Fanalone restoration

[ncundy]

As promised some pctures. Not a great deal of interest but the internals of a Fulvia for those who haven't seen. The fourth shows the corrosion starting on the water pump.

[ncundy]

Some more photos as it slowly gives up its secrets:
The first shows the sludge in the sump - proving it is a good is a good idea to completely restore the engine.
The second and third show the inlet and exhaust ports. I believe (but stand to be corrected) that the Fanalone ports were finished to a standard above that of the later 1600 ports. Does anyone have any comment or experience of this ? My memory of when we did my brothers S2 1600 engine is too dim to draw any conclusions.

[ncundy]

Finally one of the stripped head. Any advice for the valve guides - later ones had seals on them, is it worth changing these ? (I haven't checked mine yet so I have no idea if they are worn or not)

[nistri]

It is a good idea to replace all valve guide seals. My advice is not to use the black seals (old type) which have a very limited lifetime and then the engine starts burning oil. Use red seals which last much longer. Any good machine shop should stock them.
In view of the sludge you found in the oil sump, I would advise to remove the plugs from the camshfts, clean them internally very carefully and fit new plugs.


Good luck
Andrea

[ncundy]

Andrea,
Thanks for the reply. Removing all the plugs on the cams and crank (and any others I find !) is in the plan, although I was surprised at the amount of sludge in there. I will have a think about the valve guides. I don't really want to move too far away from the original engine, but obviously I also don't want to be burning oil in 10,000 miles. A small dilema but I have plenty of time to consider it. I'll do a bit of reading up, so thanks for the advice.
Neil

[nistri]

Please note that an often-forgotten plug is at the end of the shaft driving the oil pump. Good idea to remove it and clean the internals as in your case there was a lot of sludge.
Best of luck
Andrea

[lancialulu]

Re valve guides just fit to inlet as exhaust doesnt suck when valve open and needs a better lubrication regime due to the heat especially on the inboard ones.

Tim

[ncundy]

Some for photos of the engine in bits. The big surprise is that the thrust bearings are shot - I imagine because with little use they have been running at start up with no oil, but the crankshaft shows no sign of damage. Center main bearing shows more wear than the two outers, but I understand this is typical of a Fulvia engine.

With the crankshaft plugs out we found the cavities full of muck - so it's looking a good decision to pull it all to bits.

Also the flywheel ring is very poor so I will probably get it turned off and a new one shrunk on.

[Dilambdaman]

Sorry, couldn't resist the comparison!

Robin.

[ncundy]

 

Looks fantastic. I imagine moving that around and about was more than a one person job ! Is it all ok now (I have been following your tread with interest) ?

Neil

[Dilambdaman]

The flywheel has to come out with the crankshaft and I can just about lift it on my own. Likewise the head is just manageable although I sometimes use a hoist. A friend gave me a massive engine hoist which is invaluable.

Sadly she is still off the road where she has been for most of the year. The rattle in the engine has proved very elusive and having failed to get her to the French Rally I have been taking a much needed break much to Margaret's delight!

The Fanalone too is suffering similarly having received no attention since seizing the gearbox/final drive on the way to Classic Le Mans.

Robin.

[ncundy]

I imagine after a run of luck like that you feel you deserve a break ! I know from experience this can dent anyones enthusiasm for a while.I hope the winter provides the time to find a solution so that you are able to be back on the road next year.

all the best
Neil

[ncundy]

The engine is now fully stripped. The attached photo shows the muck collected over time in the crankshaft oil chambers (with crank plug removed), so always worth removing and cleaning if you go this far into your engine.

[DavidLaver]

My own "compare and contrast" picture of an Aprilia bottom end.  By the time the Fulvia came along it looks like about half the bearing area and half the material in the crankcase.

David

[ncundy]

I think these (yours and Robins) are very good compare and contrast. Here is a photo of mine taken from the same angle and one difference you can see (apart from those already pointed out) is the asymmetric web design (as opposed to the symmetric webs on the earlier engines). This tells the evolution of the understanding of balancing of V engines by Lancia. Both the earlier engines were balanced "in balance" (all the webs are essentially the same), but the Fulvia (and I guess all post Aurelia) has essentially asymmetric webs (giving a designed in "out of balance") then fine tuned by the holes in the first and last webs.

The flywheel has it's own balance holes which probably shows that Lancia did not balance the flywheel, clutch and crank as an assembly, but balanced the crank as an item and the clutch and flywheel as an item. This helps when fitting a lighter flywheel and clutch as you only have to worry about balancing them as items not as a complete assembly with the crank.