BMW Bavaria + Carter 4070 Fuel Pump

When I was unable to successfully rebuild the OE Zenith carburetors on our BMW Bavaria (no patience), I bought a pair of used Weber 32/36 DGAV carburetors (with the linkage and a manifold) on eBay for $99. I bought rebuild kits and some new jets from Pierce Manifolds (because they’re sort of close to me).

Carter 4070 Fuel Pump Mounted on Firewall
Carter 4070 Fuel Pump Mounted on Firewall

For some reason, I also decided to replace the mechanical push rod driven fuel pump with an electric rotary vane pump.

I found that Top End Performance had a discourse on the Carter 4070 fuel pump saying it was a good pump for Weber carbs. I first mounted the fuel pump on the firewall, near the overflow tank.

On the highway, I noticed that the car would occasionally stutter and I realized that the engine was becoming fuel starved because the pump was designed to be more of a pusher, closer to the gas tank.

I moved the fuel pump to underneath the car, just forward of the fuel tank. I used a Napa 1814U “Quiet Pack” that mounts the pump on rubber bushings to isolate it from the car’s frame and ran the 12v+ for the pump from the fuse box.

Carter 4070 Fuel Pump
Carter 4070 Fuel Pump (Note: wiring polarity is incorrect in this photo – it is reversed)

I also bought this Holley shut off switch that works off of engine oil pressure. Joe Weir, on the Senior Six Registry mailing list sent me a diagram that uses a relay (12 63 1 276 165) from a 320i for fuel shutoff.

The only problem I’ve had is with the electrical connections to the pump falling off – they’re held on by friction. To resolve this, I put a dollop of JB Weld on each terminal, then stuck the connectors on.

Carter fuel pump installation notes, pages 3-6 (PDF)

A Fluke 114

On a recent trip to Fry’s, I picked up a Fluke 114 Electrical TRMS Multimeter. After I got home, I realized maybe I shouldn’t have been so impulsive, because I might have bought the Fluke 115, which also measures capacitance (I’m always doing that…).

The continuity beeper was especially helpful in rewiring the headlights on the Bavaria after a short circuit melted a large portion of the harness.

Fluke 114 Electrical TRMS Multimeter (L), Micronta Multitester 22-203B (R)

I replaced my aging analog Micronta Multitester 22-203B, which was, “custom mfd in Korea for Radio Shack, a division of the Tandy Corporation.” I probably bought it back in the late 70’s, when Tandy stores still sold leather supplies.

The only other significant thing about this old Radio Shack (now RadioShack) meter is it almost qualifies as a GooglewhackRadio Shack 22-203B, finds only a single result.

Hood Insulation

The body shop removed the insulation from the inside of the hood when we got the BMW painted. I didn’t think about how hot the hood got until I was covering the car the other night and put my hand on the hood.

BMW Hood Insulation
BMW Bavaria Hood Insulation
BMW Hood Insulation
BMW Hood Insulation

Jim Stansfield at Mesa Performance sent me up some insulation that wasn’t too hard to put on. I made a paper template from the cutouts in the hood and traced that onto the insulation.

3M Super Trim Adhesive 08090
3M Super Trim Adhesive 08090

I cut the insulation with household scissors and used 3M Super Trim Adhesive (for garnitures). The glue is a contact cement that is applied to both surfaces then joined.

I finished the edges with silver foil aluminum tape. It’s all kind of shiny.

Alfetta Transmission, Part 2

I finally started taking apart the transmission. The main shaft has over 50 parts rotating around it – 1st – 5th gears, synchro hubs, synchro sleeves, bearings, etc.

Alfa Romeo Transmission Main Shaft
Alfa Romeo Alfetta Sprint Veloce transmission diagram

This is where doubt started whether this would actually work again.

Common Alfa transmission wisdom indicates gear lightening for better shifting response and as a cure for a crunching 1-2 shift. It makes, sense, having less rotating mass and the accompanying reduced inertia would wear the syncros less. Better acceleration too, but me losing 20 lbs. would increase the car’s performance more.

This is a close-up of 1st gear and the worn synchronizer ring.

Alfa Romeo Transmission Main Shaft
Alfa Romeo Synchro Ring

That wear is the cause of the crunching gears in 1-2 upshifts in the Alfa. You can see the wear in the triangle shaped shiny areas on the synchro ring. A new synchro ring has a rough surface. To tell you the truth, I didn’t know what a synchro ring looked liked before I took this apart.
More pitures.