View Full Version : Brul(tm)'s 155 Q4
In preparation of my project, maybe it?s about time to introduce my Q4. I already posted some pictures from my car a couple of times. Here?s the story about my Q4.
It all started in November 2002 when I needed another car after a crash incident with my Alfa Romeo 33. I always had a wish to own a 155 because of the beautiful design of this car. I only had one wish, it has to be equipped with air conditioning. It didn?t matter if it was going to be a 1.8 or a 2.0 engine. Well I came home with a Q4. Below a couple of pictures how the Q4 looked when I bought the car.
http://i115.photobucket.com/albums/n288/BrulTM/155%20Q4/IM002541.jpg http://i115.photobucket.com/albums/n288/BrulTM/155%20Q4/IM002542.jpg
The engine compartment
http://i115.photobucket.com/albums/n288/BrulTM/155%20Q4/IM002546.jpg
Standard interior. http://i115.photobucket.com/albums/n288/BrulTM/155%20Q4/IM002548.jpg http://i115.photobucket.com/albums/n288/BrulTM/155%20Q4/IM002551.jpg
As you all can see, quit a standard car. In the mean while I have changed a lot to the point I am at.
It started by changing the exhaust system. The original exhaust system wasn?t good enough for this car, so that has to go.
I wanted a better sound, but also improve the way the car responds.
http://i115.photobucket.com/albums/n288/BrulTM/EPS%20march%202003/IM002928.jpg
this got replaced by a stainless steel system with a 3? pipe replacing the first two silencers and fitted a small back box.
http://i115.photobucket.com/albums/n288/BrulTM/EPS%20march%202003/IM002956.jpg http://i115.photobucket.com/albums/n288/BrulTM/EPS%20march%202003/IM002938.jpg http://i115.photobucket.com/albums/n288/BrulTM/EPS%20march%202003/IM002941.jpg http://i115.photobucket.com/albums/n288/BrulTM/EPS%20march%202003/IM002953.jpg
Other modifications came along like:
- Sparco strut brace.
- Sparco roll cage.
- Sparco Evo seats.
- Sparco 3? harness with 6 fastening points.
- Squadra combi-prom with four mappings/programs.
- Goodridge braided brake hoses.
- Tarox G88 brake discs at the back.
- Brembo sport brake discs (drilled) at the front.
- Boot lid by Savali.
- 17? Tecnomagnesio Sport TM wheels.
- Custom air filter.
- Forge dual-piston atmospheric valve, FMDV0004 with valve spring tuning kit.
- Qv skirts from the Alfa 145 Qv.
- Defi link system v2 with currently only a boost pressure gauge.
- Adjustable Koni sport shocks with Intrax racing springs 50mm lowering.
- DTM wiper.
I think I?ve got the most of it, probably forgot a couple of things.
Below a couple of pictures with the modifications in place. http://i115.photobucket.com/albums/n288/BrulTM/Savali%20boot%20lid/IMG_5713.jpg http://i115.photobucket.com/albums/n288/BrulTM/Sparco%20seats/IMG_5679.jpg http://i115.photobucket.com/albums/n288/BrulTM/Sparco%20seats/IMG_5668.jpg http://i115.photobucket.com/albums/n288/BrulTM/155%20Q4%20and%20155%20Savali%20shoot/IMG_3097.jpg
And sometime I take the car to a trackday.
http://i115.photobucket.com/albums/n288/BrulTM/155%20Q4/Cicuit/Zandvoort1.jpg http://i115.photobucket.com/albums/n288/BrulTM/155%20Q4/Cicuit/Zandvoort2.jpg
At this moment I stored the car due to cam belt problems. I am planning to rebuild the engine and will share the progress from this project in this thread. Also I hope to figure out what is the root cause of my belt failure in 2007.
Currently I am planning to start in April this year by taking out the old engine. I will start by cleaning every part and also spend some time and effort in the appearance of everything. I hope to do as much as possible by myself with help from friends and hire help when required. So there will be questions from me to you for advise, but also to hear how you guys solved problems encountered.
Regards,
Marc
arjunior45
11-03-10, 14:01
two years locked in the garage is a long way!
BTW can you post a picture from the 'Sparco 3” harness with 6 fastening points'? Mostly from the rear seat.
And maybe from your custom air filter?
I just love that car, and the things done looking great!
good luck with the rebuild, mine took about two years to sort out, but I did buy it in parts with many pieces missing!
regards
David
jimnielsen
11-03-10, 20:53
I am looking forwards to reading about it all as it happens. I am going to be setting up a new (spare) engine this year so I am sure I can learn a lot!
cheers, jim.
I often used to admire your car. Lucky you to have such a 155 Q4 but more than that lucky 155Q4 to have you. Congrats and good luck with the rebuild.
Many greatings,
Cristian.
yes lovely q4 brul,i do like the 155 in black, and good to see it being used out on track.
good luck with the re-build.
Very nice Q4 you have Marc, i wish you good luck with the re-build, two years are a long time without driving your "bella" ;)
Just one question, how do you made/fit the "DTM wiper"?
Just one question, how do you made/fit the "DTM wiper"?
I bought this as a kit. It it no more than an original wiper mechanisme that is converted to a single arm with parts from an Citroen ZX ;) The blade is from a Lancia Ypsilon, don't know the excapt year.
Regards,
Marc
BTW can you post a picture from the 'Sparco 3” harness with 6 fastening points'? Mostly from the rear seat.
And maybe from your custom air filter?
Well, it took me some time to get my server running again :confused:
Here are some pictures from the air filter.
http://i115.photobucket.com/albums/n288/BrulTM/155%20Q4/IM002997.jpg
http://i115.photobucket.com/albums/n288/BrulTM/155%20Q4/IM002999.jpg
http://i115.photobucket.com/albums/n288/BrulTM/155%20Q4/IM003000.jpg
I couldn't find any specific pictures of the harnes, only the picture below.
http://i115.photobucket.com/albums/n288/BrulTM/Sparco%20seats/IMG_5674.jpg
The belts are bolted in place on the original mounting points from the belts at the back. This is far from ideal, but within the margins of the angles under wich the belts are allowed to be used.
Regards,
Marc
arjunior45
15-03-10, 09:51
thanks for the pictures Marc. It's ok for me!!!
Nice roll cage btw, congrats.
Nice roll cage btw, congrats.
The roll cage is a "bolt in" type made by Sparco.
I had the cage welded in the car instead, only some parts (bars) are stil bolted. And as Extra I have a extra bar between te B-style to fix the harness on and give extra strength from sideway impact.
Regards,
Marc
Hmm, that filter reminds me of somebody's car.
Now let me think.....
Hmm, that filter reminds me of somebody's car.
Now let me think.....
Harko? Beside yourself ;)
Regards,
Marc
:cool:
Only the top-lid is a bit different. I got screws who go into the plate. So not metal sticking out so far.
Well, finally got a bit time to spent in the garage.
What do we have on the other side of the tool board.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8799.jpg
There?s the project where I hope the spent a bit more time on.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8800.jpg
And of course the bonnet whit underneath the project that?s going to cost me some money well spent ;)
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8804.jpg
Basically I started with some labelling and removing some hoses and loosening connectors.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8806.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8811.jpg
Progress will be slow, but hopefully I can speed up towards the summer.
If any progress, I?ll be sharing it here.
Regards,
Marc
Well, little progress for today. Came home from work a bit earlier to do some work on the car.
Took the intake manifold of and some components in the direct surrounding.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8814.jpg
A couple of hoses or rubber seals are very dried out and need to be replaced. Now this isn?t going to be a problem, because I want to replace everything for silicon based hoses in a colour.
Below an overview of some of the parts that I removed today.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8815.jpg
Below the result for today afterwards.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8816.jpg
There was only one strange thing I found in the intake manifold. It?s a bit difficult to see, but it looks like some metal residue.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8819.jpg
This is shown in all the four separated pipes from the inlet manifold. Don?t know where this could be coming from.
Regards,
Marc
Bet you had fun taking the intake manifold off...never an easy job.
Interesting how they use the manifold runner as used on the NA coupe rather than the 16vt.
arjunior45
30-04-10, 08:28
There was only one strange thing I found in the intake manifold. It?s a bit difficult to see, but it looks like some metal residue.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8819.jpg
This is shown in all the four separated pipes from the inlet manifold. Don?t know where this could be coming from.
Regards,
Marc
is it metal residue or just 'color' from the petrol?
How is it different?
The injector is mounted differently, the coupe 16vt has them on the very end of the runners at a steeper angle (admittedly pointing straight at the back of the valve). The shape is different internally, on 16vt the injector boss protrudes into the runner (a larger cross section here makes it a non issue) and is quite straight, the NA is more contoured in comparison. The 16vt as cast min cross section is slightly larger than the NA, the casting is a fair bit thinner on the 16vt also. Where the rubber joint is the casting on the NA is much thicker. The floor of the NA has a pronounced curve and is generally more sweeping. The gasket opening is much smaller on the NA than the 16vt. I'm talking only of the part that bolts to the head.
I'm hacking some of each type at the minute and the material that needs removed is huge, on both of them. When I say needs I mean to suit a ported head though in the case of the NA they are restrictive even on the standard head. I prefer the NA casting like the Q4 has to work on, it's more fiddly but better IMO. I'm sick of grinding on them though, they take forever.
Nik
is it metal residue or just 'color' from the petrol?
This is deffinaltly metal residu.
Removed some of this residu and put it on a white paper to make the pictures below.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8822.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8823.jpg
When I look closly at the particles, they have different colours.
Haven't looked into the inlet ports on the engine yet, but I find this very disturbing :eek:. Not all the cylinders have the same kind of material, cylinder 1 and 4 have the most metal particles.
Regards,
Marc
Just back from the garage, couldn?t put it to rest.
The head is defiantly written of. The cause for the metal parts in the inlet manifold are from one destroyed inlet valve from the third cylinder and some of the material what used to be the valve seating? When the head is of the damage to the rest will become visible. But this explains why the engine is stuck at this moment.
Regards,
Marc
Below the pictures from the results after todays work in the garage.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8829.jpg http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8828.jpg
The coolant and the engine oil is removed today. Haven?t filtered the oil yet, but took a quick look and didn?t find any metal particles.
Today I removed the front bumper, the radiator, the exhaust manifold, the turbo, the front bar with headlights.
Also took another look at cylinder 3, this is heavenly damaged. Unfortunately I couldn?t remove the head because I didn?t have the right tooling for this job. Never done that before, so I need to order some tools next week. Then I can take a look at the damage done.
Regards,
Marc
arjunior45
04-05-10, 19:25
Hope it's just the inlet valve and nothing more serious.
i don't think it is only the valve, there will be more damage, maybe even the turbo? :eek:
The turbo is of and took a quick look at it. This seems to be fine.
Not that this will be a problem since this is a thing I will be replacing for another, bigger turbo after the rebuild.
That there will be more damage is a thing that I am sure of :eek:
The piston is heavily damaged from what I can see through the inlet port. Didn't had the right "ribe" bit to losen the head bolts. When the head is of, I will post pictures of the damage done. But I expect that this engine is beyond repair or reusability :cry: :cry:
Regards,
Marc
arjunior45
06-05-10, 13:25
But I expect that this engine is beyond repair or reusability :cry: :cry:
Regards,
Marc
hope that's not true.
Went to the local hardware store to buy the necessary ribe bit set to losen the head bolts.
After removing the timing belt, the thermostat and some of the pipes around the engine it was time to lift the head.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8830.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8831.jpg
This is just before the lifting of the head. I was very curious what I would find, had a bad feeling because of the damage I already saw through the inlet ports. Well, time for some pictures ??
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8832.jpg
After carefully removing the head, there was the broken valve that caused al lot of damage on at least the third piston.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8837.jpg
Heavy piston damage
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8840.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8841.jpg
And now for a close-up
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8842.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8843.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8844.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8846.jpg
I guess this head is beyond repair due to the damage of the valve seating?
Besides that, I don?t think I want to use this head anymore for my project engine.
I will start searching for another head to do the job.
The rest of the engine is to early to tell. Though I do find it strange to find a lot of material in the first cylinder? The material is very light, so it?s easy to travel through the inlet manifold. But why so little in the other cylinders?
Regards,
Marc
It could be repaired but it's not viable when heads aren't too expensive. Don't throw it out though, I'd stake a claim to it if it was going to scrap.
The valve head and remaining stem would make an interesting picture, is the stem loose in the guide or stuck? What's the shim clearance on that valve? Are the cams ok?
Is the cylinder bore scored?
The valve head and remaining stem would make an interesting picture, is the stem loose in the guide or stuck? What's the shim clearance on that valve? Are the cams ok?
Is the cylinder bore scored?
The valve stern and all the remaining valves are still in place, only took the head of. I measured the clearence after the recent brake down and they where all whitin tolerance compared with the repair manual. Need to look up the figures if you're interrested.
The cams look okay. The inlet is nearly 300.000 km old, the outlet cam was replaced after approx. 180.000 km of service.
I don't think I will repair this head and shall go for an very good second hand one or maybe a new head. At this point it's also interresting to buy a prepared head, depending on the price and availabilty.
Regards,
Marc
It sounds like it might be a cyclic fatigue. Wait to see if the stem is tight in the guide.
A decent second hand head with no cracks in the combustion chamber will be fine, have it worked to correct tolerances (the easy bit to get wrong) and a set of decent valves and you'll do well to exceed its potential.
arjunior45
07-05-10, 12:25
Ouch!!!
arjunior45
07-05-10, 12:32
Just a stupid question.
What will be the 'impact' to the CR using a FIAT N.A. 16V engine head?
this is very sad, how is the cylinder bore?
Tonight after diner I spent some time on the head in the back yard.
Removed both the cams. Couldn?t remove one inbus bolt on the side of the timing belt. This one was so stuck I had to grind it out.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8853.jpg
The inlet cam has almost no wear on the main caps. However, the outlet cam is replaced approximately 110.000 km ago and has more wear.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8862.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8861.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8860.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8859.jpg
Above some pictures from the outlet cam, forgot to do the inlet cam.
After removing the inlet cam, the valve cup from the broken valve was slightly higher.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8864.jpg
Finally it became clear that the broken valve has a slight bent in the stem.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8867.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8868.jpg
If you look closely, it is visable on the valve stem.
This valve needed ?a bit help? to come out.
Regards,
Marc
jimnielsen
10-05-10, 22:28
Marc, can you post a pic of the valve spring remover that you are using - I need to make one :)
jim..
Marc, can you post a pic of the valve spring remover that you are using - I need to make one :)
The valve I removed was the broken one ;)
Came out with a hamer :biggrin:
I must buy the tool for this job. Need to look first what I already have, maybe an extra part from Alfa is enough to complete the tools I already have.
Regards,
Marc
This is the one I use Jim
http://cgi.ebay.co.uk/Sykes-Valve-Spring-Compressor-Multivalve-Engine-/310109731525?cmd=ViewItem&pt=UK_Hand_Tools_Equipment&hash=item4833fafac5
Nothing happening here anymore, probably will be cleaning out the garage at home.
Regards,
Marc
Well, tonight I finally took some time to do something on the engine, so here's a small update.
I took the sump of today and found something that will need more attention later on.
There was blue silicon particles on the oil filter from the oil pump and I found some hard metal particles on the bottom of the sump.
Not a great finding after a long time of no activity in the garage. Hopefully I have a couple of hours to work on the car upcoming weekend.
Regards,
Marc
Steve Webb
22-04-11, 21:54
Any ideas where all the swarf has come from? Something breaking up in the engine?
Good luck finding some time to do the work, its something I'm lacking at the moment.
Well, after a couple of things that needed attention first I opened the garage door.
Again little progress, but I am going forward after a long time of no progress.
Today I removed the power steering pump, loosened the drive shafts. Unfortunately I couldn't reach the last two bolts from the prop shaft to the rear.
I also removed the down pipe from the exhaust to the cat's. Drained the oil from the gearbox, so I almost ready to remove the gearbox or the engine in it's whole.
After three years of standing still, the bottom of the car needs a bit attention. I can see quiet a bit of rust, also in the engine compartment. Especially where the battery is installed.
Any ideas where all the swarf has come from? Something breaking up in the engine?
I don't think the engine is breaking up. I think this is what they (the workshop who did the servicing in the past) put on to much while trying to get the head oil tight.
Unfortunately not that far to give the engine a better look and see what is happening there.
So this is for some other time to investigate ;)
Regards,
Marc
As posted in another threat, some parts I ordered are arriving :)
Just a teaser for now :hyper:
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/IMG_9356.jpg
Very funny tape is used :icon_wink:
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/IMG_9357.jpg
And now of to bed....
Regards,
Marc
jimnielsen
18-06-11, 08:29
They have Pineapples in the Netherlands???
Steve Webb
18-06-11, 09:34
Bananas too I've been told!
Steve Webb
18-06-11, 09:36
As posted in another threat, some parts I ordered are arriving :)
Just a teaser for now :hyper:
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts_/IMG_9356.jpg
Very funny tape is used :icon_wink:
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts_/IMG_9357.jpg
And now of to bed....
Regards,
Marc
Enough of the teasing, whats inside?
Enough of the teasing, whats inside?
Certainly no fruits :ohmy:
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/IMG_9358.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/IMG_9359.jpg
Regards,
Marc
jimnielsen
18-06-11, 11:22
cylinder head
cylinder head
:clap: :thumbsup:
Bought myself a brand new one :smoke:
Regards,
Marc
Steve Webb
18-06-11, 15:33
New head?
New head?
Yes, the old one is a bit beyond repair.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_8846.jpg
This old head will be donated to Nik for testing purposes.
This new head is going to be flowed before it will be used for my project engine. In the mean time I will use a standard head, my spare, to get the engine running again. After the engine is okay and is ready for the next fase in the project, the heads will be switched and hopefully the last time I need to visit the engine programmer.
Regards,
Marc
Steve Webb
20-06-11, 10:09
Ahh, I remember now. So is the head brand new or new to you?
Sold as a brand new one to me :lol-052:
Without the joking... This is a brand new never before used head.
Regards,
Marc
Today the postman found our house again :clap:
Bought the Valve compression tool from Sykes that Nick recommended in another thread here on the forum.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_9370.jpg
After diner, late from work, I used this tool to remove all the valves from the old head that came from the engine. I am also pretty confinced that this is the originl head when I look at the old valves on the oultlet valve-stern :lipsrsealed:
They have pretty much/thick dirt layer on the valve-stern :eek:
Also, more valves where bent than thought in the beginning :thinking-011:
Here are some pictures from the work from tonight.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_9374.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_9373.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_9372.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/IMG_9371.jpg
Regards,
Marc
After cleaning out the shed today, I found my spare dashboard.
So when the little ones went to bed I had some time to try out some thoughts I had for my gauges.
Unfortunately it didn't come together in the way I had planed.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/IMG_9379.jpg
On the left side from the steering wheel looked like a great spot. Could see the gauge through the steering wheel. The support bracket for the dash prevented this spot because the gauges are to thick :(
On the right side of the steering wheel was a better place, no big problems with support brackets and plenty of space.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/IMG_9377.jpg
The only problem is the position to read the gauge from behind the steering wheel.
And an overal shot with gauge.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/IMG_9376.jpg
I still have some ideas I would like to try out some day.
Regards,
Marc
Last Saturday I had planned a trip to Germany.
At six in the morning I left to visit an interesting company which has lots of interesting original parts. I recently bought a cylinder head, which unfortunately wasn’t complete. The trip wasn’t that smoothly, I was pulled over by the German customs. Probably something with the policy on soft drugs in our country.
After this short delay I finally arrived on my destination. When I walked into the shop, I didn’t know where to look….. It looked like I was in heaven. There were a couple of Lancia Delta Evo’s for display and a lovely Fiat Abarth rally car.
They have a lot of parts and interesting supplies. After I introduced myself I took the head in and we both examined the box. They kindly replaced this head for another one.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/IMG_9362.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/IMG_9363.jpg
Excellent service from them! I was very happy with the outcome of this little problem and nothing stood in the way to start talking about a new engine block.
When I left for my ride home, this is how half an hour of shopping looked like. http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/Kofferbakvolgeladen.jpg
Well, what did I buy
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/leukspul1.jpg
I bought myslef a brand new 0 KM engine block.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/blok1.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/blok2.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/blok3.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/blok4.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/blok5.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/blok7.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/blok9.jpg
Quite a nice view :D
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/Krukaslijn1.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/Krukaslijn2.jpg
Of course I needed someting to fill up the space.... So I bought myself a brand new crack
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/krukas1.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/krukas2.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/krukas3.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/krukas4.jpg
They also have sinter metal bearings (stronger), so I bought a set for the main bearings and one for the con rods.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/Peugeotneetoch.jpg
At first I thought they gave me the wrong bearings....
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/krukaslagering1.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/krukaslagering2.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/krukaslagering3.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/krukaslagering4.jpg
The engine block came with original standard pistons. I will not going to be using them, I probably will sell them again. They are the latest version an have some kind of coating on the outside of the piston skirts.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/zuiger1.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/zuiger2.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/zuiger3.jpg
Except for the crank bearings, everything is “Ricambi originale”
Well after examening all the things I bought, I happenly ended this day
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/theend.jpg
The end for now, cheers!
Regards,
Marc
Steve Webb
11-07-11, 22:36
Jealous? Nah not at all :angry:
Good luck with the build / rebuild.
That must of cost a pretty penny! We like shiny things though! :clap:
Very nice and serious job you're doing there. Good luck with the work.
Cheers,
Cristian.
*edit*
Something went wrong, see below ;)
Awww, lots of pwetty things :cool:
Looking good...
wrinx
It's been a while now, so time for an update.
Finally got the gearbox and front differential of the engine.
This was a necessity for removing the engine from the car.
After the engine was out, I could hardly wait to take it further apart and see what further damge there could be.
I currently ran out of brake cleaner so I couldn't clean the crank for a better surface inspection. It really doesn't look that bad.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/justremovedcrank1.jpg
Crank at piston number 4
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/uncleanedcrankpiston4.jpg
Crank at piston number 3
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/uncleanedcrankpiston3.jpg
Crank at piston number 2
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/uncleanedcrankpiston2.jpg
Crank at piston number 1
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/uncleanedcrankpiston1.jpg
The engine block without the crank.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Engineblockwithoutcrank1.jpg
Lets take a closer look at the main bearings, after I removed the crank. No cleaning yet.
Main bearings outside at cylinder 4
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/topmainhalfbearingsoutsidecylinder1.jpg
Main bearing between cylinder 4 and 3
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/topmainhalfbearingsbetweencylinder3and4.jpg
Main bearing between cylinder 3 and 2
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/topmainhalfbearingsbetweencylinder2and3.jpg
Main bearing between cylinder 2 and 1
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/topmainhalfbearingsbetweencylinder1and2.jpg
Main bearing outside cylinder 1
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/topmainhalfbearingsoutsidecylinder4.jpg
Cleand the main bearing with a piece of cotton.
Cleand outside bearing cylinder 4.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/cleanedmainbearingsoutsidecylinder4.jpg
Cleaned bearings between cyliner 4 and 3.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/cleanedmainbearingsbetweencylinder3and4.jpg
And another look sideways
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/cleanedmainbearingsbetweencylinder2and3-sideview.jpg
Cleaned bearings between cylinder 3 and 2.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/cleanedmainbearingsbetweencylinder2and3.jpg
And a closer look.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/cleanedmainbearingsbetweencylinder2and3close-up.jpg
Cleaned bearings between cylinder 2 and 1.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/cleanedmainbearingsbetweencylinder1and2.jpg
Anda closer look.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/cleanedmainbearingsbetweencylinder1and2close-up.jpg
Cleaned bearings outside cylinder 1.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/cleanedmainbearingsoutsidecylinder1.jpg
And a closer look.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/cleanedmainbearingsoutsidecylinder1-close-up.jpg
Some of the bearings have quite some damage marks on them.
Especially the bearings between cylinder 4 and 3. Not sure what happend there... This can't be only from the broken valve that fell on top of the piston.
The other marks could be from the beating from the broken valve when the engine seized. If not, this engine would probably fail soon if it still ran....
Haven't been able to take some descent pictures of the pistons and their bearings. Will post some pictures later on.
Now the engine is out and in to pieces, it's time to clean the parts that are going to be reused. Luckily the summer is over and the weather will probably help me with rainy days ;)
Next step will be some machining on the new engine blok and the cylinder head. When this is done, it's time to order the connecting rods and pistons.
Steve Webb
06-09-11, 08:00
Now the engine is out and in to pieces, it's time to clean the parts that are going to be reused. Luckily the summer is over and the weather will probably help me with rainy days ;)
I see you are going down the BMW F1 route of block preparation.
I see you are going down the BMW F1 route of block preparation.
:lol-052:
Well, yesterday evening it rained overhere, so I went to the garage for some more photo work.
When taking the engine apart I saw some damage on the countershaft timing pulley. It looks like something fell in the belt area :confused:
Belt cover was on it's place and while disassembling I didn't find any strange items in there.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Countershaftcontrolbeltpulley1.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Countershaftcontrolbeltpulley2.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Countershaftcontrolbeltpulley4.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Countershaftcontrolbeltpulley3.jpg
Piston number 1 with it's bearings
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Pistoncylinder1.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Bigendbearingspiston1-1.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Bigendbearingspiston1-2.jpg
Piston number 2 with it's bearings
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Pistoncylinder2.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Bigendbearingspiston2-1.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Bigendbearingspiston2-2.jpg
Piston number 3 with it's bearings
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Pistoncylinder3.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Pistoncylinder3sideview.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Pistoncylinder3sidea.jpg
This piston had some serious beating on it from the broken valve.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Bigendbearingspiston3-1.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Bigendbearingspiston3-2.jpg
Piston number 4 with it's bearings
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Pistoncylinder4.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Bigendbearingspiston4-1.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Bigendbearingspiston4-2.jpg
All the pistons have hit the valves on the outlet. This could explain the abrasions on the bearing shells.
This arrived today
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/parts/Alfa155lockset.jpg
A brand new complete lock set foor the Q4. Now I can create a car with the original keys instead of all the duplicate keys I have right now.
No time to look in to the old engine at the moment. Though I did find some more damage on the pulleys from the balance shafts. Definatly came something through there :eek: So I'll be ordering a couple of new ones also.
I have finally made some time to take some pictures from the engine block itself.
Two pictures from the top.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Damagedcylindertopview2.jpg
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Damagedcylindertopview1.jpg
Also one from the bottom view.
http://i115.photobucket.com/albums/n288/BrulTM/Alfa%20155%20Q4%20repair/Demontage/Damagedcylinderbottomview.jpg
It's a bit difficult to see on the pictures, but there are quite some pits in the third cylinder. Not in the pictures, but in one of the othere cylinders (number two) there are a couple vertical grooves. This engine block is going to the attick ;) Maybe for future use, who knows.
Steve Webb
06-10-11, 20:15
Hang it on the wall and use as a wine rack?
Juan AR155Q4
17-10-11, 17:28
Why not reboring?
Do you have contact information for this guys?
Because I can't find MAHLE bearings in Bulgaria
Let me know what exactly do you need from Mahle and I will call their representatives in my country to check if available.
Why not reboring?
Reboring is an option when I need this engine. For now it's a spare lying around as a spare.
Juan AR155Q4
21-10-11, 16:31
Sorry, I forgot you have a new spare one...
Nice to have a spare one to make it a serious race engine, while continuing driving the car.
Unfortunately the car is a non runner at the moment.
New and spare parts aren't my main problem, it's the time to actually do something. Besides this, I think the body needs some attention also.
I'll take it step by step, in no hurry :lipsrsealed:
Hi,
i am from Czech Republic and at this moment i am rebuilding my 155Q4. I have motor in very bad shape, similar to yours. I have it dismantled and colecting info where to get new parts. My block can be rebored, but when i saw your new one, my eyes started to sparkle. Can i ask you where is this magical shop in germany? And how much costed your parts? Block especially, but others like crank shaft, which i desperately need a new one. It would be very helpful for me.
I am trying to build semi-race engine with estimately 300HP, want to use wosner pistons and PEC rods.
Thank you for every help i can get:tasty:
Alfa forever :clap:
Hi,
i am from Czech Republic and at this moment i am rebuilding my 155Q4. I have motor in very bad shape, similar to yours. I have it dismantled and colecting info where to get new parts. My block can be rebored, but when i saw your new one, my eyes started to sparkle. Can i ask you where is this magical shop in germany? And how much costed your parts? Block especially, but others like crank shaft, which i desperately need a new one. It would be very helpful for me.
I am trying to build semi-race engine with estimately 300HP, want to use wosner pistons and PEC rods.
Thank you for every help i can get:tasty:
Alfa forever :clap:
First of all, welcome :welcome: Take your time and start reading the entire forum ;) There's a lot of knowledge on the forum about various subjects. Also take a moment to introduce yourself and your car :thumbsup:
You can find most of the parts at Bielstein (http://www.bielstein.com/) They have some original parts and also have reproduced other parts most commonly needed. They also sell through Ebay (http://stores.ebay.de/Fiat-Lancia-Abarth-spare-parts?_trksid=p4340.l2563), but I advise you to contact them by mail (you won't pay for the ebay fees ;) ). About the pricing I can only tell you to get in contact with Bielstein and ask them. It all depends on your needs ;) If you write them in English I am sure you will get an anwser on all your questions.
But before you start your engine project, be sure that you have thought it over and know what you want to accomplish.
Hello,
I apologize for my rush and late answer. I have soo little free time. In time i will surely look through forum and post some info and photos about my project. Curently i took your advice and made a trip into germany before cristmas to Bielstein. Very nice shop and dealings. I bought almost whole engine bottom, planning to visit them again sometime in April to take rest of parts i need (cams, injestors and such), although am still not 100% sure what to you.
Again thank you for your advice:thumbsup:
Any progress Marc?
Just had another look at the photos of all the new bits again. Lovely stuff!
No Jack, no progress at all. :ohmy:
Been very busy with other things.
I am afraid the car has to wait a bit longer.
Tomasson, great to hear you are making progress and made some nice purchases :thumbsup: Looking forward to see your project hear on BerlinaSportivo.
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