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Old 19-03-2019   #46
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Re: Engine rebuild, Stilo Abarth 2.4 manual

Video of Dyno
I will upload Dyno sheet etc. and economy run and results after compiling.


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Old 20-03-2019   #47
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Re: Engine rebuild, Stilo Abarth 2.4 manual

Quote Originally Posted by alexGS View Post
I'd like to know the answer to this. For the Alfa Twinspark engine, there is a special long, thin Ribe tool required to remove those sump bolts. I don't know whether the same tool applies for the five-cylinder motor.


It's been a few months - I wonder how this story concluded?


-Alex


Hi Alex, a bit late but build were on hold for mmm.. a few more month


And the answer is on the Stilo Abarth that you must remove the flywheel and heat plate in order to remove the 2 bolts on the sump.
Note! this is on a standard dual mass clutch, if you did a single mass conversion it might not be required.
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Old 20-03-2019   #48
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Re: Engine rebuild, Stilo Abarth 2.4 manual

Eco Run


Not perfect conditions or controlled but more realistic day to day


Distance covered: 80.7 km
Speed control set: @139, true speed 130 km/hr (Speedo not very accurate)
Consumption: 11.3 km/l
Aircon: On


You will see I must still sort out a broken fuel gauge, coolant temp gauge and then have an alarm for ABS and Air bag.
The 44 min video is a bit long, so first minute here LOL




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Last edited by Abarth L; 20-03-2019 at 16:57. Reason: addition
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Old 22-03-2019   #49
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Re: Engine rebuild, Stilo Abarth 2.4 manual

Below are the Dyno sheet.


Note: the altitude at which I am and doing the test and economy run.
If I made a mistake somewhere in a calculation, let's discuss.
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File Type: pdf 145 kW_291 Nm Stilo Abarth.pdf (384.2 KB, 2 views)
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Last edited by Abarth L; 22-03-2019 at 12:01. Reason: no attachment??
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Old 22-03-2019   #50
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Re: Engine rebuild, Stilo Abarth 2.4 manual

So after rebuilding the motor I also had to do some looooong outstanding maintenance on the front.
- Front Tyres
- Brake Disc's
- Shocks
- Lower Control Arms.
- LH CH boot rubbers.


So first time I changed the shocks since I bought the car in 2008 ( 1 owner, bought on 24000 km)
Can't remember if the brake disc has ever been changed.
Also changed the lower control arms , this was a challenge since I bought from a spares shop which shown in the book that the lower control arms important from Italy fits all Stilos, but on the Abarth the one hole is to small.
So I had to increase the size to 14mm.. (Note: I had an engineering company do this at slow speed not to overheat the metal, also clamping the steel bush not to stress the rubber.


On the old front tyres, you can see the wear on the one tyre, hence the front suspension maintenance.
I opted now for Good Year Eagle F1 sync 3. (Front)


I also recharged the air con, Note! the aircon never required refill and I am very impressed how good the Stilo Dual climate control works, compared to X2 and Si4
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Old 25-03-2019   #51
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Re: Engine rebuild, Stilo Abarth 2.4 manual

While under the running in period after the schocks, cv's etc where changed I had to look at all the ECU faults.


So I took the car to a BOSCH dealer whom also have a dyno for later use


Below you can see the Christmas Tree ( ECU errors)
The Bosch snr. technician advised to:
1. Clean MAF sensor
2. New cam sensor
3. New Lambda sensor for nr.2
4. New Knock sensor nr.2
5. Piston 5 ignition coil??


I analyzed the results vs his advise and since all ignition coils and cam speed sensor were giving alarm, I read somewhere on google how a faulty knock sensor will let your ecu advance and retard the timing to try to eliminate the "knock", hence all ignition coils and cam sensor alarms.
So I decided to only:
1. Clean MAF sensor and connections with electrical cleaner (Note I removed the sensor using pliers to "unscrew the 2 odd bolts")
2. Replace Knock sensor 2 (piston 5), was a liitle tricky , had to do it from the bottom.
NB! The knock sensors must only ne tightened to about 3Nm, extremely lightly, just lock it, if you turn to hard you are going to damage the sensor (maybe I did this is why it were broken)
3. Replace Lambda sensor 2 (after catalytic convertor, well after my mini cat)


I also bought a ECU OBD 2 Bluetooth dongle to test myself before going back to Bosch.


After all 3 items done on my list all faults cleared, engine light cleared it self next morning when I started the car, and I could fell an immediate boost in power like seriously much better, took a test drive and stopped by Bosch to check ECU again, all faults cleared


The MAF sensor I still doubt if it were to dirty, Fiat don't use the thin oscillating wires but a temp diode which is much more durable.
To remove the MAF was quite simple:
1. REMOVED the engine and battery covers.
2. REMOVED battery
3. LIFTED the battery plastic cage on the LH front.
4. LOOSENED the clamp.
5. UNSCREW the 2 bolts on the MAF.
6. TWISTED 45% anticlockwise to remove plug.


When I started I thought I would have to remove the whole air box again, luckily not.
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Old 3 Weeks Ago   #52
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Re: Engine rebuild, Stilo Abarth 2.4 manual

Hi. I am Marin from Croatia. Your work is impresive. I have 2001 stilo abarth and I will put leather seats inside. I got them for only 150. For another 300 i got complete engine with ecu, selespeed gearbox and all other parts inside the engine bay. I plan to "refresh" that spare engine with new piston rings, seals, gaskets, bearings. Can you tell me where you got piston rings...original fiat or alternative solution? I must ask someone will I use original dimensions or use first higher dimension for bearings and rings and rework crank shaft.
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Old 1 Week Ago   #53
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Re: Engine rebuild, Stilo Abarth 2.4 manual

Quote Originally Posted by mdrazic View Post
Hi. I am Marin from Croatia. Your work is impresive. I have 2001 stilo abarth and I will put leather seats inside. I got them for only 150€. For another 300€ i got complete engine with ecu, selespeed gearbox and all other parts inside the engine bay. I plan to "refresh" that spare engine with new piston rings, seals, gaskets, bearings. Can you tell me where you got piston rings...original fiat or alternative solution? I must ask someone will I use original dimensions or use first higher dimension for bearings and rings and rework crank shaft.


Hi Marin
Thank you.
I got the majority of the spares from FIAT (Original), so rings were from FIAT.
Since it is a second hand engine you are getting, I recommend to re-sleeve the block since the sleeve will now be more oval than round and out of spec. (If you don't it will leak oil into the combustion area, also DON't hone the sleaves)
The bearings I got were all original FIAT, did not do any work on crank, there were now damage that required work to be done after 257000km, but it depends on the condition of your engine.


Please ask if you require any information or procedures, good luck it is a lot of work but worth it.
Replace also the con rod bolts with new ones, head bolts, whelsh plugs and oil pump.
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Last edited by Abarth L; 1 Week Ago at 23:13.
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Old 1 Week Ago   #54
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Re: Engine rebuild, Stilo Abarth 2.4 manual

Thanks for informations. Fiat dealer in Croatia has price for spares like it sell parts for ferari instead of fiat. How much did you spend for rings and other parts?
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Last edited by mdrazic; 1 Week Ago at 22:06.
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Old 1 Week Ago   #55
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Re: Engine rebuild, Stilo Abarth 2.4 manual

Hi Marin


I quickly created a bill of material for what I have at hand, I will have to spend some time to create a more comprehensive complete list later going through all my emails.


But the list below can give you some idea.
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