View Full Version : Hungarian Q4 engine rebuild & modifications
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.
As I bought it in 2007:
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An early clutch change:
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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
...continued:
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Some new parts and stuff:
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Some engine bay washing:
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Engine block painting:
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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.
Hi!
Thanks!
Yes, I was there, but unfortunetly not with my car, because it was in pieces... :DDD
Some more parts:
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Some painted stuff:
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Battery in the trunk:
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Replaced ignition coils:
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Rebuilt starter motor:
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Little cutting and welding:
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Bumper cutting and washing stuff:
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Painting, cooler fitting:
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Painting, cooler fitting:
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Very good and neat work Gery
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
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:
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
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. :)
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!!
Exactly!
Just bad luck... :)
'New' oilcooler hoses:
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An essential for a rebuild job. Wont be long until all the originals are rusted through :(
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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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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Been busy then!
Looking very good!
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!!
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.
I was a bit busy today, here are some pictures:
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Another busy day:
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Ignition cables:
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Fuel pressure gauge:
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Custom air pipes:
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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~
Instructive indeed, thank you Gery. Keep up the good work.
Cheers,
Cristian.
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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on idle whit vacuum hose atached or detached?
on idle whit vacuum hose atached or detached?
With attached vacuum hose.
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.
Oh, thanks! I'll check that!
Do you have any other ideas what else can cause low boost pressure?
faulty pierburg vavle. faulty wiering to pierburg valve. Is it possibe taht oyu have a leak somewhere in the boost system?
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!
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.
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
http://forum.berlinasportivo.org/showthread.php?t=987 this is my car
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
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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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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Eeek! So the crank was moving about?
wrinx
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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:funnypost: Never seen that!! How could it happen? Just worn through?
:funnypost: Never seen that!! How could it happen? Just worn through?
Nooo way... That is some handy mechanic's work... :(
Probably previous owner...
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
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
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:
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
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:
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
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
Were the GTV seats a lot of work to make them fit?
Were the GTV seats a lot of work to make them fit?
Yes... :(
I do not recommend is to anyone...
Yes... :(
I do not recommend is to anyone...
I wont try then.
So when is the wooden trim coming out then? :tongue2:
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...
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
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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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
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.
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
@ 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. :)
What do you think about this?
Would they look cool on a Q4?
They are 16" big.
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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:
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:
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:
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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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:
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:
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
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:
And what about these?
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Very nice :cool: :cool:
Best colour too! :biggrin:
And what about these?
I really like these MOMOs!
But I haven't seen any 155 with them...
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Mmmmmmm:
http://www.kptuning.com/images/llantas%20magnesio%20speedline%20corse%20type%2020 22%20f3%20formula%203.jpg
OMG!!!!
http://www.storic-italia.com/catalog/images/storic_n2.jpg
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
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)
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:
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!
Strange size....they will be very big, the diameter is nearly 40mm larger.
wrinx
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!
:smile: That's the size used on the Sportpack 16" wheels ;)
wrinx
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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Gery could you please tell me the measurements of your FMIC??
Thanks
P.S.
Does anyone know the measurements of the original IC ??
The core of the IC is 310x205mm.
I can measure the full shape, including plastic end caps, if you need?
wrinx
Thanks i only needed the core size.What about the thickness?
I forgot to measure that :redface::redface::tapedshut:
Will do a full measure tonight when get home :smile:
wrinx
Gery could you please tell me the measurements of your FMIC??
Thanks
P.S.
Does anyone know the measurements of the original IC ??
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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
Thanks i only needed the core size.What about the thickness?
65mm, will measure the whole thing if anyone needs it.
wrinx
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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Link doesn't work :(
wrinx
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
Very good :cool:
Btw, the forum has been fine for a while now...looks like the host company had some probems.
wrinx
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:
I don?t think that those bolts would do the job :tongue2:
Ha-ha... :biggrin:
Probably not...
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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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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Bargain! What car is it out of?
Bargain! What car is it out of?
The seller didn't knew... Some kind of fiat... :D
Well done!
...reminds me, must go and get the engine and turbo I've been promised! :cool:
wrinx
DIY Turbo Timer almost ready, with adjustable time (1-9min).
Anyone interested? :biggrin:
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:cool:
Wish I understood electronics :(
wrinx
: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.
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
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:
If anyone needs the schematics, I can post it here...
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
Many thanks...but it's as I thought, completely challenged! :doh:
It might as well be a map of the London Underground :lol:
wrinx
And an even smaller version... :biggrin:
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Conrods are ready!
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And an even smaller version... :biggrin:
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:smoke::smoke::smoke:
...and shiny things, very nice indeed!
wrinx
Kappa intake mainfold for aprox 50EUR.
(A bit wet...)
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arjunior45
08-02-09, 15:10
Nice! and just 50Euro makes it even better.
Nick
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:
this Kappa is turbo or not?
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:
Some polished parts ready for anodizing.
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Sandblasted exhaust manifold, waiting to get heat resistant painting. :cool:
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Modified fuel rail, for kappa manifold, and a place for a pressure sensor on the end.
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Painted exhaust manifold with 800degrees heat resistant black. :biggrin:
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Standard manifold....that's a surprise???
wrinx
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:
Some new parts:
The new pistons arrived for my mazda brake calipers:
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New O-rings for injectors:
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And a new MAP+IAT sensor:
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Almost ready with the caliper rebuild, just waiting for its anodised screws... :cool:
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arjunior45
23-02-09, 19:57
Almost ready with the caliper rebuild, just waiting for its anodised screws... :cool:
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I love them. Definitively I'll go for them. Great work
Nick
I love them. Definitively I'll go for them. Great work
Nick
Thanks! :biggrin:
Rebuilt Marelli 100A alternator:
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arjunior45
23-02-09, 20:09
Thanks! :biggrin:
Rebuilt Marelli 100A alternator:
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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
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
The calipers finally became RED, with motip engine paint.
Because the motip brake caliper spray is a piece of s**t.. :(
733
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:
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
Yesterday arrived a new family member. :D
'96 155 super 2.0 TS 16V
It's my fathers car.
Beautiful...
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Mmm...Prugna :cool:
wrinx
Mmm...Prugna :cool:
wrinx
Prugna?
What does that mean?
That's the UK paint name, Italian for purple as far as I know :)
wrinx
That's the UK paint name, Italian for purple as far as I know :)
wrinx
Aubergine-metallic :D
Nah...that's not good, I don't like Aubergines :doh:
wrinx
New front brakepads, and hoses.
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AutoGauge boost and oil pressure meters. The oil pressure meter, will be used as fuel pressure meter.
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They look similar to the ones I've got (Go-Glow), how much were they?
wrinx
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.
And this is the alu part which will hold the three gauges. Boost, Fuel Pressure, Wideband AFR.
755
Something like this:
756
Around 50EUR the both. Boost gauge 30, pressure 20.
Much cheaper than mine then :(
Mine were something like 45? each!
wrinx
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.
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
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
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
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
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
Engine block finally finished.
With 85mm 8.0:1CR pistons.
763
764
765
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.
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... :(
Does it make any difference, which way the conrods stand?
What's this secret new idea for forced induction...vacuum?
wrinx
What's this secret new idea for forced induction...vacuum?
wrinx
If Dyson made turbos.....
Only need a wideband AFR now...:doh:
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
- 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???
how did you pull out the central air way???
With these:
780
Turbo joined the exhaust manifold:
781
New relay holder for engine bay: (RIPCA)
782
Drawing "HF" in to your table too! :tongue2: Dreaming of an Integrale are we?:tapedshut:
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...
Finished brake calipers, intake, and zinc-coated stuff. :cool:
805
806
807
808
Very smart! Is zinc coating quite strong? How would it compare to anodising?
Very smart! Is zinc coating quite strong? How would it compare to anodising?
It's relatively strong. Isn't anodising just for aluminium?
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
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?
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
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
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?
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.
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
jimnielsen
01-05-09, 12:01
thanks for the photos! they will help me when I put me engine back together.. hopefully soon.
What's in the bag?
A new screw for the crankshaft.
853
jimnielsen
01-05-09, 12:52
did you loose the old one??
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.
Kevlar clutch disk:
866
Regrooved flywheel:
867
New head bolts:
868
Current stage:
869
870
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
Thanks guys! :smile:
Look what arrived today! :smoke:
871
872
I was home today, here are the results:
886
887
888
889
890
891
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
Nice looking engine...the road to recovery is shortening :D
wrinx
I adore your wheels on Q4... :)
I adore your wheels on Q4... :)
Thanks!
They loook very crappy if you look closer. :)
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?
what's this Gery?
That's a steering fluid reservoir tank from a 16V TS.
Surprised it fits with the inlet there!
Surprised it fits with the inlet there!
No way!
I tried yesterday the kappa inlet. It doesen't fit. :D
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.
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!
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:
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.
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
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
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
Very nice. What is the bit on the end after the gauge?
Looks a little bit like a sight glass...:confused:
wrinx
Juan AR155Q4
14-09-09, 14:03
It seems to be a pressure sensor.
Yes I think you are right - looks a similar style to the oil pressure sensor.
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