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Alfa Romeo 145 - 146 Forum _ You & Your Car _ 145 1.6 Boxer recommissioning

Posted by: BudgetBoxer 9th November 2018 09:30

Hiya,
I just picked up a 145 boxer 8v, really nice condition, enthusiast owned. Pics to follow but right now I'm looking for hints on parts suppliers and advice on some other bits

It's A14 TUN if anyone knows the car.

Parts I'm looking for
Cambelt kit
Door seals (are universal ones ok?)

Advice I'm looking for -
What's the normal running temp of the boxer? mine seems to be 60 then up to just over 80 in traffic. I read the thread in thermostat issues in TS engines but not sure if that affects boxers

Lots more questions to come, hoping this board is still active!

Posted by: dante giacosa 9th November 2018 10:31

Hey BudgetBoxer-

yes; some of us are still alive!

Welcome along; that sounds like a really exciting project!

Can you post some pictures of the beast?



(can you see how to do that?)

Posted by: BudgetBoxer 9th November 2018 10:52

QUOTE(dante giacosa @ 9th November 2018 10:31) *
Hey BudgetBoxer-

yes; some of us are still alive!

Welcome along; that sounds like a really exciting project!

Can you post some pictures of the beast?
(can you see how to do that?)


Here we go - photos here. Really bad ones, recently changed phone and the new one seems to try and be all artistic, getting one element pin sharp and the rest all blurry.

Car is filthy, it wasn't clean before I drove it 180 miles home!

https://photos.app.goo.gl/VjL6i1TG8swEyzuE6

Questions / comments from the photos
- is that silicone sealant holding in the speakers (they are all blown and will be changed)
- is that sunroof factory?
- how much pain am I in for with the headlining?
- yes, the last exhaust hanger has partially split
- door card fabric is coming away from the doors
- what's hiding under the tape on the tailgate interior?
- where do I get a new alfa twist boot badge?
- my god it needs a clean, especially inside...
- where did the previous owner hang the 10ft flag / banner??

Posted by: sanitary 9th November 2018 12:11

QUOTE(BudgetBoxer @ 9th November 2018 10:52) *
Questions / comments from the photos
- is that silicone sealant holding in the speakers (they are all blown and will be changed)
- is that sunroof factory?
- how much pain am I in for with the headlining?
- yes, the last exhaust hanger has partially split
- door card fabric is coming away from the doors
- what's hiding under the tape on the tailgate interior?
- where do I get a new alfa twist boot badge?
- my god it needs a clean, especially inside...
- where did the previous owner hang the 10ft flag / banner??


Yes, silicone as the tabs have probably broken off

Maybe an aftermarket sunroof but does it leak?

lots... either replace the headlining with new or glue it back either way it will have to come out to repair

is hanger doing its job?

door cards can potentially be glued back but would be better by replacing them if you can find the right ones

what tape?? ah! yes... the are hiding the bolts holding the plastic trim on, should have matching covers

ebay is your friend (for most stuff) and Naanbread http://forum.alfa145.com/index.php?showtopic=25026

yes...

don't know


hope that helps biggrin.gif biggrin.gif



san

Posted by: dante giacosa 9th November 2018 13:58

it 'appears' (from that one pic) in very good nick underneath...

whats the mileage on that, BudgetBoxer??

Posted by: BudgetBoxer 9th November 2018 15:27

QUOTE(dante giacosa @ 9th November 2018 13:58) *
it 'appears' (from that one pic) in very good nick underneath...

whats the mileage on that, BudgetBoxer??


Would you believe 148k miles!

It is remarkably rust free which is why I went for it. Service history shows it's been waxoyled in the past.

Didn't want to commit until I'd actually seen it's condition but I am now searching for a permanent garage for it.

My local mechanics continue to surprise me with their willingness to work on anything.. from my experience with other classics a lot of places won't touch anything that's not new.

Looking forward to getting stuck in this weekend.. I should really go to Melton Mowbray and get the 145 QV interior that's on ebay...

Edit : oh, and can anyone confirm that there shouldn't be a annoying buzzer every time the indicator flashes??

Posted by: dante giacosa 10th November 2018 08:39

well, it's nice to have people you can rely on (for the work)

Yes- buy the interior immediately

Are you driving it around now? Or is this a 2nd car? What condition is the oil in..?

You shouldn't have a 'buzzer' as such- you should have a conventional clicking-relay sound with the indicators...


Posted by: JeremyG 10th November 2018 16:44

That looks like a nice little car - and welcome!

Posted by: BudgetBoxer 10th November 2018 19:46

Thanks all for your replies.

Well, I wasn't really up feeling it last night for another long journey having done ~8.5 hours picking up the car on Thursday, but the bargain price of a cloth interior from a 145 QV was too good an opportunity to pass up on, so 5 hours in my boring car (most often used as a mountain bike wagon), a nice chat with another enthusiast and away we were with a complete interior plus a few other bits and bobs.

This evening has been spent scrubbing the new interior a bit, now facing the dilemma of the order to do things - swap out the interior, then have to take some of it out again to do the headlining?

Probably the most sensible option is to leave it till the cambelt has been done, then I can tackle the interior as a oner. Might do the door cards in the meantime though.



Car isn't being used at the moment - drove it to get it home from buying it but it's not moving again until it has the cambelt and a service done. Judging by the service history it was done ~20k miles but more importantly, about 9 or 10 years ago!

Posted by: BudgetBoxer 11th November 2018 16:48

QUOTE(BudgetBoxer @ 10th November 2018 19:46) *
Probably the most sensible option is to leave it till the cambelt has been done, then I can tackle the interior as a oner. Might do the door cards in the meantime though.

Car isn't being used at the moment - drove it to get it home from buying it but it's not moving again until it has the cambelt and a service done. Judging by the service history it was done ~20k miles but more importantly, about 9 or 10 years ago!


Well, small steps..

Gave it an initial clean today, more to do!

4 metres of universal door seal ordered
Tweeters replaced, including replacing the grille in the o/s one as it was a bit rusty.
Gearstick gaiter replaced
Underbonnet drain blocks removed, cleared and checked.. o/s was blocked with some surface rust at the back of the shock tower. Wire brushed, kurust and some red hammerite for the moment.
New interior has cleaned up well, probably go in when the headlining gets done

Posted by: VROOM 11th November 2018 19:57

Maybe you could fit this later type of headlining, although you'd need to cut a hole for the sunroof

https://www.ebay.co.uk/itm/Alfa-Romeo-145-head-lining-headlining-non-sunroof-version-SUPER-RARE-non-sagging/282997550568?fits=Car+Make%3AAlfa+Romeo%7CModel%3A145&hash=item41e3f7ede8:g:7UwAAOSwHBdbF~Hd:rk:8:pf:0

Posted by: dante giacosa 12th November 2018 09:13

(good shout Vroom)

hey Budget'.

i think you've got your priorities right; no car ever failed it's MOT on interior trim!

You've got to start with all the big stuff that could 'end' the car; and go downwards from that. I always think (for instance) that paintwork & badges will be the LAST thing that needs attention on mine.

I'm a bit unfamiliar with the under-bonnet on the boxer; do you have a scuttle panel underneath the windscreen, in the engine bay, that houses the wiper motor?

On the TS models this can fill with leaves and stuff and become a rust spot..

Posted by: BudgetBoxer 14th November 2018 18:46

Well, I've ended up with some surprise free time this week. Cambelt is booked in for next Tuesday, so I thought I may as well start on the interior



Seats out, rear door cards off.. change the speakers from the blown units



Fairly straightforward job, although the faff of trying to get the door cards in position to allow the seatbelt anchor bolt to go back in.. if those bolts were 10mm longer it would be so much easier.

Also changed the trim that goes over the door seal. not quite kick plates but near there. Now got in the black versions rather than the original grey, but I'm not sure if they will stay.. must have different fixing types as they don't seem very secure with just a trim plug at one end and a screw at the other.

Rear seat backs from a cloverleaf have gone in, along with the rear door cards, rest to happen tomorrow. Already looking greatly improved

Confirmed that the sunroof is leaking so that needs fixing before the headlining. Had a dig through the history and it was fitted about 6 months after delivery - who does that when there's a factory option?? Fortunately Bristol appears to have one of the few people willing to try and repair these things, I'm hoping that means something more than cover the whole lot with a mass of silicon sealant.


Posted by: BudgetBoxer 15th November 2018 12:28

Another 2 questions for the more experienced of you

On swapping over the rear seat bases I ran into a problem - different brackets! the upholstery depth is different on the original and QV interiors, and the bracket length for the seat tilt is different to compensate for it.

You can see here that the QV seats have a much larger bracket sticking out to the left after the hinge. I think to make these seats work I need to either drill new holes in the body and bolt them in, or I need to remove the hinge pins and swap the brackets.



heres the other end of the same hinge



Trouble is this pin doesn't look like it's something that'll just drift out.. anyone run into this before and able to advise?

2nd question.. I don't have a key remote fob - but I do have the IR sensor and volumetric sensors near the roof lamp, and the associated code. Do I just need a key fob to programme to get remote central locking? where do i get one?

Posted by: JeremyG 16th November 2018 09:25

QUOTE(BudgetBoxer @ 15th November 2018 12:28) *
Another 2 questions for the more experienced of you

On swapping over the rear seat bases I ran into a problem - different brackets! the upholstery depth is different on the original and QV interiors, and the bracket length for the seat tilt is different to compensate for it.

You can see here that the QV seats have a much larger bracket sticking out to the left after the hinge. I think to make these seats work I need to either drill new holes in the body and bolt them in, or I need to remove the hinge pins and swap the brackets.



heres the other end of the same hinge



Trouble is this pin doesn't look like it's something that'll just drift out.. anyone run into this before and able to advise?

2nd question.. I don't have a key remote fob - but I do have the IR sensor and volumetric sensors near the roof lamp, and the associated code. Do I just need a key fob to programme to get remote central locking? where do i get one?


Hi - never tried removing the hinge pin on the rear seats, I'm afraid. How are the brackets attached to the seats - is it possible to switch the brackets over?

For the key remote - your car probably has the IR sensor instead of the later RF type. The article below provides (a lot) more detail:

http://forum.alfa145.com/index.php?showtopic=21459

So yes, if you have the receiver code you should be able to get a new key fob and program the two together.

I bought one recently for my ex-Spider from partsworld-uk which is similar:

https://www.ebay.co.uk/itm/Alfa-Romeo-164-GTV-Spider-Factory-Fit-Alarm-Central-Locking-Remote-Genuine-/231404711090?hash=item35e0cbacb2

Looks like the part number for your car is 60591663... there are a few for sale on eBay...

Posted by: dante giacosa 16th November 2018 11:05

looking good 'budget!

I'd try to mod the seats, rather than the chassis- or attempt to fabricate an alternative bracket, utilising the original mount points...

Posted by: BudgetBoxer 16th November 2018 16:19

QUOTE(dante giacosa @ 16th November 2018 11:05) *
looking good 'budget!

I'd try to mod the seats, rather than the chassis- or attempt to fabricate an alternative bracket, utilising the original mount points...


Well, door cards and speakers are in.

Back to the hinges

A bit of brute force and ignorance to remove the old hinge and see what we are dealing with



For comparison versus new hinge on the cloverleaf interior



I tried disassembling the old hinge, thinking it was something like this https://www.youtube.com/watch?v=ZoH5I-tkic8

Result - bent the pin. hmm.

Tried drilling it out... hinge pins are tough! barely made a dent in it with my mains drill. I could probably do it but I'm not sure if its the easiest option

Right now I'm thinking I just drill a hole in the cloverleaf bracket to allow it to mount in the right place. The metal looks the same thickness there so it should remain plenty strong enough.


Posted by: SteveG 16th November 2018 21:18


Couple of thoughts - take the cloth off the seats and swap; cut the hinges and weld the original to the QV seat base, or just cut 'n shut the longer QV hinge.

Posted by: BudgetBoxer 17th November 2018 17:29

QUOTE(SteveG @ 16th November 2018 21:18) *

Couple of thoughts - take the cloth off the seats and swap; cut the hinges and weld the original to the QV seat base, or just cut 'n shut the longer QV hinge.


Bracket modification : success

Phone camera : still unbelievably awful





Looking so much better. Left the drivers seat out as I suspect tomorrow will see me upside down in the footwell trying to find where this bloody indicator buzzer is so I can rip it out. By the sound of it I'm expecting to find one of these somewhere under there


Posted by: BudgetBoxer 18th December 2018 14:01

A short update..

Cambelts - done, along with the alternator belt and the water pump for good measure

Change of wheels



New bluetooth + dab radio fitted (not pictured)

and it's now off to have the leaking sunroof and headlining sorted

Of course, I still have to replace that oil pressure sensor and hope the engine is actually fine.. fingers crossed!

Posted by: dante giacosa 18th December 2018 16:58

oil-pressure; is that the one on the rear of the block above and to the right of the starter-motor?

How come you've got a buzzer under your seat???

Posted by: BudgetBoxer 29th December 2018 13:45

QUOTE(dante giacosa @ 18th December 2018 16:58) *
oil-pressure; is that the one on the rear of the block above and to the right of the starter-motor?

How come you've got a buzzer under your seat???


Haven't gotten to the oil pressure sensor yet over christmas. The buzzer is the one I've got to find that sounds whenever the indicators are on!

Get one job done and another two appear

Sunroof seal and headlining are done!
Drivers door seal replaced (but not tested yet)
Boxer badge fitted to bootlid



Needs a good scrub

Noticed one of the reflectors in the bootlid has been screwed in to place so ordered a replacement
New alternator belt is squealing!

Biggest annoyance right now is a battery drain.. the new radio remains backlit even when off and it's draining the battery, so I need to find an ignition switched live source and run it to the radio as Alfa decided in their wisdom not to bother with one

Posted by: BudgetBoxer 20th January 2019 21:36

QUOTE(BudgetBoxer @ 29th December 2018 13:45) *
Haven't gotten to the oil pressure sensor yet over christmas. The buzzer is the one I've got to find that sounds whenever the indicators are on!

Get one job done and another two appear

Sunroof seal and headlining are done!
Drivers door seal replaced (but not tested yet)
Boxer badge fitted to bootlid



Needs a good scrub

Noticed one of the reflectors in the bootlid has been screwed in to place so ordered a replacement
New alternator belt is squealing!

Biggest annoyance right now is a battery drain.. the new radio remains backlit even when off and it's draining the battery, so I need to find an ignition switched live source and run it to the radio as Alfa decided in their wisdom not to bother with one


Might as well keep this up to date!

New sunroof seals are holding up!
Resolved the battery drain by adding an ignition switched live to the radio.
New door seal seems to be holding up so another one ordered for the n/s
Alternator belt retensioned

Had a spare one of the centre console bits where the cigarette lighter is with a central locking button on so took mine out (just has a blanking plate) in the hope there would just be a connector there I could hook up, but no such joy.

New job that emerged amongst these... both n/s speakers are crackling / very quiet. I thought I must have not done the wiring joins well enough so pulled the one in the door, but the wiring is fine. Problem existed with the old radio too so there must be a bit of dodgy wiring somewhere between the radio and the n/s speakers. That'll be fun to track down..

Haven't got into finding the indicator buzzers of doom yet.

New mats ordered as well as the 25 year old originals are a bit tired

Posted by: dante giacosa 21st January 2019 09:27

hey Budget-

this all sounds great; How do you mean? -the centre console ashtray and door-check module should be on connectors; it's on three for me I think.

You should find the rear of the unit is connectorised; can you post a picture of it..? Maybe your spare one. The whole unit comes out as one; behind the ashtray there are two screws and then you get the ashtray, faglighter, clock, hazard switch fog-light switch, (boot release button) and door-check module. All as one.


The crackling speakers isn't likely to be the speakers- there's very little to the system. Remove your radio and get an AA battery and use paperclips to poke into the DIN ISO connector from the stereo (stereo removed)- you should get a gentle 'pop' from each driver. The pairing is identified through colours- if you can't work it out; I'll attach the workshop manual page.
In each door; the incoming 2-core is split to feed the HF driver (tweeter) up at the mirror; but that's it; there's very little to go wrong...
There's no crossover or anything.

Posted by: BudgetBoxer 24th February 2019 16:47

QUOTE(dante giacosa @ 21st January 2019 09:27) *
hey Budget-

this all sounds great; How do you mean? -the centre console ashtray and door-check module should be on connectors; it's on three for me I think.


Connector is absolutely MIA - not my car but if you imagine this - in place of the overhead view of the car and release button, I have a blanking plate. Removing that section there's only connectors behind for the clock and the hazards, and fog light - nothing else.



QUOTE(dante giacosa)
In each door; the incoming 2-core is split to feed the HF driver (tweeter) up at the mirror; but that's it; there's very little to go wrong...
There's no crossover or anything.


That's a good clue, I haven't found that split to the tweeters yet but the tweeters on both sides had been destroyed by water ingress.. I wonder if water has run down the wire.

Next post for the latest issue!


And the latest issue.. passenger door lock not working. It's always been hard to move, but now it just flat out won't. It felt like the key wouldn't turn fully, and that the internal switch wasn't getting full travel.

Took off the door card and the rod is just not wanting to move. It doesn't look damaged / bent (although the internal door handle rod has clearly been rubbing against the door metalwork).

Can't see why the mechanism won't move freely - trying to move it by hand is also restricted, so I'm going to have to remove the lock mechanism from the door and have a look at it on the bench.

Any tricks to disconnecting the rods? the workshop manual just says 'disconnect the rods'... hopefully it will be obvious when I try it.

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