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  Topic: 16v cambelts snapped & stripped teeth
ZeNiTh-PbArM

Replies: 9
Views: 30167

PostForum: Boxer Workshop   Posted: Fri Jun 02, 2023 6:32 pm   Subject: 16v cambelts snapped & stripped teeth
In Nov 2021 the clutch master cylinder “CMC” gave up, so I removed it to find the spring had snapped, I tried to source a replacement spring to no avail, only seals were available, so I whipped ou ...
  Topic: non starting 33. starter motor exciter wire not got enough..
ZeNiTh-PbArM

Replies: 30
Views: 25100

PostForum: Boxer Workshop   Posted: Wed Sep 30, 2015 8:32 pm   Subject: non starting 33. starter motor exciter wire not got enough..
Hi

When you checked, did you by chance open the hood? If yes, faulty connections may have cooled down at the same time...

regards,
  Topic: non starting 33. starter motor exciter wire not got enough..
ZeNiTh-PbArM

Replies: 30
Views: 25100

PostForum: Boxer Workshop   Posted: Mon Sep 21, 2015 4:14 pm   Subject: non starting 33. starter motor exciter wire not got enough..
Hi,

If you are looking for the root cause you may want to look for :
1. Harness terminal mating with solenoid tab. Crimp connection to the wire gets oxidized, and the terminal itself can loose cla ...
  Topic: 33 users beware
ZeNiTh-PbArM

Replies: 5
Views: 6310

PostForum: Boxer Workshop   Posted: Fri Sep 18, 2015 9:58 am   Subject: 33 users beware
Hi all,

Took me a few minutes to manufacture the custom tool required.
The nylon tube is firmly clamped between the half shells (four screws on the right). The barb fitting is held in place on the ...
  Topic: Any Carb experts out there?.
ZeNiTh-PbArM

Replies: 8
Views: 7642

PostForum: Boxer Workshop   Posted: Mon Aug 31, 2015 7:48 am   Subject: Any Carb experts out there?.
Hi,

I have experienced fuel starvation symptoms in the past due to reaching the fuel pump limits. With carbs it can be quite tricky to understand because you need to stay at full load for more than ...
  Topic: Any Carb experts out there?.
ZeNiTh-PbArM

Replies: 8
Views: 7642

PostForum: Boxer Workshop   Posted: Sun Aug 30, 2015 8:33 pm   Subject: Any Carb experts out there?.
Hi,

You may consider :
1. Fuel flow depends on rpm and engine load. If the pump doesn't provide enough flow, you can't detect it unless you actually drive the car (full throttle in 3rd gear) with ...
  Topic: Removing gearbox on stands
ZeNiTh-PbArM

Replies: 19
Views: 17443

PostForum: Boxer Workshop   Posted: Sun Aug 30, 2015 12:03 pm   Subject: Removing gearbox on stands
Hi,

It is already back in place! The 5hrs I quoted were for the complete job.
Getting the box back in is a little bit tricky, you need to achieve a correct alignment and rotate a little bit for th ...
  Topic: Removing gearbox on stands
ZeNiTh-PbArM

Replies: 19
Views: 17443

PostForum: Boxer Workshop   Posted: Sat Aug 29, 2015 6:17 pm   Subject: Removing gearbox on stands
Hi all,

Just finished the clutch replacement. I raised the rear on wooden ramps and the front on axle stands. I got the gearbox out and back in without too much hassle. Took 5hrs doing the whole jo ...
  Topic: Removing gearbox on stands
ZeNiTh-PbArM

Replies: 19
Views: 17443

PostForum: Boxer Workshop   Posted: Thu Aug 27, 2015 12:01 pm   Subject: Removing gearbox on stands
Hi,

Bending the gearbox shaft is next to impossible. I reckon you can struggle though, getting the gearbbox back in. If the splines won't align correctly between clutch disc and shaft, you may have ...
  Topic: Removing gearbox on stands
ZeNiTh-PbArM

Replies: 19
Views: 17443

PostForum: Boxer Workshop   Posted: Wed Aug 26, 2015 5:50 pm   Subject: Removing gearbox on stands
Hi all

Thanks for your replies.
I have replaced a number of clutches dropping the gearbox only ; this is easily done on a pit, leaving the engine attached on the front support.
You need to remov ...
  Topic: Removing gearbox on stands
ZeNiTh-PbArM

Replies: 19
Views: 17443

PostForum: Boxer Workshop   Posted: Wed Aug 26, 2015 7:26 am   Subject: Removing gearbox on stands
Hi all,

I need to replace a clutch on a 8V and don't have the garage with pit at my disposal. I'll attempt to drop the gearbox only with the car on stands.
I'm a little bit worried about the groud ...
  Topic: 33 users beware
ZeNiTh-PbArM

Replies: 5
Views: 6310

PostForum: Boxer Workshop   Posted: Tue Jun 30, 2015 8:48 pm   Subject: 33 users beware
Hi all

Getting home from work yesterday night I broke the LHS cv joint. Screws broke (all but one) when the thing seized and the driveshaft ended up rotating around the gearbox flange
Not a single ...
  Topic: non starting 33. starter motor exciter wire not got enough..
ZeNiTh-PbArM

Replies: 30
Views: 25100

PostForum: Boxer Workshop   Posted: Sat Jun 20, 2015 10:33 am   Subject: non starting 33. starter motor exciter wire not got enough..
Sure, but the point is, you measure 12V at no load, i.e. with the wire unplugged from the starter motor.
If you measure voltage while the wire is connected to the solenoid, there will be current flow ...
  Topic: O-ring mystery
ZeNiTh-PbArM

Replies: 4
Views: 4784

PostForum: Boxer Workshop   Posted: Sat May 23, 2015 11:04 am   Subject: O-ring mystery
Hi

The oring may be an error in the epert parts catalogue.
I have rebuilt quite a number of them engines and have yet to see such an oring in that location.
I'd go for the flat gasket with corre ...
  Topic: 1.7 8v heads
ZeNiTh-PbArM

Replies: 3
Views: 4726

PostForum: Boxer Workshop   Posted: Fri Apr 17, 2015 8:10 pm   Subject: 1.7 8v heads
Yes a few early 1.7 have been sold with mechanical tappets. If I remember correctly they were advertised at 114hp rather than the 118hp which was quoted for the hydraulic version.
I'm not so sure whe ...
  Topic: Few questions - fuel relay
ZeNiTh-PbArM

Replies: 8
Views: 4063

PostForum: General   Posted: Tue Dec 30, 2014 10:12 pm   Subject: Few questions - fuel relay
Hi

beware, Bosch relays with a red stripe on the metal housing (like the one on your first picture) are diode-protected and shall be replaced with a similar item

regards,
zp
  Topic: what more could you possibly ask for ?
ZeNiTh-PbArM

Replies: 3
Views: 2912

PostForum: General   Posted: Thu Oct 16, 2014 6:57 pm   Subject: what more could you possibly ask for ?
A good ol' 33, a small cabin in the mountains, and view on the sunset.
I love it this time of year when the autumn is full of colors.
zp

http://s15.postimg.org/vj1zcnayz/IMG_1745.jpg
http://s24. ...
  Topic: Wanted: Gearbox Mainshaft Pilot Bearing
ZeNiTh-PbArM

Replies: 17
Views: 12538

PostForum: Boxer Workshop   Posted: Sun Oct 12, 2014 6:18 pm   Subject: Wanted: Gearbox Mainshaft Pilot Bearing
Hi
I am currently away from home but I'll be back in one week time if you aren't in such a hurry i can get one measured for you just let me know

Regards,
ZP
  Topic: Wanted: Gearbox Mainshaft Pilot Bearing
ZeNiTh-PbArM

Replies: 17
Views: 12538

PostForum: Boxer Workshop   Posted: Sun Oct 05, 2014 11:26 am   Subject: Wanted: Gearbox Mainshaft Pilot Bearing
right. It's the same stuff which is used for starter motor bushings, etc.
I have machined some of the stuff and it's not that difficult. Carbon steel tools work the best and these must be razor sharp ...
  Topic: Misfire when pulling left. Any ideas?
ZeNiTh-PbArM

Replies: 9
Views: 6468

PostForum: Boxer Workshop   Posted: Sat Oct 04, 2014 11:14 am   Subject: Misfire when pulling left. Any ideas?
Hi,

Check carb floats first and fuel circuit.
Other than this, i experienced a similar problem long time ago. Turned out to be a dead battery, plates inside would move a little bit under centrifug ...
  Topic: Wanted: Gearbox Mainshaft Pilot Bearing
ZeNiTh-PbArM

Replies: 17
Views: 12538

PostForum: Boxer Workshop   Posted: Sat Oct 04, 2014 11:13 am   Subject: Wanted: Gearbox Mainshaft Pilot Bearing
Hi,

this is a bronze bushing, any decent machine shop can make one for you.
I don't recommend using a needle bearing - shall this seize you'll have to replace crankshaft and mainshaft as they will ...
  Topic: Removal of front suspention lower ball joint on alfa 33
ZeNiTh-PbArM

Replies: 8
Views: 7586

PostForum: Boxer Workshop   Posted: Thu Aug 21, 2014 7:37 pm   Subject: Removal of front suspention lower ball joint on alfa 33
Hi,

This is not a complicated job.
You only need to remove the driveshaft.
Once this is done you remove the bolt attaching the front suspension arm to the front crossmember and the bolt attaching ...
  Topic: 16v boxer timing belt question
ZeNiTh-PbArM

Replies: 19
Views: 13420

PostForum: Boxer Workshop   Posted: Fri Jul 25, 2014 8:25 am   Subject: 16v boxer timing belt question
Hi,

the six clutch bolts are M8 indeed
Be sure to center the clutch correctly otherwise you'll struggle to get the gearbox back in.

regards,
zp
  Topic: Petrol Filler Neck
ZeNiTh-PbArM

Replies: 9
Views: 6801

PostForum: Boxer Workshop   Posted: Wed Jun 18, 2014 8:38 pm   Subject: Petrol Filler Neck
Hi,

A pic of my tool
http://s16.postimg.org/go7518wrp/fillerneck.jpg

and the safety ring
http://s10.postimg.org/r1o973rll/fillerneck2.jpg

regards,
zp
  Topic: 16v boxer timing belt question
ZeNiTh-PbArM

Replies: 19
Views: 13420

PostForum: Boxer Workshop   Posted: Wed Jun 18, 2014 12:34 pm   Subject: 16v boxer timing belt question
Hi,

Yes that's the general idea. Get some lube in the area as well and you should be fine.

Regards,
zp
 
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