Lancia Motor Club

I am helping a guy in Holland next week recommission a series 2 Appia. Neither of us have a service manual so some basic information would be really helpful. The engine runs OK but not really smoothly and there are no brakes. The reservoir is empty so may be a simple job but I fear not. (wheel cylinders?)
1. Spark plug type
2. Best oil
3. Grease points
4. Valve clearances? and is a special adjusting tool required like the Fulvia?
5. Ignition timing
What oil goes in the sliding pillars and what is the procedure to service them.
Is there a service manual that I can download?
What are the common problems we will encounter? The car has not been on the road for about 8 years but the engine has been run fairly frequently.
Thanks
Simon
Fulvia S1 Sport

There are a couple of good sources of info (plus handbook). There is a very good workshop manual in English and I have added the relevant pages , but also Don Cross wrote a helpful section in Wim Oude Weernink's excellent book on Appias. I can't share that here due to copyright , but briefly:

1/ Champion N5 or equivalent
2/ Everyone has their favourite - mine is Penrite 20w50 or 60
3/ See chart below
4/ See photos - can be done easily with ring spanner and pliers (to hold the tappet when tightening)
5/See photos
6/ top suspension 20/50 or 60, bottom 90 or 120/140 if v worn. I wrote a suspension guide a few years ago and is available on the Forum - I can resend if you can't find it !

The brakes can be difficult, but try running a hone through all the cylindres and fit new seals - if you are lucky you'll have no leaks, but new cylindres are available from Cavalitto

Give Jim a ring at the Appia Consortium, I am sure he and others will help as well

Good luck !

Getting the brake drums off can be difficult without a special puller. The oil sump plug needs a 22 mm Allenkey. Refilling the gearbox is not so simple without a suitable syringe. Systematic cleaning of the cooling system is advisable as these cars are quite sensitive to overheating and the various pipes and hoses can be blocked by debris. The correct operation of the radiator louvres is important. Etc. A manual can be a great help.

I would pay a visit to the Viva Lancia site here https://viva-lancia.com/specials/cd/appia-cd.php
They provide documentation on most of our favourite Lancia models on CD in PDF format invaluable!
Clarkey AKA Appia Consortium Manager

Rear drums came off easily, but the fronts want to stay put. Does the Consortium have one for rent? I am going over to Holland on Sunday

Fraid not...any reasonable sized puller should do the trick. Just a thought but have you removed the large nut from the end of the stub axle?
Clarkey

This is the puller I use bit of an overkill really but it was only £25 from a car boot.
Clarkey

Jim's puller may be OK but the risk of damaging the drum is substantial. I prefer the proper puller as shown here.

It would be nice to see your puller set up on a drum as mine is not ideal but has done the job without damaging the rim of the drum.

It grabs all for studs with the wheel nuts and presses on the center of the stub axle.

Yes, the nut is off. Getting a puller that fits is the problem. We cwill get there.

On Aurelias, early cars can have just the drums removed (usually with just a little help from a hammer) whilst leaving the hubs in place whereas later cars where the drum is very securely attached to the hub itself require that the hub and drum are  removed in one piece.
To do this one uses a puller which  screws into the thread on the hub where the large castellated nut has been removed so there is no concern about putting any pressure on the brake drums themselves.
If one is changing brake shoes or wheel cylinders the hub itself really needs to come off anyway to gain proper access.
Photo to follow.
Chris

Recommisioning going Ok but slow! Engine runs really well...... for  while. Fuel pump sucking a lot of crud from the tank so unfortunately looks like tank out and purge and clean. Looks pretty straightforward, any unseen difficulties?
Generator not charging. Hoping it is the regulator. Repair manual says no repairs, but a good clean of the contacts etc normally works but I cannot see how to get the cover off. What's the trick? Or is there a solid state alternative?
Big job is the wiring. Back end looks good, it is the front end that looks like an Italian kitchen after a pot of black spagettii has exploded. I suspect a PO has crossed + and - to burn out some wires to the headlights. Does not help that Lancia only used black wiring.
Ignition barrel is so worn that the key drops out. Is a new barrel and key available?
I better join the consortium. Whats the procedure?
Cheers
Simon

send me an email on appiasparesconsortium@outlook.com

The generator and V/R have been sent away for testing. Whilst removing the generator we noticed that it was out of alignment with the crank and water pump pulleys by about 5 degrees. When the top stay was loosened it became worse. Once the generator bottom bolt had been loosened the generator could wiggle about a large amount. The reason for this was the bottom bolt did not fit snugly through the block, the bolt was far too small a diameter. The bolt is of correct size as it fits the generator bracket perfectly.
I would have thought that a steel bolt going through an ally block should have a bush or insert to protect the block from wear. Should there be a bush?
The fixes are either
1/ Put a bush in (fabricating one if necessary
2/ Put in a larger diameter bolt but this would mean reaming out the holes in the gen attachment bracket which may weaken it.
Has any on else had this problem?
Thanks
Simon

Have you any pictures of your issues as I have not yet come across a hole being too big for the bolts?
Clarkey

pictures will not really help.
The hole in the engine block that the generator attachment bolt goes through has either been widened/damaged/worn by the bolt moving in it or an insert/bush is missing. The result is the generator can rock from side to side if the top stay is loose. When the top stay is tightened it pulls the front of the generator towards the engine block so the pully is not aligned with the crank pulley. It works but it must be putting a large load on the front generator bearing.
I will try and draw a diagram to explain the problem

I think I probably have a simpler reason for this problem: maybe the wrong generator is fitted. The generator attachment bracket holes are smaller than the hole in the engine block.

Some pictures of a recent strip down of a S2/3 engine showing the bottom dynamo mounts.
Clarkey

That is very useful. It confirms that the bolt fitted should be larger and that the generator is not from a S2. I will be enlarging the holes on the bracket to accept the bigger bolt.
I also note the rear hole in the engine is threaded. Does any one know the bolt and thread size?

i meant the rear hole of the dynamo.

This is  common problem with Appias, mine included. I went with drilling then reaming the hole to 10mm. Of course the holes in the generator mounts need to be enlarged as well. Longer term, I'm thinking of either re-bushing the hole back to standard or fitting a lightweight alternator.

Hi Tony
I am relieved that I am not the only one with this problem.
The generator is the correct part number. Simply speaking the two holes on the gen to accept the through bolt are smaller than the hole through the block.
Either there should be a sleeve/bush in the block or the hole in the block has worn itself wider of the decades. (unlikely).

Apologies for the delay in posting the photo of my front hub puller. You can see it doesnt distort the front brake drum at all.
Chris

Nice piece of kit. I'll bet a correct Lancia tool. Would it fit an S2 Appia?

Had the S2 on the road this week after recommisioning:
1/ Electrics and lights now all work with help from a S3 loom from the consortiom
2/ Dynamo needed an overhaul
3/ Brakes: Master cylinder and two brake cylinders needed O/H kits. Now after a LOT of bleeding they are not bad. Pressure comes after about 40% pedal travel. Is that about right? Other brake cylinders probably need doing as well.
4/ Indicator switch fixed
5/ Wheels sanded and repainted
6/ Oil and flter
What is needed and can be put on the 'to do list'
1/ Speedo not working. Changing the cable does not look easy.
2. Horn needed
3/ Mega Internal clean
4/ More brake work
5/ Someone put a new headlining in and covered over the roof light
6/ Rad flap thrmo

If I knew how to post pictures  I would do so.
It drives really nicely so the plan is to drive it 500 miles and see what the bugs are. Am not interested in a concours car, just a fun, reliable hobby car.
Cheers
Simon

The progress sounds amazing well done! The Consortium will have a horn and possibly a new radiator shutter thermostat.
Clarkey

Not having much luck in posting some pictures. Must be doing something wrong
(http://)

Looking very nice!

Looks very smart, looking forward to seeing it on the next Sliding Pillar 😄.
You need to resize your photos, the file size is too big ✔️

Sliding Pillar is right...if you resize your pics to around 700kb each you can post 3 or more at a time as the limit is 4mb in total.
Clarkey

Yes, I've just found out that 4 meg is the maximum. Looking forward to next year's sliding pillar. Is it confirmed as Northern France/Dieppe area? Rally easy to get to with the Newhaven/Dieppe ferry.
Enjoyed recommisioning the Appia but it is not the easiest car I have worked on. Lancia must have started with the brake master cylinder and built the car around it. Nightmare getting it on/off.  Also the dynamo looked easy but the exhaust manifold in the way so also a bit of a mare. Found some nice 15" Michelin tyres so it handles really well.

Sliding Pillar details for next year:
https://www.lancia.myzen.co.uk/forum/index.php?topic=14289.0

I have also booked a hotel for 2026 😉