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(Post Link) post #1 of 15 Old 16-08-13 Thread Starter
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TS rebuild

After just over 117,000 or so trouble free miles without so much as missing a beat (MAF related misfires accepted), the 2.0 TS in my 166 has had its big end go on Wednesday. It sounds like a tribe of pixies are trying to sledgehammer their way out of the block. A slow, low revs trip down the road to the chaps in TI has confirmed the worst.

So, time to bite the bullet. I'm going for a full engine refurb/rebuild. Early investigations have turned up a couple of interesting options in the UK. Deliver the car to them and 1,600 or so will see the unit removed, stripped and basically "zero houred" with the crank ground/polished, new shells/shims, valves cleaned, tapits checked, oil galleries cleaned, oil pump refurbed, pistons and bores checked, new seals/rings/gaskets all around and everything pressures tested when nailed back together.

Has anyone on here used the services of any engine rebuild/refurb specialists they can recommend or warn me off? Be very interested if there's someone in Ireland who can do the job.

V.
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IF you are going to the UK may be better asking over there perhaps.
Engines (TS, JTS, JTD & V6) - Alfa Romeo Forum
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Is this the 'new' 166 you were on with? You are having no luck man! Surely there must be a cheaper option than that? Maybe source an engine here, plenty of TS's around for breaking.
 
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Quote:
Originally Posted by Variator View Post
After just over 117,000 or so trouble free miles without so much as missing a beat (MAF related misfires accepted), the 2.0 TS in my 166 has had its big end go on Wednesday. It sounds like a tribe of pixies are trying to sledgehammer their way out of the block. A slow, low revs trip down the road to the chaps in TI has confirmed the worst.

So, time to bite the bullet. I'm going for a full engine refurb/rebuild. Early investigations have turned up a couple of interesting options in the UK. Deliver the car to them and 1,600 or so will see the unit removed, stripped and basically "zero houred" with the crank ground/polished, new shells/shims, valves cleaned, tapits checked, oil galleries cleaned, oil pump refurbed, pistons and bores checked, new seals/rings/gaskets all around and everything pressures tested when nailed back together.

Has anyone on here used the services of any engine rebuild/refurb specialists they can recommend or warn me off? Be very interested if there's someone in Ireland who can do the job.

V.
Forgot to mention to have a look at Autolusso, they really are the expesrts when it comes to Alfa's. They can do all sorts of engine upgrades as well:
Autolusso - Alfa Romeo Specialist | Alfa Romeo Engine Rebuilds
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Quote:
Originally Posted by Variator View Post
After just over 117,000 or so trouble free miles without so much as missing a beat (MAF related misfires accepted), the 2.0 TS in my 166 has had its big end go on Wednesday. It sounds like a tribe of pixies are trying to sledgehammer their way out of the block. A slow, low revs trip down the road to the chaps in TI has confirmed the worst.

So, time to bite the bullet. I'm going for a full engine refurb/rebuild. Early investigations have turned up a couple of interesting options in the UK. Deliver the car to them and 1,600 or so will see the unit removed, stripped and basically "zero houred" with the crank ground/polished, new shells/shims, valves cleaned, tapits checked, oil galleries cleaned, oil pump refurbed, pistons and bores checked, new seals/rings/gaskets all around and everything pressures tested when nailed back together.

Has anyone on here used the services of any engine rebuild/refurb specialists they can recommend or warn me off? Be very interested if there's someone in Ireland who can do the job.

V.
Of course there are people here who can do the job. At the very least you had the car in with one. Why is it assumed that the only route is the UK. Its not as if the engine is a complicated multi cylindered unit, its a simple 4 cylinder DOHC 16v. Maybe a few difference to other similar sized engines, but common nonetheless.
Think of what you are getting for 1600 for a minute, a simple strip down, plus components checked and cleaned.
Maybe things have changed, but I did not think it was possible to regrind this type of crank, if it was too far gone.
Howards or Faulkners are two that spring to mind (in Dublin), I'm certain there are plenty more around the country. High Precision Engineering in Tullow is another. These places have been in business for decades, I'm certain at this this they know what they are doing.
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(Post Link) post #6 of 15 Old 19-08-13 Thread Starter
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Thanks guys

Swarlb; yes you're right there are options in Ireland. The UK guys came up top of the list on web searches where as only 1 Irish guy did (if you discount all the guys who only do big diesels) and responded very quickly to a query. By contrast, the first local reply took 3 days and two requests.

Will make a decision on who to use this week following a couple of conversations then book the car in and have the engine "zero-houred".

V.
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Thanks guys

Swarlb; yes you're right there are options in Ireland. The UK guys came up top of the list on web searches where as only 1 Irish guy did (if you discount all the guys who only do big diesels) and responded very quickly to a query. By contrast, the first local reply took 3 days and two requests.

Will make a decision on who to use this week following a couple of conversations then book the car in and have the engine "zero-houred".

V.
Don Baker supplied and fitted my new 2.l ts crate engine , and its a sweet as a nut link below.

Alfa Romeo Service Land rover repair by Don Baker Ireland
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Don Baker supplied and fitted my new 2.l ts crate engine , and its a sweet as a nut link below.

Alfa Romeo Service Land rover repair by Don Baker Ireland
30 per hour labour is very reasonable!
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(Post Link) post #9 of 15 Old 02-09-13 Thread Starter
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If anyone's interested in the rebuild progress; pictures of the strip down are on the TI Autos FB page.

https://www.facebook.com/pages/TI-Au...26897410724626

A lot of dark deposits in the cylinders ... guess that explains the increasing oil consumption!

The good news is the crank can be saved.

V.
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It's pretty hard to know what is going to be required without stripping the engine. I'm a little dubious of these quoted rebuilds to say the least.
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(Post Link) post #11 of 15 Old 12-09-13 Thread Starter
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Some very shiny metal now on show ...

https://www.facebook.com/media/set/?...0724626&type=1

Sourcing an oil pump proved to be a little trickier than expected.

V.
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(Post Link) post #12 of 15 Old 25-09-13 Thread Starter
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I collected the car from David & Gerry last week. Engine is lovely and smooth. The little rattle in the head that's been there since I got the car in 2003 is gone along with the nasty big end knock. Gerry showed me the box of bits that were replaced.

The most noticable change post the rebuild is that there's more torque lower down the revs. Apart from a short motorway spin I'm keeping her below 3K revs for a while and being very gentle with my right foot so I don't know what the power is like yet.

So far, very happy.

V.
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Quote:
Originally Posted by Variator View Post
I collected the car from David & Gerry last week. Engine is lovely and smooth. The little rattle in the head that's been there since I got the car in 2003 is gone along with the nasty big end knock. Gerry showed me the box of bits that were replaced.

The most noticable change post the rebuild is that there's more torque lower down the revs. Apart from a short motorway spin I'm keeping her below 3K revs for a while and being very gentle with my right foot so I don't know what the power is like yet.

So far, very happy.

V.
Great stuff!
When Gerry rebuilt the head and put new piston rings in my old 166 he told me to keep under 3000 RPM for about 1000 miles to let it 'run in.'
Wishing you many happy years motoring!!!

Last edited by Mufasa; 27-09-13 at 08:07.
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Quote:
Originally Posted by Variator View Post
I collected the car from David & Gerry last week. Engine is lovely and smooth. The little rattle in the head that's been there since I got the car in 2003 is gone along with the nasty big end knock. Gerry showed me the box of bits that were replaced.

The most noticable change post the rebuild is that there's more torque lower down the revs. Apart from a short motorway spin I'm keeping her below 3K revs for a while and being very gentle with my right foot so I don't know what the power is like yet.

So far, very happy.

V.
Great outcome V, I hope it goes well! Take her handy under 3k revs then look forward to letting her rip
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I found it impossible to keep the V6 under 3000 rpm....
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