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Gery83
04-05-08, 19:58
Hello!
I'm from Hungary. I think I'm the only one on this forum. :D

So... When I bought my Q4 (around ARPIL of 2007), it was quite weak. (As it turned out, the head gasket was guilty.)
So I decided to rebuild the engine, and do some modifications that I always wanted to do.
So I'll post some pictures, with short comments.
If you'd like to know something, just ask me! ;)

Oh, by the way...I'm not a professional, just a hobbist.

Gery83
04-05-08, 20:18
As I bought it in 2007:

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Gery83
04-05-08, 20:23
An early clutch change:

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Gery83
04-05-08, 20:33
And the strip begun:

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Steve Webb
04-05-08, 20:34
Hi Gery, looks like you are pretty handy with a spanner. Good luck with all the work. Oh I moved your thread into the readers cars section.

Steve

Gery83
04-05-08, 20:35
...continued:

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Gery83
04-05-08, 20:46
Some new parts and stuff:

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Gery83
04-05-08, 20:50
Some engine bay washing:

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Gery83
04-05-08, 20:52
Engine block painting:

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Xti
05-05-08, 12:58
Hi Gery !
Welcome to the forum.
Keep up the good work, I wish you good luck.

Btw...were you this year at Alfacity in Esztergom? I realy enjoyed it, it was such a great event with so many beautiful Alfas.

Cheers,
Cristian.

Gery83
05-05-08, 17:14
Hi!
Thanks!
Yes, I was there, but unfortunetly not with my car, because it was in pieces... :DDD

Gery83
05-05-08, 17:55
Some more parts:

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Gery83
05-05-08, 17:56
Some painted stuff:

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Gery83
05-05-08, 17:59
Battery in the trunk:
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Replaced ignition coils:
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Rebuilt starter motor:
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Gery83
05-05-08, 18:23
Little cutting and welding:

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Gery83
05-05-08, 18:27
Bumper cutting and washing stuff:

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Gery83
05-05-08, 18:30
Painting, cooler fitting:

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markgq4
05-05-08, 19:26
Painting, cooler fitting:

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Very good and neat work Gery

Gery83
05-05-08, 20:25
Thanks! :)

AlfaJack
05-05-08, 21:41
This is some fantastic work. I love the paint job on the rocker cover. I may do something similar. Keep up the good work! :D

Gery83
08-05-08, 18:55
Some stuff:

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Steve Webb
08-05-08, 19:10
Looks like you are going to be pretty busy with all of this.

Never heard of Castol Edge before, any good reviews of it?

And are you sticking with 10mm headbolts or going up to 12mm?

What head gasket have you gone with?

Steve

Steve Webb
08-05-08, 19:14
Better class of mechanic over in Hungary by the looks of it:

http://www.alfaamore.hu/files/users/0000014/0000014328-4d66a7a6c30ced43.jpg

Mechanics over here are usually fat, balding and covered in grease!

Apologies for ripping pics off of your website :tasty:

Gery83
08-05-08, 19:18
No problem!
She is my girlfriend. She wanted to help by the stripping of the car,
so I gave her some of my worker clothes!
I can tell you, she has talent! :D

Gery83
08-05-08, 19:25
Yes, I heard no problems with it.
Previously I used Castrol Formula RS, but they don't sell it anymore in hungary. The EDGE replaced it. So I bought it! :)

Yes, I'm using 10mm factory headbolts and Victor Reintz head gasket. Nothing extra.
I'm not going to tune my car that much:
- it has a modified chip (bigger pressure)
- bigger cooler

That's all temporarily. :)

Gery83
08-05-08, 19:33
182

Steve Webb
08-05-08, 19:40
No problem!
She is my girlfriend. She wanted to help by the stripping of the car,
so I gave her some of my worker clothes!
I can tell you, she has talent! :D


So let me get this straight, she is your girlfriend and she was stripping in your work clothes :rolleyes:

Why do I never meet girls like that!!

Gery83
08-05-08, 20:01
Exactly!
Just bad luck... :)

Gery83
10-05-08, 20:28
'New' oilcooler hoses:

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AlfaJack
11-05-08, 12:31
An essential for a rebuild job. Wont be long until all the originals are rusted through :(

Gery83
17-05-08, 21:14
Some more new stuff:

SKF bearings:
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Belt tensioners, with the new bearings:
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Custom water pipe - stainless steel (I'm not the one, who invented it! :biggrin: ):
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New factory air hose:
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Gery83
17-05-08, 21:21
Beginning to reassemble the engine:

Rebuilt head with brand new factory camsafts:
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Installed starter:
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Oil catch tank with new filter:
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Oil sensors fitted:
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Head fitted:
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New GATES-XS timing belt:
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AlfaJack
17-05-08, 22:38
Been busy then!

Looking very good!

Stuntz
18-05-08, 10:04
Ok i do not understand something i ordered a new factory hose conection and the main alfa dealer in slovenia said they are not in stock anymore not even in italy so the question is where did you get it!!

Gery83
18-05-08, 17:23
From a friend of mine, he sells stuff for alfas, and has some in stock of special, and rare parts.

http://www.torjay-tuning.hu/site/?page=Kapcsolat

Send him a mail, and he will answer.

Gery83
18-05-08, 17:30
I was a bit busy today, here are some pictures:

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Gery83
22-05-08, 19:26
Another busy day:

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Ignition cables:
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Fuel pressure gauge:
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Gery83
08-06-08, 11:47
Custom air pipes:

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AlfaJack
08-06-08, 23:49
That is a long inlet now! Will it cause much lag?

Great job btw! :cool:

jimnielsen
09-06-08, 00:37
Great pictures, thanks for posting them, its very instructive to be able to see exactly how others are approaching the same issues that you are trying to deal with.

Jimn~

Xti
09-06-08, 12:10
Instructive indeed, thank you Gery. Keep up the good work.

Cheers,
Cristian.

Gery83
09-06-08, 16:37
Thanks guys! ;)

Gery83
15-06-08, 16:59
A few new shots.

It's working now, but I still have the problem that the boost won't go any higher, than 0.5bars. Before rebuild it reached even 1.5bars sometimes.
( Not original chip, I have the file from maxiboost:
http://members.lycos.co.uk/maxiboost/
(http://members.lycos.co.uk/maxiboost/) http://members.lycos.co.uk/maxiboost/Temp/ )
My other problem is that on idle, fuel pressure is a bit under 2bars.
Oh, and I have a little oil leak somewhere on the underside of the engine.

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Stuntz
15-06-08, 18:06
on idle whit vacuum hose atached or detached?

Gery83
15-06-08, 18:22
on idle whit vacuum hose atached or detached?

With attached vacuum hose.

Stuntz
15-06-08, 18:35
hehe standard is 2.5 bar whit detached vacuum hose check that! i think nothing is wrong. But check it and also if you have boost at 1.4 bar pressure should be set to 3.0 bar whit detached vacuum hose. not boosting could be several problems mine was a faulty temeprature sensor.

Gery83
15-06-08, 18:39
Oh, thanks! I'll check that!
Do you have any other ideas what else can cause low boost pressure?

Stuntz
15-06-08, 19:05
faulty pierburg vavle. faulty wiering to pierburg valve. Is it possibe taht oyu have a leak somewhere in the boost system?

Gery83
15-06-08, 19:16
There is no leak, thats sure now! :)
I tested the system, so that I plugged the inlet side of the turbo, and I connected an aircompressor on it. I filled it up to 2bars, and the only place where air came out was the oil vapour air filter.
The pierburg valve is new, so if there is any problem with it, than with it's cable.
Tomrrow I'll put a signalling led on it, so I can see if it's working while I drive.

What sensor was wrong in your car? The IAT (= Intake Air Temperature) sensor on the mainfold?

Thanks!

Stuntz
16-06-08, 09:02
No the water temeprature on the thermostat.

Ps your friend is going to get me the ruber hoses. You should come to show us your q4 somtime.

Gery83
17-06-08, 16:45
Thanks!

I know, I asked him to send one for you! ;)
By the way... I want to see some photos of your car! :D
Where can I find them?

arjunior45
17-06-08, 17:38
great job Gery congrats

Nick

Gery83
17-06-08, 17:56
Thanks, Nick!

Stuntz
17-06-08, 20:06
http://forum.berlinasportivo.org/showthread.php?t=987 this is my car

Gery83
18-06-08, 16:08
Thanks! ;)

na15575
19-06-08, 10:04
hi nice work
just check that the hose A and B is it in the right plase
if A is in the place of B and B in the place of A then you can go uper than 0.48bar
A is in the center of pierberg
and fix the fuel pressure imidietely i damage my engine from a lean mixture now i rebuild it with a help from stuntz

Gery83
22-06-08, 09:14
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Gery83
26-07-08, 09:01
And here we go once again... :doh:
The whole story starts again.
The reason that was causing the lack of power was low compression (around 8bar = 116psi ), so I took the whole engine, and drivetrain apart...
So this time there will be some bigger modifications. :cool:
- forged pistons
- equal length exhaust mainfold
- Lancia kappa intake
- T3/T4 turbo
- Gr.A head gasket
- bigger oil cooler
- bigger AC
- kevlar clutch
- 4piston brakes
etc...

Here are some pictures:

279 - Dedra Integrale Rear Diff

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Gery83
02-08-08, 11:02
So here is what caused the lack of power... :(
So the hole is 1.5 times bigger as it should be, as the red line shows.
So I had the very first VPT (Variable Piston Timing) engine Q4 ever... :D
Patents Pending! :D

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wrinx
02-08-08, 13:24
Eeek! So the crank was moving about?

wrinx

AlfaJack
02-08-08, 15:55
So here is what caused the lack of power... :(
So the hole is 1.5 times bigger as it should be, as the red line shows.
So I had the very first VPT (Variable Piston Timing) engine Q4 ever... :D
Patents Pending! :D

300

:funnypost: Never seen that!! How could it happen? Just worn through?

Gery83
02-08-08, 15:57
:funnypost: Never seen that!! How could it happen? Just worn through?

Nooo way... That is some handy mechanic's work... :(
Probably previous owner...

Gery83
02-08-08, 16:00
Eeek! So the crank was moving about?

wrinx

No, but it was moving back and forth each stroke.
It sounded like the valve clearances were really bad...
(Clattering noise.) :S

wrinx
02-08-08, 21:22
Sorry, that's what I meant, so it messed the timing :doh:

Very strange...can't think why anyone would do that. That slot is for a woodruff key I presume?

wrinx

Evodelta
02-08-08, 22:14
That's a weird one, I've never seen that before. :eek:

Maybe a hamfisted mechanic lost the woodruff key and had to file it out for a bigger one?

Should have got Jack to slacken the nut off, it would have never come loose then eh... :biggrin:

wrinx
02-08-08, 23:35
Maybe a hamfisted mechanic lost the woodruff key and had to file it out for a bigger one?


That's what I was thinking...:confused:

wrinx

AlfaJack
02-08-08, 23:36
That's a weird one, I've never seen that before. :eek:

Maybe a hamfisted mechanic lost the woodruff key and had to file it out for a bigger one?

Should have got Jack to slacken the nut off, it would have never come loose then eh... :biggrin:

:redface::redface: But I even consulted the arse about face diagram in the manual!:deal:

Gery83
30-08-08, 16:57
Rebuilt brake-booster:
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Beginned to rebuild the engine-bay and the cables: (in gunmetal)
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New hybrid turbo:
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Recaro seats from a GTV:
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Mazda RX7 turbo aluminium 4piston brake calipers:
(they need a rebuild...)
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arjunior45
30-08-08, 17:38
love these 4piston alu calipers.
Please let me know how they fit and what about rims clearance.

Nick

Gery83
30-08-08, 17:52
love these 4piston alu calipers.
Please let me know how they fit and what about rims clearance.

Nick


Ok, as soon as it's ready, I will tell you and send some pics. ;)
I'm going to use standard 285mm disks, because they must fit under my 15" AZEV rims.

arjunior45
30-08-08, 19:48
Ok, as soon as it's ready, I will tell you and send some pics. ;)
I'm going to use standard 285mm disks, because they must fit under my 15" AZEV rims.

I'd like to keep the standard disk too. A little more breaking power at the front wheels wont be bad though.
From the other hand, I do trust more the good old piston type calipers. And if they are 4 piston will be great.

Waiting for the pics as soon as you complete it.

Good luck

Nick

AlfaJack
03-09-08, 10:40
Were the GTV seats a lot of work to make them fit?

Gery83
03-09-08, 16:45
Were the GTV seats a lot of work to make them fit?

Yes... :(
I do not recommend is to anyone...

AlfaJack
03-09-08, 16:56
Yes... :(
I do not recommend is to anyone...

I wont try then.

So when is the wooden trim coming out then? :tongue2:

Gery83
03-09-08, 17:02
I wont try then.

So when is the wooden trim coming out then? :tongue2:

As soon as I figured out, how to "remove" the holes, witch the previous owner drilled for 2 leds and a cellphone-holder... :(

If you want this kind of seats, than better go for the 145 TI, I think they have the same bolt pattern...

Gery83
14-09-08, 19:59
love these 4piston alu calipers.
Please let me know how they fit and what about rims clearance.

Nick


Hi!

Here are a few pics of the temporary setup.
So after this, I can tell you it's nearly impossible to fit it under 15" rims. The cooling lamellas need to be shortend on the outside of the caliper, and you need a wheel spacer (for my ET45 AZEVs at least 15mm).
I wouldn't like this solution, so I'll go for 16" rims.

(PS: I chopped the mazda label off... :cool:)

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arjunior45
15-09-08, 08:44
thanks for the info Gery. Very helpful.

Nick

Gery83
16-09-08, 18:43
thanks for the info Gery. Very helpful.

Nick

Here are some pictures of the holder prototype of wood, and first mesurements.
Fits perfectly, but a washer is needed between the holder and the wheelhub mountings.

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Gery83
16-09-08, 19:45
Here are some pictures of the holder prototype of wood, and first mesurements.
Fits perfectly, but a washer is needed between the holder and the wheelhub mountings.

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Dimensions are available here:

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arjunior45
17-09-08, 09:06
Dear Gery,

I hate to bother you again but I can not open this xdf file. are there only the dimensions or the drawing?

Nick

Q4Jan
17-09-08, 11:07
Dear Gery,

I hate to bother you again but I can not open this xdf file. are there only the dimensions or the drawing?

Nick
It is a .pdf file. It has a drawing+dimensions.
Just save the file somewhere and open with acrobat reader.

Gery83
17-09-08, 18:47
Dimensions are available here:

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A bit modified.

And I would use at least a 10mm thick metal plate.

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arjunior45
17-09-08, 19:29
@ Q4Jan

I did exactly that but came up an error message ... could not open file...

@ Gery

the new pdf is ok - I managed to open it without problems. Thanks again

Nick

Gery83
17-09-08, 19:38
@ Q4Jan

I did exactly that but came up an error message ... could not open file...

@ Gery

the new pdf is ok - I managed to open it without problems. Thanks again

Nick

You don't need to thank. :)

Gery83
19-09-08, 21:15
What do you think about this?
Would they look cool on a Q4?
They are 16" big.

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Evodelta
20-09-08, 10:07
Bleeeeuuuurgh.

Gery83
20-09-08, 10:12
Bleeeeuuuurgh.

:smile:
I'm not that good in english, so I don't really get what this means... :)

Positive, or negative?
Is it a throw-up 'noise'? :biggrin:

AlfaJack
20-09-08, 10:33
Is it a throw-up 'noise'? :biggrin:

I believe so ;)

I think there are better wheels out ther for the 155. OZ superturismos are my obvious choice :biggrin:

Evodelta
20-09-08, 10:54
I think some noises mean the same in any language. :biggrin:

http://i103.photobucket.com/albums/m127/Deltona_II/Yumour/V.jpg

Sorry, It was early and I had not had my morning coffee, I'm feeling a little better now. :tasty:

Gery83
20-09-08, 11:03
I believe so ;)

I think there are better wheels out ther for the 155. OZ superturismos are my obvious choice :biggrin:

And what about these?

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Gery83
20-09-08, 11:05
I think some noises mean the same in any language. :biggrin:

http://i103.photobucket.com/albums/m127/Deltona_II/Yumour/V.jpg

Sorry, It was early and I had not had my morning coffee, I'm feeling a little better now. :tasty:

Just as I tought! :biggrin:
I know what you mean. I'm an expert of this area, I'm reapiring coffee machines all week long. :cool:

Evodelta
20-09-08, 11:23
I see, so you until you arrive and get your spanners out there are lots of grumpy people around? :eek:

Just as a matter of interest, there is a link between coffee machines and our Q4s/integrales.

Some time ago I was in touch with a guy who realised that the pump in a coffee machine works at very high pressure, so he got one (cheap??) and fitted it to his car with a 12v ~ 220v transformer, he used it to power some high pressure misting jets to cool his intercooler!

Keep up the good work with the car, I am enjoying reading it. :smile:

wrinx
20-09-08, 12:14
The Venom style wheels were fitted to a UK 155 (owned by "Daiblack") and didn't look too bad imho...and I don't usually like them!

wrinx

Gery83
20-09-08, 12:39
I see, so you until you arrive and get your spanners out there are lots of grumpy people around? :eek:

Just as a matter of interest, there is a link between coffee machines and our Q4s/integrales.

Some time ago I was in touch with a guy who realised that the pump in a coffee machine works at very high pressure, so he got one (cheap??) and fitted it to his car with a 12v ~ 220v transformer, he used it to power some high pressure misting jets to cool his intercooler!

Keep up the good work with the car, I am enjoying reading it. :smile:

Yes, there are such pumps. They are produced 24V or 220V versions. They can produce up ta 15bar pressure with water.
They cost ~15-20USD a piece.

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And thanks! :cool:

AlfaJack
20-09-08, 17:58
And what about these?

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Very nice :cool: :cool:

Best colour too! :biggrin:

Gery83
21-09-08, 15:49
And what about these?

I really like these MOMOs!
But I haven't seen any 155 with them...

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Evodelta
21-09-08, 19:17
Mmmmmmm:

http://www.kptuning.com/images/llantas%20magnesio%20speedline%20corse%20type%2020 22%20f3%20formula%203.jpg

Evodelta
21-09-08, 19:24
OMG!!!!

http://www.storic-italia.com/catalog/images/storic_n2.jpg

Xti
21-09-08, 23:09
And what about these?

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Definitely white, especially if you're going for a red bodypaint. Good luck for your final choice.

Cristian

Varypodaros
22-09-08, 21:25
I suggest you to wait for those wheels...
http://static.blogo.it/autoblog/mito_1.jpg

Gery83
24-09-08, 18:40
I suggest you to wait for those wheels...
http://static.blogo.it/autoblog/mito_1.jpg

I don't like them... :(

But I think I'll buy these on the weekend:


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Varypodaros
24-09-08, 22:04
are you sure???
http://img143.imageshack.us/img143/4580/aaaaaaaaaaaaaaaaaaaag2.th.jpg (http://img143.imageshack.us/my.php?image=aaaaaaaaaaaaaaaaaaaag2.jpg)http://img143.imageshack.us/images/thpix.gif (http://g.imageshack.us/thpix.php)

Gery83
25-09-08, 13:43
are you sure???
http://img143.imageshack.us/img143/4580/aaaaaaaaaaaaaaaaaaaag2.th.jpg (http://img143.imageshack.us/my.php?image=aaaaaaaaaaaaaaaaaaaag2.jpg)http://img143.imageshack.us/images/thpix.gif (http://g.imageshack.us/thpix.php)

Now I'm totally sure... :biggrin:

Gery83
25-09-08, 16:29
What do you guy's know about Silverstone FTZ Sport tyres?
I'm planning to buy them in 225/50 R16 size.
Does anyone have some experience with them?

Thanks!

wrinx
25-09-08, 23:53
Strange size....they will be very big, the diameter is nearly 40mm larger.

wrinx

Gery83
26-09-08, 16:05
Strange size....they will be very big, the diameter is nearly 40mm larger.

wrinx

You're right!
Then I'll go for 205/45 R16 :)

That is much better!

wrinx
26-09-08, 16:21
:smile: That's the size used on the Sportpack 16" wheels ;)

wrinx

Gery83
27-09-08, 19:46
Here are some photos, today I tried them on.
Well obviously the 215/40 tyres are too small in the diameter.
So I will probably use 205/45 or 215/45 ones.

And I think I'm gonna need some lowering springs, because this way it looks like a grasshopper. :)
Note that the engine is missing... :)

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And now I know why I liked these rims at the first look.
They look very similar... :)

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axaQ42
29-09-08, 21:00
Gery could you please tell me the measurements of your FMIC??

Thanks


P.S.

Does anyone know the measurements of the original IC ??

wrinx
29-09-08, 22:14
The core of the IC is 310x205mm.

I can measure the full shape, including plastic end caps, if you need?

wrinx

axaQ42
30-09-08, 12:04
Thanks i only needed the core size.What about the thickness?

wrinx
30-09-08, 13:11
I forgot to measure that :redface::redface::tapedshut:

Will do a full measure tonight when get home :smile:

wrinx

Gery83
30-09-08, 15:57
Gery could you please tell me the measurements of your FMIC??

Thanks


P.S.

Does anyone know the measurements of the original IC ??


415

Gery83
30-09-08, 16:13
415

Oh, and by the way. You can buy it here. It's really-really cheap...

http://shop.wiltec.info/index.php/cat/c189_Ladeluftkuehler.html

wrinx
30-09-08, 19:06
Thanks i only needed the core size.What about the thickness?

65mm, will measure the whole thing if anyone needs it.

wrinx

Gery83
23-11-08, 12:23
Finally, they are finished.
They are made of 10mm thick steel plate.

Unfortunately now I have very little time for my car... :cry:

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wrinx
23-11-08, 12:25
Link doesn't work :(

wrinx

Gery83
23-11-08, 12:39
Link doesn't work :(

wrinx
Because this page is a piece of shit these days... :(

It's down all the time, and now I can't upload pictures...

Here's a link:

http://www.alfaamore.hu/files/blog/0000021/0000021345.jpg

wrinx
23-11-08, 13:09
Very good :cool:

Btw, the forum has been fine for a while now...looks like the host company had some probems.

wrinx

Gery83
04-12-08, 17:45
The main parts of the calipers have been sand-sprayed.

The results:

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They are going to get brand new pistons, and a yellow painting.

Juan AR155Q4
04-12-08, 19:21
I don?t think that those bolts would do the job :tongue2:

Gery83
04-12-08, 19:31
I don?t think that those bolts would do the job :tongue2:

Ha-ha... :biggrin:

Probably not...

Gery83
12-01-09, 18:07
My conrods.
Soon they are going to be lightened, balanced and polished.

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They are going to look like these:

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Gery83
25-01-09, 14:49
Look what I bought today!
A complete block, crankshaft and the connecting rods.
For only ~50EUR.... :D

So I solved the crankshaft problem... :cool:

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669

670

AlfaJack
25-01-09, 16:48
Bargain! What car is it out of?

Gery83
25-01-09, 16:51
Bargain! What car is it out of?

The seller didn't knew... Some kind of fiat... :D

wrinx
25-01-09, 18:09
Well done!

...reminds me, must go and get the engine and turbo I've been promised! :cool:

wrinx

Gery83
27-01-09, 18:11
DIY Turbo Timer almost ready, with adjustable time (1-9min).
Anyone interested? :biggrin:

673

wrinx
27-01-09, 18:58
:cool:

Wish I understood electronics :(

wrinx

Gery83
28-01-09, 19:29
Finally finished! :D

674

AlfaJack
28-01-09, 20:34
Nice job! :cool:

Evodelta
28-01-09, 22:13
:cool:

Wish I understood electronics :(

wrinx


Me too, it's like a tax return, it just throws up a mental block! I do have admiration for people who can do it well.

wrinx
28-01-09, 22:28
To be fair I've not really tried, but as I have enough trouble with electrics the odds on me understanding it are slim :doh:

Gery, out of interest...what was the cost of the complete job?

wrinx

Gery83
29-01-09, 16:10
To be fair I've not really tried, but as I have enough trouble with electrics the odds on me understanding it are slim :doh:

Gery, out of interest...what was the cost of the complete job?

wrinx

Hmmm... 7EUR approximately. :cool:
Plus 4-6 hours of work and thinking... :biggrin::biggrin::biggrin:

Gery83
29-01-09, 16:12
If anyone needs the schematics, I can post it here...

wrinx
29-01-09, 22:46
Schematics would involve understanding! No good to me :lol:








Actually...go on, I need a challenge ;)

wrinx

arjunior45
30-01-09, 08:08
although I've already made my 'own' turbo timer with EGT, boost pressure,air temp, differential temp and afr meter I think it will be good to have a simple turbo timer schematic in here just in case some one need it - or have a friend you can solder electronic parts.

Nick

Gery83
30-01-09, 17:15
Here you go:

678

wrinx
30-01-09, 20:00
Many thanks...but it's as I thought, completely challenged! :doh:

It might as well be a map of the London Underground :lol:

wrinx

Gery83
01-02-09, 09:15
And an even smaller version... :biggrin:

679

Gery83
01-02-09, 19:40
Conrods are ready!

681

682

683

wrinx
01-02-09, 21:56
And an even smaller version... :biggrin:

679

:smoke::smoke::smoke:

...and shiny things, very nice indeed!

wrinx

Gery83
07-02-09, 18:12
Kappa intake mainfold for aprox 50EUR.
(A bit wet...)

692

arjunior45
08-02-09, 15:10
Nice! and just 50Euro makes it even better.

Nick

Gery83
08-02-09, 15:37
Nice! and just 50Euro makes it even better.

Nick

The seller wanted almost 150EUR first...
But you know... I needed to offer him a bit lower price. :biggrin:

na15575
11-02-09, 18:33
this Kappa is turbo or not?

Gery83
11-02-09, 18:55
this Kappa is turbo or not?

Yes, I think it was a Kappa Turbo, but I haven't asked.
I think, it doesen't matter if it's a turbo or a simple suction engine. The intake mainfold must be the same... I think... :smile:

Gery83
11-02-09, 18:57
Some sprays... :D

697

Gery83
14-02-09, 13:04
Some polished parts ready for anodizing.

699

Sandblasted exhaust manifold, waiting to get heat resistant painting. :cool:

700

Gery83
14-02-09, 18:21
Modified fuel rail, for kappa manifold, and a place for a pressure sensor on the end.

701

702

Gery83
15-02-09, 18:05
Painted exhaust manifold with 800degrees heat resistant black. :biggrin:

703

wrinx
15-02-09, 21:51
Standard manifold....that's a surprise???

wrinx

Gery83
16-02-09, 18:34
Standard manifold....that's a surprise???

wrinx

Yes, I decided to use it, because of several reasons:
- I don't want to spend a ton of money for a stainless one from
england for example
- I don't want that much power (just around 250HP) now
- It's really hard to get one of them in Hungary

Later I will probably make myself one, but until then, this will do just fine.
If the engine works fine this way, than we can talk about higher power, and more custom parts later. :cool:

Gery83
19-02-09, 17:35
Some new parts:

The new pistons arrived for my mazda brake calipers:

717

New O-rings for injectors:

718

And a new MAP+IAT sensor:

719

Gery83
23-02-09, 18:12
Almost ready with the caliper rebuild, just waiting for its anodised screws... :cool:

728

729

arjunior45
23-02-09, 19:57
Almost ready with the caliper rebuild, just waiting for its anodised screws... :cool:

728

729

I love them. Definitively I'll go for them. Great work

Nick

Gery83
23-02-09, 20:00
I love them. Definitively I'll go for them. Great work

Nick

Thanks! :biggrin:

Rebuilt Marelli 100A alternator:

730

arjunior45
23-02-09, 20:09
Thanks! :biggrin:

Rebuilt Marelli 100A alternator:

730

did you change the voltage regulator too? Do you have the Marelli part number for this regulator? Need to change this one in mine too.

Nick

Gery83
23-02-09, 20:15
did you change the voltage regulator too? Do you have the Marelli part number for this regulator? Need to change this one in mine too.

Nick

No, I didn't changed it. It is in really good condition.

arjunior45
23-02-09, 20:20
ok

Gery83
01-03-09, 14:20
The calipers finally became RED, with motip engine paint.
Because the motip brake caliper spray is a piece of s**t.. :(

733

AlfaJack
01-03-09, 14:35
I once hand painted my calipers and did an awful job of them. Spreay paint from now on!

Hope the paint can take the heat! :cool:

Gery83
01-03-09, 14:44
I once hand painted my calipers and did an awful job of them. Spreay paint from now on!

Hope the paint can take the heat! :cool:


It's easy... just use heat resistant paint, like I did. :D

arjunior45
02-03-09, 18:34
The calipers finally became RED, with motip engine paint.
Because the motip brake caliper spray is a piece of s**t.. :(

733

RED?
Why did not you kept them alu look?
I think I'm going just to polish mine with abrasive brush and make them ...shine. But to tell you the trough it is just because I do not like the red color that I comment these. They look gr8.

Nick

Gery83
08-03-09, 17:23
Yesterday arrived a new family member. :D
'96 155 super 2.0 TS 16V

It's my fathers car.
Beautiful...

742

wrinx
08-03-09, 18:53
Mmm...Prugna :cool:

wrinx

Gery83
08-03-09, 19:00
Mmm...Prugna :cool:

wrinx


Prugna?
What does that mean?

wrinx
08-03-09, 19:06
That's the UK paint name, Italian for purple as far as I know :)

wrinx

Gery83
08-03-09, 19:12
That's the UK paint name, Italian for purple as far as I know :)

wrinx

Aubergine-metallic :D

wrinx
08-03-09, 21:17
Nah...that's not good, I don't like Aubergines :doh:

wrinx

Gery83
09-03-09, 18:27
New front brakepads, and hoses.

745

Gery83
15-03-09, 09:17
AutoGauge boost and oil pressure meters. The oil pressure meter, will be used as fuel pressure meter.

754

wrinx
15-03-09, 10:12
They look similar to the ones I've got (Go-Glow), how much were they?

wrinx

Gery83
15-03-09, 14:43
They look similar to the ones I've got (Go-Glow), how much were they?

wrinx

Around 50EUR the both. Boost gauge 30, pressure 20.

Gery83
15-03-09, 14:45
And this is the alu part which will hold the three gauges. Boost, Fuel Pressure, Wideband AFR.

755

Something like this:

756

wrinx
15-03-09, 18:44
Around 50EUR the both. Boost gauge 30, pressure 20.

Much cheaper than mine then :(

Mine were something like 45? each!

wrinx

wrinx
15-03-09, 18:47
756

I'm planning on using the same place but bought a triple pod piece which has "steps" in for each gauge, so they turn a bit to the driver.

If it looks rubbish I'll be doing the same as you! :D

wrinx

jimnielsen
15-03-09, 20:13
Gery.. How much do those new front brake hoses cost? And where do you get them?

Thanks, jim.

Gery83
15-03-09, 20:15
Gery.. How much do those new front brake hoses cost? And where do you get them?

Thanks, jim.

At the local dealer. They are really cheap.
Around 4EUR a piece. :D

Gery83
15-03-09, 20:20
I'm planning on using the same place but bought a triple pod piece which has "steps" in for each gauge, so they turn a bit to the driver.

If it looks rubbish I'll be doing the same as you! :D

wrinx

I also saw such a plastic part.
But I think it's really hard to fit it properly and nice.

http://www.fonixtuning.hu/content//termekek/650-1.jpg

wrinx
15-03-09, 21:24
Yup, same idea but mine are metal and without the tabs on each end ;)

I think they will have to be in a surround of their own....I have a few ideas :D

wrinx

Gery83
16-03-09, 17:44
Yup, same idea but mine are metal and without the tabs on each end ;)

I think they will have to be in a surround of their own....I have a few ideas :D

wrinx

Want to see some pictures! :D

I took my alu plate to the machine shop today to cut nice, precise 52,5mm holes in it. :D

wrinx
17-03-09, 00:16
Will be a while before I get around to it...as I've been messing about with a small lathe and then remembered about fitting the replacement (2nd hand) turbo and stainless manifold :cool:

wrinx

Gery83
17-03-09, 16:41
Engine block finally finished.
With 85mm 8.0:1CR pistons.

763

764

765

Gery83
17-03-09, 18:13
Shit...
Just noticed, that the pistons are sitting in the wrong way...

jimnielsen
17-03-09, 20:15
you'd better fix that! :) . . . Do you have any pics of the pistons/rods before or during assembly?

cheers, jim.

Gery83
17-03-09, 20:17
you'd better fix that! :) . . . Do you have any pics of the pistons/rods before or during assembly?

cheers, jim.

Sorry, but I don't... :(

Gery83
17-03-09, 20:20
Does it make any difference, which way the conrods stand?

wrinx
18-03-09, 08:31
What's this secret new idea for forced induction...vacuum?

wrinx

AlfaJack
18-03-09, 09:45
What's this secret new idea for forced induction...vacuum?

wrinx

If Dyson made turbos.....

Gery83
18-03-09, 19:21
Finished. :D

766

767

768

Gery83
18-03-09, 20:57
Only need a wideband AFR now...:doh:

wrinx
18-03-09, 22:25
Very good :cool:

I decided not to bother with WB AFR as I probably wouldn't use it properly, so just went with a ?50 Narrowband version...it'll only give yes/no but was much cheaper :D

wrinx

Gery83
22-03-09, 18:18
- new brake master
- engine bay is almost tidy
- fixing damaged cables
- connecting gauges (interior is a bit messy)
- TS 16V steering servo reservoir tank

(need to change IAT, MAP connector to new one)

776

777

778

779

Varypodaros
24-03-09, 15:55
how did you pull out the central air way???

Gery83
24-03-09, 19:22
how did you pull out the central air way???


With these:

780

Gery83
26-03-09, 16:28
Turbo joined the exhaust manifold:

781

New relay holder for engine bay: (RIPCA)

782

AlfaJack
26-03-09, 16:59
Drawing "HF" in to your table too! :tongue2: Dreaming of an Integrale are we?:tapedshut:

Gery83
26-03-09, 17:03
Drawing "HF" in to your table too! :tongue2: Dreaming of an Integrale are we?:tapedshut:

Holy shit!
That is still visible? :D

Varypodaros
27-03-09, 15:22
With these:

780

thank you a lot...

Gery83
01-04-09, 19:21
Finished brake calipers, intake, and zinc-coated stuff. :cool:

805

806

807

808

AlfaJack
01-04-09, 19:24
Very smart! Is zinc coating quite strong? How would it compare to anodising?

Gery83
01-04-09, 19:26
Very smart! Is zinc coating quite strong? How would it compare to anodising?

It's relatively strong. Isn't anodising just for aluminium?

AlfaJack
01-04-09, 21:01
It's relatively strong. Isn't anodising just for aluminium?


:doh:No idea actually.

arjunior45
02-04-09, 08:17
Finished brake calipers, intake, and zinc-coated stuff. :cool:

807



Just a thought.
Why don't you make some adjustable cam pulleys? Just in case you might need them later.
I did not make a couple when I had the time and the head apart and now I regret it!

Something like them will be nice.

Nick

Gery83
03-04-09, 20:47
Just a thought.
Why don't you make some adjustable cam pulleys? Just in case you might need them later.
I did not make a couple when I had the time and the head apart and now I regret it!

Something like them will be nice.

Nick


I never tought about this before.
Why do I need them exactly?

Gery83
03-04-09, 20:51
Installed calipers, new main- and conrod bearings:


816

817

818

819

arjunior45
03-04-09, 21:15
I never tought about this before.
Why do I need them exactly?

If you ever want to 'play' with the cams - advance of retard the valves timing - or if you ever decide to mount the FIAT Tipo 16V high lift inlet cam, they will be useful to you.

Otherwise, you do not need them.

Nick

arjunior45
03-04-09, 21:18
I like a lot those calipers. And I would have mounted them if I could use the oem 15" Speeline rims. Great job.

Nick

Gery83
03-04-09, 21:21
Thanks Nick!

Stuntz
04-04-09, 09:49
If you ever want to 'play' with the cams - advance of retard the valves timing - or if you ever decide to mount the FIAT Tipo 16V high lift inlet cam, they will be useful to you.

Otherwise, you do not need them.

Nick


How muc deegres of setup do oyu need for cam advance? is 5 degrees left right ok ?

arjunior45
04-04-09, 14:46
How muc deegres of setup do oyu need for cam advance? is 5 degrees left right ok ?

if you mean with the Tipo inlet cam, I believe it's 2 or 4 degrees. I do not remember exactly. Need to check my notes.

Nick

na15575
04-04-09, 21:27
Does it make any difference, which way the conrods stand?
Yes it make difference
the conecting rod is complete symetrical
but you must notice the litle cuts for the berings hold must be on the oposite site of the rotation


the new turbo is t3 lancia integrale?

Gery83
06-04-09, 16:47
Yes it make difference
the conecting rod is complete symetrical
but you must notice the litle cuts for the berings hold must be on the oposite site of the rotation


the new turbo is t3 lancia integrale?


Thanks!

No, It's a T3/T4 hybrid turbo.

Gery83
17-04-09, 14:48
Things are going a bit slowly...
I'm waiting since two weeks for one oil jet. :(
This is the reason why I can not continue the assembly of my engine. I'm stock at this stage:

840

841

Ohh, and besides, I have new thrust bearing halves too.

842

Gery83
01-05-09, 11:51
846

847

848

849

850

Gery83
01-05-09, 11:52
851

852

AlfaJack
01-05-09, 11:59
What's in the bag?

jimnielsen
01-05-09, 12:01
thanks for the photos! they will help me when I put me engine back together.. hopefully soon.

Gery83
01-05-09, 12:26
What's in the bag?

A new screw for the crankshaft.

853

jimnielsen
01-05-09, 12:52
did you loose the old one??

Gery83
01-05-09, 13:31
did you loose the old one??

No, I didn't had any.
My old crankshaft had another type of screw.
When I purchased this one, the seller didn't gave me the screw for it.

Gery83
10-05-09, 16:49
Kevlar clutch disk:
866

Regrooved flywheel:
867

New head bolts:
868

Current stage:
869
870

AlfaJack
10-05-09, 23:12
Could eat your dinner off it!

arjunior45
11-05-09, 08:41
use it as coffee table in a living room?

Love to see things like your engine Gery.

Nick

Gery83
11-05-09, 18:42
Thanks guys! :smile:

Look what arrived today! :smoke:

871

872

Gery83
15-05-09, 18:06
I was home today, here are the results:

886

887

888

889

890

891

Gery83
26-05-09, 18:42
Pulled out of the dust last weekend, and installed engine.
Still a lot of work to do, but now I can finally see the end of the tunnel...

908909910

Two beautiful asses. :D

911

wrinx
26-05-09, 19:02
Nice looking engine...the road to recovery is shortening :D

wrinx

mindus
26-05-09, 20:40
I adore your wheels on Q4... :)

Gery83
30-05-09, 11:18
I adore your wheels on Q4... :)


Thanks!
They loook very crappy if you look closer. :)

Gery83
30-05-09, 11:19
Nice looking engine...the road to recovery is shortening :D

wrinx

I think I need another 2 mounths for it. :) :doh:

arjunior45
30-05-09, 12:15
what's this Gery?

Gery83
30-05-09, 12:38
what's this Gery?

That's a steering fluid reservoir tank from a 16V TS.

AlfaJack
30-05-09, 13:33
Surprised it fits with the inlet there!

Gery83
30-05-09, 13:45
Surprised it fits with the inlet there!

No way!
I tried yesterday the kappa inlet. It doesen't fit. :D

Gery83
28-06-09, 19:42
Current stage of things:

Bunch of new hoses:
1030

Dedra integrale wheel:
1031

Ignition modules:
1033

Steering fluid reservoir:
1034

Messy engine bay:
1032
1035

Still a lot of work to do.. :)

jimnielsen
28-06-09, 23:02
Great work Gery! I would love a kappa manifold - I have never seen one for sale (actually I've never even seen one before :( ...)

I have removed the 'felt' on the firewall, as it provides a little extra room. I like the new power steering bottle..

at the rate you are traveling, yours will be going before mine...

what about doing a 'first fire up' video?

cheers, jim.

1NRO
29-06-09, 06:26
Fiat will sell you a Kappa manifold, I think I paid about ?200 ish for a new one, a little while ago so can't be sure on the price.

Nik

arjunior45
29-06-09, 14:53
I hate you guys {Gery and Jim} for you are going to make me mess with my car too!

AlfaJack
29-06-09, 14:57
I hate you guys {Gery and Jim} for you are going to make me mess with my car too!

I have the same feelings! :cry:

Gery83
29-06-09, 17:49
It's not too hard to get one...
Yes, I'll probably make a video, or more. :)



Great work Gery! I would love a kappa manifold - I have never seen one for sale (actually I've never even seen one before :( ...)

I have removed the 'felt' on the firewall, as it provides a little extra room. I like the new power steering bottle..

at the rate you are traveling, yours will be going before mine...

what about doing a 'first fire up' video?

cheers, jim.

Gery83
04-07-09, 13:28
Needed to modify fuel-rail again: (not ready yet)
It needed a bend, and the FPR holder.
Needs some welding and new anodising tough...
1048

Mess in engine bay:
1049

Alu shield for turbo oil outlet silicone hose:
1050

Gery83
26-07-09, 11:20
New oil cooler hoses, and 100A alternator from a '96 2.0 TS GTV.
Quite a pain in the ass to get it in... :doh:

1098

1099

1100

Gery83
27-08-09, 18:42
So...
Back again, after a longer time.
Because of the bigger turbo, the factory fan didn't fit anymore.
I had to purchase a new one.
It's a SPAL 380mm blower fan, with only 52mm thickness.
You can see the results with the brand new watercooler.

1141

1142

1143

1144

1145

1146

Gery83
13-09-09, 17:24
Modified fuel rail:

1149

AlfaJack
14-09-09, 00:29
Very nice. What is the bit on the end after the gauge?

wrinx
14-09-09, 08:17
Looks a little bit like a sight glass...:confused:

wrinx

Juan AR155Q4
14-09-09, 14:03
It seems to be a pressure sensor.

AlfaJack
14-09-09, 14:42
Yes I think you are right - looks a similar style to the oil pressure sensor.