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> Cujo's 145 20vt, In Belarus
Cujo
post 6th February 2011 12:52
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1.4 16v
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From: Minsk, BY



PART 1. As diesel died.

At first, I want to say I'm sorry for my english: this text was written on russian at belorussion alfa-lancia forum and translated by google with my help. So ask me if you don't understanв something.

Gone mad desire for power and finally got tired of servicing the machine, I'm closer to the New Year spat at everything and decided to do only what is necessary and without fanaticism. At the same time, I decided that power after the second chipping I have enough. Sawa (my mechanic) beckoned turbine from 2.4 and bustkontrollerom, but I thought this event at that time an expensive and unnecessary.
What a time I could just go in peace with itself and enjoy the process. But it did not last long - and wanted to comfort. When the "chase", comfort is not the first place, but the quiet ride it is needed. I must say that the diesel sound did not bother me, and sometimes even loved. I strained vibration, especially on the steering wheel on the twentieth. They got me with the car initially.
I'll tell you that the source of vibration and failed to localize. It was a suspicion of the crankshaft pulley, but it was not him. Nozzles were tested, were outside the limits and were put in order. But it did not help. It was further agreed not to transfer a lot of money on a consistent exception to the reasons to remove the motor, disassemble and conduct Troubleshooting.
Troubleshooting revealed the worst: there is no explicit stocks. Ie, to somehow be assured of victory, it was necessary to bring the whole motor in good condition, which meant, as a minimum: the replacement of pistons on the 1 st repair size, grinding valves, replacement liners with knee recess, etc. etc. Incidentally, the upper ear were noticeably worn, but blame it on the chip-tuning is not possible due to lack of evidence base)))
But there is one crucial fact emerged: the pistons 1 oversize there was only one place for $ 350 apiece, turning repair unjustifiably expensive process cost about 2.5k. Then immediately have alternatives, and the first one: buy the same motor used. Consideration of this option, take a few seconds, because buy a mower the same iron pot in an unknown state was not the slightest desire. The idea at the expense of 2.4jtd, but offered to SAWA, once to change the four to five, then it would be interesting to stick in fiat 20vt, even more so Valera (seller of used parts) had a right whale, and yes even cheapened because of the crisis. Sawa quite optimistic suggested the deal is approximately two months. Indicative budget was less than the amount repair, flywheel with clasped and Webasto. We must also note that Webasto place was simply nowhere to go, even if I move battery to the trunk, this should have been a creative approach to the problem.
In general, after weighing the arguments and facts, I concluded that the swap is commensurate with the cost reduction in order diesel and still and very cute! Not pretty horses, and refinement of technical ideas. So, March 2, 2010 to 1.9jtd was applied euthanasia.

Without heart)))



to be continued...

This post has been edited by Cujo: 6th February 2011 12:54
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Cujo
post 6th February 2011 13:01
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1.4 16v
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PART 2. Beginning.

9.03.2010 20vt-kit appeared in garage. Looks so:




It was immediately performed a series of operations:
1) Engine put to the wall

Somewhere at this moment Sawa saved me a lot of money to replace the clutch disc, and not in the collection basket. But on this motor is not cheap clutch with reverse squeezing. Well - this version is an ordinary flywheel - not damper.

2) liners (i'm not sure. maybe bearing) was replaced:





Liners have changed, rather, to prevent, as Foot-and the old liners were in very good condition.

3) Further timing belt was replaced with the rollers

Delighted that this motor inexpensive procedure. Although, if it is not on, removed the motor, it would be painful - change timing just hanging out with the motor smile.gif



And in this way is slightly updated stood waiting for a motor installed in the car, and I went on dreaming about the imminent finale :-[

to be continued...
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Cujo
post 10th February 2011 19:08
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PART 3 (short). Сервис мотора.

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Cujo
post 10th February 2011 19:10
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PART 4. Transplantation.

Engine:


Process:








Long engine)))

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Cujo
post 10th February 2011 19:16
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PART 5 (short too). Battery.

Battery was immediately decided to resettle in the trunk for weight distribution, and to release only valuable space under the hood.



Sawa instructed me to find a positive lead. Cross-section, I found quickly on the basis that the current order of 700-800 amps for 10 seconds warmed, this lead of 20 degrees (of nominal air temperature) to 90 degrees (the maximum temperature for the insulated conductors). Identified a sufficient section of 35 mm square copper. Because I work in power suply, then quickly found a particularly soft-phase second-hand Cable is something at 3 kV cross-section 35 a square. The cable has been issued with a condition of returning unwanted veins. When the return cable, I was told that he was a specialist (like mine): it is on top of core insulation was conducting graphite coating, and the center was bare copper wire of smaller cross section. All this made for a rapid transition of the formed insulation defects in the closure of a current, sufficient for its immediate shutdown. I immediately call Sawa and say that he ripped off before laying the wires with his graphite envelope, but he was already stretched. Then I asked him to have that moment in mind when joining the terminals. As I understood later, they did not believe me: Sawa called me and was laughing, and said that a shell have good conductivity ))))))
So I have in the cabin shielded "+":)
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Cujo
post 10th February 2011 19:21
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PART 6. Exhaust manifold.

As it turned out, it was not included in the kit.
Again, I was instructed to find. Searches in Minsk to no avail. Only after I accidentally found out that someone has cracked manifold.
Firms which carry used part from Europe under the order, offered to bring him over $ 300. So, in one of the Lithuanian showdown I found two of mouthguards with such motors, and even a collector! But they refused to unscrew from the turbine due to safely break the studs. Then I asked how much it costs? - Was 280 $. For the turbine as part of kit, I immediately gave $ 400. As a result, deliver me to the collector to the turbine cost $ 310 USD. I had to wait 2-3 weeks, but the choice is still not there.
In the photo you can see how the turbine, and finding place for intercooler.
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Cujo
post 10th February 2011 19:32
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PART 7. Parts.

You can see as control right-left headlight touches the bracket of compressor. This was solved by using the cutting device control. Now i've purchased new headlams and I will cut the bracket.



Without "trousers"


Changing oil filter is coprophagy (it's called so by my mechanic))))))




And here we see the brilliant generator, to search for that, too, took about a month: on our cars front-mounted generator - a rarity.














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stevepx
post 10th February 2011 19:39
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Awesome thread, Naan........enough pictures for you fella smile.gif

Looking forward to the next installment


--------------------
I've seen things you people wouldn't believe.
Attack ships on fire off the shoulder of Orion.
I watched C-beams glitter in the dark near the Tannhauser gate.
All those moments will be lost in time... like tears in rain... Time to die.
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Cujo
post 10th February 2011 19:52
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PART8. Parts.

Jets and other trash closed beautiful chrome clamps sad.gif
Although the inscription has my favorite color smile.gif







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Fin
post 10th February 2011 19:53
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Love the work guys!

Please tell me you will leave the 1.9JTD badge on the back of it when it's finished? laugh.gif


--------------------
Keep left unless overtaking - Use mirrors and signals when changing lanes - Keep within the white lines - Don't tailgate

Its not exactly f**king rocket science is it?


If you cut a horse in half, then bang the two halves together, you get exactly the same noise as someone riding a coconut!
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Cujo
post 10th February 2011 19:56
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1.4 16v
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PART9. Breathing.

The air became stage in this metamorphosis. From what he cooked I do not want to know. It is known that there including chrome legs went to the kitchen table biggrin.gif



Scholars may notice that the connection to the air filter attached below rather than above, as in the original - it is a pleasure worth $ 40 I have an unknown master.



Sawa, referring to horseradish removal of air from the staff room (which I completely agree with him), proposed to place the intercooler horizontally under the hood. The air intake to make on the spot fog (to the right place - a symmetrical air intake for oil cooler), and the air outlet to do through the hood in the direction of front glass. I idea seemed interesting, and I agreed.
That work on the boxes to the air intake in the bumper. "Sketch" Sawa carved out of empty cans and jars, connected by screws, and then plastic-maker is all embodied in a neat box.




And here and so looked initially ducts:

I have to say: Sawa - not a welder, and, of course, the seams turned horrible. But from him anything more than the mechanical strength and tightness is not required. Second left jamb on the principle: "best is the enemy of the good" - Sawa so carefully polished joints that sanded them to the holes. Here Bassett - poor thing - their one and a half hours scald:


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Cujo
post 10th February 2011 20:02
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QUOTE(Fin @ 10th February 2011 21:53) *
Love the work guys!

Please tell me you will leave the 1.9JTD badge on the back of it when it's finished? laugh.gif

Savva wantad the same)))) But I've already purchased "turbo" of 75th smile.gif


I really sorry for my english and I will be very appreciated if moderators correct errors blush.gif
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stevepx
post 10th February 2011 20:05
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QUOTE(Cujo @ 10th February 2011 20:02) *
Savva wantad the same)))) But I've already purchased "turbo" of 75th smile.gif
I really sorry for my english and I will be very appreciated if moderators correct errors blush.gif


я надеюсь, что мой русский язык столь же хорош как ваш английский язык huh.gif


--------------------
I've seen things you people wouldn't believe.
Attack ships on fire off the shoulder of Orion.
I watched C-beams glitter in the dark near the Tannhauser gate.
All those moments will be lost in time... like tears in rain... Time to die.
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ALFACOOL
post 10th February 2011 20:06
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Well done guys.
Its amazing what can be done with a little amount of money and lots of enthusiasum.


--------------------
Alfa Romeo cars are fitted with high performance engines derived from their strong racing heritage.It is therefore important to check your oil level regularly,maintaining the correct level using the recommended lubricant, as stipulated in the handbook.
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stevepx
post 10th February 2011 20:06
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1.6 16v
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трубы выглядят большими, что Вы использовали, чтобы покрыть их?


--------------------
I've seen things you people wouldn't believe.
Attack ships on fire off the shoulder of Orion.
I watched C-beams glitter in the dark near the Tannhauser gate.
All those moments will be lost in time... like tears in rain... Time to die.
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Cujo
post 10th February 2011 20:17
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1.4 16v
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From: Minsk, BY



stevepx, your russian is better than more of my countrymen have thumbsup.gif
Если хочешь пообщаться по-русски, пиши в личные сообщения, чтобы не утомлять остальных wink.gif

It's polymer coating. On the bracket under intercooler too.

I remembered funny thing about "jtd": once at our Minsk car-market twin spark 156 with broken variator was sold as a diesel)))))))

This post has been edited by Cujo: 10th February 2011 20:18
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stevepx
post 10th February 2011 20:22
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1.6 16v
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Local Time: 13th December 2017 17:40
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Member No.: 6,258
Driving: 146 1.6 TS 16v
From: Hampshire



QUOTE(Cujo @ 10th February 2011 20:17) *
stevepx, your russian is better than more of my countrymen have thumbsup.gif
Если хочешь пообщаться по-русски, пиши в личные сообщения, чтобы не утомлять остальных wink.gif

It's polymer coating. On the bracket under intercooler too.

I remembered funny thing about "jtd": once at our Minsk car-market twin spark 156 with broken variator was sold as a diesel)))))))


roflmao.gif clapping.gif


--------------------
I've seen things you people wouldn't believe.
Attack ships on fire off the shoulder of Orion.
I watched C-beams glitter in the dark near the Tannhauser gate.
All those moments will be lost in time... like tears in rain... Time to die.
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kirk46
post 10th February 2011 20:35
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1.7 16v
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From: doncaster



roflmao.gif roflmao.gif roflmao.gif


--------------------
R.I.P 146 :(

QUOTE(groovylee @ 13th August 2011 08:41) *
(easy naan, the other type of helmet :lol:)

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purple
post 10th February 2011 20:50
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Forum Moderator
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excellent work
thumbup.gif
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Cujo
post 10th February 2011 20:59
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1.4 16v
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time you like, then on the regular state technical inspection a 147TS was checked on the smoke (rather than CO) and inspector said that he had never seen such a serviceable diesel engine

variator is really funny thing. On my new car it was changed immideatly to prevent smile.gif

This post has been edited by Cujo: 10th February 2011 21:00
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