Engine Change Brera 3.2 Q4
I brought a 2006 Brera Q4 manual about two months ago and all was well for the first few weeks then the engine started to get very "tappety".
The car had done 112,000 miles with a full service history with bills and old MOTs, it did need a service though.
On the motorway one morning it let go: big time, seized solid, locked up all four wheels which was interesting to say the least.
Anyway I found a new engine, 27,000 miles which was an auto.
I brought it complete with auto box, loom and all the sensors.
The engine swap was quite easy, although as others have said it does take time.
Jacked her up on two axle stands and proceeded as follows:
1). Remove under tray, Torx heads will probably be a bit corroded, mine had self tappers for extra measure as well.
2). Remove front bumper, valance, sides pull off and you have to be a bit aggressive to pull them out, having removed the 8mm self tapper in the front of the wheel arch and the self tappers that hold the splash guards in.
3). Remove head lights, power steering and air con radiators, tie wrap them out of the way, or remove completely, as others have said you will then need an air con regs which i decided to do as it was weak anyhow. I did not disconnect the crash sensor, only moved it out of the way.
4). Remove the battery tray, ECU and all electrics in the area above the gearbox and all of the fan wiring behind the radiator.
5). Remove water radiator, be careful with all the horrid quick release water couplings, squeeze the stainless clips carefully and check the O rings inside, I had a leak on reassembly.
6). Remove all the air intake pipework, gear linkages, (just prize off the ball ends), exhausts, (bolts should not be corroded), hydraulic clutch hose.
7). I took off the front wheels and then took out the top ball joints on the front wishbones to remove the drive shafts, they just then pull out of the gear box.
8). The rear steady bar is a pain to get to and you will need to jack up the rear wheels to rotate the driveshaft to remove the bolts in that too.
9). now you are close to getting her out, attach engine crane, mine is a Clarke creepy but did the job just fine. There is a lifting loop on the gear box but I used an engine mount bolt at the engine end and made up a loop as there doesn't seem to be a natural lift point?
10). Loosen off engine mount bolts and swivel the engine out engine side first, clearance is very tight indeed but it all comes out easily. Be careful of the power steering pipes along the front subframe as they are easily crushed.
I know this is simplifying it slightly but I haven't played around with a car like this for maybe 10 or more years and don;t be daunted it's not hard.
So I then removed the gear box and Q4 transfer box, the Torx bolts are very tight, you will also loose gearbox oil. Talking of which how do you set the gearbox oil level? I drained and refilled with the 2.7 or whatever the figure was litres of oil as I couldn't find a level hole?
I then took the auto box off my donor engine, replaced the dual mass flywheel and added a new LUK clutch and release bearing as it was all apart.
All went together easily although you do have to take the exhaust manifolds and all manner of other stuff off to remove the gearbox.
I imagine that a clutch replacement has to be an engine out job?
It all went back in pretty smoothly and all now seems to be good 500 miles later. I still need to get the zircon recharged but its been so cold that I haven't needed it yet.
Whilst I had the bumper off I re-painted all of the grills and generally tidied it up as at some stage it had had some paint.
I added a pair of new Alfa badges, front and rear.
I also changed the headlight bulbs for Ultra 6000K which give a pleasing cold white light and upgraded the side lights to LED although they do give off the occasional bulb failure warning. Typically Alfa like its not every time, maybe once a week !
So I did the post mortem on the old engine: a piston broke up and destroyed the block and conrod, punching a hole in the side.
I have a big box of useful spares including the auto box, torque convertor, drive plate, heads, sensors, engine loom, etc.
Should be good for another few years !
I apologise if this has been covered before in more detail but I did enjoy it and now have a lovely car, although I have to say that it doesn't seem that quick ?