Re: [alfa] Engine rebuilding and maintenance abilities

["Frank Smith" <alfafan@xxxxxxxxxxx>]

Biba....
   It has just occurred to me after listening to you "cutting out"problem
for so long....I had a similar problem soon after converting to the
Plex....the cutting out near drove me nuts, would usually come back after a
cool down, but at inconsistent lengths of time....finally traced it to the
module and always carried multiple spares.....I had a homemade air box that
made changing modules a PITA so I made a heat sink out of two 3x6 pieces of
an old lower pan.....JB'd together back to back and milled a spot on one
side to mount the module.....all done for ease of switching
modules......BUT, I never had a module failure since [ 7 years ]......my old
location [stock] was only 10 in. back on the same intake side inner
fender.....can only offer "heat" as the initial problem, either from the
coil or a less efficient heat sink......could this be your problem?
Frank Smith
69 1750 Spider
72 GT JR
Cockeysville, MD
----- Original Message -----
From: "alfacybersite" <acs@domain.elided>
To: "AD" <alfa-digest@domain.elided>
Sent: Monday, November 24, 2003 2:31 PM
Subject: [alfa] Engine rebuilding and maintenance abilities


> Jonathan Smithies comments: "It sounds like we've got a man who is very
> good with bodywork and cleaning things up (the disguised 2L for the '69
> looks amazing), but clearly shouldn't be allowed near a running engine.
>
> "Biba, may I respectfully suggest you take your car to a mechanic who
> knows Alfas - I'm sure you'll get a lot more pleasure out of your
> Alfetta (and spend less time by the side of the road).  It might not be
> a bad idea to have your restorations checked out by someone who
> understands engines as well.
>
> "We all have our limits (I sure do) - the trick is recognizing them."
>
> ********
>
> Feel I need to reply to this one since Jonathan is saying in essence I
> shouldn't be allowed near an engine.
>
> As it is, my attitude when restoring an Alfa is always, "Whew the damn
> bodywork, paint, and polishing is finally completed, now I can go to
> work. I very much enjoy rebuilding Alfa 4-cylinder engines and of course
> 'detailing them' to the nth degree.
>
> I will admit I don't consider myself a demon tweaker, nor do I have much
> in the way of diagnostic equipment. So, yes, I have taken client's cars
> to a mechanic I trust (and who does this on a daily basis and does have
> diagnostic equipment) for a final tweaking. Note the rebuilt engine runs
> well enough to make it the 25 or so miles there (and many miles
> afterwards).
>
> So, yeah, I feel I know my way around Alfa 4-cylinder engines pretty
> well. That doesn't mean I have all the answers and feel quite lucky
> people on this Digest have been willing to offer suggestions - many of
> which I've taken.
>
> I will also mention I've never been totally happy with the lack of idle
> consistency on my own car. Since I don't have a supply of various jets,
> not to mention being an expert on Webers, I have considered taking the
> car to the same shop. It's the finding a friend to meet me there early
> a.m., then take me back to my shop, then pick me up and take me to the
> mechanic - which has prevented this.
>
> If I could afford it and had a spare car to drive, I would take my
> Alfetta to this mechanic and say, "Drive it until it cuts out on you,
> then fix it along with the idle."
>
> I could easily see the hours racking up. I've driven my car for miles
> without a hiccup an it does not run at all rough in between times. It
> simply starts cutting out and eventually stopping completely, almost
> always at speed, never on city streets.
>
> The engine always fixes itself, at least for awhile. While I did fiddle
> with the timing a bit the first time it cut out on me yesterday, It
> started and ran fine for about 15 miles. Next time all I did was lift
> the hood and wait about six to eight minutes. Incidentally, the engine
> nor the MarelliPlex was not at all hot, oil pressure and water temps
> were fine. It 'merely' seems to require sitting for a bit. Engine
> started and I made the final 20 or so miles home / to shop without
> further incident.
>
> A Professional Mechanic - meaning, I guess, someone who can be trusted
> around engines would have to hook up any diagnostic equipment to the
> engine within seconds. I can almost always start the engine right away
> after it stops. It just seems to cut out again sooner if I don't wait
> those extra minutes.
>
> Tell you what Jonathan, show this to your Alfa mechanic, assuming you
> have one. If he is able to diagnose the problem from what I've described
> and it solves the problem I'll send you two checks in your name each for
> one hour of his hourly rate. Keep one, keep both, give them to him, your
> choice.
>
> I will say, I have not switched out the MarelliPlex with the Bosch
> mechanical system yet. If that solves it, then a suggestion of getting
> rid of the MarelliPlex won't count.
>
> I'll be the first to admit I find it very Unprofessional to start
> installing new / different parts or trying various settings on items
> such as the ignition timing going on the theory, "Well that didn't work,
> I might as well try this."
>
> That said, I am obviously at my wits end and perhaps I'm wrong, but feel
> strongly a Professional Mechanic might end up doing the same.
>
> Note: 2000 engine rebuilt less than 50k miles ago, rather hot cams,
> Weber 40DCOE's with (Alfa) stock jets, Euro inlet manifold and airbox,
> Euro exhaust manifolds, MarelliPlex ignition.
>
> The following parts have been replaced:
>
> New magnetic pickup
> New ignition control module
> New distributor cap
> New distributor rotor
> New ignition wires
> New sets of spark plugs - NGK BP6ES, Bosch +4R #089, (currently) NGK
> BP7ES
> New 4.5 to 6.5 psi Facet electronic fuel pump
> New rear fuel filter
> New Filter-King filter
> Fresh clear fuel filter between Webers to be used as a sight glass
> Any flex fuel lines showing even minor cracks have been replaced
> New (non-original) Bosch starter relay simply because the other was 18
> years old.
>
> Labor:
>
> Checked fuel vapor recovery valve. It was okay. However, never got a
> whosh from removing gas cap.
> Checked (several times) ground / continuity - okay. 13V to fuel pump
> both when off and running.
> Double checked ignition setting pointer on waterpump using a dial gauge
> in #1 spark plug hole.
> Have timed ignition using a quality timing light both on the somewhat
> retarded end since the MarelliPlex has a rather shallow timing curve.
> Seemed to run best at slightly retarded from when max advance  lines up
> with 'M' at 5500 rpm, hot.
> Obviously removed and replaced all parts / items listed above.
>
> Perhaps I'm missing some Labor or Parts, but that should be the
> majority.
>
> Should anyone else care to print out and take to your Professional
> Mechanic, by all means do so and if more than one winning answer
> arrives, the first in, which solves the puzzle gets the checks.
>
> Biba
> Irwindale, CA USA
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