[alfa] Alfetta GT Engine Rebuild - Final Note

[TJCallahan@xxxxxxx]

Previously, our intrepid DIY home mechanic reported the '77 Alfetta GT 2.0L 
engine rebuild had, chronologically - been required; was going well; 
necessitated an align bore on the mains; had moderate head/cam work; reassembled well; 
and ended up with a nasty mechanical engine knock after just a few miles. :-(

Said Alfetta GT was trailered (thanks Steve!) to Wes Ingram's shop for a 
little investigative disassembly and, hopefully, repair.

Initially, the suspicion was that the flywheel bolts (that portion that would 
be a flywheel on a non-transaxle engine, anyway) were installed and a) not 
torqued; and b) dry - with no Loctite. Investigation, over the course of a 
couple days time, lead us down the path of: removing the spark plugs and hearing no 
knock while spinning on the starter; reinstalling one plug and hearing the 
knock return; the flywheel exhibiting no fore/aft movement; removal of the oil 
pan to check the rod and main bearing nut torque (and seeing no filings in the 
bottom); suspecting, momentarily, a broken crankshaft; and finally ending with 
discovering a rotational looseness of the flywheel.

It was, indeed, the flywheel bolts that were loose. Not loose enough to feel 
the flywheel wobble, but loose enough for the flywheel to move against the 
bolts in a rotational direction. Those bolts were pretty well trashed.

A quick removal of all things attached, pulling of the damaged bolts, 
checking of the crank threads, installation of new flywheel bolts (with Loctite and 
torqued properly), return of all things otherwise removed, and the Alfetta was 
ready for a road test.

Bingo, she's quiet (no knock) and strong and ready to continue the break in. 
Picked it up from the shop late Thursday night and already have double the 
previous break in mileage on her. An expensive lesson for me but I'm happy that 
the other engine work that was done is still good.

A big thanks to Wes and Herb for their experienced ears and talented hands. 
Many thanks, again, to Steve for the tow and the restaurant recommendation. 
And, of course, many thanks to all of you for your contributions during this 
[extended] rebuild. Couldn't have done it without you.

The *tart* is extremely sound now in the power train and reasonably so in the 
other mechanicals. Now to work on the parking lot terrorist key scratch on 
the hood (bonnet) and some paint work and the 'Arrest Me Red' Alfetta GT will be 
ready for the 2005 Alfa convention concourse ... :-)

Y'all are invited to come see her on display at that time. Or, join us on the 
NWARC Fall Wine Tour (thanks Dave!) this next weekend (18/19 Oct) and see her 
in her rough glory.

Tom
Seattle (a GREAT place to be - now and in 2005)
6310123 (the sisty ugler)
7711615 (tarted up and ready to go, go, go)
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