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In 1999, my
car developed some engine problems that forced me to park it, until I could
put together enough funds for a new motor.
March of 2003 I drove to St Louis, Mo. (2.5 hrs) and picked up a
remanufactured 1600 DP long block, new clutch, throw-out brg,
Pertronix ign. for my 009, gaskets, etc.
My intention was to re-use the 34 PICT (BOCAR) that I had installed in
1998. All I ever wanted out of this project was a dependable daily
driver.
Working in my shop weekends and some evenings, I was able to get the tin,
manifolds, dist. and all the rest installed on the new long block. With
the aid of the same friend who helped me pull the old motor, we got the new
motor installed.
I had flushed the gas tank and filled it with fresh gas. I had also
cleaned and rebuilt the carburetor. Note: this would be the
first of three times the BOCAR would be rebuilt.
With the static timing set at 7 degrees BTDC, and a new battery and I
was all set (or so I thought).
The motor fired right up, but refused to idle. In fact the only way
to keep it running was to pump the accelerator.
My friend and I tried every trick we knew, and could not keep it running.
(Yes I did bench test the idle cutoff solenoid and it checked out OK.) We
checked for vacuum leaks and found none. I had even capped off the
vacuum line to the stock air cleaner. Our best guess was that the
carb was still dirty. That next week I pulled the carb, tore it
completely down on the bench, and soaked it 24 hours in a special
carburetor cleaning solution at a repair shop I frequent.
Then I carefully re-assembled the carb with all new gaskets and parts from
the kit, and re-installed it.
The motor would still not idle! That next weekend, I pulled the
carb again, and with yet another kit, I had the carb professionally soaked
and rebuilt. (this would be the third time) Once re-installed
the motor would still not idle. We even set the timing at 28 degrees
at 2500 rpm, but no improvement.
Another Thing owner I corresponded with suggested I replace the intake
manifold gaskets. The gaskets that came with the motor were stamped silver
tin. I purchased composition gaskets from an on-line source to
replace them. Since I needed to pull the engine to do this I decided
to give up on the BOCAR carb and upgrade to a 32/36 DFEV Weber
Progressive. The pictures on this page show the second engine pull
and the installation of the new Carb set-up.
This past weekend, May 10-11, 2003, I pulled the motor for a second time
this spring, installed the new gaskets and Weber carb, and put it all back
together. So far, the engine starts right up (electric choke) and
idles just fine. The problem may have been the manifold gaskets all
along, but I am glad I went ahead and changed out the carb.
Now all I need is to fine tune (mixture etc) and I should be all set for
summer fun!.
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