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(Post Link) post #1 of 39 Old 02-09-13 Thread Starter
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Ar166 v6tb

So, after some delay, I finally got time to open this thread. This is now my new ride. It's a 166 V6TB '99 Dec. with 113000km on the clock (it had 111000km when I bought it). It was in fairly good condition, but it needed a lot of TLC, because the previous owner was not the best in car maintenance. Car was sitting for over a year, so brakes were shot. It also had electrical gremlins, but at least it was dirt cheap (600€ + 150€ transport). This is how it looked when I brought it home...
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Another project for my dad and I was at hand. First thing I did, was complete interior cleaning and swapping the seats with the ones I had planned on using in my 164. Luckily the rear's didn't fit, and that I didn't modify them, because I could use them in this car now.
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Then the engine came out, because the car had an engine fault. Previous owner claimed, it only needed a head gasket change, and we believed him... How wrong were we.

Anyhu... engine was disassembled, so I got my porting tools and went to work on the heads:
Before
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After
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Engine in bits
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Of course, we believed the previous owner that "only" the head gasket needed changing... In fact all the main bearings were shot (half bearings were OK)
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(Post Link) post #2 of 39 Old 02-09-13 Thread Starter
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Crankshaft was shot
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So we needed a replacement crankshaft
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And so we started the assembly
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After 4hours the bottom end was done. STD main and half bearings, all the seals, all the gaskets & all the o-rings were replaced
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We also decided to do a major service, since the previous owner did not remember, if it was done or not
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New parts for the overhaul started to pile up:
- New radiator
- All filters + iridium spark plugs
- Steering boots
- CV boots
- Both knock sensors (they're a pig to get to, so we decided to replace them while we have easy access)
- All gaskets for the engine & dif
- Clutch + slave cylinder
- All four brake discs ATE & ATE pads & ATE brake fluid & handbrake cables & all four brake lines
- Tie rod ends
- Mobil SHC 75W90 3l gearbox oil
- Paraflu UP 3l
- Petronas 10W60 8l engine oil (I am very satisfied with this oil in my 164!)
- Oil vapor can
- Rear right engine mount
- All ARB bushes & all ARB links
- Valve guides
- Both alternator bearings & voltage regulator
- Starter motor brush set
- Misc sensors & switches
- exc.
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I've also received a package from the UK:
- 6x universal exhaust hangers
- 3x 3" pipe joiners
- 3" flexi pipe
- Lambda probe adapter
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- 5x 1m 3" stainless steel pipe
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And the work continues... Rear right engine mount was not in mint condition, so we've decided to replace it, because it's a real hassle to get to it, once the engine is in
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Engine being put together
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We've replaced every single gasket, o-ring and seal there is. We've also replaced seals in the gearbox & dif
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Engine in place
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Lambda probe adapter
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(Post Link) post #4 of 39 Old 02-09-13 Thread Starter
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It took a whole day to modify and fit the 3.0 24V intake manifold (it has 2,5l capacity, TB manifold has only 2l) and 45mm intake runners (TB has 38mm)...
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Next on the list were the brakes. ATE are the only brakes that I will ever put on my cars. I am very satisfied with them...
Front discs + ceramic pads
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Rear discs + normal pads
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Car is without any rust on the chassis and to keep it that way, we used undercoating for additional protection. Other bits and pieces on the chassis that do show signs of rust, like the rear ARB, fuel tank holder & axle body's, I plan on spraying some other time...
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Before
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After
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Everything ready for the first start up
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(Post Link) post #5 of 39 Old 02-09-13 Thread Starter
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Preparations for making the exhaust
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Stock vs. 3"
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Stainless steel welding wire
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All the lubricants ready to go in the car
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Before we could start the car, my A/C condenser decided to give up, so a new one was bought. And since the dryer is really cheap, we bought that as well
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Mounted
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Front section
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We couldn't make a 3" pipe fit in this section, so we left it stock. But as soon as I go for the bigger turbo, I will have 3" all the way...
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But we did shorten the downpipe for a few cm's, which means both pipes are not touching each other, like they were from factory
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Eliminated pre-cat (cat removed and welded back together)
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Eliminated main cat (cat removed and 3" pipe put through)
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Middle silencer replacement pipe
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Mounted
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(Post Link) post #6 of 39 Old 02-09-13 Thread Starter
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Only thing left to do with the exhaust, is make a custom hanger for this section. We've tried with those universal hangers, but it did not pull the pipe enough, so it was touching the chassis. Temporary fix for now was the wire...
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Supersprint backbox which is for the 164, so it had to be modified a bit to fit on the 166...
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I've also decided I wanted a Dukes of Hazzard horn So I got one
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Mounted
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And after a successful test drive... I've expected it to be loud as hell, but it turns out you can barely hear the engine. Compared to the 164, which has a smaller diameter exhaust, but also freeflow, that one is angry and loud like a train compared to the 166
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Both Bella's together
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Then I got a CD changer + amp
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And black floor mats
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And since I had grey seats and stock interior was beige, I had to buy the complete grey interior set. It was not cheap, but I think it came out rather OK! That triangle shape next to the ICS is next to impossible to take out, so I plan on putting some vinyl on there. If I won't find a suitable grey color, then I will go for black...
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Unfortunately since my car didn't have an amp factory fitted, I have no cables for it either. So that "project" will be for next year, together with the rear speakers. I also need to find the best way to mount this gauge holder on the A-pillar...
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Last thing was to replace both badges. Of course I'm not prepared to buy those stock expensive ones, so I've got an alternative... 13€ for two pairs with shipping.
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I like it, because it's cheap and looks surprisingly good
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So that's it so far. My plan for the future is:
- Bigger turbo from a Toyota Supra = 60mm/76 mm - 67.9mm/51.9mm (already at home just need to buy that bigger 76mm comp wheel & housing)
- Bigger injectors
- Bigger fuel pump (already at home)
- Better cooling for the turbo (I'll probably go for the chargecooler system, not the classic FMIC, because I don't want to cut bumpers anymore )
- Chip tuning
- Wideband lambda kit
- Maybe a F430/Maserati throttle body

Until next time...
'talla
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Now that is dedication. Good work, keep us updated.
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why didn't you upgrade the engine itself?
like a 3.0 blok with 2.5 crank? easy and cheap to get , would've upgraded your engine to 2.8
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(Post Link) post #10 of 39 Old 04-09-13 Thread Starter
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No need for that. This engine is strong as it is. Also, I doubt I would see any benefit from simply going to a bigger displacement, only additional costs for a block & crankshaft...
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well mostly , because you could..
Squadra 2.8 v6tb spider
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(Post Link) post #12 of 39 Old 09-06-14 Thread Starter
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It's been a while since my last post. Much has been done to my car. Let me continue where I left off..

Oxygen sensor was replaced out of precaution
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Manual boost controller was next
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Then I got a wideband oxygen sensor as well, so I could see what the engine is doing
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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...
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I had to replace both indicators. Luckily you can get a copy of the original, which is three times cheaper. And since the 166 does not have an oil pressure sensor, I've got one from a 164
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I've got a gasket for the cover under the wipers, all 10 bolts that hold it down and the windscreen washer fluid hoses
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Before
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After
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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
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Then I got connectors for the injectors. I was being methodical with the electrics - once you own an Alfa, you understand why
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Next was the front speaker system which got uprated
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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
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Difference between stock and 3" intake
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Time to install that 164's oil pressure sensor. Some modification was needed of course, to get the sensor installed in the head, where the turbo gets it's oil feed
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Next on the list, was a bigger throttle body. I was deciding between two TB's:
- A Ferrari 360
- A Porsche Cayenne Turbo S

Both have exactly the same pin-out as Alfa. Ferrari TB's are getting rare and expensive, so I got a Porsche one instead...

Stock vs. Porsche
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Stock has 69mm inlet
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Outside 75mm
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Porsche has 79mm inlet
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And 87mm outside
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To be continued...
'talla
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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
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Replacing the old vacuum line
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Some more vacuum lines
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Replacing this piece of spaghetti of lines (we had to botch something together, to make the car drive, this is what came out)
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And installed
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Then I got a special tape as used by the factory for wiring harnesses
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Some more connectors for the engine sensors
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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...
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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
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I've also got a special oil for the engine. Mobil 1 10W60 full synt. It's not cheap, but I know it's one of the best 10W60 oil's out there...
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External 300lph fuel pump with cradle
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Some more exhaust parts
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Now we had all the parts, to make a custom 3" downpipe
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This heat shield for the A/C compressor was in the way, so we removed it
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We've removed this lot
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And installed this lot
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Everything installed, together with a brand new front O2 sensor and a wideband O2 sensor
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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)
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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)
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MAP sensor installed
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Replaced connectors on all the sensors
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And a bit of tidying up the cables
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The engine was in this state after all that work
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To be continued...
'talla
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Wideband oxygen sensor & LC1 mounted and connected
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Wiring went through the firewall
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Quite a few cables
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There was no other place for the wires to go in the cabin, without taking the engine out, except under the windscreen
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Just behind the passenger airbag
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I've also installed wires for three gauges, which were mounted on top of the dash (no other place for proper mounting in the 166)
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Tidying up the wires
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Silicone around the hole, to prevent any water to come inside the cabin
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Making an adapter plate for the Porsche throttle body, out of an old intake manifold
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Drilled holes
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Test fit on the manifold
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And on the TB itself
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Putting everything together, to see if it fits. I had an old coupling hose laying around, just so I could start the car
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Of course, there's always a problem with customization. TB is too wide, so the original expansion tank would not fit anymore...
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The appropriate tank was from a Golf III, which is also one of the cheapest around
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Test fitting
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Port matching on the TB
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Enlarged intake manifold entrance
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I've enlarged the entrance by 9mm...
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Some more port matching
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It looked like this before the very first start up with the new TB
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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
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to be continued...
'talla
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Moving on... Replaced rear subframe bushes
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Status before the first test drive
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After the shortest test drive... ever. This coupler hose sucks, so back to the drawing board
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In the mean time, I've replaced all the bolt inserts around the engine bay
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Because the bolts were becoming loose
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Replaced drive belt lid
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And pièce de résistance. Proper silicone hoses and clamps!
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We had to modify the T-pipe for the dumpvalve
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And weld on the nut for the intake air temp. sensor
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But we got the original header 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...
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Status before the second test drive. I had a good feeling this time
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After a successful test drive, I made three daylight pics of the engine bay. I think is looks pretty much stock
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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
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In the mean time, I have also installed the original rear subs, which I got with the original amp
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I've also received a front mount radiator for the chargecooler system
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Quite a big unit @ 597mm x 171mm x 70 mm
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I've also got a "repair set" for the gear shifter. I also found a company which makes a bush for the upper engine mount for 30€, while the OEM upper mount is 120€...
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This is the culprit. 120€ for this... they must be mad!
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Bush was in a bad state, which was noticeable when doing hard acceleration. Engine was rocking back and forth too much for my liking
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Fixed
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To be continued...
'talla
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Shifter repair set was next
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Now, I have crisp gear changes once more
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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
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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 out of plastic and I think it turned out pretty good
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We have 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
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Then, I turned my attention to the original amp and parcel shelf woofers. I've asked quite a few AR brakers, but none had the original wiring loom for this car. So I had to make a wiring loom from scratch
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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...
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Then I got the electric water pump and flexible wire hoses
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We've also replaced the temperature switch, because my previous one had corrosion on all the contacts
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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
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Brand new 0,9bar cap and two brackets for the CC filler neck
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Then I got 3" silicone elbows, pipes and W2 clamps for the CC system
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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%
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And finally, the installation of the chargecooler system...
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Good thing I got an almost identical size cooler than stock. And even this one just barely fits
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It's a tight squeeze
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Home made bracket for the filler neck
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Turbo pipes installed
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Upper pipes were next
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Just enough room for everything to fit
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Front radiator for the CC was also installed with home made brackets
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This is how it looked nearly finished
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Very tight squeeze between the coil and intake pipe
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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
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It fits, barely
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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...
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And finished
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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
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I found another thing I can change on my car. MAF housing will be uprated...
Stock = 70mm
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Not so stock = 82mm
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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
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'talla
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Originally Posted by peruccy View Post
I found another thing I can change on my car. MAF housing will be uprated...
Stock = 70mm
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Not so stock = 82mm
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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
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'talla
Hmmm, not to be a naysayer, but will your ECU love you after that? You will most probably have to recalibrate/remap for that. For the same volume (mass) of air, it will flow slower in the bigger housing, thus the cooling on the sensor will be different and readings will be different for the same volume / mass of air.
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(Post Link) post #18 of 39 Old 25-06-14 Thread Starter
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Car will be remapped, don't worry.
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147ts plus bits

Epic amounts of love going into that there alfa!!!
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And finished

Nice job, well done!
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(Post Link) post #21 of 39 Old 03-07-14 Thread Starter
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Thanks!

Hopefully I will begin the next phase of the build soon... uprated fuel injection.
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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...
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Today I finally received my JDM chimney pipe
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3" inlet
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5" outlet
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I think for now, this diameter will suffice
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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...
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I've also got 60mm x 900mm alloy for velocity stacks
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This will be for a home-made 4l capacity intake manifold. I need to get an alloy plate, and begin with construction. I've also ordered 6x440cc bosch green injectors and external high flow 30micron fuel filter. Which I will mount together with an external 300lph fuel pump and intake manifold.

'talla
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Chimney installed...
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What to say about the noise... Supra loudness meets F-Type backfiring meets GTA burble 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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Thats a very nice project, i just think the exhaust doesnt suit the classic nature of the design..it's a bit too japanese,a rectangular tip with rounded edges or even a quad tip exhaust would suit it much better,but really nice project nonetheless
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(Post Link) post #25 of 39 Old 06-08-14 Thread Starter
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Thanks! About the backbox... I know it doesn't suit this car very well, but I like it when my car is different. This is now my JDM Alfa

Here's a preview of the exhaust note:
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More to come in the near future...

'talla
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