Join Date: Feb 2004
Location: Post Falls, Idaho
Two steps forward one step back!
The brake & clutch hydraulics are finished; all cylinders bled correctly, no leaks, and firm pedals. Mounted the wheels/tires on the car and put it on the ground.
The car starts on the second crank everytime now but runs very rich. The injection pump gap (at the throttle arm) cold is approximately 1/4" so I warmed the car up to operating temperature and the pump gap remained at a 1/4" (should be .019" or less). While the car idled and warmed up I noticed the NOS front crank seal that I had put in was leaking!!! (too old & hard?). I let the motor cool down and removed the thermostatic actuator (TA) so I could test the plunger off of the car. The 4mm studs that hold the TA to the intake manifold both snapped (even with me being careful, using PB blaster, and coaxing the nuts of)!!!.
The TA plunger measures 23mm (from the flange) at room temperature and 29mm at 175F (I believe this is within spec). The plunger that the TA pushes (inside the pump) was 1/8 turns from full seating (Wes Ingram says to start at 2 turns out and test/re-adjust etc.) so hopefully that's the problem.
I then removed the intake manifold, disassembled, cleaned, redrilled & tap'ed the studs (used stainless studs), replaced the vacuum hoses, and reassembled the manifold.
I removed the radiator & hoses to inspect the crank seal & install a new one (seal on order have not inspected bad seal yet).
While I have the intake manifold off I changed out the starter for an S4 spider (90 - 94) rebuilt starter I had on the shelf (smaller, lighter, higher output then the original and uses the same 130 tooth ring gear). The metal plate that goes between the starter and bellhousing was missing as was the shoulder bolt (installed both of them). I also replaced both motor mounts.
I installed a repro plastic upper windshield strip as well as sun visors.
I found the SPICA o-ring seal for the vacuum manifold as well as the TA o-ring (seals the TA to the intake manifold) At Alfa Parts in Berkeley.
As in many of my previous posts parts are on order!
We had our first snowfall about a week ago but no more predicted until the 25th so I still may drive the car this year yet.