GTV ts

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KevJTD
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GTV ts

Post by KevJTD »

I bought this green twin spark earlier this year off Rich, originally I was going to fit an engine to it for him but as time went on and things got delayed I bought the car from him rather than delay the job any longer as my time was (and still is...) being taken up with the Dedra turbo rebuild.
It's a low miles (46k) car in great condition but had the dreaded "hammer in a cement mixer" soundtrack rather than the raspy ts engine note.
As I had an engine sat there from the bulk bought from Lou a while back then we figured that to be the easiest route..
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

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KevJTD
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Re: GTV ts

Post by KevJTD »

Although it's green, not my favorite colour, it does look nice when clean.
A phase 2 car so the nice silver dash with the climate dials as the 156, cloth seats which I much prefer to leather especially on hot days like today!
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Giulietta JTD 170
Lancia Delta integrale
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Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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KevJTD
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Re: GTV ts

Post by KevJTD »

Still a nice looking car the GTV I reckon
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Giulietta JTD 170
Lancia Delta integrale
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Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
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KevJTD
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Re: GTV ts

Post by KevJTD »

Anyway, the engine swap which had been waiting for the last few months finally began last Saturday as I am waiting for parts on the Dedra.
The plan is to rebuild the original engine and refit it so it keeps "numbers matching" even if that doesn't mean a lot to a car like this.

The engine I had available though is a CF1 motor which has the alloy top and inlet manifold, not the plastic parts as per my CF2 car.

Fitting the early type isn't as straightforward as it may seem as every system and connection is different.

Not only are the manifolds different (exhaust manifold too..) but every sensor has a different connection and all the water pipes are connected in a different place.

The simplest solution was to swap everything over from my engine to the donor, so that's crank sensor, knock sensor, cam sensor (meaning cam pulleys removed..) and leaving everything on the plastic manifold so the whole control system swaps over.
The front water rail is different, the thermostat too so both swapped. Even the power steering bottle is different although thankfully the pump itself is the same.

So with everything removed from the old engine that needs swapping you end up with this!
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IMG_20220717_143443.jpg
IMG_20220717_143437.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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KevJTD
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Re: GTV ts

Post by KevJTD »

But end up with this ready to fit now CF2 looking motor..
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Giulietta JTD 170
Lancia Delta integrale
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Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
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KevJTD
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Re: GTV ts

Post by KevJTD »

All lifted back into place yesterday afternoon
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IMG_20220716_144115.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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KevJTD
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Re: GTV ts

Post by KevJTD »

Took me until 10PM last night to get it all plumbed in but it's now a runner again.
The CF1 motor also had never had AC fitted so the mount holes were very rusty but cleaned up OK with a tap, hopefully the system will work once regassed..
Plan now is to replace all the discs and pads next Saturday and give it a check over for the mot which will be the following Saturday hopefully.
Looking forward to using the car.

I'll also do the heated rear window wiring mod that I did on the red car recently, which I forgot about so need to order a relay ready..

Over the winter I'll get the sump off the original and see what's happened, and if it can be repaired..
Attachments
IMG_20220716_213443.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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LooLooSud33Spider
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Re: GTV ts

Post by LooLooSud33Spider »

Great work Kev. I’m sorry I meant to say that all the electric plugs are different. Some are in slightly different locations but mostly it’s the plug design they changed. For no apparent reason. Is this the CF1 that i gave you ?
Alfasud Ti 1984
Alfa Spider 2.0 Ts 916
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KevJTD
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Re: GTV ts

Post by KevJTD »

Yes, it's the one that had the gearbox attached to that I rented a big van to come over and fill with all that stuff! :lol:
The other complete engine you had a ride back over to collect didn't you, so at least both have found new life!
The one that's in bits may come in useful for when the rebuild starts.
At least this unit has turned out to decent so was worth the ride over in the end.
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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Re: GTV ts

Post by LooLooSud33Spider »

You know me I like to help .
Alfasud Ti 1984
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KevJTD
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Re: GTV ts

Post by KevJTD »

Plan was to mot the car next Saturday, spend today checking things over and fitting the new front and rear discs and pads. Fit the new boot struts, give it a clean inside and out etc.
Unfortunately Chris isn't at work next Saturday but said if I got the car to him by 12 he'd drop me back at the unit and test it next week.
So a frantic rush to get things done, brakes done last night then back up to the unit this morning to put all the bodywork back on and check as much as I could before having to set off to see Chris.
Thought I ought to at least pressure wash the dust off before it went so it looked a bit more presentable.
The 6 miles to the garage showed that it's a great car, drives smooth with no nasty noises or bangs from the suspension. No warning lights, temps etc all good.
Fingers crossed that come Wed's or Thurs it will get into the workshop and maybe, just maybe it will get a ticket ready to use.

Really pleased I decided to start getting it ready a few weeks back rather than it sit gathering more dust, has the makings of a great car.. 8-)
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IMG_20220723_122208.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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LooLooSud33Spider
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Re: GTV ts

Post by LooLooSud33Spider »

Looking good Kev. Glad the engine has found a new home. Im sure it’ll fly through the MOT
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KevJTD
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Re: GTV ts

Post by KevJTD »

Result!
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Giulietta JTD 170
Lancia Delta integrale
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Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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Re: GTV ts

Post by LooLooSud33Spider »

There something very satisfying about getting a fresh ticket. great work Kev
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Re: GTV ts

Post by junior »

Good effort, yet again. Well done. Blimey its low mileage as well.

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KevJTD
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Re: GTV ts

Post by KevJTD »

Taxed the car yesterday, didn't twig it being a 2001 car so would be emissions led rather than cc if I'd have gotten a W or X plate car so that's £360 a year please to use our potholed broken streets for a few miles a year please :evil: oh yes, if you have a nice new modern "eco" car that must skip along the road causing no damage in its 30k a year then that's just £20, or free if you like to carry extension leads around.
Thanks, but no thanks. A small price to pay....

Took it to work today to regas the AC as it had all been apart of course for the engine swap.
What a lovely thing to ride home in after a crap day at work, climate control working a treat while riding along in something distinctive with a huge "Mini" countryman in the mirrors looking like a 7T truck behind.

As I say, worth the extra money to actually have an opinion of your own.
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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KevJTD
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Re: GTV ts

Post by KevJTD »

Thought I'd put some pics up of the wiring modification to the rear window heater, if only to show how a basic relay is nothing to be feared.

The issue with the GTV rear window heater burning out the fuse box is quite well known, in extreme cases it can cause the car to catch fire!
Why these cars suffer from it is odd, after all most cars have a fuse box at the front and the rear window position speaks for itself!

The solution is to take advantage of the battery being in the boot so that the high amperage wiring is kept much shorter and almost completely away from the fuse box.

A simple 4 pole normally open relay is mounted handily near the battery and away from any danger.
The wire colours don't really matter as long as you know which terminal they end up at on the relay.
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IMG_20220810_181407.jpg
IMG_20220810_181506.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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KevJTD
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Re: GTV ts

Post by KevJTD »

This plug came pre wired for simplicity and neatness, in this case the yellow wire goes to terminal 30 on the relay which goes to the battery positive which will provide the power for the heated rear window rather than using the long wires from the fuse box.
For extra safety I added an inline fuse next to the battery in case of any chafing or short circuits in the future.
You will also note the white wire going to earth..
Attachments
IMG_20220810_181335.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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LooLooSud33Spider
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Re: GTV ts

Post by LooLooSud33Spider »

Great tip Kev.
Alfasud Ti 1984
Alfa Spider 2.0 Ts 916
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KevJTD
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Re: GTV ts

Post by KevJTD »

The opposite side connection on the relay to the yellow (battery+) is the blue wire, this goes up to the heated window.
To do this find the original wire (brown with white trace on this) and cut it in a place so you have access to both ends. So the blue wire from the relay is connected to the brown/white original wire going up.
The black wire on the relay goes to the other end of the chopped original brown/white wire which is from the switch in the car so it will all work as it originally did.
The white wire on the relay goes to the earth, as noted before.

So how does it all work?
Imagine the battery positive is now connected to the rear window heater, which it almost is. But there's a break in the wiring, which is the relay part.
As you press the switch on the dash for the heated window it energises the relay via the aforementioned black wire (very low amps needed to energise the relay so virtually no load going through the original relay and fuse box in the car) the relay then joins the "broken" wire from the battery to the window, making it work.
As the original switch is still used it still retains the "ignition on" only function of the system so no danger of leaving it on.
The advantage being that the wire run now that carries the highish amps is very short so won't overheat like the original.

So the relay is really just a switch, or think of it as a break in a wire that it can remake at will.
This relay is called "normally open" as the name suggests, when power from the supply switch is removed then it breaks the circuit of the supply.
Attachments
IMG_20220810_181549.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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KevJTD
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Re: GTV ts

Post by KevJTD »

Took the car for a ride to a local secluded beach, really is a nice thing to drive 8-)
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IMG_20220829_195301.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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LooLooSud33Spider
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Re: GTV ts

Post by LooLooSud33Spider »

What a nice picture. We should get the Gtv and spider together for photo shoot
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Re: GTV ts

Post by alfadave »

Don't bother fitting the HRW mod to a Spider..........unless you find a hard top that is!

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LooLooSud33Spider
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Re: GTV ts

Post by LooLooSud33Spider »

Thanks for that Dave.
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KevJTD
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Re: GTV ts

Post by KevJTD »

With winter around the corner and the plan to rebuild the original engine so it can go back in whilst laid up so it's ready for the spring I have stripped it down to have a look and see what was making all the racket.
The phrase "hammer in a cement mixer" was about right!
Numer 1 big end was very loose, not the bolts being loose, more that the shells had been worn away and turned in the con rod itself. One ended up on top of the other!
Attachments
IMG_20220919_171520.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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KevJTD
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Re: GTV ts

Post by KevJTD »

Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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KevJTD
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Re: GTV ts

Post by KevJTD »

The shells mounting each other meant they had also gripped the crank at some point and have ground the con rod journal itself so not only is the crank knackered but the con rod is also done for.
Luckily I have a bottom end which I hope will have salvageable parts within.
Off work next week so should get a chance to access the situation.
Although I have a perfectly working engine in the car now I would like to rebuild the original motor so it should then last a long time..... Fingers crossed!
The other shells had also all but lost their bearing material, just a flaky surface left behind so was really in the death throws it seems despite, (or maybe because of?) the low mileage. Sometimes cars being stood does them no good.
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IMG_20220919_172722.jpg
IMG_20220919_172737.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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LooLooSud33Spider
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Re: GTV ts

Post by LooLooSud33Spider »

Btw Kev. Mine was number 1 aswell. the brg had spun and squashed out the side of the rod I think I posted a pic on my thread
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alfadave
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Re: GTV ts

Post by alfadave »

and only 46k miles on the clock!

Maybe it had been run low on oil?

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LooLooSud33Spider
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Re: GTV ts

Post by LooLooSud33Spider »

That is the most likely cause Dave.
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Alfa Spider 20v Turbo

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