I had just completed some work on my 86 Alfa and went to start engine to check coolant level and heard a loud "THWACK" no starter motion then the voltage went to zero and the dash lights went out. When i tried later again a faint click then the voltage gage went to zero. I looked through a number of posts but did not find a clear description for starter removal. Although i did find a post from UK for a carburetor equipped car. I looked through the access when the WW bottle is removed, you can see the starter to flywheel housing bolts,however it is crowded on an AC car. There is access from below however the steering linkage is in the way.
I decided to remove the plenum chamber of the intake manifold to provide access.
To start drain the coolant and dis-connect the battery.
The first photo shows the intake area at the start, I've marked the vacuum lines. Next loosen all the intake runners and the throttle housing clamps. Remove all vacuum lines( 3front , 1 rear) also the brake booster hose. The idle speed control hose and the bypass were removed at the rigid plastic inlet pipe but let on the pplenum.Also removed the three clamps/hoses on the left of picture, crankcase vent plus, so they could be easily moved. Next the twoo hoses for the throttle heat.
The next photo shows the hoses removed, the throttle switch connector and the cold start injector were removed later i had problems with both the throttle switch connector eventually loosened, but the cold start injector (plastic) was flexing so I removed the two 5mm socket head cap screws instead. The throttle linkage has been popped off. Next I had to locate the ground wire and fasteners on the bottom of the plenum. To provide access the coolant overflow tank was removed. The next photo shows improved access.
There are two 13mm capscrews tha hold the throttle linkage pivot to the plenum, the front one has the ground strap from the engine. The two 17mm cap screws holding the plenum to the bracket, thatis fastened to the engine and the motor mount area. The forward one is accessible from the front, the rear one will have to be accessed from the rear on manifold access is tight use a short ratchet. The plenum will lift off you have to move a hose slightly at the fender.
The next photo shows the bottom of the plenum showing the cap screw positions.
Now we finally have access to the starter motor, remove the black trigger wire and the 13mm nut to remove the main 12 volt leads. The next photo shows the starter motor, removing the bolts is more difficult sine two have 16mm heads and because of clearance can only be held with open end wrenches. All of the nuts are 13mm as is the head of the special body bolt, position top outside. I removed the bottom bolt from underneath, jack the car for access.
When i removed the starterI found out what the "THWACK" was, one tooth on the flywheel ring gear was removed and the starer motor nose was cracked through all the way around. These are shown in the next three photos. The starter was tight to the flywheel housing, there is no witness marks on the starter,housing or the spacer plate between them.
I brought the starter to EUROTECH Motors, they had not seen this type of failure.
I placed the car in gear and rolled to make sure the engine was free.
Has anyone had this type of failure? I am currently waiting for a rebuild starter and will install.
Another reason to remove the plenum was to clean the engine and the inner fender, in the photo showing the bracket you may see aluminum foil with rubber bands covering the runners and throttle opening, I also removed and cleaned all the boots and clamps.
Tom, New Jersey
86 Alfa Quad
I decided to remove the plenum chamber of the intake manifold to provide access.
To start drain the coolant and dis-connect the battery.
The first photo shows the intake area at the start, I've marked the vacuum lines. Next loosen all the intake runners and the throttle housing clamps. Remove all vacuum lines( 3front , 1 rear) also the brake booster hose. The idle speed control hose and the bypass were removed at the rigid plastic inlet pipe but let on the pplenum.Also removed the three clamps/hoses on the left of picture, crankcase vent plus, so they could be easily moved. Next the twoo hoses for the throttle heat.
The next photo shows the hoses removed, the throttle switch connector and the cold start injector were removed later i had problems with both the throttle switch connector eventually loosened, but the cold start injector (plastic) was flexing so I removed the two 5mm socket head cap screws instead. The throttle linkage has been popped off. Next I had to locate the ground wire and fasteners on the bottom of the plenum. To provide access the coolant overflow tank was removed. The next photo shows improved access.
There are two 13mm capscrews tha hold the throttle linkage pivot to the plenum, the front one has the ground strap from the engine. The two 17mm cap screws holding the plenum to the bracket, thatis fastened to the engine and the motor mount area. The forward one is accessible from the front, the rear one will have to be accessed from the rear on manifold access is tight use a short ratchet. The plenum will lift off you have to move a hose slightly at the fender.
The next photo shows the bottom of the plenum showing the cap screw positions.
Now we finally have access to the starter motor, remove the black trigger wire and the 13mm nut to remove the main 12 volt leads. The next photo shows the starter motor, removing the bolts is more difficult sine two have 16mm heads and because of clearance can only be held with open end wrenches. All of the nuts are 13mm as is the head of the special body bolt, position top outside. I removed the bottom bolt from underneath, jack the car for access.
When i removed the starterI found out what the "THWACK" was, one tooth on the flywheel ring gear was removed and the starer motor nose was cracked through all the way around. These are shown in the next three photos. The starter was tight to the flywheel housing, there is no witness marks on the starter,housing or the spacer plate between them.
I brought the starter to EUROTECH Motors, they had not seen this type of failure.
I placed the car in gear and rolled to make sure the engine was free.
Has anyone had this type of failure? I am currently waiting for a rebuild starter and will install.
Another reason to remove the plenum was to clean the engine and the inner fender, in the photo showing the bracket you may see aluminum foil with rubber bands covering the runners and throttle opening, I also removed and cleaned all the boots and clamps.
Tom, New Jersey
86 Alfa Quad
