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Alfa Romeo 166 V6TB
Hello chaps!
Let me introduce my latest project. It's an Alfa Romeo 166 V6 Turbo '99 with 111000km on the clock. I bought the car for silly money - 600€. It has been parked for nearly 5 years, because it had an engine failure. Previous owner said, "it only needs to have the head gaskets replaced". I obviously believed him, how silly of me. All the work on the car will be done by my dad and me. Anyways, here's how she looked when I got her... http://shrani.si/f/2h/Zx/1mm6hqps/1/ma-car963.jpg http://shrani.si/f/3B/Xi/2IhfOIyw/ma-car964.jpg First thing I did to her, is to replace the dull velour seats with leather ones I had at home. Also from an AR166 http://shrani.si/f/8/ar/2CBFCLO7/ma-car965.jpg http://shrani.si/f/2h/Yc/3Tfx8RGf/ma-car966.jpg http://shrani.si/f/3p/s2/1QbnOMu/ma-car967.jpg Next thing was to get the engine out, and have a look at the "damage" http://shrani.si/f/3W/10V/28aKeAca/ma-car998.jpg Main bearing were all worn. So much for "just a head gasket replacement"... http://shrani.si/f/1A/lY/1hcMrLW/ma-car1000.jpg And of course, the crankshaft was also gone http://shrani.si/f/2a/fh/YHiSitK/ma-car1001.jpg http://shrani.si/f/29/kJ/1I5RYg7U/ma-car1002.jpg http://shrani.si/f/1E/bj/1y8IXekd/ma-car1003.jpg Luckily the block was OK. So we got a new crankshaft http://shrani.si/f/E/fL/3ENiyqys/ma-car1004.jpg And got to work. First thing we did, was to enlarge the ports on the heads as much as we could... Intake port before http://shrani.si/f/1e/WK/28b8NmUt/ma-car969.jpg Exhaust port before http://shrani.si/f/1Y/3v/410bOrIZ/ma-car971.jpg Intake port after http://shrani.si/f/2w/tQ/3uAu7lbo/ma-car972.jpg Exhaust port after http://shrani.si/f/1V/q3/3O4vkNRD/ma-car974.jpg Then the engine was disassembled completely http://shrani.si/f/2r/A7/2rpADold/ma-car999.jpg http://shrani.si/f/3O/1r/3IAqJt9G/ma-car1005.jpg And after 4hours the bottom end had brand new bearings, o-rings, gaskets, seals exc. http://shrani.si/f/3R/nr/6Z5YaMV/ma-car1006.jpg http://shrani.si/f/2P/X/42WDdJvR/ma-car1007.jpg http://shrani.si/f/3a/G9/2OCxxuhg/ma-car1008.jpg Since we didn't know what has been done to this engine, we decided to also do a major service on the engine. New belts, pulleys, spark plugs exc. http://shrani.si/f/2m/OQ/4XzM6LPs/ma-car1015.jpg And a "few" other bits ready to go on the car, started to pile up. New radiator, A/C condenser, brake discs + pads front and back, brake cables, brake lines, clutch, gaskets, seals, suspension bushes, cv boots, exc. exc. http://shrani.si/f/T/Au/1RZAOEqO/ma-car1009.jpg http://shrani.si/f/1c/Tu/239YDuoK/ma-car1010.jpg http://shrani.si/f/2E/WV/3WRxY71A/ma-car1011.jpg http://shrani.si/f/3Z/9R/cZqUfLv/ma-car1012.jpg http://shrani.si/f/1Y/GX/4sBbhC0o/ma-car1013.jpg http://shrani.si/f/3m/Na/1MzFnTLw/ma-car1014.jpg New valve guides and bearings for the alternator http://shrani.si/f/2e/3o/1BJ8EmkV/ma-car1016.jpg 3" stainless steel exhaust http://shrani.si/f/2U/QG/1yrMWHfT/ma-car996.jpg http://shrani.si/f/1X/UR/1qAI0nwO/ma-car997.jpg To be continued... 'talla |
Wow! Love all the detailed pics. Look forward on following this build. Please keep updating it.
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I'll have to look again when I'm on my pc (now looking from a tablet), but I love what I saw. How come it's a 2 litre turbo, where are you from? I thought only a few markets received those. That's the one I would personally choose for me if the ones I see over here are not mostly wrecked. Like the pictures of basically a complete engine build!
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That looks great, I will own an Alfa myself someday. There's some lovely models over here.
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What ended up being wrong with the engine? I guess it was more then a head gasket. :)
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Thanks!
@Shaggy: The water pump's propeller broke, which led to overheating, which led to failed head gaskets, which led to crankshaft failure. Furthermore, after owning this car for nearly a year, I realized that the previous owner has not taken care of this car very well. Many many things were broken, half repaired, or not repaired at all - just hidden... @Johnny: I'm from Slovenia. AFAIK, these 2.0 V6 TB engines were only made for Italian, German and our market. These are getting pretty rare, as not that many "survived". Usually they are dirt cheap to get, because they are neglected by their owners. It's not the cheapest car to maintain, so if you buy it for let's say... 600-800€, and you have to replace the clutch, you're looking at 400€ without labor, so... Drive it as long as it goes, then sell it :-) But I do agree with you completely. A N/A 3.0 or 3.2 V6 is nice, but sooner or later you get bored with stock HP, and the turbo engine is way better tuning wise. Less effort and money, for more gain. And after owning two AR164 V6TB's and one-of-a-kind AR145 V6 TB (AFAIK, no one else has put this engine in a 145 body), I must admit that I love this engine :-) http://shrani.si/f/2I/11s/vOCx0C0/ma-car561.jpg http://shrani.si/f/1S/fJ/2rKPtZpE/1/ma-car571.jpg I sure miss this car! http://shrani.si/f/1t/IN/1jqR1rEf/ma-car639.jpg Sadly I had to take it apart, because I was unable to register it anymore, because of our stupid laws. What has become of this car? A street race project car, which is still in development at the moment. Here's a sneak preview: You take one of the lightest stock cars, a standard Trabant which weights only 612kg (mostly out of fiberglass) http://shrani.si/f/3a/13z/3roeCFFY/1/ma-car849.jpg You cut the modified front end from a AR145 which can hold a V6 TB engine http://shrani.si/f/3S/tg/3QlQvqjc/1/ma-car857.jpg And "put" it together :-) http://shrani.si/f/3U/Al/1Ukz8LQb/1/ma-car893.jpg But more on this car some other time... http://shrani.si/f/A/U7/1NlisLUZ/ma-car902.jpg So... back to the AR166 project... Rear engine mount was looking shabby, so a new OEM one was ordered http://shrani.si/f/2F/VF/3twnYgIq/ma-car1017.jpg Engine assembling http://shrani.si/f/47/T6/3UumnPAZ/ma-car1019.jpg Replacing gaskets, washers, seals exc. in the engine, gearbox and dif, as we go along. A brand new Valeo clutch was also fitted http://shrani.si/f/3w/yZ/42mB6jho/ma-car1020.jpg Then the engine went in. The second mod to the engine, after head porting, was to fit a bigger intake manifold and intake runners from a 3l. The manifold has 0,5l more capacity, and the intake runners are 7mm bigger. We also replaced CV boots for the half shafts and steering rack. http://shrani.si/f/3U/GF/jiv7yya/ma-car1021.jpg Brand new OEM lambda probe was fitted, with an adapter which keeps the ECU happy, since there will be no pre-cat or main-cat http://shrani.si/f/42/R8/2ljxpegE/ma-car1023.jpg Intake runners fitted. AFAIK, no one has yet fitted this manifold or 45mm intake runners (stock are 38mm) on this engine. After that day, I knew why, because it was a pain in the #%! to make them fit... http://shrani.si/f/45/gF/1lR72LpZ/ma-car1024.jpg http://shrani.si/f/1w/Ns/35M8GvQR/ma-car1025.jpg Since the car sat for so long, all the brakes were seized and shot. So a brand new ATE front 310mm discs and ATE ceramic pads were fitted http://shrani.si/f/2p/Ok/1rReGU3N/ma-car1026.jpg And for the rear, we fitted 276mm ATE brake discs and normal ATE pads. (ceramic are not available) http://shrani.si/f/2R/2P/2wyoIhRq/ma-car1027.jpg Luckily, this car has no rust at all, since it is zinc-coated. To keep it that way, we added some additional protection http://shrani.si/f/2j/q0/1JTtlGP/ma-car1028.jpg Everything around the engine almost done. Only fluids missing... http://shrani.si/f/R/jx/2AiYsRse/ma-car1030.jpg Material for a custom home-made exhaust. Stainless steel 3" pipes, hangers, flexi pipe, and a second hand Supersprint backbox http://shrani.si/f/11/2x/rGZr9Bp/ma-car1031.jpg Difference between stock exhaust pipe, and 3" :) http://shrani.si/f/1t/6a/4sERGWyR/ma-car1032.jpg Fluids ready http://shrani.si/f/L/tQ/30weHjx1/ma-car1034.jpg Just before we started the car, there was a problem. Darn A/C condenser crumbled in my hand as I touched it. So we had to get a new one, together with a new dryer http://shrani.si/f/3S/Xh/3KYi1AwT/ma-car1035.jpg Looking good next to a shiny new radiator http://shrani.si/f/i/ue/2HkVutXf/ma-car1036.jpg Home-made middle section of the exhaust http://shrani.si/f/2N/WM/2GBe03sb/ma-car1037.jpg Supersprint mounted. PS: Those orange marks are copper paste :) http://shrani.si/f/21/qb/3YiejPWr/ma-car1038.jpg After a successful test drive http://shrani.si/f/2e/9r/xxmlQep/ma-car1039.jpg Both my Alfa's together (I've sold the 164 last year) http://shrani.si/f/K/g8/NnA5vas/ma-car1040.jpg Still a lot to come. To be continued... 'talla |
Hm... that's strange. I've made a reply a few days ago, but it still hasn't posted on the forum. Was is deleted?
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Quote:
So, how's the build going? Anything new? Where did you manage to find this car? What state is the turbo in? |
Duplicate post
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I am certain I didn't hit the wrong button, because two days ago, I made a new reply with plenty of new pics. But again, it has not been posted. It said, please wait for the moderator to check your post...
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Hm, in that case I hope that we have a mod checking out this thread and that the post will go live... We want the pics! :)
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Duplicate post
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Yeah, me too! I just made my third and final attempt on replying, and as soon as I add some pictures, again I got the "moderator must check..." message. I just hope that if eventually, someone does allow my posts, that they won't add all three duplicate posts because that would look silly...
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Shaggy pls check this out, we know you want to see the images too!
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Yea, sorry. For some reason it was moderating your post. You can see them now. Build is looking good peruccy. Keep adding to it!
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No problem! I'm just glad we sorted it out. I did however edited some of my posts, because all three were added now.
To be continued... 'talla |
Moving on...
Both my Bella's together http://shrani.si/f/2b/XO/3Cz16SP7/ma-car1054.jpg http://shrani.si/f/10/12q/1XqcJAKn/ma-car1053.jpg Since my car didn't leave the factory with a CD-changer and amplifier, I had bought a second hand one http://shrani.si/f/26/hB/3DG2tSq9/ma-car1055.jpg I've also added new floor mats http://shrani.si/f/2v/123/1P4QIpjx/ma-car1056.jpg http://shrani.si/f/1i/2x/3Ootce9r/ma-car1057.jpg Then, I've decided I wanted a "Dukes of Hazzard" style horn, so I got one :happy107: http://shrani.si/f/36/co/2aV0DvOK/ma-car1058.jpg Mounted http://shrani.si/f/u/VX/gE1DJJJ/ma-car1077.jpg I've also added a bit more undercoating protection on the inner wings. These cars have no rust, because they are zinc coated at the factory, but I wanted to keep it rust-free for years to come... Before... http://shrani.si/f/30/b6/1cCYwJOm/ma-car1059.jpg http://shrani.si/f/3J/dd/1Lh2ScHK/ma-car1060.jpg http://shrani.si/f/2e/HH/3zFBKV8G/ma-car1061.jpg http://shrani.si/f/2S/K9/4ycxZVoU/ma-car1062.jpg After... http://shrani.si/f/2c/VD/4UBanWKN/ma-car1063.jpg http://shrani.si/f/27/50/3w6UR8oQ/ma-car1064.jpg http://shrani.si/f/v/Yo/MnVVG5m/ma-car1065.jpg http://shrani.si/f/9/rd/39KEyDlj/ma-car1066.jpg And a pic of our custom made exhaust. Downpipe is shortened a bit, so it had enough clearance with the bell housing http://shrani.si/f/1n/12N/3AezqAGF/ma-car1067.jpg Removed pre cat http://shrani.si/f/18/rU/4As1Qyz1/ma-car1076.jpg Removed main cat, with only a straight 3" pipe going through it http://shrani.si/f/1t/w8/4Iby9GUk/ma-car1068.jpg Mid silencer replaced with a home-made "S" pipe http://shrani.si/f/3p/f8/1CXnK8jd/ma-car1069.jpg And at the back, we couldn't get a 3" pipe to fit through and over the back cross-member. So I had a 2,25" stock pipe just before the backbox http://shrani.si/f/3q/ap/CMhMp2g/ma-car1070.jpg At the back I have an original Supersprint backbox. Although it is for the 164 model, we have modified the inlet, so it would fit on a 166 http://shrani.si/f/2d/121/4BdQnNab/ma-car1072.jpg And front connecting pipes to the turbocharger http://shrani.si/f/45/Tu/3omwnFof/ma-car1073.jpg Barely any space between the connection from the 1-2-3 exhaust manifold to the turbo, and downpipe http://shrani.si/f/46/we/21VpYi8s/ma-car1074.jpg http://shrani.si/f/27/U4/1n16x958/ma-car1075.jpg As for the interior. Color change from beige to grey was finally done, apart from that odd shape at the middle of the dash. That is a part of the dash, so it cannot be removed. I plan on putting some black vinyl on it in the near future, just so it doesn't stand out so much as with being beige in color http://shrani.si/f/2f/ht/3vtCzjCA/ma-car1078.jpg http://shrani.si/f/2M/Xo/3xhwJ0/ma-car1079.jpg http://shrani.si/f/B/ZH/4m7oGVFe/ma-car1080.jpg To be continued... 'talla |
Really nice to finally see the pics! I don't think they made it for the German market, but we got them, and pretty much all of them over here are rubbish by now due to hard driving and seriously poor maintenance - btw big hello from Belgrade :) Love the car, and the effort that has been put into keeping it on the road! How does it drive now?
It would also be nice to see that Trabant, it just seems wicked! You have to open a dedicated thread! |
Cheers!
I will open a thread for the Trabant in due time, don't worry. It drives really nice. The suspension on the car is superb. It might be overkill when you think about it - three control arms on each corner, but it sure makes the ride enjoyable. So, next I had to replace my emblems. Of course, OEM ones are way to expensive for a piece of plastic, so I got an alternative. Stickers might look cheap, but these are in fact of high quality and properly thick. Best 10€ I've spend on the car so far :) http://shrani.si/f/2J/IG/4y9VCGDp/ma-car1083.jpg Installed http://shrani.si/f/1C/rs/3ywds128/ma-car1084.jpg Then the oxygen sensor was replaced out of precaution, not necessity http://shrani.si/f/1q/KC/3g8agTtn/ma-car1086.jpg Manual boost controller was next http://shrani.si/f/34/zD/1p5vswYh/ma-car1106.jpg Then I got a wideband oxygen sensor as well, so I could see what the engine is doing http://shrani.si/f/3Y/Ou/1QssWkhl/ma-car1108.jpg Once I was going crazy with replacing electrical parts, sensors exc. I had to get an insert for the MAF, and also a crankshaft sensor. I know from experience that on Alfa's, faulty sensor can make you go mad trying to diagnose a problem. So I've decided to replace practically all the sensors on the car with new ones just to be on the safe side, and also for tuning purposes... http://shrani.si/f/2z/zZ/3BkWp2Xb/ma-car1111.jpg This car's engine is very quiet. The Italians made sure of that, since it was suppose to be a luxury cruiser. I don't like quiet. So going in that direction, the resonator chamber in the intake was blocked off http://shrani.si/f/1i/nD/1d3PWAFJ/ma-car1124.jpg http://shrani.si/f/2d/xH/3jXXkb1q/ma-car1117.jpg http://shrani.si/f/3x/111/2HI90y1h/ma-car1125.jpg Next I replaced the gasket for the windscreen wiper cover, and the windscreen washer fluid hoses http://shrani.si/f/3j/uT/36qzKM8R/ma-car1118.jpg http://shrani.si/f/2Z/RD/1Z3a4o3k/ma-car1121.jpg http://shrani.si/f/1L/7R/3tmb8KFY/ma-car1122.jpg Then I got connectors for the injectors. I was being methodical with the electrics - once you own an Alfa, you understand why :):rofl3: http://shrani.si/f/33/jl/4aCuSvDL/ma-car1126.jpg http://shrani.si/f/Z/QO/4fDYtXQg/ma-car1127.jpg Next was the front speaker system which got uprated http://shrani.si/f/3z/ao/1R9rGhaK/ma-car1136.jpg Since I had a FMIC on both of my previous cars, I've decided to go down a different route on this car. I've decided to use a chargecooler system. So first item to get was a CC. 3" inlet / outlet http://shrani.si/f/t/vc/3A77IUUa/ma-car1137.jpg http://shrani.si/f/2Z/w1/1flXXhpi/ma-car1138.jpg Difference between stock and 3" intake http://shrani.si/f/n/3Z/2M7ZNoAU/ma-car1139.jpg Since this car does not have an oil pressure gauge, nor an oil pressure sensor, an universal one was installed. Some modification was needed of course, to get the sensor installed in the head, where the turbo gets it oil feed http://shrani.si/f/2o/YX/2hXsMn1N/ma-car1140.jpg http://shrani.si/f/2x/r1/3QZHPaDx/ma-car1141.jpg Next on the list, was a bigger throttle body. Since my car uses a fly-by-wire TB, I basically had two options: - A Ferrari 360 TB - A Porsche Cayenne Turbo S TB Both have exactly the same pin-out as Alfa, but have a bigger inlet. Ferrari TB's are getting rare and expensive, so I got a Porsche one instead... Stock vs. Porsche http://shrani.si/f/2m/KY/4CApiZgR/ma-car1147.jpg http://shrani.si/f/j/J/3pMsZsRl/ma-car1148.jpg http://shrani.si/f/1y/Nk/4XVwUBSt/ma-car1149.jpg http://shrani.si/f/3w/12e/2g6H0u4k/ma-car1150.jpg http://shrani.si/f/3e/Df/3o79fdq1/ma-car1151.jpg Stock has 69mm inlet http://shrani.si/f/1m/Pi/xEaxfdT/ma-car1152.jpg Outside 75mm http://shrani.si/f/3F/AF/1poElDr1/ma-car1153.jpg Porsche has 79mm inlet http://shrani.si/f/3J/iM/3gkofhmJ/ma-car1154.jpg And 87mm outside http://shrani.si/f/3r/Qq/6rvDWW4/ma-car1155.jpg To be continued... 'talla |
Next on the list were the vacuum lines around the intake manifold. Since we installed an intake manifold from a 3.0 24V, which has a completely different vacuum line plumbing and mounting holes on the valve cover, we used what pipes/lines there were lying around, so the car was drivable. Now I have decided, it's time to install these lines properly...
New vacuum line http://shrani.si/f/1e/uR/4bksT4TR/ma-car1128.jpg Replacing the old vacuum line http://shrani.si/f/3S/Db/2nWQkZ7b/ma-car1129.jpg Some more vacuum lines http://shrani.si/f/D/lo/13RHghvo/ma-car1157.jpg Replacing this piece of spaghetti of lines (we had to botch something together, to make the car drive, this is what came out) :) http://shrani.si/f/41/3X/3e5hCz4b/ma-car1162.jpg And installed http://shrani.si/f/2I/CD/3EdYYjNz/ma-car1163.jpg http://shrani.si/f/3C/Bj/2bcqkS5a/ma-car1164.jpg Then I got a special tape as used by the factory for wiring harnesses http://shrani.si/f/n/wZ/3akeyHZI/ma-car1156.jpg Some more connectors for the engine sensors http://shrani.si/f/2S/yK/291SYCbd/ma-car1158.jpg I have also decided to use a 3Bar MAP sensor, so I could squeeze a bit more boost out if the engine. Since this car has no MAP sensor so to speak - with a nipple for reading manifold pressure directly from the intake. Instead, it only uses an old school altitude sensor which has a set value for every altitude and then it translates this into manifold pressure for the ECU. Anyways, this "technology" goes back to the 80's when Audi Quattro's used it for the first time... http://galleryplus.ebayimg.com/ws/we.../1000x1000.jpg Replacing that thing above, with a new 3bar MAP sensor. Now at least, my ECU will have proper manifold pressure readings, not just approximate set values http://shrani.si/f/2t/6A/3KsWHw4L/ma-car1161.jpg I've also got a special oil for the engine. Mobil 1 10W60 full synt. It's not cheap, by I know it's one of the best 10W60 oil's out there... http://shrani.si/f/1W/Vm/4ry84Gby/ma-car1159.jpg External 300lph fuel pump with cradle http://shrani.si/f/2M/9K/3gBL6EEc/ma-car1168.jpg Some more exhaust parts http://shrani.si/f/3d/4r/3CH6D6Xa/ma-car1167.jpg Now we had all the parts, to make a custom 3" downpipe http://shrani.si/f/Q/mS/27Ea5v6A/ma-car1173.jpg This heat shield for the A/C compressor was in the way, so we removed it http://shrani.si/f/3f/r9/1hWWESAi/ma-car1175.jpg We've removed this lothttp://shrani.si/f/C/AZ/36tolKKX/ma-car1176.jpg And installed this lot http://shrani.si/f/e/13n/3iym0v33/ma-car1178.jpg Everything installed, together with a brand new front O2 sensor and a wideband O2 sensor http://shrani.si/f/j/Xk/i7Vv4jO/ma-car1186.jpg http://shrani.si/f/2h/fH/10jcfVK0/ma-car1185.jpg http://shrani.si/f/3f/47/3YZR270L/ma-car1184.jpg We've also installed a bigger turbo of course! I had this unit on my previous AR145 V6TB, which had only done 5000km. The turbo was rebuilt completely before it went in the AR145, so it would have been a shame not to use it on this car. :) The turbo in question is a Mitsubishi TD05 Big16G (68mm compressor), where as the stock turbo is a tiny TD05-12B (58mm compressor). I know your DSM owners love that B16G turbo :Big Laugh: http://shrani.si/f/3j/11N/2W8BGHbD/1/ma-car1181.jpg On this turbo, we've also added a Forge Sierra Cosworth T3 wastegate actuator, which can hold 2bar of boost with ease (I've been running that much boost with this turbo before) :) http://shrani.si/f/1H/tA/1wwgK0z4/ma-car1179.jpg MAP sensor installed http://shrani.si/f/1t/xl/41Ji9sO5/ma-car1192.jpg Replaced connectors on all the sensors http://shrani.si/f/1b/mZ/4K5Tynuo/ma-car1194.jpg And a bit of tidying up the cables http://shrani.si/f/2o/a5/3Dt6OIYu/ma-car1196.jpg The engine was in this state after all that work http://shrani.si/f/1/lG/4m5SBj9F/ma-car1191.jpg To be continued... 'talla |
Man, that is one mean, detailed rebuild! Love the effort that went into it!
How does it run now? |
Thanks! Car runs very good now. But it still isn't the way I want it. I've got that tuning bug in me :)
Anyhu... back to the build. Wideband oxygen sensor & LC1 mounted and connected http://shrani.si/f/2Y/VX/2veE7HHc/ma-car1198.jpg Wiring went through the firewall http://shrani.si/f/2i/mp/2nw43D3e/ma-car1200.jpg Quite a few cables :) http://shrani.si/f/1a/Xs/32E7VeWU/ma-car1201.jpg There was no other place for the wires to go in the cabin, without taking the engine out, except under the windscreen http://shrani.si/f/1D/vv/1sWpo4jw/ma-car1202.jpg Just behind the passenger airbag http://shrani.si/f/1r/Ou/4RHB9sbY/ma-car1203.jpg I've also installed wires for three gauges, which were mounted on top of the dash (no other place for mounting in this car) http://shrani.si/f/Q/sH/2ghfczWT/ma-car1204.jpg Tidying up the wires http://shrani.si/f/42/Zk/4tjovON/ma-car1205.jpg Silicone around the hole, to prevent any water to come inside the cabin http://shrani.si/f/2Q/kR/nruB3lw/ma-car1206.jpg Making an adapter plate for the Porsche throttle body, out of an old intake manifold http://shrani.si/f/27/BF/2tZytzxn/ma-car1207.jpg Drilled holes http://shrani.si/f/2P/ih/1ksqnGGb/ma-car1208.jpg Test fit on the manifold http://shrani.si/f/3z/v3/4MilCOzz/ma-car1209.jpg And on the TB itself http://shrani.si/f/2c/7G/1uDiZ2kL/ma-car1210.jpg Putting everything together, to see if it fits. I had an old coupling hose laying around, so I could start the car http://shrani.si/f/f/em/19d6FZ70/ma-car1211.jpg http://shrani.si/f/3V/ju/4zTlWAeV/ma-car1213.jpg Of course, there's always a problem with customization. TB is too wide, so the original expansion tank would not fit anymore... http://shrani.si/f/9/Sl/2oWf1QUx/ma-car1212.jpg The appropriate tank was from a Golf III, which is also one of the cheapest around :) http://shrani.si/f/1n/Vm/39I7UQ1x/ma-car1214.jpg Test fitting http://shrani.si/f/36/fx/26RbDrsD/ma-car1219.jpg Port matching on the TB http://shrani.si/f/0/SA/UHBxK2D/ma-car1215.jpg Enlarged intake manifold entrance http://shrani.si/f/3Q/6p/2ez5NxoM/ma-car1216.jpg I've enlarged the hole by 9mm... http://shrani.si/f/2V/E1/3ciV2Z4y/ma-car1217.jpg Some more port matching http://shrani.si/f/42/dE/1E5ycQZd/ma-car1218.jpg It looked like this before the very first start up with the new TB http://shrani.si/f/2g/sR/3AWaU2SF/ma-car1220.jpg And with mounted gauges. Some people would say they look "ricer", but frankly I don't care that much about that. I prefer function over esthetics :)all day long http://shrani.si/f/D/fh/4zURk4cI/ma-car1225.jpg To be continued... 'talla |
Moving on... Replaced rear subframe bushes
http://shrani.si/f/2S/nL/KKUfvDS/ma-car1226.jpg Status before the first test drive http://shrani.si/f/2q/qg/easHjqK/ma-car1227.jpg After the shortest test drive... ever. This coupler hose sucks, so back to the drawing board http://shrani.si/f/S/H5/HEwnaGF/ma-car1228.jpg In the mean time, I've replaced all the bolt inserts around the engine bay http://shrani.si/f/3U/Xx/3cOILfDK/ma-car1230.jpg Because the bolts were becoming loose http://shrani.si/f/2w/ql/2aDi1Keb/ma-car1231.jpg Replaced drive belt lid http://shrani.si/f/3k/x4/3elNhevX/ma-car1233.jpg And pièce de résistance. Proper silicone hoses and clamps!http://shrani.si/f/i/QI/im5mzFr/ma-car1234.jpg We had to modify the T-pipe for the dumpvalve http://shrani.si/f/1M/Cs/2tdt26lW/ma-car1235.jpg And weld on the nut for the intake air temp. sensor http://shrani.si/f/2b/Ef/1icDbD34/ma-car1236.jpg But we got the original expansion tank to fit, which is a great bonus, because it looks fairly stock now. The only thing that was in the way, was this bracket for the cover around the engine... http://shrani.si/f/1h/3w/21Z65PXK/ma-car1237.jpg Status before the second test drive. I had a good feeling this time :happy3: http://shrani.si/f/1N/ZK/1KeZ3Nm0/ma-car1238.jpg After a successful test drive, I made three daylight pics of the engine bay. I think is looks pretty much stock. http://shrani.si/f/3O/11q/4Lueg2lo/ma-car1239.jpg http://shrani.si/f/1D/64/1Qzp34Ua/ma-car1240.jpg http://shrani.si/f/39/G1/Ub0RyOw/ma-car1241.jpg Next on the list, was the remote central locking, which has failed on my car. I got a Chinese copy for silly money, and went to work on it http://shrani.si/f/l/g9/4T05Ryq/ma-car1242.jpg http://shrani.si/f/2P/Vt/4s5JKjJ/ma-car1243.jpg In the mean time, I have also installed the original rear subs, which I got with the original amp. There were two versions which left the factory 1) 10 speaker system which had an amp & two parcel shelf subs 2) 8 speaker system without the amp & subs. Getting from #2 to #1 is quite a challenge, because complete wiring harnesses are next to impossible to come by, and making one from scratch is not so easy. Because Italians haven't left the harness in the car if it didn't have an amp... Two thumbs up for the Italians! http://shrani.si/f/3x/1X/3Xym9Ges/ma-car1244.jpg I've also received a front mount radiator for the chargecooler system http://shrani.si/f/40/P0/4P0bXuz3/ma-car1245.jpg Quite a big unit @ 597mm x 171mm x 70 mm http://shrani.si/f/2w/oX/3i1gXn62/ma-car1246.jpg I've also got a "repair set" for the gear shifter. These plastics wear out over time, and you don't get that smooth gear change feeling. It was cheap so I had to have it! I also found a company which makes a bush for the upper engine mount for 30€, while the OEM upper mount is 120€... http://shrani.si/f/1q/BY/3uKaeC4h/ma-car1247.jpg This is the culprit. 160usd for this... they must be mad! http://shrani.si/f/2j/1a/4VXelhJf/ma-car1248.jpg Bush was in a bad state, which was noticeable when doing hard acceleration. Engine was rocking back and forth too much for my liking http://shrani.si/f/k/33/3b7O56E0/ma-car1249.jpg http://shrani.si/f/1R/zf/Wc3Q9LF/ma-car1250.jpg Fixed http://shrani.si/f/3h/OR/2Opq700H/ma-car1251.jpg http://shrani.si/f/1p/FP/oPsHwPY/ma-car1252.jpg To be continued... 'talla |
Shifter repair set was next
http://shrani.si/f/2/UL/2KNzKGrb/ma-car1253.jpg The whole mechanics is made out of plastic. Which wears over time. Now, I have crisp gear changes once more http://shrani.si/f/2w/Ck/zl6LcgQ/ma-car1254.jpg We also had to replace the brand new oil pressure sensor from an AR164, because it had switched polarities. So the pressure gauge would read from 8-0bar. So I got a replacement sensor for the RaidHP gauge. Now I have correct readings as it should be. http://shrani.si/f/2T/tv/1TMvsNdT/ma-car1255.jpg Now for the chargecooler system. I needed a filler neck with cap for my system. Since I couldn't purchase the only one I found on ebay, which was compact enough, because the seller didn't ship to my country, we had to make one from scratch. It's made from plastic and I think it turned out pretty good http://shrani.si/f/3X/1R/3lZGijYU/ma-car1257.jpg http://shrani.si/f/i/fS/h4Ng0ov/ma-car1258.jpg We replaced the 1,4bar cap with a new 0,9bar cap. Since this system will never have such a high pressure, there was no need for the 1,4bar cap http://shrani.si/f/1W/Tv/1SzXRiv3/ma-car1259.jpg Then, I turned my attention to the original amp and parcel shelf woofers. As I have previously mentioned, to get an original wiring loom for this car, is next to impossible, since everyone want's this amp'ed 10 speaker system in their 166. So I had to make a wiring loom from scratch http://shrani.si/f/G/6k/1hygyxnv/ma-car1260.jpg All the wiring goes through the car's ICS unit. This unit controls everything from trip computer, fuel consumption, radio, navigation exc. http://shrani.si/f/24/CX/FBssuco/ma-car1261.jpg I found the wiring diagram online, and went to work. It took me 3 days to complete this task... And I must say, it makes one hell of a difference in sound quality. But I will definitely not be doing this task any time soon! It was a real pain in the :emotions33: http://shrani.si/f/2k/Ws/wYmTV0H/ma-car1262.jpg I got the electric water pump and flexible wire hoses http://shrani.si/f/1b/CU/I1gIlLg/ma-car1271.jpg We've also replaced the temperature switch, because my previous one had corrosion on all the contacts http://shrani.si/f/1h/xS/2cIDZRmq/ma-car1272.jpg We've also made our own gasket for the Porsche throttle body. Previous one we made, was from a thin paper. And it didn't last very long, because I got a vacuum leak after a month. So I got this Elring gasket kit, which has various thicknesses for various applications. Now I have no more leaks http://shrani.si/f/G/jc/2JPAPyU7/ma-car1273.jpg Brand new 0,9bar cap and two brackets for the CC filler neck http://shrani.si/f/k/5m/2LLrpuiI/ma-car1274.jpg Then I got 3" silicone elbows, pipes and W2 clamps for the CC system http://shrani.si/f/1f/fs/azQK6QI/ma-car1275.jpg We have also replaced the old fuel pressure regulator. Since I plan on using bigger injectors and an external fuel pump, I want the whole system to be 110% http://shrani.si/f/2f/dC/11iCiHht/ma-car1276.jpg And finally, the installation of the chargecooler system http://shrani.si/f/42/kk/1uzfE9Zf/ma-car1277.jpg Good thing I got an almost identical size cooler than stock. And even this one just barely fits http://shrani.si/f/2k/bE/4E8YU6Xa/ma-car1278.jpg It's a tight squeeze http://shrani.si/f/1c/mD/1X60mQnN/ma-car1279.jpg Home made bracket for the filler neck http://shrani.si/f/3b/Jj/2WYqLkuG/ma-car1280.jpg Turbo pipes installed http://shrani.si/f/1t/5h/2q7aBhFZ/ma-car1281.jpg Upper pipes were next http://shrani.si/f/3G/xZ/3siYpTZe/ma-car1282.jpg Just enough room for everything to fit http://shrani.si/f/3q/xN/1Nf15QGY/ma-car1283.jpg Front radiator for the CC was also installed with home made brackets http://shrani.si/f/3x/Lr/BwpiJao/ma-car1284.jpg This is how it looked nearly finished http://shrani.si/f/2B/X/wVMicK3/ma-car1285.jpg Very tight squeeze between the coil and intake pipe http://shrani.si/f/3f/lc/1KYX2O0T/ma-car1286.jpg We had to remove the original airbox and air filter, because it was just to big. So I got an universal one, which had the correct ID and was reasonably sized http://shrani.si/f/J/bt/3kohIXmp/ma-car1287.jpg It fits, barely http://shrani.si/f/1V/58/4RaEU58M/ma-car1288.jpg Now all I need, is an intake funnel which would go in front of the universal air filter, so I would have cold air intake. That's next on the list... http://shrani.si/f/29/yA/3YHk4Yg4/ma-car1289.jpg And finished http://shrani.si/f/3W/Ze/3ej9qZcg/ma-car1290.jpg Of course, there is always something to do on a car. One of my upper steering arms had play, so we replaced both sides. And my front brakes didn't perform as they should, so we overhauled all four brake calipers, just to be on the safe side. And to top it off, I got the best dot4 brake fluid I could find http://shrani.si/f/1Z/QT/31r4XCT8/ma-car1291.jpg And that's it. This is the current state my car is in. It pulls really well with this CC system. Dumpvalve makes one helluva noise! Me like :Rock on: And now, I will save money to get bigger fuel lines, bigger injectors, and a custom chip. I already have an external 300lph fuel pump and cradle. So, until next time... 'talla |
Do you know where you're doing your chip? How much do they cost in Slovenia? And what happened to Trabant? :)
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I'm still deciding where to get the car chip tuned. Prices for a custom chip with a dyno in Slovenia are from 500€ - 1000€. Depends on the ECU, and how much work goes in to it. And since I have the rarest of ECU's, Bosch Motronic ME2.1, which was only in an AR166 from 1998-2003, with no upgrades or anything, I think I am in for a nice bill... I've seen many people give up on these ECU's, because they are damn hard to work on. It was an Alfa prototype ECU, which can memorize and adapt to various engine changes by itself. Also, it has multiple injections per cycle, which for it's time in a normal saloon, was almost unheard of. But they gave up on it after a few years. Confirmation about it's ability to adapt by itself was when I replaced the old altitude sensor with a MAP sensor. First one tells the ECU an approximate intake pressure via the preset value of the altitude, while the MAP sensor reads pressure directly via a vacuum hose from the intake manifold. Another thing was, when I added a bigger turbo and opened up the boost. ECU adapted to these changes instantly, without a chip tune. My AFR readings are spot on with this setup: 14,4-14,8 @ idle and 13,2 @ WOT..
Trabant is still in development. First I want my daily driver to be complete, and then we will focus all our attention on the Trabant. We have until May next year to complete it. I wish to participate in our annual drag race event here in Slovenia. |
Keep up the posting on this. Love the detailed pics you are adding!
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I think SM chiptuning would do a custom chip for 600 (550 if you put on their decal), that could be worth a trip to Croatia (or Bosnia, Serbia, if you have someone to visit there), but I don't have a personal experience with them, so I can't say for sure how good they are. Maybe the best option would actually be not to chip, and if the need arises, go a Megasquirt way?
Hope you're making photos of the Trabant build! Aiming to pit it against monster Fica from Croatia or absolutely mental Yugo from Bosnia? |
@Shaggy: Thanks! I will post updates as they happen...
@johnnny: I still have time to decide which tuner it will be. Thanks for the info though, I will count them in for sure. As for the Trabant, I have some pics of the build so far, but as I have mentioned before, it is still in development. As soon as the 166 is done, my attention goes to the Trabant. But the car will definitely not be a record breaker. I will use stock internals for starters. I only plan on doing minor engine mods to it, because first I want to see what I can achieve with a set budget, before I start spending silly money on it. Mods I plan on doing are: head porting, FMIC, bigger exhaust, bigger injectors & pump, custom chip and maybe a bigger intake system. And that's about it... I am relying on the silly weight of the car, to make it at least half competitive. By my calculations, with a V6 engine and a roll cage, together with a lighter hood, thin plexi glass all around, removed unnecessary weight, different rear subframe (the heaviest piece on the car), slicks, and a bucket seat... I hope I will get the car to 650kg (1300lbs)... And with the mods I want to do to the engine, I am hoping for 260-280hp. So for a starting project, it should suffice... |
I found another thing I can change on my car. MAF housing will be uprated...
Stock = 70mm http://shrani.si/f/2r/nR/m4NqZMi/ma-car1295.jpg Not so stock = 82mm http://shrani.si/f/2n/w4/3LTru7zo/ma-car1296.jpg In the meantime, I will replace the pipes that go to the turbo inlet to the same diameter as the MAF housing. So it will go from 63mm to 90mm http://shrani.si/f/2F/Cz/2PNQBGV7/ma-car1297.jpg 'talla |
Quick update fellas...
I've ordered a set of 440cc injectors and external 30micron fuel filter (300lph external fuel pump already at home). A "jap style" backbox (3" inlet / 5" outlet), titanium heat wrap, and two mandrel bends, because I want the whole system to be a true 3" from start to finish (my current Supersprint backbox has 2,25" inlet). I've also bought alloy sheet and alloy tube, because we'll be making a custom intake manifold. At least 4l capacity (stock is 2l, my current 3.0 manifold is 2.5l) with velocity stacks inside. When I get the parts, I will post some pics... 'talla |
Something is finally happening around my Alfa. I had to replace the coil, because occasionally @ 1.5bar of boost, I lost power because of bad spark. Now I have a proper spark...
http://shrani.si/f/3J/Gf/4T06A19q/ma-car1298.jpg Today I finally received my JDM chimney pipe :):emotions33: http://shrani.si/f/32/Gl/2hqrdCGA/ma-car1299.jpg http://shrani.si/f/L/O6/4PM9Ut8J/ma-car1300.jpg 3" inlet http://shrani.si/f/3j/nf/3xRB7jwx/ma-car1301.jpg 5" outlet http://shrani.si/f/2K/hj/ZK5VSMx/ma-car1302.jpg I think for now, this diameter will suffice :):wink3: http://shrani.si/f/19/10O/4YjIS6NG/ma-car1303.jpg And all the parts for the exhaust on one place. Only thing I might need, is another 10m titanium heat wrap. I plan on wrapping both manifolds + connecting pipes to the turbo + downpipe. 10m obviously won't be enough... This will be the final chapter for the exhaust. Now, if it will not give a proper noise, I will give up :) True 3" from turbo to backbox + 5" tip... To go for a bigger diameter pipes and more free flowing exhaust, is simply not possible... http://shrani.si/f/1N/yj/41ynDWbO/ma-car1304.jpg I've also got 60mm x 900mm alloy for velocity stacks in the intake manifold http://shrani.si/f/2b/Aa/3Ef76Sd9/ma-car1305.jpg 'talla |
Chimney installed...
http://shrani.si/f/h/EJ/2MeJpoh9/ma-car1306.jpg What to say about the noise... Supra loudness meets F-Type backfiring meets GTA burble :wink3: :) It literally cannot be better! But sadly, it is a tad too loud, so I am already looking for a dB killer, so I won't get into any trouble... 'talla |
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I got a baffle/dB killer for the backbox. It truly reduces dB
http://shrani.si/f/2O/pt/3FN0KB3y/ma-car1311.jpg Injectors have also arrived. Bosch green top 440cc @ 3bar / 550cc @ 4bar. V6TB has 3,8bar stock fuel pressure, so it should have more than enough flow for future tuning... http://shrani.si/f/z/w0/2gR3Rvpw/ma-car1312.jpg http://shrani.si/f/1a/il/vBbY5E8/ma-car1313.jpg Four spray nozzles, stock has only one http://shrani.si/f/2p/In/F5UZZOR/ma-car1314.jpg 'talla |
Finally got to see the video, your exhaust was so loud that my speakers started farting ;) Throaty sound too, I like it (I do believe that it was a tad too loud for normal driving though, although I believe mine is still louder).
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Baffle is only temporary:smile: :) As soon as I homologate the back box, I will remove it. I grew fond of the noise it made, and since I'm a 5 year old inside, I can't help myself :):smile:
You got any videos of you exhaust? I would love to hear it. |
No video yet, especially until I fix my ride. But believe me, Fica with broken carb is Loud ;)
P.S. I would have answered a lot sooner, but the forum is sometimes really late to send an email about new posts (I'm following this thread, and got the mail today). |
Chimney is homologated, and so I removed the baffle. Me chuffed to bits! :smile:
I have also ordered 4" intake pipes for the turbo, which I will mount together with: http://shrani.si/f/1U/s9/3qBTdsN3/ma-car1319.jpg http://shrani.si/f/n/3p/23GNrMoh/ma-car1320.jpg Sometime next month, I am scheduled for chip tuning. Hope it will turn out OK... If anyone is interested from which car this MAF housing came from (82mm inside / 92mm outside)... Audi A8 '98-'02 4.2 V8 228kW http://shrani.si/f/2s/tQ/MhBkXhA/ma-car1318.jpg 'talla |
Package has arrived. It will be mounted this week...
http://shrani.si/f/d/GS/1JIP8YBv/ma-car1321.jpg 'talla |
Nice. Keep the pics coming!
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Please upload some AR 164 photos!
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I don't have the 164 anymore... A few weeks ago, I've also sold all the Trabant V6TB project parts. A guy needed the turbo kit for a AR155 2.5V6 project, but I told him if he wants the parts, he has to buy everything. So he did. So unfortunately the Trabant project is no more...
Now sad news about the 166. A few weeks ago I went to the tuner, the only one in our country, who does mostly Italian cars and has the correct emulator for this car's ECU. And even he couldn't make any proper chip tuning, because of the extreme limitations of this Motronic ME2.1 ECU. Since I've put a bigger turbo on it and extremely big pipework (for 500HP+), turbo spool is not the best. 5500rpm max boost, 6300rpm revlimit:smile: So to make the best of this high spool, we decided to up the revlimiter to 7800rpm. Sounds good! At least I will have 2300rpm of usable power. Thing is, even he didn't know where the revlimiter map is, because of such an "exotic" ECU. He said he will contact some Italians about it, and let me know. Two weeks have passed and still nothing. So I pretty much gave up on the idea of having ~300hp in this car. It is a wonderful cruiser with excellent ride quality, but it is not intended for tuning. Leaving it in stock 205hp form is when it is the most satisfied. But that's not for me. I need to have a car with tuning potential. Therefore, after much consideration I have decided to keep the 166 as is, for leisure driving. And for the 5 year old inside me, I will get another project-car-toy. Goes by the name Skyline :wink3: It will be imported. I have all the info I need about the import, and a transport arranged. Money is ready, and in about 2-3 weeks time, I will go to Germany and import it. Looking at 4-5 candidates. We are in contact so all I need is to wait for my transport to be ready - he goes to Germany twice a week, so he is quite busy. I am prepared to go 1200km for the right Skyline, so I want to be 100%, which one to buy. My budget is limited however, so realistically, the one I can afford is an R33 and not R34. But more of that when the time is right... 'talla |
But no more trabant :(
Alfa probably could go further with a custom ECU, but of course it's no Skyline :) And again, no trabant :( |
Alfa cannot go further, with any ECU. Trust me. On an Alfa, everything is custom made, expensive and not tested a million times over. For a Skyline, I make three clicks and I can buy stage 1 318hp version. I will still be a true Alfist, even if I sell the 166 - which I doubt, since it will take some time to get used to RHD and RWD, I bet it will stay at my side for some time. Nonetheless, I will be an Alfist with a Japanese car, that's for sure:smile:
Yeah, it's sad that TrebiV6TB project is gone. But considering that all the parts I had for it were used, and only good for someone that needs them for a similar project, I had to take the opportunity. I still have Trebi at home, but it's a bare shell with wheels. Perhaps some day... :wink3: |
So no one will think that Alfa has no faults now that there is a Japanese car next to her :smile:
Universal high pressure hose for the power steering, because the car started to leave red spots near the power steering cooler. Either the hose is at fault, or it's those days of the Month??? :smile: http://shrani.si/f/3k/wS/Z1VrknJ/ma-car1385.jpg And since I've got the car, I knew someday I will have to replace my gear stick, because it has gotten all rubber-ish. Now it has gotten so bad, that every time I shift, I have black hands like I have replaced a clutch. I've got an universal one for the lift-up reverse. OEM is like 310$ - instane! I just hope this one will fit... http://shrani.si/f/10/nL/32ggGpFP/ma-car1386.jpg Apart from that, I am planning on some mods once Sky is on the road. RH wheels from the Sky + lowering + some bits around the engine. But more on that next year :wink3: 'talla |
It took me awhile, but I finally replaced those blue silicone couplers with black ones. It looks much cleaner now
http://shrani.si/f/1t/yJ/3vWzSmhd/ma-car1390.jpg 'talla |
So, the Alfa rides again :) Which one do you usually drive now?
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No, I only drive the Alfa at the moment. Sky is still waiting for surgery :smile: Starting next year, Alfa will be my winter car, and Sky for the rest of the year.
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Happy New Year fellas! Let this year be with less repairs and more boooost! :happy160:
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