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Thread: engine rebuild

  1. #1
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    Default engine rebuild

    hi guys, it's time for rebuild my engine, so i would like to share with you my progress. i hope the photos will be fine because i took them with my mobile.
    day 1. little progress, not so many things. it is not so easy to take the engine out and strip it


    the engine is already out


    and the car looks like this...



    parts everywhere


    at the same time some modifycation to my new Kappa inlet manifold



    i decide to make it shorter about 60mm and of course porting and polishing

    thank you, i hope tomorrow i will have more progress.
    good night to all

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    That's not bad for a day work
    Looks like you have plenty of room to work in

    Looking forward to see this project going forward.
    In a world full of compromise...
    ...some don't.
    ___________________________
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    The car is at my mechanics garage. We were 3 people so that's why we did a lot of work in one day. I hope everything will go well. In my progress I want to change
    Forged pistons
    Light flywheel
    Clutch
    Head gasket
    Arp head bolts
    And I will remove completely the balance shafts. I have already buy a removal kit

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    how much did it costed and where to buy it?

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    Most parts I bought them from www.scara73.it about what part you mean? I guess about balance shafts removal kit. I bought it 135 euros but the kit didn't include 2 more taps that I made them here in Greece and cost 25 euros. I will post photos tomorrow

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    Look forward to seeing this happen..

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    Good luck with your project!
    Alfa Romeo 155 Q4 WB '95
    Alfa Romeo per sempre !

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    it was a long day today
    first of all we finished the inlet manifold. after that we will paint it completely


    we take out the pistons and all inside the engine


    i was surprised when i saw these




    very good condition in case of 345.000 km
    we sent already the block engine for grinding and we start to port and polishing the head



    that's for today. a lot of work but i hope the results will be good enough

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    Quote Originally Posted by mpampis_ View Post
    at the same time some modifycation to my new Kappa inlet manifold

    I see health and safety rules haven't reached Greece yet. There are at least 3 in that pic.

    Seriously though, looks like you are well on the way with things.

    Just a question, what is the reason for shortening the Kappa inlet? Is it just to make it fit a little better?
    1994 Alfa Romeo 155 Q4: Dozeing in the garage.
    2009 Audi A4 tdi: Everyday drive.
    1994 Alfa Romeo 155 , 1995cc Std Standard Black

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    Quote Originally Posted by Steve Webb View Post
    There are at least 3 in that pic.




    Safety isn't always the first thing to be thinking of. I am also skipping this a lot.....
    In a world full of compromise...
    ...some don't.
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    Yes you are right about safety rules I make the manifold shorter for being quicker in respond. But I think maybe I will loose some torque at low rpm.

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    I also show a damaged Valve rubber but anyway I have a new set to replace. Also some valves needs to be rubbed. That's why some loosen compression in the cylinder.

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    Quote Originally Posted by mpampis_ View Post
    i was surprised when i saw these
    Head gasket?

    wrinx
    My Q4 in the Garage

    www.alfaromeo155.co.uk ............................ □□□-V-□□□ .................................. www.ilmostro.co.uk

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    My head gasket was in good condition too. Now I have a spesso with steel fire rings

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    Was that an inlet or exhaust valve? Looks like it wasn't seating at all well.
    1994 Alfa Romeo 155 Q4: Dozeing in the garage.
    2009 Audi A4 tdi: Everyday drive.
    1994 Alfa Romeo 155 , 1995cc Std Standard Black

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    This was an exhaust valve. You are right. I had 3 valves that didn't seat well. No everything is ok

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    a little progress today too. the engine block and the head came from griding





    it is time to remove the balance shafts, and this is the removal kit


    it was a quite easy job i can say



    first of all we need to tap the oil conductors that drives the oil to the balance shafts


    and the second one


    after that i had to tap tha balance shaft's hole


    the other side on monday after painting the engine block. thanks for your patience

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    i was a little busy these days, so now i will share with you some last fotos

    the engine ready to be fitted


    new coilover by XYZ with adjustment top mount


    and this is almost ready



    i have no other fotos with everything complete in the engine area but i will put some these days and i post

    thank you for your patient my friends

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    the only thing for finishing the engine rebuild is the camshafts. i wish until summer i can buy a pair of C&B and i will start my next project with the body kit. i imagine it already wider like zagato....!!!! aaawww.....my sweet dreams

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    Are the plugs that are used to block off the balance shaft oil-ways thread-locked in?

    Looking very nice by the way, how much power are you looking for when its all back together?
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    That was quick!!!
    I thing we have a record for a Q4's engine rebuild.

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    Quote Originally Posted by Steve Webb View Post
    Are the plugs that are used to block off the balance shaft oil-ways thread-locked in?

    Looking very nice by the way, how much power are you looking for when its all back together?
    The balance shafts removal kit is working. I didn't see more oil pressure but the good point is that the oil pressure is ok. 7 bar in the morning when the oil is cold and 3 bar at idle when the oil is warm. I don't know about the power but I am planing to boost the turbo 1.6 bar and 2,2 bar with methanol on track days. I hope to peak 50kg of torque and 370-380 hp. In full boost I remain more but the dyne will show the truth.

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    Quote Originally Posted by Juan AR155Q4 View Post
    That was quick!!!
    I thing we have a record for a Q4's engine rebuild.
    That was because I bought all parts before the rebuild. We were 3 people working on the engine. We spent 1 week and the most difficult was to relocate things like fuel pressure regulator, idle valve and some cables. The result is great by the way. Now I have to drive 1000 km in normal condition with low boost and after that to remap the ecu

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    Nice work there and quick rebuild. Mey i ask how much did the XYZ coilovers kit costed you?

    regards coly

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    Quote Originally Posted by colibry View Post
    Nice work there and quick rebuild. Mey i ask how much did the XYZ coilovers kit costed you?

    regards coly
    Here in Greece XYZ set costs about 1200 euro for front and rear axel

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