Alfa 156 GTA

Post pics of your car in here
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Tue Mar 03, 2015 1:14 pm

Some more pictures
Attachments
Photo203.jpg
Engine & Box seperation
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Engine
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Photo212.jpg
Removed inlet manifolds
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TB cover removed
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Gearbox on bench
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Diff cover removed
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Old open vs New Quaife Torque Biasing Diff
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New seals for driveshafts
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Pressing on new bearings with press
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New diff re-fitted with crown wheel(difficult to torque up bolts, so also loctite threads aswell)
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Internal welds on exhaust manifolds don't look good. Have polished these back and cleaned off large nuggets
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Starting to give engine a good clean. Engine will be taken to Alfa specialist to get new belt, idlers, tensions, pulleys fitted
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Fri Mar 06, 2015 1:21 pm

So another job i have been working on is getting the exhausts manifolds ready for fitment, this has included getting ready to fit a lambda sensor.
See pictures
I did practise on a scrap piece of exhaust similar diameter before just drilling a big hole, highly recommended to see how it will work. Found the step drill was too long, so it needed a bit of fettling etc.
I wouldn't call it detailed research, however i used position taken from other Alfa GTV manifold design with sensors fitted. Then looked into a few different pictures of how bosses and sensors should be fitted and asked alot of friends. Not the most scientific way but since Alfa GTV V6 owners don't have issues with lambda error readings i think i am pretty safe with my converted manifolds. The only difference between 156 V6 & GTV manifolds is that the GTV one has a sensor fitted.
Next job is now to clean everything up well and weld it it. These will be MIG welded in, so need to check i get a good seal.
The fit of the lambda boss in the manifolds is very good, which should help when welding up.

Hint given to me is to fit a bung or old lambda when welding to prevent distrotion of boss which may occur during high heat from welding.

After these have been done i will wire brush by hand to give them a good clean and spray with black high temp paint to help them live as long as possible.
Attachments
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Manifold(rear bank)
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Rough approx position of lambda boss as per Alfa GTV manifolds
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Side on view
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Drilled hole using step drill, very easy to do
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Boss
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Using angled boss M18x1.5
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With lambda fitted
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Front view
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Boss protrudes into flow, therefore yellow marked section will be ground down flush to internal shape
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Lambda boss fitted with sensor, shows how far protrudes into flow
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Nobby
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Re: Alfa 156 GTA

Post by Nobby » Fri Mar 06, 2015 2:25 pm

Keep up the good work Will. Why is your engine bay so rusty? Are the roads incredibly salty up north?

Get yourself some ACF50. Once all the alluminium pieces are cleaned up it keeps them looking nice and clean.
Chris Burgess
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Fri Mar 06, 2015 8:46 pm

Thanks Nobby.
The rocker covers will be painted red and i was looking for stuff to keep the heads looking clean. Most of the rocker cover is hidden so it will not look too in your face. Will look up the ACF50.
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Mon Mar 09, 2015 12:46 pm

So for once i can say alot was done this weekend! I am bloomin worn out.
Not the warmest of weather but we must soldier on.

Saturday we took the engine down to a new local specialist in Penrith. Quite a drive for us still but definetely worth the travel.
Autolusso have opened up a new branch here and is the 3rd branch now.
The guys are very knowledgeable and have plenty of helpful advice.
The engine did decide it was going to be a real pain as some of the bolts were corroded in(alu block) and some sheared off.
I saw alot of high quality workmanship trying to rectify whilst i was starring over their shoulders. It was also nice that the included me in the whole experience as i was interested to see what they were doing so i can understand what was going on.
Turned out the waterpump was leaking and found a few other leaks around, so a new upgraded (metal not plastic impellor)waterpump was fitted with new gaskets etc.
Complete new timing belt OE with idlers and tensioners and new aux idlers/tensioners and pulley were installed.

On Sunday i then set about rebuidling the engine and mating with box and other parts etc.
First step was to check the diff end float, applied thread lock and torqued up crown wheel bolts(pain in the but to do)and once this was checked the casing was sealed up nicely with Wurth RTV sealant to make sure we have no oil leaks. Everything else was then also torqued down.
Next step was to fit the new clutch kit to the flywheel, first of all the face was cleaned back with wire wheel and then de-greased. Pressure palte was also degreased to rid the storage oil.
Everything was fitted and torqued up. Some new flywheel locking tools came in really handy here.
Note to myself and others. Do not push the thrust bearing onto the plate, it is alot easier to put on the clutch fork and then click into position when installing box. (i think) i actually fitted to the pressure palte and hada hard job lining up clutch fork onto the thrust bearing.
Again everything was torqued up ready.
Next job was then to start fitting other parts, so i took my time to clean up the exhuast studs and replace where neccessary(some were in tight and were left so as to prevent any shearing off). New nuts fitted also where possible.
I have fitted new exhaust manifold gaskets and then fitted the front bank manifold(CF2 without pre-cat).
The starter motor was reinstalled and connected up to the electrics.
Just waiting on the rear bank lambda boss to be welded and then it can also be fitted to the engine.
Basically the engine and box is now ready to be lifted and put back into the car. Just have a few bits on the car which still require a little cleaning up and undersealing before we do though.
Also rebuilt driveshafts with new boots, clips and grease. One of them decided to be a real pig and i managed to sepearate the cv joint. Was a right pain to rebuild but got there in the end. Also meant i could properly clean perfectly and apply completely new grease.

Started to change over all the coolant hoses aswell for new silicone ones(red). I have decided to try some new colours under the bonnet to make it look a bit different and experiment a little. Just want it to look good and cleaner than a rusty corroded nasty thing. Also added a few pictures of other parts to be fitted.
Attachments
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Rocker covers off with cam locking blocks in situ
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Belt and pulleys etc stripped off
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WP being a pain with sheared bolt, had to be drilled out and re-tapped(good job)
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New upgrade pump fitted and sealed up nicely, engine being cleaned up and starting to go back together
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Clutch kit fitted, note thermostat housing removed as seals were leaking(new seals required and have cleaned up housing etc)
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Starter re-installed
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Box back on 1
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Box back on 2
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Front manifold being fitted
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New studs and stainless bolts fitted
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Driveshaft stripped and getting new boots and grease etc
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Other driveshaft getting new boots etc
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Radiator getting new silicone hoses vs old std ones
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Other coolant pipes, note new stainless lower pipe to remove old mild steel rusty thing
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New stainless downpipes to match up CF2 manifolds to original cats on car, also tuned slighlty differently aswell for better fit and match the pipe OD etc
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Wed Mar 11, 2015 12:26 pm

Ok maybe i am a little too excited about my new parts for the Alfa, but i just had a complete top engine Stainless bolts, washer, nuts kits arrive.
Can't wait to get this on the engine once i have painted up and made look more presentable.
Attachments
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Stainless fasteners all nicely bagged up ready for going on
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Sat Mar 14, 2015 9:40 pm

So engine size now back in the car with new engine mounts. Whilst I had space I also decided to waxoyl Un painted surfaces to slow down corrosion.
Putting engine in was pretty easy. However connecting up everything is a different matter. Still need to reinstall the subframe with new arb.
This time I will fit the driveshafts before subframe to give more access for torque the bolts up.
Fitting the painted thermostat housing was pretty difficult with new seals. However it does need touching up now.
I also took the opportunity to fill the gearbox with fresh oil. Alot easier than doing in situ.
Re fitted oil cooler. This was a pain as I forgot to put in place before fitting the engine mount. Lesson learnt.
Once everything is done up below I will drop the car down and remove the rocker covers ready for paint.
Red for rocker cover and the plenum and top cover to be painted in OE colours. Fuel rail will be gold/bronze. I will also be fitted a new poly bushed top steady and have started fitting the red silicone hoses.
New covers will be fitted with new seals and new plugs have been fitted as the back 3 are hidden below plenum.
I also hand brushed the the rad fan cowling and sprayed satin black to make look bit cleaner.
Once this is sorted I can also connect up the new stainless downpipes.
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Mon Mar 16, 2015 12:41 pm

So first i thought i would post some pictures of my wife's handywork with starting to paint up items for the engine bay.
To start with the thermostat housing which was removed due to noticeable leak from the coolant pipes. New seals were purchased for these pipes.
Where the coolant pipes clamp on i taped these up so that paint wouldn't find its way into the cooling system and this was then painted with high temp paint suitable for Rocker covers. Ferrari red as the closest colour match to the car.
All in all it took 3 coats, unfortunately due to it being so hard to re-fit it does now need a touch up, but not to worry.
Obviously before paint was applied the housing was cleaned up with wire brush, then rubbed down with fine grade paper and then de-greased with brake cleaner and allowed to dry. Paint was applied by brush which makes the finished result even better than you'd expect. The rocker covers will also be done, however they will be sprayed.

The radiator cooling fan shroud was looking a bit sorry for itself being orange. I must admit i have not stripped this down and cleaned to bare metal and re-painted, instead i rubbed back with hand brush and sprayed Hammerite smooth satin black. This will need to be re-done in future, but is easy enough to remove so it can wait for proper job next time.
There are a few items on the car which i want to clean up, but i will do this all at once e.g. Rad fan shroud, chassis stiffening plates which run subfrmae to underneath of floors, odd brackets etc, subframe. These can wait until the car is fully retired as daily driver. No point yet.

Also i got the lambda boss welded in to the manifold by a friend as i didn't trust myself. At some point in the future i may have these removed and ceramic coated, but again these can wait. I didn't see a point in painitng vht paint as my experince is it doesn't last very long. I also didn't like the idea of wrapping the exhaust as the pipes are very old and it will probably help make them rust away quicker or the extra heat could cause them to crack. The other option is to go stainless manifolds, but these are a costly option.

On Saturday with help of my father we got the engine back in situ and started re-connecting everything.
Hopefully the final painting gets done during the week and next weekend and then the engine will be ready for firing up. :). I can't wait.
Attachments
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Thermostat housing
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Thermostat housing
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1st coat
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2nd coat
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3rd coat
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Cleaned up all the ports
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Engine where housing sits with housing removed and new seals on 3 pipes shown
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Thermostat housing shown in situ
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Quick spray over fan shroud
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Ex Rear manifold with lambda boss welded in and sensor fitted
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Manifold fitted and clear
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Engine back in, next job, more cleaning and painting
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Thu Mar 19, 2015 12:46 pm

So a few evenings this week i have been contiuning to keep putting the car back together.
Recon driveshafts were fitted back on the car and once this was done i also re-fitted the subframe and started to tighten everything up underneath.
Unfortunately it seems i forgot to order exhaust gaskets so i will haev to wait on these now before i can fit the new exhausts. a little bit of a pain but my own fault. Easy to miss a few parts on the order however when buying soo many parts however.
There are alot of parts which i am re-fitting to the car which i am thinking do i just fit as it is, or should i send off for blast cleaning and re-painting. For now since soo much has been spent it is good enough to get the car mechanically sound again.
The cosmetics can wait until the car is fully retired from active daily usage. Then i can maybe detail a little more.
One thing to note is that when i was fitting the driveshafts, rotating the output shaft is now alot tighter than it used to be with the open diff fitted. Be interesting to see how this transforms how the power is handled.
Next jobs are to get the top covers off the engine and get them painted ready for re-fitting with the new stainless fasteners and gaskets. Getting very close now.
More pictures to follow
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Mon Mar 23, 2015 12:40 pm

Starting to make real progress now, almost at the stage of firing her back up. Can't wait, although this bit is quite fun as it pretty clean and not getting coated in grease and oil is a bonus, as everything underneath is more or less sorted.

Also few pictures of the rocker covers before(dirty) and then being cleaned up, and then painted by my great wife.
We also took the plenum and inlet manifold and beauty cover cleaned up and painted aswell. This should relaly help clean up the engine bay.
Whilst i was at it, i cleaned and sprayed the timing belt cover black. I will repalce htese next time with freshly powdercoated parts for more longevity.
Also cleaned up the top engine steady bracket and fitted a new converted PU top mount.
Cleaned up the fuel rail and coolant pipe and have sprayed these also.

Particualr attention has been paid to all mating faces to keep clear of paint so as not to affect seal and also clean under bolt heads where it is not favourable that something comes loose.
Alot of hard work was put into doing this. It may not be a perfect finish, but it looks a damn sight better than corroded metal.
Attachments
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Dirty rear bank rocker cover
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Hand brushed rear bank cover
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Painted rear bank cover, 3 coats of high temp
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Dirty front bank rocker cover
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After cleaning and wifey painting
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3 coats again for front bank cover
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Front bank beauty cover dirty
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Hand brushed clean
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Aluminium silver paint, still got wifey to do red lettering
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Plenum dirty
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Plenum hand brushed
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Plenum silver, again red lettering still to apply
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Coolant pipe sprayed silver
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Dirty fuel rail were hand brushed
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Gold fuel rail
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Gold fuel rail
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PU top mount steady fitted and sprayed mount and timing belt covers black also
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Inlet manifold painted red also
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Inlet manifolds and fuel rail with injectors before cleaning
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Rocker covers fitted, stainless fasteners going on
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Wiring connected up
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Inlet manifolds on and connecting up with injectors re-fitted etc. Starting to look good once again
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Tue Mar 24, 2015 12:50 pm

So last night, yes more painting.
Got my wife to finish off painting the plenum and engine top beauty cover with red paint for the lettering. She did a very good job, very impressed. We used a new dishwashing sponge and applied much liek you used to do in primary school. Two coats were needed to get good finish. Using cotton buds to mop up and paint that went were it wasn't supposed to.
Also fitted the gold fuel rails back onto the injectors and connected up with newly sprayed black clips.
Weather permitting i would love to fit the rest of the parts tonight. Then it just leaves chrome pipes to polish up!
Attachments
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Fuel rails fitted
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Trial fitted red silicone intake connectors. ALso notice small Alfa logos on a pair of intake connectors to look a little different. Will use oroginal clips to hold in place
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Red lettering on Plenum done
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Red lettering on top engine beauty cover done
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Wed Mar 25, 2015 1:25 pm

Boring you lot again with more pretty painted pictures of engine going back together in the car.
I have shown two pictures of chrome pipes as there are 2 different types
Attachments
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Beauty cover back on looking good
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Plenum back on with Red intake pipes
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Stripping down Chrome intake pipes for cleaning and polishing!
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Rusty pipes
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Rusty pipes
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After clean with hot soapy water and very lightly using brillo pad
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After clean with hot soapy water and very lightly using brillo pad
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TomLouwrier
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Re: Alfa 156 GTA

Post by TomLouwrier » Wed Mar 25, 2015 1:59 pm

Hi Will,

Lots and lots of elbow grease on display. I do hope you'll enjoy driving it as much as it looks good now.

regards
Tom
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Wed Mar 25, 2015 10:59 pm

Same here Tom
Hopefully all be worth it once done
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Will01
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Re: Alfa 156 GTA

Post by Will01 » Thu Mar 26, 2015 12:32 pm

Last night didn't get too far with rebuild. I decided to try and polishg up the chrome intake pipes on the benchgrinder and some metal polish. Unfortunately the pitting is a bit too bad for it to work properly. However they do look slightly better again.
I may just hand polish with more and a rough cloth once fitted to help make them look shinier.
I wont bother uploading any pictures now until its finished.
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