Steve Webb 1995 Alfa Romeo 155 Q4 Sport "widebody"
My 155 GTA Stradale, project in progress...
http://forum.berlinasportivo.com/vbr...8c4ab9be56.jpg
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Steve Webb 1995 Alfa Romeo 155 Q4 Sport "widebody"
My 155 GTA Stradale, project in progress...
http://forum.berlinasportivo.com/vbr...8c4ab9be56.jpg
So finally I decide to make a thread for this my car into this forum :) .
I see a lot of fields about car and modifications, that I skip for now, but will update them also with other description information during progress in this thread.
I prefer chronological explanation of progress and here will post pictures and information about car and work on it.
The story for me with this car started from this forum and one advert several years ago. As I sad to a good friend of mine (big car enthusiast, with several alfas) then, sending him a picture with text "because blue is my favorite color ..." :D. And then after long discussion with ditlev with a lot of PMs, pictures on mail and thinking I decided, that really want this car to be mine. The car was really far from me (the car was in Denmark and I'm in Bulgaria) and there isn't easy way to see and hear it for real and such discussion was the way know more about the car. Good circumstance for me then was that look like there wasn't other serious buyer for initial period of advert and during our long discussion, then some appear and I have to make a decision and compare with him if I wanted the car.
The car was delivered by used cars dealer and the deal was actually made by truck driver with money in cash with him. And when the car was in Bulgaria I receive a call, that can go at used cars dealer place and see it for real for first time :).
This is from registration process
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The car have some modifications: tubular exhaust manifold (from Italy from what I remember, 38mm external diameter of piping), some part of exhaust made of stainless steel 63.5mm (2.5"), Forge dual piston BOV, short shifter, 16" Borbet Type E 7'5J ET35 with 215/40-16 tires, wheel spacers at front and 20mm I think at the back (at front I think was original one for widebody cars I think).
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(spark plug cover was available with car and now is installed)
The car also came with a lot of parts with it: Squadra Tuning chip, 4 used Compomotive TH2 17" with tires 215/35-17 (other wheels of the car) + 1 new wheel in the box, front wishbones, ball-joints, old exhaust manifold, intercooler, steel head gasket, AC control panel, board computer panel and others...
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Here is a pictures of the car with Compomotive TH2 wheels (from ditlev, I haven't used these wheels on the car yet):
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The car have nice leather interior:
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I think that this is enough for beginning :D (I may add or change some things in this post if remember something else needing mentioning here)
Hi @kunev , thanks for posting your car up. Looks nice and clean. Love the TH2's as well.
Thanks Steve :).
In first post I reach the limit of maximum pictures per post, so continue with something that have to be there. In folder with papers and receipts for the car, that came with it, there is also a dyno graph and it show good result :)
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And after acquisition and coming in my hands I started and continue for some time with common stuffs - basically maintenance, changing and repairing some things. Not sure that remember everything (don't say that they are so many things either), so may change this post several times.
Oils, for engine I use Motul Sport 5W-50 Ester based lubricant (I want something more special and think that Motul ester oils are such) and for gearbox and rear differential use Motul 300 Gear 75W-90, which is also step up than normal gearbox oil. Balance shafts was "disabled" and its belt removed at changing of belts and pulleys. Ignition system was renewed - coils, plug wires and spark plugs
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For spark plugs I go for standard, copper Denso and decided to go one step colder for some increase in boost in the future... For this model are showed Denso W20EPB (equivalent NGK BP6ET) and I go for W22EPB (equivalent NGK BP7ET). Look like this engine (Lampredi's 2.0 16V turbo) is used with colder spark plugs (7 hear index on NGK) on some of the earlier version with distributor ignition from what I see.
Reverse gear lights wasn't working, which turned to be the sensor. The mechanic sad then that is different than what it was expected and have seen on italian cars from this period and also the position was different. Here it is:
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Front windshield crack (maybe was my fault during one washing of car...).
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First was ordered Saint Gobain, but the only one available was broken during transportation from Europe and then Pilkington was ordered, which arrive successfully. The installation guy sad that it is like armored :D, thicker than previous one (which was not original one I think, Saint Gobain).
One wheel bearing was replaces, rear from what I remember. Valve's cover gasket was replaced, because of leaking. Plug wires cover was installed (it was available) with one new thread fixed/newly made from what I remember also one such manipulation for timing belt cover (I have seen such issue on one Coupe 16VT, so I guess, that is not so uncommon for this engine). Windshield wipers was modern beam type and I change them to conventional one. Front scudetto/grille was tightly fixed and that is a major problem for 155 with its plastic pins from what I read.
Also bought some parts just in case or because was at good price - pair of cheap white Depo front indicators (one on the car is cracked, but haven't changed it yet), several sensors (intake air temperature (two I think), water temperature, low oil pressure...), track rod end, lambda probe... Common problem on 155 are outside door handles as you know and are difficult to find. All on the car are fine now, but because of this common issue I bought second hand handles to have, one time two right and after that two left one of which was modified to be stronger with adding of material.
So basically nothing special here. More interesting things in next posts :)
One picture of the car from first years of ownership, the quiet years let say :D
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And here are some of the more interesting let say things, which I bought from time to time:
Brand new OZ Racing Alleggerita HLT 16" 7J 4x100
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I bought these because was really an amazing offer, which I could not miss and also like very much light OZ wheels - Ultraleggera, Superleggera... and these are even lighter. Alleggerita are the lightest OZ wheels and the only one from them, which came with "Weight certificate" for each wheel (can be seen on above photos)!
Silverstone/Formula rear spoiler
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This spoiler I bought it, because was able to get it at good price and is a rare, original part, which will become more rare in the future I guess, so just to have it. My car is "Sport" modification and have the corresponding spoiler, so already have original rear spoiler and don't plan to use this for now...
Lancia Kappa 16V turbo intake manifold and fuel rail
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The best standard manifold for Lampredi's 16V turbo engine and very sought after item as many of you know. Have read with data, that original one with some porting can flow more than such unmodified, but straight runners of this are better design performance wise, so definitely good to have. At one point started to look for one, but turned out it is more sought after that I expected and this made me a little mad and want it even more :D. Generally when I have called on advert for such car for spares, the answer was "this was first thing, which I sold..". A friend of mine told me, that one guy have such for sale and I catch that chance.
As I reach the limit of 10 pictures per post will continue on another one :). Stay tuned...
I've got the same inlet manifold and fuel rail, I'm planning on getting it fitted in the near future and moving to a coil on plug setup at the same time.
Coil on plug (COP) is more modern and advance ignition system for sure, but original wasted spark is not bad at all and is capable enough for 400hp and even more on this engine from what I have read. But if is planed aftermarket ECU then this is the route in my opinion. With original ECU can be implemented coil on plug setup, but it will fire 2 coils/plugs at same time.
About installation of Kappa 16VT inlet manifold on our cars there is one "modification", which I really don't like - cutting of mounts for upper part of original manifold. And from what I read these original mounting points obstruct fitting of flange to engine head of Kappa manifold. I like performance modifications for sure and plan and do such on my cars, but also have one general rule - to be able to return to original state. So generally no cutting of metal, dashboard, interior trim ... if there isn't spare one.
I continue with some interesting parts, which I acquired:
Walbro GSS341 high pressure in-tank 255/h fuel pump
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A friend of mine was in USA for business trip and I use the moment and him :D to order more serious fuel pump from Walbro for my eventual future plans and also as our vehicles are now at age and their original (most likely) fuel pump also can be expected that they will not work as new and will not be so unusual to break at some moment. These model flow more at high fuel pressure compared to their normal, old 255l/h variants.
OZ Racing Ultraleggera 17" 7J ET37 4x100 Crystal Titanium
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Again wheels, but these are my favorite model and was bought to be put on the car for sure. I was a little unsure about going with 17" and some very low tires (because of very small wheel arches on this model as you know) and bad roads here and delayed this decision for some time... The Compomotive TH2 wheels, which came with the car as part of the deal are with tires 215/35-17 and I don't want to drive with such size here. So size in mind was 215/40-17 and to see how it will be...
Also other reason for bigger wheels is big brakes upgrade on which I'm really big fan :love-001: and it happen to be first real performance modification I make on my cars. I don't want to do the things in most popular and simple way and want to make something more unique. I have some brake calipers models in my mind already and looked for them from time to time (later I will have all of them and that will be seen here of course, but that is in let say in the future for moment for which I write). And I bought that of them to which I leaned most
Brembo 17Z 6 pistons monoblock brake calipers
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* The plastic bottle of 1.5l was just for comparison :D.
This model was originally used on early Porsche Cayenne V6s and VW Touareg with 330x32 discs and as its name suggest it was intended for 17" wheels. As my brake upgrade will be limited to 17" wheels :loco: and wanted something to be as big as can be put into 17" then this caliper model look as very good option to me :). This particular model is from Touareg I guess, because Porsche generally put its name on it and paint them in more eye catching color let say. The total piston's area of this model is not small at all - 34/36/38 = 3060mm2. That was concern for such brake upgrade. For example on calipers from 166 and on earlier GTA with 305mm discs and GTV V6 also I think area is 38/42 = 2520mm2.
Good point about the modification, but there are a number of things I dislike about the original manifold, the lack of access to the coils, lack of access to the injectors, the rubber joiners and the shape of it. When I install the new manifold, I doubt the old one will ever go back on, if it ever needs to, well I'm sure something can be fabricated for the mounting points.
The manifold means that you need to relocate the coils and a couple of other bits so I was thinking of moving to COP at the same time, however being sensible it might be best to just get new standard coils (cheap) whilst I move things about.
Yes, Kappa's manifold have more than one benefit than our original one and generally no useful reason to return once done except going for originality.
Then other brake calipers, which I check from time to time appear at good price and I decided to buy them also :D.
Brembo 18Z monoblock brake calipers
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17Z and 18Z are very similar calipers, used on same cars and wheel hubs basically. The difference between them is pistons size, length of mounting "ears" and pads size. Total piston area of 18Z is smaller - 30/34/38 (2750mm2), so smaller increase from stock compared to 17Z and that was a good reason to bought them. 18Z are used originally with 350x34mm discs on Audi Q7, Porsche Cayenne and VW Touareg. Basically almost the same body and overall size calipers are spaced differently to work with different size discs (330 and 350 mm) on same cars.
And here are them side by side (18Z are on the left):
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Both calipers are popular as upgrade in VAG community mainly, because they can be fitted directly to the hub on many vehicles.
Pads are interchangeable between them, so 17Z pads can be used on 18Z and vice versa (both pair calipers was with 18Z pads). 18Z pads are bigger and here is some comparison
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To not occur overhang with higher 18Z pads, disc should have high working area.
And as a final for introduction of 17Z and 18Z calipers will post some funny pictures from internet :D
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As I then have two model calipers, the plan was to be checked with both and to be made adapters for both...
I remember, that have installed Squadra tuning chip at some point before front brake upgrade and there was noticeable improvement of performance :thumb:.
And now front brake upgrade implementation. The plan was going with OZ Ultraleggera 17" wheels to happen at same time as brake upgrade. Here is one visual check with Brembo 18Z :)
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This process was executed by one one Bulgarian company specialized in fabricating of custom parts - NS Custom Parts. Both caliper pairs and wheels was given to them and they started with checks. They determined what discs parameters are needed for close installation and I found one, which are close enough. Both calipers was given for refreshing with sand blasting and painting with custom paint. I order brake discs and pads for 17Z calipers. 4 new Hankook Ventus V12 Evo2 215/40-R17 tyres was bought. With such size, there isn't many options unfortunately.
Unfortunately was seen that 18Z calipers can not be installed on my car with 17" wheels and such discs. Mounting holes touch wheel hub.
And here is some pictures from fabrication company with 3 bolts, not completely ready :D
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And some
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On these pictures wheels are without center caps, but I have them, just have removed them before giving the wheel to guys :)
And as a resume of front brake setup:
- Brembo 17Z calipers;
- EBC yellowstuff pads for 17Z calipers;
- EBC standard 330x32 brake discs for Volvo S60 R, V70 R on which was made grooves;
- custom steel adapters for calipers - they sad that there isn't enough material with this design for strong fit with aluminum one;
- custom made braided brake lines;
- 12mm aluminum hub centric spacers front and rear and 2mm behind front disc - disc's offset is just a little smaller, than it have to;
- Motul RBF600 brake fluid.
That is some serious brake upgrade there kunev :clap:
Are you planing to do some trackdays and/or tune your engine to 400bhp+ 'cause that 6piston caliper screams for them :tongue2:
Thanks for the comment and interest jNk :)
Generally I have plans for the car, not accidentally it is named GTA Stradale :D . But will see what will happen, because plans are changed from time to time... :) Stay tuned, I still write for old things and haven't reached to current moment ;). But for sure the car have to be street.
Some more pictures of the car after front brake upgrade and OZ wheels
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And now ... more parts.
New rear torsen differential
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I saw advert for this differential in ebay from one guy in Austria I think and he even have 2 or 3 differentials from what I remember. The price was good and decided, that is good to buy one.
Later I also bought new rear differential housing and I think that was from same guy... The price was good and decided, that have to buy it. Don't have picture of it, but when do some will add it here.
Apexi AVC-R electronic boost controller
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From what I have read this boost controller is very good. Two settings and also one more when is off (then by wastegate spring only), boost by gear, by rpm with 500rpm increments and other settings. Yeah they are two, but I have two turbo cars. I bought first one for my GTV, then I don't have 155 yet I think. Then there was one at good price and decided to buy one more also
And again brake calipers - Brembo 8 pistons
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Here agains 18Z. These are used on RS4 B7, RS6 C5, Phaeton V10/W12, R8, Gallardo, Murcielago. These are the 3rd model which I consider for my front upgrade, but then I have suspicious about using it on 17" (which was my limit). I bought these after brake upgrade and If I have to do it again will use these. Total piston area is smaller than 17Z calipers - 38/42/38/42 = 2840mm2. 4 pads per caliper, radially mounting so more freedom for installation. Now my calipers are a little out of disc and for this mounting best fit will be with a little bigger than 330mm discs and also with 18Z pads, which are higher, but this I understand after I already bought the discs and pads and everything was ready...
The next on the list was suspension.
As you know not many options for our car. The car have Eibach springs so also option was to buy just dampers, but I wanted to try with complete kit, that should have matched dampers and springs. Intrax have kits for our model and are very good probably, but expensive. I decided to try H&R monotube coilovers for Alfa Romeo 155 2.5 V6. From what I have read it should fit, but have doubts how the rear will be ... Q4 is definitely heavier at the back and on the front V6 is not so light so maybe not so big difference. From looking at documentation Q4 rear springs are thicker than 2.5 V6 - 13.9 vs 12.4. Free length is given the same as 305mm. But H&R springs are generally stiff so it may work I thought ...
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I did not make pictures of the kit, because was well packed. But is like on second picture. From what I have read dampers are made by Bilstein to H&R spec and springs are H&R, but not 100% sure. So coilovers on front and separate dampers and springs at the back. Rear dampers are shorter than original from what I have seen on one kit for TS, so probably something like Bilstein B8, which are for bigger lowering, which sound normal considering 40mm lowering (B6 for standard ride height or up to 30mm).
But after installation the mechanic call me that at the back is not ok and the car go very low when put on the ground, like sit on the tires. And was used old Eibach springs at the back. Unfortunately I didn't saw how exactly was this on real or picture... I have make a thread about this issue on the forum.
On the front is ok as ride height, I think even higher than before. I definitely feel the difference from before and is much better, but dampers, which was removed was leaking. Rubbing at the back is improved, but if someone is the back it is an issue, so that will not be the end regarding back suspension...
Here is how is now at the back and with H&R springs from the kit was several cm down, top of the tire was not seen from what I remember to been told by mechanic
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And here are rates of springs in that kit, I have asked H&R and surprisingly receive an answer:
"29992-2 uses springs with 55N/mm front and 45N/mm rear.
Our coilovers are just available in one specification, not with any other spring rates."
More pictures of the all car in the next post
Then there was one big trip to some very interesting places and with some special activities :D
End destinations was Nürburgring Nordschleife and Spa-Francorchamps :driving-014:
The trip lasted 13 days and more than 4800km. The group was with 2 cars with Lampredi 2.0 16V turbo engines and more than 600hp in total ... mostly from other car have to mention :) .
Other destinations and places was Budapest; BMW Welt, Museum and factory in Munich; Audi museum and factory in Ingolstadt, Porsche museum in Stuttgart, Mercedes museum in Stuttgart, Bamberg, beer fest in Erlangen, Nurnberg, Maybach museum, Gyor in Hungary
And here is some pictures just with the car as the topic is about the car (will be difficult to limit myself to 10 images :D )
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Unfortunately don't have photos from driving on Spa.
Any track times from the Green Hell or Spa ?
My car was only twice on trackdays but seeing your pics I might considering to go this year again. :)
Haven't tried to measure times and haven't pushed the car too much as these was my first track drives and also have to return with that car back home, which is far from there. No official timing on both as driving is not with competition nature. Nordschleife is officially public road and on Spa have noise check/control.
On the ring you go to the track and then have to exit after one "lap", you can not drive multiple laps at once on public driving sessions as we was (there is trackdays where you can). Manufacturer measure full lap and people don't measure complete lap.
"During tourist driving sessions, the full main straight cannot be driven at speed due to the exit/entrance. These laps are usually timed "bridge to gantry", which is only 19.1 km (11.9 mi). The lap goes from the "bridge" to the "gantry" (currently carrying Audi sponsorship.)"
Spa is modern circuit with all the safety features and zones, Nordschleife is exactly the opposite, it's a little scary.
Recommend them for sure and want to go again, but this time better prepared as a car and personally :)
I continue to write in this original thread for that car.
I want to do something for the rear brakes also, but want to keep hand brake also so these calipers are prepared for that goal
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These are rear calipers used on latest 145,146 and other alfas from that time also. These particular one are from GTV I guess (not from Phase 1 as mine is not with such), because there was GTV inscription on them when I bought them. They are aluminum unlike these on 155 and are known as bolt-on upgrade for 155s in Bulgaria. There is reports for feel improvement and for hand brake also. Calipers was sandblasted, painted and rebuild.
My plan is to be used with bigger discs and custom bracket of course. For the choice of discs I filter the selection to two particular discs - one is 280x11 (Volvo C30 and others) and other is 290x11 (Toyota Avensis) mm. Haven't decided finally which one...
I haven't closed the chapter for rear suspension as I sad already in the thread and decided to try with some standard solution for which I read good responses here
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Intrax springs for 155 Q4. Intrax offer 5 models springs for 155 off the shelve! And one in particular for Q4, which are above ones - ALF1173. Only rear will be used. Something else, which bothers me about them is that is stated that they lower with 50mm, but from pictures of Brul(tm)'s car with same size of tyres rear look almost like mine with Eibach, so will see...
Never heard of that rear caliper upgrade, maybe the aluminium ones won't seize up quite so often as the regular ones.
I do know that Tarox (?) did a rear brake upgrade, larger disk with bracket for the standard caliper, but it seemed very expensive for what it was.
Very interesting on the upgraded rear brakes. Although mine got through the MOT as second time of trying I suspect on of my calipers is not working so well.
Do you have the part numbers for them at all?
Tarox offer such rear kit for many italian cars from same period and its expensive mostly because of two piece discs I guess. I don't know part number, but they are not so rare or special I think, although when I searched for such in advert for later 145/146 for spares I receive several answers that they are already sold :? (that was really a surprise for me - to have demand on rear calipers from 15-20 years old Italian cars!). I can check what is written on them, but you can quickly figure out the visual difference between them and earlier (will say) model rear calipers. Generally speaking look at Italian cars from late '90 - early '00 and not only alfas. I guess that this have to be some improvement from Fiat/Alfa Romeo from factory. I have read to be used on TS 155 here as direct replacement of original calipers. Initially my plan was to do the same and not go to custom route, but then decided that really want bigger discs at the back also. For now thats the plan and will see. Brake force regular have big influence for poor rear brakes and seized calipers. It blocks on old cars and will be checked also, because my rear brakes are not really working right now.
The new season for the car is not opened yet, but preparation of modifications for my "GTA Stradale" for the future haven't stopped at all :).
Pedders Suspension front and rear anti-roll bars for Alfa Romeo 155 Q4
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These are 28mm front and 24mm rear and Pedders Suspension Australia is the only manufacturer who offer such items for our cars. Who have read the forum for a while probably will know how these become available for our cars.
The idea for these really grew in my mind after driving on Spa and Nordschleife. Such items can not be seen on their website, but I contact Pedders Bendigo (for that particular office I have read in the forum) and luckily they still offer such items and these particular ones was already available there. Different sizes are also possible (I ask), but will have to be wait some time for preparation. They also mention that last time, when they sell such was to Latvia in 2015 and I guess that this is probably to someone on here. And choose sending on sea as cheapest option and after approximately 3 months they reach me. Have to mention that packaging was not the best for such heavy items and long trip around the world and there is marks on them. I have mention this to Pedders with pictures and they sad that will think about that and how can be improved. But generally they was very friendly and responsive. So if someone is interested in anti roll bars for his Q4 to know that they still offer such.
I remember speaking to Pedders as well, I think it was Jim Neilsen who originally got the ARB's made up, I did try to organise a group buy previously, but there wasn't enough interest and obviously shipping these is a lot harder than shipping the quickshif kit.
Good luck fitting the front, I seem to remember you need to drop the subframe to get it into place.
I thought to post a quick summary of the story of these bars in previous post from what I have read in the forum (I have try to find whatever I can in the forum about anti roll bars). So for the newest member.
Many years ago jimnielsen (Australia) have send his rear anti-roll bar to Pedders Bendigo (Australia) for making of thicker its version. After that na15575 (Greece) have send front anti-roll bar to them for preparing of thicker version and I guess he is the first one to have upgraded front and rear anti-roll bars on his car.
For the front is prepared something custom for perfect fit, but will write when it is at my hands...
And this post to not be just comments here is one great find, which I made a little accidentally.
Behr thermostat for 155 Q4
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New old stock, something which is not produced from some time now. It was staying at one local dealer of alfa romeo parts for more than 10 years for sure and maybe more than 20 :D
And also here is a new original OZ carbon center caps for my Ultralleggera
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I bought them just in case, but hope the current one, which are on the wheels to not disappear strangely.
And something, which I waited for some time now...
SuperPro bushes for Pedders 28mm front anti-roll bar
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As Pedders anti-roll bars don't come with anything in addition to bars itself I start to look for solution for bushes for front bar. I ask some companies who made polyurethane bushes for such custom order, but either no reply or answer that can not made it. But SuperPro were responsive and their European office sad that they can made such. They offer front anti roll bushes for alfa romeo 155 for standard sizes (22mm and 23mm) and also 27mm and 30mm, which I guess was made for Whiteline anti roll-bars, which was available in such sizes. So after one package was send to Asian office by mistake, new order was made to the factory and after a lot of waiting I receive the long awaited bushes. The Australian anti-roll bar will be complemented by Australian bushes :). From what I see they are modified 23mm version with enlarged holes for bar. At same time was ordered same type of bushes for a friend of mine with Fiat Coupe, who have bought Eibach anti roll bars at very good price, but the kit, which he receive wasn't complete, just the bars and he needed 26mm version.
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I guess and hope that bushes for front anti roll bar for Q4 are with same design and size as on other 155 and other Italian cars from same period...
And something else, which I mentioned in earlier post, but can not add its picture there because of limit of 10 pictures per post :)
New rear differential cover
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I bought it some time ago. The price was good. The delivery was near price to the price of it. So good to have it I think. Also have new rear torsen differential unit, which goes inside this and can be seen in earlier post.
Nice looking rear diff indeed, mine had to be rebuilt couple of years ago and its working like a brand new one since then :)
New, unused original Silverstone front splitter
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I accidentally saw a thread in another forum by wrinx where he mentioned that plan to put that on eBay's auction soon. Then I checked eBay for some time and decide to wrote him a private message here to write me when this happen and he wrote me. And not so surprisingly for me I win the auction :D :). He sad that he bought it from Alfa Romeo dealer some years ago. Probably the only one such new in the world, so something very rare that wanted to have :) . Some time ago I asked one dealer for original Alfa Romeo parts for this and some other parts and he answer that it was out of production, nothing unexpected. Some time ago I bought used Silverstone rear spoiler and now if I can find original lifting kit :roll: ...
I haven't wrote here from some time now, but as I have started it and wrote and show so many things I have to continue.
For the next upgrade I have waited a lot of time to be completed. The car was having some middle part of exhaust system build from 2.5"(63.5mm) stainless steel with sport cat I think, but was not complete job and old rear part have cracked and two back silencers have fallen on one drive, so I needed to take care on that. And a custom stainless steel exhaust system was arranged to be build by "JS-design" from my home town, which in my opinion is the best exhaust specialist in Bulgaria and not only. I have been many times in his workshop and have seen craftsmanship and beauty of his work. Here is a link to his fb page, where you can see his creations -> JS-design. During that period I have changed the plan twice from initial one at 63mm (2.5") or 70mm (2.75") with two silencers to reach the final implementation at 3" (76mm) from bend pipe just after the turbo to the end with one custom straight through muffler and double titanium exhaust tips at 3", to match the color of the car :8
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This exhaust system configuration was chosen to comply to the future plan for the car, which I have decided that want to start...
And from now on the project become really serious.
That is my approach on building 155 GTA Stradale nowadays and beginning of documenting it here :). The project will be executed by ICI Design, a well known tuning specialist here for Delta Integrale and alike models sharing same engines, drivetrain and not only.
Starting with the hearth of the car - the engine and in particular the bottom end of it.
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ZRP billet 4340 steel crankshaft for standard 90mm stroke
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That is a lightweight design with all counterweights, balanced to 1gr/cm with report included and many good manufacturing features.
JE Pistons asymmetrical 9:1 CR pistons from 2618 T6 high tensile forged aluminum
Attachment 3059
As this have to be a modern build I decided to go with more up-to-date static compression ratio than standard one of 8:1. And expecting better fuel, power and thermal efficiency with it.
MaxSpeedingRods H-beam 4340 steel connecting rods
ARP2000 rod bolts (included with rods)
King Racing XP-series main bearings
King Racing XP-series connecting rod bearings
Custom engine girdle plate
Attachment 3062 Attachment 3061 Attachment 3070
Just noticed in the Exhaust pics, but does your car have a tow bar installed?
There used to be one on mine but its been removed for a long time now.
No, at least since it is in my possession, but probably there was such at some point in the past...
I haven't updated since long time, so here is such about head and engine closing.
Cylinder head have been serviced by head specialist with new bronze valve guides and 3-angle valve seats job. It have been ported by ICI Design
Attachment 3071 Attachment 3072
Valves have replaced with:
- Supertech black nitrided intake valves
- Supertech inconel exhaust valves
Attachment 3073
- camshafts have been replaced with new intake and exhaust ones for Tipo 2.0 16V Sedicivalvole
- Athena racing MLS head gasket
- ARP M12 head studs
- adjustable cam wheels for fine tune of valve timing
- balance shafts have been removed
- 22mm width timing belt
Attachment 3074 Attachment 3075
I haven't posted more information here recently, because of issue with forum, but as now is fixed I will continue.
So logically after engine came clutch and gearbox.
As the plan is for big increase of power and also general opinion is that gearbox is not so strong let say I start to think for options in advance.
And some time ago I bought Scara73 Gr.N gear kit consisting of 1-3 gears and main shaft
Attachment 3082Attachment 3083
These gears have wider tooth base than original, i.e. less number of teeth. Here is a comparison photos made by another guy, who have use that kit (nickname Stichl), which I have found. On picture below are showed original and Scara73 3rd gear wheels as original ones are on left.
Attachment 3084
Also needle bearing (if that is correct name in English) on 3rd gear is different as can be seen from below picture where original one is on the right.
Attachment 3085
Main shaft is thicker and also splines. Original one is at bottom on below picture.
Attachment 3086
After some time I started thinking that will be better with 4rd and 5th gears also if possible and we contacted Scara73 again and they reply that it is possible to be "upgraded" that kit and there is options for 5th gear ratios only. And gears were ordered with 5th slightly taller and 4rd is approximately the same ratio no option there. At same time was ordered from them rigid 5-puck ceramic clutch disc with splines for thicker main shaft. And all gearbox's bearings was changed with new one to be as new.
Attachment 3087Attachment 3088
Gearbox casing also need to be reinforced. Originally there is one plate on one side of gearbox. Custom "spectacle plate" was made to prevent both shafts from splitting (below is not final state).
Attachment 3089
Final drive is kept original one.
Looking good, can't wait to see pics as the project move along.
Hopefully the site will behave itself now and not fall over again anytime soon.
After gearbox power distribution continue with drivetrain.
Center differential was in perfect condition fortunately
Attachment 3095
While driving on Spa and Nürburgring the car exhibit a lot of understeer and after that I start to think for some options for improvement. The purchase of front and rear anti-roll bars came mainly from these drivings. I have seen that Quaife offer torsen front differential for these cars I bought such.
Attachment 3090 Attachment 3091 Attachment 3092 Attachment 3093
Original front differential is of open type. With that diff I expect improved handling, better transfer of power from front wheels to the road, strength and reliability as I have heard for cases of broken front diff on 4WD Italian cars of that type let say.
Attachment 3097 Attachment 3098
Original rear differential is used again, which is of torsen type and to it have been changed two new bearings. I also have new rear torsen differential unit and main case for it, which will stay in storage, but hope to not reach a point that need to use them.
Generally almost all bearings on drivetrain was changed I think.
Attachment 3096 Attachment 3099
Next will be the source of power - turbocharger and exhaust manifold on which is mounted.
As this is a modern build, then have to be used modern turbocharger. I haven't considered at all popular and easy to install options for upgrade from time when this and other models with same engine was more popular used cars let say like T3 or T34 variants from other cars like Cosworths for example or hybrids. The technology in general have moved on a lot in the last 10-15 years let say. Basically the choice came down to one turbocharger from two modern turbo series - Garrett G25-660 and Borg Warner EFR7163. Then G25 was newly released and there wasn't much real life info about them, but its data for given size look impressive. On the other side EFR7163 was available from some time and there is good reviews for its performance. After some research my choice fell on EFR7163 with T4 twin scroll 0.80A/R turbine housing with internal gate.
Attachment 3101 Attachment 3102 Attachment 3103 Attachment 3104 Attachment 3105
That is best responsive version of it and with internal gate and integrated compressor recirculated valve, plumbing will be simplified and close to "like original" look. Here is a official information about that series of turbos -> EFR Technical Data
Attachment 3107
And one good explanation video
https://www.youtube.com/watch?v=EIHQDw0mBV0
For mounting of that turbo was made custom tubular twin scroll manifold with as close as possible equal length runners .
Attachment 3108 Attachment 3109 Attachment 3110
Twin scroll turbine housing and exhaust manifold have many benefits in low and mid rpms and that approach is used on many modern turbocharged vehicles.
Borg Warner EFR series are rich on features from the box, but for that build some of them will be replaced with upgraded items.
For EFR turbos with internal gate Borg Warner offer three wastegate actuators depending on intended boost - low, medium and high. By default turbochargers came with canister for medium boost. From what I have read even high boost canister is struggling to keep high boost levels, which these turbochargers are capable of. As the plan is to be run a lot of boost, then upgrade on this part is highly desirable and fortunately aftermarket industry have already something to offer.
And have been bought Turbosmart IWG75 twin port wastegate actuator for that particular turbo
Attachment 3111
With twin port actuator, as the name suggest, air can be fed to both side of membrane and in that way can be achieved much higher boost level for same spring rate compared to single port. In that way can be run wider range of boost levels compared to single port. Also boost control is better and can be achieved faster boost response. And my goal is to be run at two widely spread boost level. This actuator is for 14psi base boost pressure with two springs inside I think, but that can be changed with different springs configuration.
Here will mention that I have a concept for tuning parts - generally they have to be ... black :D and/or silver/metal color.
That twin port wastegate actuator is perfectly matched with Turbosmart 4 port boost solenoid (on the left on below picture) for best boost control on internal gate turbo
Attachment 3112
As a result from above, two standard EFR's features are out directly from the box, but that is the best way and cannot be ordered without them.
To keep turbo happy also will be installed Turbosmart inline oil filter on supply line.
Attachment 3113
With more power came more heat and for that some improvements on cooling of different fluids have been introduced.
Direnza performance aluminium radiator
Attachment 3114
That is a radiator for Fiat Coupe 20VT and they don't offer such for Q4, but they are very similar. It is 40mm thick and original one is around 25mm I think, but not sure. Look as a quality item, better than one Chinese for Q4, which can be seen on the net.
30 rows oil cooler
It is much bigger than original one and ... black 🙂. It is approximately two and a half times bigger that original one. It will be seen as installed in some of next posts. With such big difference in size its position on car needs to be compromised and will be at angle and not directly frontal, but such installation have been used and look to be working (it is not optimal for sure).
Energie Racing Parts bar&plate intercooler
Attachment 3115 Attachment 3116
On 155 with original bumper doesn't have much space for big front mount intercooler, which to be "hidden" behind it. Here basically the goal was to be found off the shelf item, which to be good compromise between its capacity, for sure shouldn’t be cut front bar and metal in general and as little as possible from the bumper. This intercooler is with core size of 650x235x90mm and from initial measurements and checks look to be good solution for what is desired.
Here also will mention about one type of cooling, which is a little different than above ones. As the car will be street, as the project name suggest :cool:, it will continue to have an air conditioner ... and this time it should work. I didn’t have the chance to see it working as when I bought the car the condenser was missing and there was some cut pipes going to it! So some work in that direction will be done also. It will make installation of intercooler and bigger coolant radiator even harder and will have impact on their efficiency and they to it also, but this is how it have to be done in my opinion.
Now some pictures from assembly work in the engine bay.
Front subframe have been cleaned and painted before installing it back.
Attachment 3117
Some pictures from work on exhaust manifold
Attachment 3118 Attachment 3119
Some more pictures related to engine assembly and not only
Attachment 3120 Attachment 3121
Turbo installation and not only
Attachment 3122 Attachment 3123 Attachment 3124 Attachment 3125
Downpipe have been wrapped, but exhaust manifold will stay exposed.
Aeroflow big cone air filter with length of 230mm is located at lower left on front of car with short, straight route to it.
Intercooler piping are custom made stainless steel as can be seen from photos.
The big increase in power require such of fuel flow.
I decided to go to route with additional surge tank. Pump in the standard fuel tank will feed small surge tank, from which external fuel pump will draw. And as they say, one picture speak more than hundred words, so here is one simple diagram, which I get from internet.
Attachment 3126
Thus it should be avoided possibility for fuel starvation and can be driven with low fuel level in main tank.
For main fuel pump after surge tank will be used external Aeroflow one, similar to Bosch 044 with spec of 300l/h at 3bar pressure.
Attachment 3127
In-tank pump, which now will serve as a lift pump, was replaced with new Magneti Marelli one. It will now operate not on pressure unlike original configuration and will have higher flow than what is intended for.
Custom made surge tank and Aeroflow external pump are mounted at the back, below the car.
Attachment 3128
Original fuel rail with Kappa’s inlet manifold is plastic one, which is not very performance oriented and is used aluminium one from Fiat Coupe non-turbo engine, which have pressure regulator mounted at side of it. And for fuel pressure regulator is used standard Bosch 3bar one, so base fuel pressure will be increased from standard one for that car of 2.5bar and that will improve fuel atomisation.
For fuel injectors are used up-to-date performance aftermarket items - Fuel Injector Clinic 1000cc3/min high impedance ball&seat injectors
Attachment 3129
They are dynamically flow matched by Fuel Injector Clinic and came with report for that and data for each particular injector in that set, which to be used for configuration in the ECU. That will benefit fuel tuning and general performance.
In this post I will write about the brain, which will monitor and control the engine and other related systems.
Original ECU is not bad at all and do its job very well. It use speed density strategy with MAP sensor, which have benefit performance wise from lack of restriction in the intake compared to need of MAF sensor for measurement of air mass. But as with any electronics there is progress of the technology. With any old ECU it is possible to start to happen some strange running issues related to it and more specifically to aging of capacitors. Some electrical inspection of it is not a bad thing generally. Some time ago I considered extending capabilities of original ECU by using of RP-Lab services. If that project was executed 10 years ago let say probably for sure that will be the route to go, but I decided to go with a more modern approach with more capabilities and have been chosen and bought Ecumaster EMU Black
Attachment 3130
This is their premium ECU and offer a lot of features for its value and look as a very high quality product. Ecumaster is a polish brand and their ECUs are intended for 4 and 6 cylinder engines. The engine will be controlled with sequential ignition and fuel injection. And that mean that factory waster-spark ignition with two coils and ignition cables will be replaced with the more modern and capable coil-on-plug setup :) . Also is planned to be added some additional sensors to the ECU for engine protection basically, which I'm not sure is it possible with just extension of standard ECU.
In the above picture can be seen also a bluetooth module for that model of ECU (Ecumaster CAN-BUS Bluetooth module), but that will not be used actually. Later I also decide to add an option for logging of data without a laptop connected to it, which on that ECU can done with additional Ecumaster EDL-1 module. That module also incorporate a bluetooth module and that will be used instead of initially purchased separate module.
Attachment 3131
As is probably clear, the purpose of using a bluetooth module is to be able to view real-time data on phone or tablet without the need to connect a laptop to the ECU. Ecumaster have their own application for presenting data only for Android devices - EMUDash. And there is another popular one, which support this and many other ECU -> RealDash.
My plan is to have close to zero additional gauges in the interior to keep it as clean as possible and basically that will be the concept to view data when desired without the need to connect a laptop to the ECU.
Some more information about additional sensors, which will be used with mentioned in previous post ECU and not only.
I have already mentioned about ignition and fuel injection concept, which will be used with that ECU. Another major aspect in engine control is about the feedback for burned fuel from oxygen sensor in exhaust gases. Originally is used so-called narrow-band oxygen sensor, which is very accurate just very close to stoichiometric air-fuel ratio i.e. λ=1, which is aimed at low load conditions like idle and light cruise. With new ECU will be used so called wide-band oxygen sensor instead, which is accurate in much wider A/F ratio range as its name suggest. And such sensor is an indispensable tool for engine tuning as you probably know. For that goal was purchased AEM X-Series Wideband UEGO AFR Sensor Controller Gauge (showed with some other pars in below picture :) )
Attachment 3132
The ECU have controller for wide-band sensor, but will be used AEM one in the gauge. My plan is the gauge to not be installed in visible place in the car, but it will be in the car and will provide AFR as analogue signal to ECU. The gauge will be used during engine tuning for quick reference.
Some additional sensors will be connected to ECU for engine protection. Again, no gauges for them in the cabin :) . Below are showed two Titan Motorsport stainless steel 10bar pressure sensors, which have been bought for such use.
Attachment 3133
One will be used for engine oil pressure. There is a sensor with such function already on the car, but it is only for viewing on the dash and it will remain. The new one is stainless steel (don't know from what material is original one) and much more accurate I guess.
Other will be used for fuel pressure in the rail to look for issues with fuel supply like issue with pump/s or fuel lines.
Another AEM 3.5bar stainless steel pressure sensor will be used for the pressure in cooling system. Cylinder pressure will be much higher than originally and with this sensor will be look for signs of issues with cylinder head sealing in earlier stage.
The next sensor added is for the speed of turbocharger
Attachment 3134
The compressor cover of turbo is prepared and almost ready for installation of this Borg Warner turbo speed sensor on it (it can be seen installed on it on some of previous pictures). That series of turbos with titanium aluminide (or Gamma-TIi) turbine wheels are very sensitive to overspeeding. For that case and as the turbo will be pushed the turbo speed will go into ECU also. With using of this data and turbo pressure can be seen on compressor map (which are available for all EFR turbos) where exactly is operated and are we close to maximum possible airflow from turbo in particular setup. Also data from it can be very useful for finding boost leaks or how much harder the turbo start to work in much higher altitudes.
This sensor return frequency with 0-5V amplitude, which unfortunately cannot be used as input in that ECU. And for that was purchased additional converter - DCCDPro Turbo Speed Scaler
Attachment 3135
This unit convert the frequency signal from turbo speed sensor to 0-5V analogue signal, which can easily be used as in input in ECU or another data logging system. It have matching connector for speed sensor and power supply it. So look like something specifically made for this task ... and now start bad things - we didn't see it working at all from the start. We contacted that Canadian company again, which "produce it" (DCCDPro) and from which have been bought, but after we showed them pictures from oscilloscope showing that there is signal from sensor, but nothing (0V) after their unit they sad that will not support us, because we have order it by another company for parts and it that way we are not first hand buyer for them! After that I gave that unit to a friend of mine, which was good with electronics and have worked in electronic service shop at some point of time. Inside he saw Chinese modules with deleted numbers and generally bad assembling with used a lot of silicone! He try to make it work as it should and I hope to succeed. But with this unpleasant experience, I highly not recommend that company DCCDPro :angry:!