts you know my plan was to pull the 1750 out of the Sprint, put it in the Berlina and then drop the original 101 1300 into the Sprint. A slight complication was revealed on Saturday when, while the sun dried the gas out of the Fiat gas tank, I set to work preparing the 1300 for its new (old) home. It seemed like a good idea to open the engine up enough to at least check the bores, a main bearing or two and the combustion chambers to establish a baseline of its condition.

It turned out that the spark plugs being out of the holes for 13 years (only 2 in my keeping…) allowed moisture to attack the bores and rings. I tried to hone one of the liners but wasn’t happy with the result. Oh well, piston and liner sets are not too expensive, but do I go for the 1300 normale 9.1:1, veloce 10:1 or a 1400 kit or really punch it out and go for the Conrero spec 1500? Time to fish through my wallet!

The business end of a Giulietta 1300. All and all pretty clean in here. Someone decided polishing the crank was the way to go. Note 101 1300 Nomales have the dip in the block side for the close in oil filter.

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Fiat centoventiquattro ongoing fix it again

Ahhhh yes. You think things are going your way but really the elements are conspiring against you. Within an hour of making the Berlina run I get a call from the better half. “Uh… I smell gas strong in the Fiat.”

“Where are you?”

“Right in front of work.”

“Where is it coming from? trunk? Engine compartment?” I am already pulling the gas tank out in my mind

If you’re reading this blog you’ve experienced this sort of thing. That night I spot a puddle forming under the passenger side rear corner below where the gas tank lives. Great.

There is dirt, there is gunk and a spaghetti of fuel lines and wires but no reason for the bottom of the gas tank to have rusted out.

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72 Berlina revival part 2

I don’t know if I should start this by saying I’m ahead or behind. I thought it would take me a few weeks to get the 1750 out of the Sprint and into the Berlina, but I guess I thought wrong. I will admit that taking a full time job, hosting my dad for a week, going out of town for most of the weekends between buying this car and my birthday a few weeks ago and other everyday life interruptions have played a part in retarding my progress, but I’ll also say hey, it is coming along. I’m in no danger of selling this thing on eBay in 20 years after cowering in the corner of procrastination.

To the point. Once I got the engine out of the Sprint it required a bunch of parts change over to prepare it for its new life in the Berlina. The biggest job was swapping the oil pan and pump. The second biggest job was cleaning it up after leaking around the rear main seal and valve cover gasket heavily over the last 20,000 miles in the Sprint.

I had never replaced an Alfa oil pump before this. The bull-nose or whatever you want to call it oil pan requires a specific oil pump. That’s the 1300 in the background that is going in the Sprint when all this Berlina hootenany is done.

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Sprint to Berlina engine swap advances: Part 1 of Sprint engine rebuild and Berlina revival.

After I picked up the new windshield for the Berlina in Berkeley I headed down to the shop to finish the pulling portion of the job.

I am new to pulling and dropping in engines so I probably spent way too much time thinking about it compared to just doing it. I decided to pull the transmission from below due to the tight fit of the 1750 in the Sprint, which turned out to be a good idea, though difficult. To pull the transmission the tunnel opening cover has to be removed along with both shift boots (and a whole bunch of stuff on the underside). It took about an hour to get the right angle and grip on it but eventually the trans slid free of the main shaft. I put a tire under it so if it got loose unexpectedly it wouldn’t hurt itself crashing on the cement floor.

I hated pulling up the nicely glued in carpet but there was no getting around it. The cover had two Philips and two slotted screws, nice touch. The boot you see here is what keeps you from smelling gear oil when you drive. Stinky stuff.

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