My Alfa Romeo 33 rebuild - FIRST TIMER

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Brit01
Posts: 825
Joined: June 28th, 2011, 4:54 pm
Location: Uruguay

My Alfa Romeo 33 rebuild - FIRST TIMER

Post by Brit01 » July 5th, 2011, 8:23 pm

Hi all,

I'll start this thread as my project. I have an Alfa Romeo 33 1.7 QV 1988 Series 2 with twin Dellorto carbs 40DRLA.

A tappet sound started in Feb and just got worse. Tried changing oils, Liqui Moly products etc to eliminate the possibility of block oil passages.

It was time to rip it apart and see what's going on inside. It was not nice to see the damage.

I've always been mechanically minded but never tackled such a big project before so it's a learning curve for me.

I have plenty of pictures. I will start adding a few each day. Also of course some of my car.

Regards
Attachments
all tappets.JPG
all tappets.JPG (64.37 KiB) Viewed 9243 times
damaged lobe 3.JPG
damaged lobe 3.JPG (60.25 KiB) Viewed 9243 times
damaged lobe taken out.JPG
damaged lobe taken out.JPG (48.62 KiB) Viewed 9243 times
damaged tappet.JPG
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alfa 1.JPG
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alfa 6.JPG
alfa 6.JPG (118.54 KiB) Viewed 9237 times
alfa 2.JPG
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alfa 3.JPG
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alfa 5.JPG
alfa 5.JPG (90.89 KiB) Viewed 9237 times
Last edited by Brit01 on July 6th, 2011, 12:00 am, edited 1 time in total.

Brit01
Posts: 825
Joined: June 28th, 2011, 4:54 pm
Location: Uruguay

Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by Brit01 » July 5th, 2011, 11:26 pm

cylinder cross hatch pattern.
smooth feel to them as I run my finger down them. Maybe too smooth. After de-glazing do you feel a slightly rough feel to the surface?
Still a good pattern showing.
Your opinions would be appreciated.
Attachments
cross hatch 2.JPG
cross hatch 2.JPG (52.57 KiB) Viewed 9238 times
cross hatch 1.JPG
cross hatch 1.JPG (52.88 KiB) Viewed 9238 times
cross hatch 3.JPG
cross hatch 3.JPG (59.39 KiB) Viewed 9238 times
cross hatch 4.JPG
cross hatch 4.JPG (64.82 KiB) Viewed 9238 times
cross hatch 5.JPG
cross hatch 5.JPG (76.79 KiB) Viewed 9238 times
cross hatch 6.JPG
cross hatch 6.JPG (63.34 KiB) Viewed 9238 times
cross hatch 7.JPG
cross hatch 7.JPG (54.92 KiB) Viewed 9238 times

WhizzMan
Posts: 459
Joined: August 13th, 2010, 8:05 pm
Location: Amsterdam, the Netherlands

Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by WhizzMan » July 6th, 2011, 7:44 am

It's not what you see, or feel with your finger, when it comes to honing for new rings. It's about a very precise structure of the cylinder walls that is required for the new rings to bed in properly. This structure can really only be viewed when using microscopes and such. Every time you change piston rings, you need to re-create that precise finish, or the new rings will not bed in properly on the cylinder walls and you're worse off than re-using the old rings.

Having done a few of these myself, judging by your pictures, I'd say you have 5 of 8 tappets worn irregularly. That means that at least 5 of the lobes on your cams are worn. You can tell by the circular patterns on top of the tappets. Those are very typical for Alfa hydraulic tappets. I guess it's the same for other brands, but I haven't seen any of those myself so it may be different.
Book #348

Brit01
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Joined: June 28th, 2011, 4:54 pm
Location: Uruguay

Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by Brit01 » July 6th, 2011, 2:33 pm

Thanks Whizzman.

Yes very true, quite a few tappets worn and lobes.
Have new cams and 8 new tappets, new oil seals, valves, gaskets and also new gears for the oil pump.
I imagine the oil pump sucked up bits of that lobe and pitted the gears.

Also my ex-mechanic put new tappets in the car 2 1/2 years ago but left the old cams in. No wonder the tappets only lasted a short time. He was the owner of the care at that time.
Attachments
pump4.JPG
pitted pump gear 1
pump4.JPG (13 KiB) Viewed 9220 times
pump9.JPG
pitted pump gear 2
pump9.JPG (12.65 KiB) Viewed 9220 times
new camshaft.JPG
One of the pair of new cams
new camshaft.JPG (11.44 KiB) Viewed 9220 times
oil pump.JPG
oil pump.JPG (17.81 KiB) Viewed 9220 times
NEW TAPPETS.JPG
NEW TAPPETS.JPG (20.19 KiB) Viewed 9220 times

Brit01
Posts: 825
Joined: June 28th, 2011, 4:54 pm
Location: Uruguay

Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by Brit01 » July 6th, 2011, 5:42 pm

Flexi-Hone being shipped!

some more pics:
Attachments
pair tapas sabah.JPG
cylinder heads ready with new valve seals, seats and guides checked.
pair tapas sabah.JPG (10.86 KiB) Viewed 9216 times
finishedcamsupport.jpg
finishedcamsupport.jpg (41.55 KiB) Viewed 9216 times
headhe.jpg
headhe.jpg (93.39 KiB) Viewed 9216 times
multiple de admision con un poco mas pulido.JPG
multiple de admision con un poco mas pulido.JPG (14.81 KiB) Viewed 9216 times
new petrol pump gaskets and o-rings.JPG
new petrol pump gaskets and o-rings.JPG (13.87 KiB) Viewed 9216 times
test 1.jpg
test 1.jpg (17.1 KiB) Viewed 9216 times
tapa con pintura 2.JPG
tapa con pintura 2.JPG (15.06 KiB) Viewed 9216 times

mitch strada
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Joined: November 3rd, 2006, 6:02 pm
Location: London, UK
Contact:

Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by mitch strada » July 7th, 2011, 1:57 pm

Great car, I love the Boxer engine what a fantastic sound, I have had a few Alfa Suds but never a 33. My Sud had a 33 1.7 16v engine and outboard front brakes too, the sound was like music to me and I would regularly find myself going for pointless drives just so I could hear the engine!
Were many Old Alfas imported to Uruguay?

Brit01
Posts: 825
Joined: June 28th, 2011, 4:54 pm
Location: Uruguay

Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by Brit01 » July 7th, 2011, 2:57 pm

Thanks mitch strada.

yes they have a beautiful addictive sound that just makes you drive them hard and the overun is sweet. (unless you have broken tappets!!)
Also the induction sound if you can release it is just sweet also.
I've opened up my airbox a little to release the induction sound more.

Foam socks are not really suited for our climate here. We have too much dirt and dusty roads.
K&N panel filter is fitted.

Not so many suds/sprints/33's.
Only a handful of 33's in good condition. mine is well known here.
My brother-in-law has a sud 1981 4 door 1.5 super and his father has a sprint for racing.

Great cars but in good climates due to their awful rust problems.
Attachments
petrol pump polished.JPG
petrol pump polished.JPG (69.44 KiB) Viewed 9202 times
painting in progress of all parts.JPG
painting in progress of all parts.JPG (72.73 KiB) Viewed 9202 times

Guy Croft
Site Admin
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Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by Guy Croft » July 7th, 2011, 3:36 pm

Nice - but more time your end should be devoted to reading about basic engine overhauling - and less to dressing and painting.

G

Brit01
Posts: 825
Joined: June 28th, 2011, 4:54 pm
Location: Uruguay

Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by Brit01 » July 7th, 2011, 4:04 pm

GC - this dressing was done due to extra time available in the house and not being able to get to the garage.
Wife and son responsibilities/issues.

Not because I was neglecting engine overhauling basics.

Regards

Guy Croft
Site Admin
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Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by Guy Croft » July 7th, 2011, 4:21 pm

Don't feel got-at. There is a method to everything I write here.

I said it because having coached you here from the beginning I think that undertaking an engine overhaul with so little basic engine knowledge is a bad thing and again, with your evident interest, I think you should get into some good books on this. There are plenty around incl mine and even in my new book I have referred to others in a favourable light. Remember that whilst you may think you and I are the only ones reading your posts (this is a commonly held belief) in fact the site gets over 2 million hits a month so I and I am on a mission to improve folks' general understanding of what I believe to be an important DIY skill (for a bloke anyway) and from time to time I make these observations to 'jolt people'. The difference betw us - you understand - is that I write for all - and you write for yourself.



G

Brit01
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Joined: June 28th, 2011, 4:54 pm
Location: Uruguay

Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by Brit01 » July 7th, 2011, 5:38 pm

Oil vapor circuit 7 piece connector shattered (24 year old brittle plastic). Creating a new circuit. Pictures will be posted once installed.
Oil sump drain plug changed to hex bolt making it easier to take out. (damaged 12mm allen bolt previously installed).
Crowns cleaned up.
Outlet manifolds cleaned. Same size as gaskets so no modification needed. Kept as original size.
New big end shells.
Attachments
broken connector.JPG
broken connector.JPG (60.81 KiB) Viewed 8977 times
clean exhaust outlet.JPG
clean exhaust outlet.JPG (77.03 KiB) Viewed 8977 times
crown 2.JPG
crown 2.JPG (69.76 KiB) Viewed 8977 times
new big end shells.JPG
new big end shells.JPG (92.94 KiB) Viewed 8977 times
new oil plug.JPG
new oil plug.JPG (62.63 KiB) Viewed 8977 times

WhizzMan
Posts: 459
Joined: August 13th, 2010, 8:05 pm
Location: Amsterdam, the Netherlands

Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by WhizzMan » July 8th, 2011, 7:34 am

Brit01 wrote:Oil vapor circuit 7 piece connector shattered (24 year old brittle plastic). Creating a new circuit. Pictures will be posted once installed.
New big end shells.
That part is not for oil vapor. It is the central "distributor" for engine vacuum. The carter ventilation is also hooked up to it, but it has much more function than just that.
Book #348

Brit01
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Joined: June 28th, 2011, 4:54 pm
Location: Uruguay

Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by Brit01 » July 8th, 2011, 1:10 pm

I tend to disagree a little Whizzman sorry.
rethinking about it from a different angle yes this circuit has a role in crankcase pressure also.
I'm considering whether to take off the air intake tubes(trumpet inlets - not inlet manfiolds) and add a filter or oil catcher to reduce the hot oil vapor entering the carbs.

The main oil vapor pipe comes out of a connection on the oil fill pipe. This leads to 4 inlets on each carb.

1 small one on the inlet manifold that draws when idling and the carbs are closed, and the other attached to the trumpet which sucks the vapor through the carb when you open the throttle.

Sorry I made this diagram with names in Spanish for a friend here but it gives you an idea of the Alfa circuit.
Attachments
diagram of oil vapor circuit.JPG
diagram of oil vapor circuit.JPG (37.75 KiB) Viewed 8961 times

Brit01
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Location: Uruguay

Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by Brit01 » July 9th, 2011, 4:17 pm

This is the mod I'm thinking of making.

The small pipes on the inlet manifolds will have clean filtered air from the airbox flowing into them.
The inlets on the trumpets blocked off so carbs will keep clean and no contamination of the fuel will occur.

On the oil filler pipe, I have a catch tank and also a filter directed vertically to release crankcase pressure.
Attachments
new vapor circuit design bigger.JPG
new vapor circuit design bigger.JPG (27.94 KiB) Viewed 8948 times

Brit01
Posts: 825
Joined: June 28th, 2011, 4:54 pm
Location: Uruguay

Re: My Alfa Romeo 33 rebuild - FIRST TIMER

Post by Brit01 » July 9th, 2011, 9:06 pm

Just a small DIY oil catch container but I can check on it regularly to see how much it collects (honestly I have no idea how much will collect for now).
Other end will have a pipe attached leading to a filter.
I noticed on my brother in laws alfasud there is just a pipe pointing down to the ground and see lots of oil splatters on the front drive axle and rubber gaiters! No filter or anything just an escape pipe spitting it out to the ground. (we don't have emission tests here).
Attachments
oil catch tank.JPG
oil catch tank.JPG (55.13 KiB) Viewed 8946 times

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