[AndyB777]

Brilliant brilliant thread. Well done. You are an inspiration, my friend. Many Alfa lovers will benefit from your efforts and your enthusiasm in posting all this inspirational information. Have a beer.

 

[joeymannero]

Looks fantastic, meticulous work...hope you enjoy the car for many years to come 👍🏻

 

[Jonc3725]

Looks fantastic, meticulous work...hope you enjoy the car for many years to come 👍🏻

Thanks mate.

I have to say she's fought me every step of the way. Currently waiting on the low side AC pipework as that was leaking on pressure test and I noticed the front exhaust pipe Flexi was leaking🤦‍♂️so changing that as well. Hope to enjoy her daily very soon

 

[W1NST]

Great work and great looking car - brought back many fond memories of my old Red 159ti.

 

[Jonc3725]

Disaster this weekend and I'm not sure why. The new crankseal let go big time and the engine blew all its oil out. Luckily I noticed it before I lost oil pressure.

Unfortunately for my son the roof blew off his house so that takes priority.

Not sure wtf has gone wrong tbh. All sorts gone through my head from scrap it to rebuild myself over time. Let's see what the next few days bring🙄

 

[M800BNT]

@Jonc3725 - what happened in the end? Waiting for the next chapter with bated breath.

 

[misterflaps]

@Jonc3725 - what happened in the end? Waiting for the next chapter with bated breath.

Not sure what he decided in the end, but this appeared some time after the last post here:

Alfa 159 project breaking

Haven't seen anything on here from him since then, and am gutted that the car let him down so badly after all the effort he put in to it. He truly deserved better luck and I am in awe what he achieved on this thread!

 

[Jonc3725]

Hi All,

So the crank seal had gone and was replaced but then I had a problem with the engine. Once it got to running temp there is a fork load of smoke, massive vibration and pressure in the crank. I'm 100% positive its a sticking valve. The car is very low mileage and hadn't really run much in my ownership. Frustration and anger led me very close to breaking her but after a week or so and a couple of ciders I tucked her in the corner of the garage under some sheets and decided to give my other cars some well overdue TLC (and they don't fight me like the Alfa🤣).
Both the MG and Supra are now back to as they should be so the Alfa has moved back to the centre ready to strip down and get the head off.

With all the effort, time and money spent I felt she deserved another chance even if I wasn't in the right frame of mind at the time. My sons roof being blown off in the storms probably didn't help my frame of mind either tbh🤣
I will let the heat subside a bit mind before starting. I do have quite a few updates to do looking back over the thread but I will get her running right first.

Where is the best place to get a top end engine seal kit from?

Cheers

Jon

 

[joeymannero]

Hi All,

So the crank seal had gone and was replaced but then I had a problem with the engine. Once it got to running temp there is a fork load of smoke, massive vibration and pressure in the crank. I'm 100% positive its a sticking valve. The car is very low mileage and hadn't really run much in my ownership. Frustration and anger led me very close to breaking her but after a week or so and a couple of ciders I tucked her in the corner of the garage under some sheets and decided to give my other cars some well overdue TLC (and they don't fight me like the Alfa🤣).
Both the MG and Supra are now back to as they should be so the Alfa has moved back to the centre ready to strip down and get the head off.

With all the effort, time and money spent I felt she deserved another chance even if I wasn't in the right frame of mind at the time. My sons roof being blown off in the storms probably didn't help my frame of mind either tbh🤣
I will let the heat subside a bit mind before starting. I do have quite a few updates to do looking back over the thread but I will get her running right first.

Where is the best place to get a top end engine seal kit from?

Cheers

Jon

shop4parts are generally great for this kind of thing , Admirable levels of patience and perseverance ...very best of luck with it , you deserve a break with this car !

 

[Jonc3725]

Major update.


So head off and signs of blow back through pots 1 and 2. All Injectors tested by Bosch tester and 3 were defective one way or another and were rebuilt.

The head was skimmed, de carbonised and there was a lot of carbon around pot 1 and 2 valves. At the same time the head was pressure tested (just in case) and all good.

Head rebuilt and valves lapped in.

Thats the good news.🙄😒

Ran the car up, started 2nd turn but once the engine gets to 70 degrees I still have a lot of smoke and engine vibration. FFS🤦.

So I've done a bit more playing with multiscan. There ate no error codes but watching the injectors and Air flows something significant happens at 70 degrees engine temp.

The injectors go into post Injection hence the loads of smoke and unsettled engine. Reading up it seems post injection is for DPF regeneration. Now I have a new DPF on the car which has not been registered with the car but I can't see this being the issue because the car was doing this before the new DPF.

Does anyone with in depth knowledge have any ideas why the car activates post injection and what I should be looking at?.

Cheers

Jon

 

[Colin2.4redracer]

Great thread, haven't finished reading it yet. How do you find front subframe bolts and rear are plastic clips from etc?

 

[Jonc3725]

Hi Everyone. Its with great regret I will be breaking the car. Obviously a long term resto project that has had everything done but the engine has an issue I can't resolve and I dont want to spend anymore time or money. Most things available including really good condition:- Ti interior unmarked, heated seats Ti skirts Ti steering wheel and clocks Ti wing mirrors Ti alloys in fairly good condition with good quality Avon tyres. 6 to 8mm tread on all 4. Stainless dpf back exhaust FMIC kit including cooler, brackets and hoses Front tins all blasted and powder coated ( slam panel and front arch panels). Ti callipers overhauled. Ask for anything and it will probably be available. Keeping front sub frame and struts with car so it can be moved. Lots around the engine bay replaced or overhauled I dont want to make massive profits but a lot of parts too good for the crusher. I will be removing the listed parts this week and then moving the car to the scrappy in a couple of weeks. All parts postal prices will be confirmed on request. Collection always welcome but I am in plymouth

 

[teapot]

It always saddens me to see posts like this. I've read your posts and seen all the time money and effort you've put into this project, only for it to end like this. I'm so sorry all your effort has effectively been in vain.

However reading your thread has helped me make a decision. I was considering replacing my 17 year old vauxhall signum 1.9 cdti workhorse with a 159 estate 1.9 or 2.4, as I love the look of them and it would have gone nicely alongside the Giulia that I bought last year. But seeing all the issues you found, especially the rust on the 159 has put me off. The signum looks old and boring, but it doesn't rust, everything still works perfectly on it, and the engine is still sweet despite being tuned and regularly caned, so I'll stick to one alfa and the old vauxhall.

 

[AmicusPro]

It always saddens me to see posts like this. I've read your posts and seen all the time money and effort you've put into this project, only for it to end like this. I'm so sorry all your effort has effectively been in vain.

However reading your thread has helped me make a decision. I was considering replacing my 17 year old vauxhall signum 1.9 cdti workhorse with a 159 estate 1.9 or 2.4, as I love the look of them and it would have gone nicely alongside the Giulia that I bought last year. But seeing all the issues you found, especially the rust on the 159 has put me off. The signum looks old and boring, but it doesn't rust, everything still works perfectly on it, and the engine is still sweet despite being tuned and regularly caned, so I'll stick to one alfa and the old vauxhall.

I had a Signum 1.9CDti. Filled a gap* but not the same as the 159, but then I was never a diesel guy and switched to my TBi Sportwagon and didn't regret it. To be fair, I did consider the 2.0 diesel for a moment. I once had an Astra that was decent enough for an A to B but just a functional car. 159 is a different class - but then you know that as an Alfa owner!

*Probably didn't help that it was bought cheap and the brakes seized etc so I sold it for scrap value.

 

[joeymannero]

Such a shame , but there's a point with these things when chasing sunk cost in both time and money is not the wisest course of action. I also find when a car does this to you your relationship with it is forever sullied.... The reason I mostly don't work on my Alfa's anymore ( save basic stuff like oil and brakes and general maintenance) I hope this doesn't put you off Alfa's forever. They give a lot of driving pleasure when they're right.

 

[teapot]

I had a Signum 1.9CDti. Filled a gap* but not the same as the 159, but then I was never a diesel guy and switched to my TBi Sportwagon and didn't regret it. To be fair, I did consider the 2.0 diesel for a moment. I once had an Astra that was decent enough for an A to B but just a functional car. 159 is a different class - but then you know that as an Alfa owner!

*Probably didn't help that it was bought cheap and the brakes seized etc so I sold it for scrap value.

Sounds like it wasn't the best example of a Signum . I've owned this one since 2018 and upgraded the suspension, brakes, exhaust, intercooler, and lots of other little bits as it was extremely dull and got out of shape easily during enthusiastic driving in standard form. It is still fun in it's own utilitarian and agricultural way, and extremely versatile for transporting large items.

But every time I get in the Giulia it's a different world and even the most dull journey leaves me happy. Hence why I was considering replacing the signum with a 159 1.9, 2.0 or 2.4jtdm. But I guess it's safer to stick to one Alfa for fun, and a dull but known quantity for the mundane. I'm a 'dieselhead' through and through so never even considered a petrol Giulia. When you look at the 2.2d you can see it has its roots in the 1.9d and 2.0d, which I have fixed, mapped, and modified for years and have confidence in.

I must say though I have no regrets about buying the Giulia, it's the most entertaining car I've owned in nearly 30 years of driving, and I enjoy diagnosing and fixing its quirks and age-related wear as much as driving it. I'll keep the 159 in my dreams until the Signum dies or rots, but I fear I might go senile before that happens! Ironically the 2017 Giulia has nearly 10k more miles than the 2006 signum on it at 118k.

Apologies to the OP for hijacking your thread. I still keep admiring the photo's of your 159 in this thread 😳

 

[AmicusPro]

Sounds like it wasn't the best example of a Signum . I've owned this one since 2018 and upgraded the suspension, brakes, exhaust, intercooler, and lots of other little bits as it was extremely dull and got out of shape easily during enthusiastic driving in standard form. It is still fun in it's own utilitarian and agricultural way, and extremely versatile for transporting large items.

But every time I get in the Giulia it's a different world and even the most dull journey leaves me happy. Hence why I was considering replacing the signum with a 159 1.9, 2.0 or 2.4jtdm. But I guess it's safer to stick to one Alfa for fun, and a dull but known quantity for the mundane. I'm a 'dieselhead' through and through so never even considered a petrol Giulia. When you look at the 2.2d you can see it has its roots in the 1.9d and 2.0d, which I have fixed, mapped, and modified for years and have confidence in.

I must say though I have no regrets about buying the Giulia, it's the most entertaining car I've owned in nearly 30 years of driving, and I enjoy diagnosing and fixing its quirks and age-related wear as much as driving it. I'll keep the 159 in my dreams until the Signum dies or rots, but I fear I might go senile before that happens! Ironically the 2017 Giulia has nearly 10k more miles than the 2006 signum on it at 118k.

Apologies to the OP for hijacking your thread. I still keep admiring the photo's of your 159 in this thread 😳

(Apologies from me too!)
Not really - it cost £935 back in late 2014 (can't recall the mileage now though). It was black and had a bit of turbo whistle. Focusing on the functional aspect it was, like the Astra, decent enough. The engine wasn't the greatest and it was bought with being a "2 month car" in mind to get us on holiday and back (which it did). Don't think it's been taxed/MOTed for 6 years when looking on-line at Vehicle Score/RegiSearch - I bought it with very little inspection (an error in hindsight!) and it deteriorated quickly. It looks like it had only made it to around 145k miles whereas my 159 has made that with far less issues - the only MOT failure was a loose rear-view mirror and hand brake that I should have expected. Annoyingly the MOT advisory for the front tyres being close to the legal limit is for readings over 3mm I think - not sure if they are supposed to highlight from 4mm and below or not. I'd love to move to a Giulia but my wife is "encouraging" me to not get an Alfa (can't afford a Stelvio, are considering a hybrid and there isn't a Giulia Sportwagon!) so my Alfa limit for now will be 2 (a 156 JTS Saloon and the 159 TBi Sportwagon). It may be "mid-life crisis delayed" when I get another chance.