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  1. #1
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    Default Inlet mainfold rubber hoses

    I searched the forum for info about how to change the 4 rubber houses connecting the inner and outer parts of the intake runners. I found one old thread giving some hints of how to get them off, so if anyone who is active now have more info to share I would appreciate it a lot. What I have in mind is:

    - How on earth do you tighten the clips again after replacing the hoses?
    - The local very experienced Alfa Romeo workshop recommended me to go for aftermarket silicone hoses. Comments?
    - Pictures of the disassembly process would be just great!
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    155 Q4 -96
    Giulietta ti -59
    Giulia 1600 Sprint -62
    Stelvio 2.2 Q4 - soon to arrive
    Fiat 500 TwinAir -11
    Lotus Evora S -11
    Peugeot 306 GTI -99
    159 SW 1.8 tbi -11 (recently sold)
    156 SW 2.0 TS 16V (recently scrapped)

  2. #2
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    This might help a little:

    http://alfa155.org/forum/viewtopic.p...8773&start=300

    If the clips are the usual horrible Alfa things I just stick a screwdriver in and twist them off, then replace with jubilee clips! When replacing, make sure you put the worm drive on the upside to make them more accessible.

    On mine, the clips had been replaced with jubilees but the idiot before me had put the worm drive underneath which meant I had to remove the throttle body and squeeze my arm through the tiny hole to get at each one...I was COVERED in buises!

    Alfajack has done this job a few times and may have more advise...my parting comment is to be aware of the earthing straps at the rear, unless you undo them they will prevent you from removing the inlet until you break them!

    wrinx
    My Q4 in the Garage

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

  3. #3
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    When my engine got rebuilt before I got the car, the clips were replaced by jubilee clips but unfortunately they rebuilt the whole thing on the bench so the clips are at a bitch of an angle to get to.
    I do want to get the manifold off at some point, when I eventually get the car back from the garage and back on the road, as I'm swapping over to the Integrale manifold.
    1994 Alfa Romeo 155 Q4: Dozeing in the garage.
    2009 Audi A4 tdi: Everyday drive.
    1994 Alfa Romeo 155 , 1995cc Std Standard Black

  4. #4
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    Quote Originally Posted by #84 View Post
    I searched the forum for info about how to change the 4 rubber houses connecting the inner and outer parts of the intake runners. I found one old thread giving some hints of how to get them off, so if anyone who is active now have more info to share I would appreciate it a lot. What I have in mind is:

    - How on earth do you tighten the clips again after replacing the hoses?
    - The local very experienced Alfa Romeo workshop recommended me to go for aftermarket silicone hoses. Comments?
    - Pictures of the disassembly process would be just great!
    - How on earth do you tighten the clips again after replacing the hoses?
    Once you have the jubilee clips on then you can, as advised above, get a screwdriver down. I find the easiest way is to remove the inlet pipe that runs beside the battery and then the 90 degree rubber pipe. This allows you to get your arm under the inlet to hold the clips whilst you undo them.

    - The local very experienced Alfa Romeo workshop recommended me to go for aftermarket silicone hoses. Comments?
    I doubt they are available, other than straight pipe of silicone pipe - the originals are stepped at each end to provide a tight seal.

    - Pictures of the disassembly process would be just great!
    As mine is in pieces like this at the moment, I'll get some good pics over the weekend.

  5. #5
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    There are stepped silicone hoses available but you'd have to cut them down so it's a lot of messing about, the originals are very hard wearing and don't move, so unless they're in pieces I would just put them back on.

    wrinx
    My Q4 in the Garage

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

  6. #6
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    Thank you all for your very quick replies and good input!

    The hose for cylinder one is extremely greasy, the one for cyl 2 a little bit. So, I need to replace at least one of them and then I suppose it is best to replace all of them. At least I have to get it all off and check. Even though there is no visual damage, I cannot see any other explanation than a leaking rubber hose for the greasy hose/pipe.

    When cold the car runs perfectly, then when it gets hot there is zero idle capability. I had a similar (not that bad) problem back in 2003. A Magneti Marelli specialist in Milan compensated for it by adjusting the throttle position sensor, but I kept on having problems until I late 2007 discovered that one of the gaskets for the EGR pipe flange connection was missing. Amazing. I had checked everything and had it in 4 workshops and no one could identify the reason for the idel problem. The gasket must have been lost when I had it in for a cam belt change. However I believe that one of the intake runner hoses had started to leak by then since I kept having idle problems and fuel smell.

    So, when I finally brought out the car 1:st of May this year after many years in the garage, the hot idle problem was extreme and when I slowly tried to rev the engine more and more when the engine was warmed up throughly, the turbo whining was absurd, it sounded like a jet fighter before take off. So, at 5500 rpm it "took off" with a giant blue cloud behind the car

    Now the turbo has to be fixed as well, but at least it lead my clearly to the root cause.
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    155 Q4 -96
    Giulietta ti -59
    Giulia 1600 Sprint -62
    Stelvio 2.2 Q4 - soon to arrive
    Fiat 500 TwinAir -11
    Lotus Evora S -11
    Peugeot 306 GTI -99
    159 SW 1.8 tbi -11 (recently sold)
    156 SW 2.0 TS 16V (recently scrapped)

  7. #7
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    It does sound as though getting the inlet off would be a good idea after the car has been stood for that long. Give you a chance to clean things up and get a good look at what might be leaking.
    1994 Alfa Romeo 155 Q4: Dozeing in the garage.
    2009 Audi A4 tdi: Everyday drive.
    1994 Alfa Romeo 155 , 1995cc Std Standard Black

  8. #8
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    First confirmation of my theories was given abruptly sunday morning when the family went shopping clothes, I had a slight hangover and decided to remove the turbo. It went well until I removed the "?-shaped" hose between turbo and IC. The hose and the bottom of the IC was filled with coal black oil pouring out over me .... Around half a liter. I had to interrupt the work while the absorber was soaking up the oil from the floor, all droplets coming out and changing clothes.
    -
    155 Q4 -96
    Giulietta ti -59
    Giulia 1600 Sprint -62
    Stelvio 2.2 Q4 - soon to arrive
    Fiat 500 TwinAir -11
    Lotus Evora S -11
    Peugeot 306 GTI -99
    159 SW 1.8 tbi -11 (recently sold)
    156 SW 2.0 TS 16V (recently scrapped)

  9. #9
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    Sounds like a failed oil seal in the turbo.

    Is it the original turbo in your car?
    1994 Alfa Romeo 155 Q4: Dozeing in the garage.
    2009 Audi A4 tdi: Everyday drive.
    1994 Alfa Romeo 155 , 1995cc Std Standard Black

  10. #10
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    No, not exactely. It is called KRX-400, but is basically a modified KKK K26 which was used on the original Audi RS2 for example. Swedish Turboservice, who do a lot of OEM development and also produces their own turbochargers for WRC (or did at that time) developed it as part of a 400 hp kit for the Volvo S60/V70R back in 2004 something. That is why it has the typical Volvo flange. It didn't give the improvement in spool up and low end torque as I hoped for when I started to look at the Mitsubishi TD04/05 units which were better than the Garrett GT25's, which in turn were much beter than the GT3's they replaced. Therefore it has been modified a few times and the most spectacular part is the minimal ported shroud on the compressor inlet, which was created when we managed to improve the low end boost with several tricks and it instead went into stall in some occasions.

    I just got it off the car and the turbine outlet had millimiters of thick semi-coxed oil rests . Other than that and the failed sealings it appears to be in good condition.
    Attached Images Attached Images
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    155 Q4 -96
    Giulietta ti -59
    Giulia 1600 Sprint -62
    Stelvio 2.2 Q4 - soon to arrive
    Fiat 500 TwinAir -11
    Lotus Evora S -11
    Peugeot 306 GTI -99
    159 SW 1.8 tbi -11 (recently sold)
    156 SW 2.0 TS 16V (recently scrapped)

  11. #11
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    Sounds like a strip down and rebuild are in order, but for a failure of that magnitude I'd like to see exactly where the seal failed and why?
    1994 Alfa Romeo 155 Q4: Dozeing in the garage.
    2009 Audi A4 tdi: Everyday drive.
    1994 Alfa Romeo 155 , 1995cc Std Standard Black

  12. #12
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    Some pics of the inlet off the car:

    01_08.jpg

    01_09.jpg

    01_10.jpg

    01_11.jpg

    01_12.jpg

  13. #13
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    Thanks a lot!

    Now the turbo is sent away for renovation and the boring part remains, but with your pictures I am less scared. Lets just fix the 306 GTI for the race in 1 1/2 week and the Evora for the MOT before the end of October and .. and .. and ..
    -
    155 Q4 -96
    Giulietta ti -59
    Giulia 1600 Sprint -62
    Stelvio 2.2 Q4 - soon to arrive
    Fiat 500 TwinAir -11
    Lotus Evora S -11
    Peugeot 306 GTI -99
    159 SW 1.8 tbi -11 (recently sold)
    156 SW 2.0 TS 16V (recently scrapped)

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