Smoky when cold.

[cuore_sportivo_155]

i'd use brake cleaner iso petrol, slightly less flammable or the wife's dishwasher...

[AlfaJack]

Forgot to ask...does anyone know a supplier for the plastic trunking which covers the wiring? A lot of mine near the radiator/fan is old and falling apart?

Found this stuff... http://cgi.ebay.com/ebaymotors/ws/eB...m=270278586477

wrinx

This is the place:

[jimnielsen]

Wrinx, are you going to use an "original" style radiator - or go for something in aluminum?

any disassembly pics?

jim.

[wrinx]

I was just going to stick a "normal" radiator in there, got a price of just under ?120 delivered, which I think is great!

Will post a few pics when I get some more work done...

wrinx

[wrinx]

This is the place:

Ahaaa, thanks Jack, this is their website:

http://www.wrightsautosupplies.com

..and the article in question, about halfway down:

http://www.wrightsautosupplies.com/p...entpageref=773

wrinx

[AlfaJack]

No probs

[wrinx]

A few pictures of the progress so far....ok, a lot more than a few, you may want to put the kettle on....!

Grill out


Bumper off


Wiring etc out of the way


Intercooler shroud with the little spray


Oil!


More oil! Intercooler pipe


Not so shiny


MORE oil!


Intercooler off


Intercooler pipe not sealing well either, not surprising there is oil everywhere


This is getting silly now


Oil in the engine bay


Disconnected the aircon...there was nothing in it!


Radiator loose, ready for removal


The worst I've ever seen!





Read on......

[wrinx]

After a light rubbing



Someone's idea of a good job


Removed the support panel too, for cleaning and painting


Cleaning the tubes


Lots more room to get at the tubby now


The next job, removing the turbo


The car now, turbo is held on with one bolt...for tomorrow!


The garage...Alfabits everywhere!



I need to go and buy a blast cabinet and lots of paint!!! Planning to refurbish and paint everything that's come off and perhaps the chassis legs while I'm there!

What fun....

wrinx

[AlfaJack]

If you want, I can blast anything for you. Postage might be on the expensive side though!

Is there any oil left in your sump???

[wrinx]

After checking out the price of cabinets I might take you up on that!

Think I'll just get some rust preventer and hammerite the support panel

Least I found out where the oil was going...!

wrinx

[AlfaJack]

Think I'll just get some rust preventer

Might be too late

[wrinx]

Got some Hammerite jelly stuff...seems to be working so far.

Been busy again tonight, stripping the tubby (yes MORE pictures!):

Underneath the turbo..oil!


Removed...


Blowing exh-manifold gasket


The beasty


The oil in close up...

[wrinx]

Turbo strip down....
Removed oil pipe

Remove wastegate actuator

Undo bolts and remove cover


Remove exhaust elbow...more oil!

Undo bolts on other side and remove cover...to reveal MORE oil!


Remove shaft and firmly clamp in vice (there's a flat on the triangular centre), undo the splined nut using an 11mm socket (not six sided)

Remove turbine

...and the bit underneath, this shows the underside

Remove the bearing

Remove circlip

Lift off the body

Yeewwww, guess this is contaminated and burnt oil!

What's left

One brass bearing will come out and you'll have to remove another circlip to allow the second bearing to drop out

The turbo in bits

[wrinx]

Ohhh, how did they get in there?


I did a phone video of the side play in the impellor shaft but it's disappeared. There was roughly 2mm of sideways movement! Thankfully no float on the shaft but I'll replace the bearing anyway.

The brass bearing with visible scoring was about 0.5mm bigger internally than the new replacements, the other is about 0.2mm...I guess that's where the movement came from!

If I'm posting too many pictures please say so...

wrinx

[wrinx]

One question...there are some spring retainers on the ends of the shaft, how do I get them into the casing when reassembling?

wrinx

[AlfaJack]

Cool, we dont often get photos of tubby rebuilds, more photos the better please

Sounds like its royally buggered though!

[wrinx]

Yup, I have a rebuild kit kicking around so will throw it back together and see what happens

wrinx

[Juan AR155Q4]

The shaft is ok? No marks on it?

[wrinx]

Seems to be ok, there's some light wear marks but as it runs inside the softer (phosphor bronze?) bearings there shouldn't be a problem.

I will check the measurements, but without a spec sheet I won't know if it's within tolerance anyway

wrinx

[Brul(tm)]

Yup, I have a rebuild kit kicking around so will throw it back together and see what happens

I have this kit also, but my turbo is beyond repair when it broke down.
The axle between the both turbines is broken Also some blades on the turbine on the exhaust side are burned away and some broke when it suddely came to an hold from way to many RPM's till standstil

Keep those pictures coming I am also curious for the results after youre done Wrinx.

Greetings,
Marc

[cuore_sportivo_155]

no wonder your jtd was faster than the q4

[axaQ42]

Will you use 360 degree bearings now?It will help the turbo to last longer

[AlfaJack]

How does a 360 degree bearing differ from a normal bearing?

[jimnielsen]

great pictures wrinx - umm.. could you weigh the fan and shroud for me if they are still off the car?

jimn~

.. that radiator is the worst I have ever seen - can believe it was on a functioning car!

[wrinx]

The axle between the both turbines is broken Also some blades on the turbine on the exhaust side are burned away and some broke when it suddely came to an hold from way to many RPM's till standstil

Ouch...!

wrinx