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Discussion Starter · #1 ·
So I introduced myself in the newbie section last Autumn. I was thinking of getting a 159 2.4.

Ideally I was after a TI but a lusso would suffice and I could spec it up to TI.

So picked this up last week

IMG_20200226_173752.jpg

It's a lusso 2.4, 80K on the clock with the auto lights, windscreen wiper pack, blue and me and a nice suprise rear folding seats.

It sits on 18 inch rims already and has had the following done:-
New rear discs and callipers
Mapped to 250 bhp
All belts and water pump 18 months ago
EGR blank
Cat replaced
Swirl flap blank by Alfa specialist
Replaced injectors

Now for the not so good
Clutch is shot
It has had bodywork done down the driver's side
Runs a little rough at idle sometimes
Wheels are awful. As I will be hunting TI 19s it was not an issue for me.
Don't think it has seen a decent clean since new.

I am also a fan of the grey colour.

This is my first venture into Alfas and my current fleet includes a fully restored 2.5 MGZT, MKIV Supra and a Merc C250.

I did a project thread for 4 years on the ZT which had a full but and bolt resto.

My plans?

Firstly change the clutch. I won't get around to it yet because of other things but that is the first job.
Then go over her from top to toe to find all those issues including driving her for a while.
Spec her to TI spec (some bits already collected).

Here is to a long and fruitful ownership, some frustrating evenings in the garage and a lot of help from this forum
 

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Bodywork looks very sharp! Alloys look good at first glance but a bit rough up close (like my own!)

Given 159s are 10+ years old, are Ti's really asking that much of a premium that it's worthwhile buying a Lusso and upgrading the spec?
 

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Discussion Starter · #3 ·
Bodywork looks very sharp! Alloys look good at first glance but a bit rough up close (like my own!)

Given 159s are 10+ years old, are Ti's really asking that much of a premium that it's worthwhile buying a Lusso and upgrading the spec?
Yea the body work is fairly tidy and the interior is not bad either. If I kept the alloys they would need a total refurb. I thought it was unusual for them to be 18 inch but although I have been reading about these for ages I dont understand quite a bit.

TBH I could have got a TI but I was looking down the lower end of mileage range which for a 10 year plus car is always a challenge. My overall budget is quite strong but I do get your sentiments. Half the fun for me is in the doing and making a car I have bought better than when I bought it so I dont have a problem with hunting the parts, refurbing everything I can and getting her to the standard and spec I like. The MG took 4 years as a rolling project and I dont see this being any different, Some will say its a waste of time/money but its my hobby and stress relief from quite a high profile stressful job:D:oops:

my other tribe

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Thanks for the comments
 

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I absolutely appreciate that sentiment! It's not always the destination - it's the journey. :)
There's jobs on my 159 I have "banked" for that days when I have that magical time to spend on it. As you suggest, car love is stress-relief. Unless, as my wife likes to point out, it involves her Citroen Grand Picasso!

Going by your previous efforts, I look forward to seeing what the 159 will turn out like.
 

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Yea the body work is fairly tidy and the interior is not bad either. If I kept the alloys they would need a total refurb. I thought it was unusual for them to be 18 inch but although I have been reading about these for ages I dont understand quite a bit.

TBH I could have got a TI but I was looking down the lower end of mileage range which for a 10 year plus car is always a challenge. My overall budget is quite strong but I do get your sentiments. Half the fun for me is in the doing and making a car I have bought better than when I bought it so I dont have a problem with hunting the parts, refurbing everything I can and getting her to the standard and spec I like. The MG took 4 years as a rolling project and I dont see this being any different, Some will say its a waste of time/money but its my hobby and stress relief from quite a high profile stressful job:D:oops:

my other tribe

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Thanks for the comments
" The MG took 4 years as a rolling project and I dont see this being any different, Some will say its a waste of time/money but its my hobby and stress relief from quite a high profile stressful job".


"There is no Profit, in a life without the love of something or someone along the way"
 

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Alfa 166 Ti, Giulietta Veloce
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Welcome. Your car looks nice ! I used to have a 2.4 Lusso which i made look like a Ti but sans the seats. If you 're interested i have set of genuine Ti sideskirts i could sell you. They are in the same colour as your car (It looks like Stromboli Grey?) but if you're fussy you'd probably want to respray them. PM me if you want more details. I got them as I was looking at another 159 recently but ended up buying a brera. Cheers
 

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Discussion Starter · #7 ·
Welcome. Your car looks nice ! I used to have a 2.4 Lusso which i made look like a Ti but sans the seats. If you 're interested i have set of genuine Ti sideskirts i could sell you. They are in the same colour as your car (It looks like Stromboli Grey?) but if you're fussy you'd probably want to respray them. PM me if you want more details. I got them as I was looking at another 159 recently but ended up buying a brera. Cheers
Wow thanks mate. That is a very kind offer. TI skirts are one of the things I already have. Saw some for sale when I made my mind up to go for a lower mileage Lusso.

Thanks for the comments and welcome everyone. What a nice place to be(y)
 

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Discussion Starter · #8 ·
So after nearly 10 months of driving and learning the car she is now in the garage up in the air and I've started the project. Is there anywhere to put a project thread or do I just run it on this post?

I have loved the driving the car and can see why you have all been Alfa fans. It's been a learning process and I have a list of jobs as long as my arm. Plenty of photos to follow on the project :D
 

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Discussion Starter · #10 ·
Always liked a supra
Thanks mate. Been in Supra ownership for nearly 17 years (current one just the 10 years). They are superb cars.

I have been over the moon with the 159. She needs plenty of tlc but that's why I bought her cheaply. Loads of pics to follow.
 

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Project Thread can be this or a new one - I'm not aware of any rules in that regard. Your other projects do look good :) I was considering an MG until I was finally in a position to get my current Ti TBi SW. I wish I was more hands-on (I used to happily service my older cars but I never have time and end up with a local garage). Would save me some money as well! I've had few issues so far in my 2yrs+ of ownership (my 2nd Alfa), although I now have a few bills on the horizon... Tyres are approaching replacement (at least 2 prior to MOT), light stalk has just failed (so driving with dipped on all the time which is no major issue in the winter and not an MOT fail) and I need a breaker's one for the garage to kindly fit rather than me paying for new. Pads are ready for replacing and it's due a belt replacement (both expected). Finally, the rear wiper has failed. Not sure if it's a "disconnection from the motor" or "fuse", or something more so hoping to investigate over the holidays.
 

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Discussion Starter · #12 ·
I have started my project and will post pics on this thread as I go. I do take loads (normally for my reference😀) so this may be pick heavy.

Since driving the car I have been gathering spares as I go (and continuing!!).

Most of the TI bits sourced (I think).

Exterior styling

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Dash panels, Steering wheel, gearknob, sill panels, Sun visors, door card and dashoard trims, TI clocks etc

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Ti seats. Drivers seat needs to go to the the trimmers but I was very happy with their condition. These are manual but heated fronts.

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I went the full hog also getting the black headlining, :oops:handles and trim

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I will replace the struts and springs with new (Bilsteins probably with Eibach springs) and already have the larger Brembo brakes anti roll bar fitted.


Clutch and DMF sat in the boot, christ that's the most expensive DMF I have ever bought:oops:. Speaking to an Alfa specialist he advised against going for a refurbed unit as in his experience they only fail again.

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I tend to work on all my projects in the same way.

Start at the back
Into the boot
Into the main cabin
Engine bay
Brakes and suspension
Underside of car /

I don't think this project will be any different. I post this sort of thing on the forums to help others who can scan over my ramblings and photos for references. Some might think its a waste of my time and money but cars are my hobby and 90's and early 20's cars are where I feel happiest nowadays. I have done 80's and 70's cars in the past but tin rot and bodywork are my least preferred jobs (spent 2 x years welding a Jag in the past, hated the car when I finished it:D ). Its my way of relaxing and not a money making venture.
Next step the rear end and boot.
 

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Alfa 159 1.9 JTDm Sportwagon
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Hopefully picking up my 159 today, a new project for me, and look forward to seeing your progress.
 
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Discussion Starter · #15 · (Edited)
little bit of an update.

Starting at the rear end a few jobs to do:

Empty the boot and check all areas including paintwork and metal plus deep clean
Remove rear bumper and crash bar assy checking all the metal work and paintwork
Change Boot badge.
rear bumper by boot entry needed looking at, Heavily scratched and marked had glue on it as well

Well that was the plan :)

First stripping out this bad boy
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quick half hour later and we are down to this

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Removing side trim:
1. a couple of fir tree clips on the floor passing into plastic sockets. These are not normal fir tree clips. I think they must be Fiat, Alfa specific. Very thin and long and easily broken if over stressed on removal. I broke 2 before I learnt my lesson. Had to order some OE replacements.

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2. Normal style fir tree clip into the top under the parcel shelf.
3. A plastic M5 nut into the top of the under the parcel shelf
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4. Self tapper ether side of the plastic protector over the boot catch
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5. The loading D's are also screwed through the side trims as well
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6. If you have collapsing rear seats the trim around the aperture needs to be moved as well as the side trims tuck under this. I removed the fir tree clips to allow movement.

To remove the plastic on the boot entry:-
1. The self tappers mentioned above need removing
2. Those strange flat headed M6 torx screws which seems to be fitted everywhere on the Alfa
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3. The D ring load restrainers
4. the unit is then held in place by 2 x clips. These are very tight so dont pull the unit from the edges. I found it better getting my hand under the plastic and getting close to the clips when pulling up.
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I cant seem to post any more photos as I get told I can only attach 10 photos. How do I overcome this?
 

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Alfa 166 Ti, Giulietta Veloce
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Not sure re the number of images. Maybe a moderator or admin can help?
 
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Discussion Starter · #17 ·
With the boot empty I could give it a good survey and deep clean.

Structurally very good and paint wise solid however I found some surface corrosion which would have only got worse around the holes where the ABS looms pass into the rear wheel arches. Is this a known area on the 159?

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so wire brush attached to angle grinder and both sides attacked to get rid of the rust and see what the damage is. Once cleaned up the rust was treated and then painted using a rust stabilising paint internal and in the wheel arch

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The boot was then deep cleaned

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Next up was the boot badge replacement
 

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Discussion Starter · #18 ·
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I decided to replace the whole switch unit with the badge rather than just the badge, The work involved is fairly easy but I suppose there is a cost implication for a badge against a whole switch unit.

Firstly remove the boot lid liner by removing the 10 fir tree clips and the self tapper in the shut handle. These fir tree clips are more substantial than the boot side panels

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The boot lid liner will just fall away

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The switch unit is mounted up underneath the bootlid. You can see the 2 x M6 nuts which mount the unit and also the wiring. On my new OE unit the black wrapped cable is not used and the car loom plugs straight onto the unit at the small connector.

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You can see the difference in the units here on the bench. The unit on the left is my original and the unit on the right is the replacement. Also note the rubber gasket. This needs to be in place when fitting

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With the Switch removed you can see the locating hole which the units have a lug on them to locate and the holes the M6 studs from the unit pass through

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A good clean around the aperture and the new unit was fitted noting the smaller connector now plugs straight onto the switch unit

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And finally a much crisper look. I do lacquer badges before fitting to try and keep the elements at bay. It was something recommended to me years ago and it does seem to work.

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Next up rear lights removal whilst the boot lid liner was removed
 

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Always enjoy reading threads like this Great work


Sent from my iPhone using Tapatalk
 
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