Engine Rebuilds

Rebuilt Twin Spark & JTS Engines

We are meticulous in preparing our rebuilt engines, and whenever we carry out a full rebuild on a Twin Spark or JTS engine, the following work is always done:

• Crankshafts are sent to our machine shop and fully inspected to check for imperfections. Polished and ground where neccessary.

• Cylinder heads are sent to a specialist cylinder head company where they completely dismantled, and skimmed to ensure a perfect seal on the block. All valves are resurfaced and lapped to ensure a gas tight seal with the valve seat. Valve guides are checked and replaced if there is any damage (damage occurs if the cam belt has snapped, causing the valves to be bent where they impact with the pistons). Once rebuilt, the head is pressure-tested.

• Engine blocks are carefully inspected for imperfections or cracks. If necessary, cylinder bores are honed or the blocks re-bored.

• Oil pumps are stripped down and their tolerances checked. If rotor clearance is found to be outside the manufacturer's recommended limits then the oil pumps are replaced.

New parts: The following new replacement parts are used in every engine rebuild:

• Piston rings
• Big end bearings
• Main bearings
• Thrust washers
• Cam belt kit (cam belt, tensioner & idler pulley)
• Variator
• Water pump
• Head gasket set
• Bottom end gasket set
• Rear main oil seal
• Spark plugs
• Oil
• Oil filter
• Air filter
• Balance shaft belt (2litre only)
• Head Bolts

Prices (VAT inclusive)

Twinspark engine (supply only)

JTS Engine (supply only)

Twin Spark Engine supplied and fitted

JTS Spark Engine supplied and fitted

£1,200

£1,500

£1,500

£1,800

Engine repair following a cam belt failure (Twin Spark TS) 1.6, 1.8 & 2.0 16v: £850 inc VAT

The cam belt interval on these engines is 3 years or 36k miles whichever comes sooner, this is often overlooked and we see many of these engines suffering this failure. Very often these engines are repaired “on the cheap” and 500 – 1,000 miles following the repair suffer a big end bearing failure. We always change the big end bearing to prevent this happening.   

We will strip and re-build the engine in situ using the following new parts:

• Cam belt
• Tensioner
• Idler pulley
• Reconditioned cylinder head
• Head gasket set
• Balance shaft belt (2.0 only)
• Big end bearings
• Oil and filter change

This failure can easily be avoided by changing your cam belt on time.

Engine repair following a cam belt failure (JTD engines) 1.9 JTD & JTDM 16v: £850 inc VAT

It is becoming apparent that the 147, 156, 159 and GT diesel engines are starting to suffer water pump failures which is causing the cam belts to fail prematurely on these cars. If you have full service history you may have a good chance of compensation from Alfa Romeo UK. If they are not willing to help you or you don’t have a full service history we offer the following service.

We will strip and re-build, using the following new parts:

• Cam belt
• Tensioner
• Idler pulley
• Water pump
• Cam carrier gasket
• 4 x Injector seals
• 16 x Rockers
• Oil and filter change

The good news is that this is the only common engine fault we see with this engine, very reliable as a whole. Rarely see other problems and this can easily be avoided by bringing the belt change forward.

Engine Warranty

Our fully rebuilt engines have proved so successful and reliable that every rebuilt Twin Spark and JTS engine supplied by Autolusso now comes with a 3 year or 36,000 mile warranty (whichever arises the sooner).

Terms and conditions of warranty

The warranty is in two parts: a first-year warranty, and a follow-on second and third year warranty.

To validate the warranty the following terms and conditions must be adhered to:

No earlier then 400 miles, and no later than 550 miles after fitting the engine must be drained of oil, a new oil filter fitted, and the engine refilled with the appropriate quantity of Valvoline MaxLife oil

Thereafter engine oil and coolant levels must be checked weekly or every 500 miles (whichever arises sooner).

Oil starvation, overheating and water ingress, howsoever caused, will void the warranty.

The engine must be run in carefully, and must not be revved above 3,500 rpm for the first 1000 miles.

Any electrical fault causing mechanical failure will also void our warranty as this separate to any engine work carried out by us.

Follow on 2nd and 3rd year /12 - 36,000 mile (whichever arises the sooner) warranty

To validate the follow on warranty the following must be adhered to:

The initial 500 mile oil and filter change must be carried out on time by us using Valvoline MaxLife oil.

The car must have a Premium service carried out by us after each 12 thousand miles or 12 months (whichever arises the sooner) after the engine is fitted and within 1,000 miles or month of this interval.

The warranty is not transferable should you sell your car.