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> Boxer 16v Rebuild Pictures, My rebuild is nearly done
laaf
post 17th November 2005 18:53
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1.6 8v
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Seems a good idea to go for a moment of glory and risk looking like a complete tw*t when it melts down on the first run. unsure.gif
The car's a 145.gif and it had a con rod end cap bolt snap (see photo) which made the engine self destruct (see hole in crankcase).
I binned that engine but kept the good head and bought another from Darbs666 gleam.gif on this forum that had bent valves so they made one good engine between them.
This was in great condition but had over 90,000 miles on it hence the new main bearings, shells and new oil seals and gaskets all round and a new water pump.
This rebuild has been cheap- all in for around 60 plus the cost of the engine.
I've never driven a 1.7 16v or this car so am really looking forward to getting it going. A track day at Donnington would make it all worthwhile. If anyone else is doing the same I have a ton of spares, from block to pistons, valves, heads, cams, rings, shells, gaskets etc. for 8 and 16v engines. If I can help you and clear some room in the shed let me know.

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G-ster
post 18th November 2005 12:13
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nice one, looks like good work to me, I hopefully should be using darbs gearbox, so there is a nice little link between your car and mine soon.

your certainly not wasting your time on the 1.7 boxer it's a fantastic engine, though some advice if you want some - I had a problem on mine with the flywheel, it lost a tooth and the failure is due to that when the engine stops the fly always stops in the same postion so the starter ends up starting from the same teeth - so they ware out, then you need a new flywheel, which alfa do not sell.

This side of the 3.2 v6 (which will be thirsty) the boxer is great, performance AND sound. T-sparks are faster, but I feel have lost the point of this car and alfa romeo stand for to an extent(and too boot the spark plug leads are megabucks for them!).

the sound is superb, I advise to avoid aftermarket louder exhaust for the extra 3 bhp there not worth it it only spoils the sound thats produced from the engine intakes.

remember that alfa make some of the finest engines known to man, but they can't construct a strong gearbox to save there lives, I had a 33 before this and the box had the same faults, so go easy and if you have large alloys 16"or up,oh and then easy on the pull away in 1st (I broke the diff), and change slowly and smoothly to prolong life of it.
happy boxing and write back your result and impressions
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Daaaveee
post 18th November 2005 12:41
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1.6 16v
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nice pictures biggrin.gif hope it all runs smooooth!

Dave


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Dragon146
post 18th November 2005 12:52
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I'll cross my fingers that it runs smooth ... nice work there smile.gif
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laaf
post 18th November 2005 13:49
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1.6 8v
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Thanks for all your feedback.- I can't wait to fire it up. I heard a 33 P4 a while back and it sounded fantastic so I hope mine's as good.
Gster- I have two spare 1.7 flywheels and really need to clear the shed. While you have your gearbox off why not change yours?
I'm just hoping the gearbox is OK as the engine would've jammed while the car was doing about 70. sad.gif


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Darbs666
post 18th November 2005 15:18
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Hi matey,

I wrote a nice long reply and then suddenly it disapeared off my screen, marvellous..

The engines looking great and im really pleased its in good condition, i hope the diagnostics i gave you were correct and you didnt find anything else too bad!

Cant wait for you to try the first start once shes all back in the car,

G-Ster is right, the sound of the boxer is amazing, i really miss it. The QV just doesnt cut it for sound, but it makes up for it with lack of reliability, frozen handbrake, horrendous ideling laugh.gif only joking, Qv isnt soo bad smile.gif

Really looking forward to seeing what happens! Best of luck mate

Tim
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laaf
post 19th November 2005 08:51
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Thanks Tim,

What you said seems to be right about the engine. The oil was clean, there was very little wear and the belt seems to have just snapped without any real reason.
At 10 each I'd be tempted to change them quite regularly now.

If it runs OK I'll be back for some more parts if OK with you.
I think the rear brakes have issues as well as the dangly bits that support the front bumper have gone a bit frilly (below the headlights in the top picture) if you would consider cutting these bits off yours.

Peter


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Crazy Cabbage
post 19th November 2005 23:02
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hey, looks familiar!

I took my engine out thru the bonnet, leaving the gearbox in situ, looks like you dropped the subframe there?

meh...waiting to get my heads back from the engineers......doing mine on the driveway! im kinda glad youve done your first tho, gives me some pointers wink.gif
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laaf
post 20th November 2005 21:17
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I got mine out the same as you. After several pints for superhuman strength 2 of us tried to lift it out, forgetting the small bolt under the plate under the flywheel. We ended up lifting out with the low self esteem of the morning after sad.gif

There's 1 tip that would be useful when you put it back together. There's an oil plug at the top of the engine under where the coil goes. I'd recommend taking it off and getting that oilway full of oil once you have the engine back in the car. That will prevent you starting it dry.

Good luck with it, and thanks for the information on the clutch.


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Crazy Cabbage
post 20th November 2005 21:24
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Oil way? i take it thats the raised 'spine' down the center of the engine at the top, and the largeish 17mm(i think) bolt near the coil then?

PS: im leaving the coil off till i crank it over a few times to get some oil pressure up
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laaf
post 20th November 2005 22:19
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That's the one. Have you decided what you are going to change on your engine yet?


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Crazy Cabbage
post 20th November 2005 23:54
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Just the head gaskets/valve oil seals....

the gaskets were the only problem with it. stoopid car!
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Dragon146
post 21st November 2005 16:40
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@ laaf and darbs666 ... any of you guyz have spare parts from the air intake hose where the air temp sensoir and a vacuum hose is attached for the 1.7 16V engine ? ... I need one so I would like to buy it ...
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Crazy Cabbage
post 21st November 2005 23:26
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Try Keith at Auto Spares in Liverpool, spke to him today, and he said he had two 1.7 16v engines there, not sure what bits they'vce got tho...

01519283338

HTH!
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laaf
post 22nd November 2005 08:55
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1.6 8v
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QUOTE(Dragon146 @ Nov 21 2005, 04:40 PM)
@ laaf and darbs666 ... any of you guyz have spare parts from the air intake hose where the air temp sensoir and a vacuum hose is attached for the 1.7 16V engine ? ... I need one so I would like to buy it ...
*



Hi Dragon,

Can you just put a ring around the part that you need?

I should end up with a spare one but won't know until the weekend.

Regards

Peter

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Dragon146
post 22nd November 2005 11:57
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Cant figure out how to post new pic's ... its the part between the AFM (connector pointing upwards) and the alu piece saying Boxer 16V Alfa Romeo ... the rubber hose with the air temp sensor (seen on the pic pointing downwards) ... ... the last piece of rubber hose before the alu piece ... mind you I dont wanna pay much for it if used, a new piece costs 25 over here ...

This post has been edited by Dragon146: 22nd November 2005 11:59
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laaf
post 10th December 2005 17:27
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Here are some photos of the engine going back in - twice rant.gif One of the studs was missing and would not go back in because the driveshaft was in the way.

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kerstien
post 10th December 2005 20:50
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so how long did it take u to do all the work?
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laaf
post 11th December 2005 08:00
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It's been a few months blush.gif . I guess it's far quicker and often cheaper to get a good second hand engine and just swap it over a weekend.


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Crazy Cabbage
post 11th December 2005 23:41
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Is that a dig at me, monsiour? tongue.gif
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