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Discussion Starter #1 (Edited)
With the sun shining and temperatures on the up, time has come to get my 156 back on the road. She has been SORN'ed for about 15 months, sitting outside and latterly pushed into the new garage.

When she was sorned, she was in fairly good shape having just had quite a major service at NJS Pershore.

So this morning I put a new battery on her, stuck some new petrol in her and she fired up straight away! God I have missed that sound...!

A quick drive down the (private) lane, and everything is working perfectly. Not bad considering the length of time she has sat still.

I have a list of jobs to do on her before taxing and insuring again:

1. replace front lower radiator pipe
2. clean out CDA
3. Repair fog light housing which has fallen apart
4. Repaint front scuttle and wiper arms
5. Leaking rear cam cover gasket replace
6. Clean up manifold inlet pipes and fit my Italian themed rubbers
7. Refit main cats (currently running a decat pipe with silencer which is a bit quiet)
8. Fit new wheel arch liners
9. Sort out rust on front wing and repaint
10. Replace all coolant hoses
11. Renew brake fluid
12. Oil change
13. Check for other rust in floor pan
14. Wheel refurb
15. Seal underneath
16. Repaint calipers
17. Replace door check straps


I'm going to try and do all myself. I'm more used to heavy mechanics on the Defender, but inspired by a certain Resolution on the 159 forum, I'm feeling confident .....

I've got all the bits and pieces I need now for the above.

So, I've given her a quick jet wash off and moved into prime central location in the garage, ready for action....

After 15 months in an XC90, I am so looking forward to getting her back on the road. I'd forgotten how nice sitting low down is....!
 

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With the sun shining and temperatures on the up, time has come to get my 156 back on the road. She has been SORN'ed for about 15 months, sitting outside and latterly pushed into the new garage.

When she was sorned, she was in fairly good shape having just had quite a major service at NJS Pershore.

So this morning I put a new battery on her, stuck some new petrol in her and she fired up straight away! God I have missed that sound...!

A quick drive down the (private) lane, and everything is working perfectly. Not bad considering the length of time she has sat still.

I have a list of jobs to do on her before taxing and insuring again:

1. replace front lower radiator pipe
2. clean out CDA
3. Repair fog light housing which has fallen apart
4. Repaint front scuttle and wiper arms
5. Leaking rear cam cover gasket replace
6. Clean up manifold inlet pipes and fit my Italian themed rubbers
7. Refit main cats (currently running a decat pipe with silencer which is a bit quiet)
8. Fit new wheel arch liners
9. Sort out rust on front wing and repaint
10. Replace all coolant hoses
11. Renew brake fluid
12. Oil change
13. Check for other rust in floor pan
14. Wheel refurb
15. Seal underneath
16. Repaint calipers
17. Replace door check straps


I'm going to try and do all myself. I'm more used to heavy mechanics on the Defender, but inspired by a certain Resolution on the 159 forum, I'm feeling confident .....

I've got all the bits and pieces I need now for the above.

So, I've given her a quick jet wash off and moved into prime central location in the garage, ready for action....

After 15 months in an XC90, I am so looking forward to getting her back on the road. I'd forgotten how nice sitting low down is....!
Let me know when you are getting close mine is due a full body respray and engine overhaul in April at NJS.
 

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Discussion Starter #5
Let me know when you are getting close mine is due a full body respray and engine overhaul in April at NJS.
I thought yours had recently had engine work I the last couple years? Are NJS doing /organising the respray?

Good little list! What was the reason for being SORN'd for 15 months?
Oh she just needed a rest. I wanted to get these jobs done, but never had the time, and she was starting to look tatty. Now I've got a bit more time and a garage to work in. Also I had a bad back and the sitting upright position in the XC90 was far more comfortable and better for it.
 
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I thought yours had recently had engine work I the last couple years? Are NJS doing /organising the respray?



Oh she just needed a rest. I wanted to get these jobs done, but never had the time, and she was starting to look tatty. Now I've got a bit more time and a garage to work in. Also I had a bad back and the sitting upright position in the XC90 was far more comfortable and better for it.
I did, in 2012 but somewhere along the way one of my pistons overheated and now it burns oil so its back for new pistons, rings and whilst it's there cambelt etc. Not decided whether to leave it with NJS for a full overhaul, check suspension, clutch and full body respray or have the respray locally. Awaiting confirmation on a delivery date (and price) for a Giulia QV before I make the final decision on the respray.
 

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Discussion Starter #7
Also got a split inner CV boot to deal with.

Can anyone advise where the can get the bolts that hold the wing to the bumper?

Also the small screws/catches that hold the metal grills into the bumper?
 

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Discussion Starter #8
Well some good progress over the last couple of days....

Undertray and bumper off


Bumper cracks and mounting brackets repaired with fibreglass. Just need to rub down the filler on the underside.


Fog light housing siliconed in place.
Headlight mounting brackets repaired (one was broken)
Front calipers, rubbed down and painted and new graphics.

Engine plenum off, and covers prepped and painted.

Chrome intake runners cleaned and polished. They are actually in excellent condition - not bad considering they have never been refurbed. My son, Harry did a lot of that work!



Ordered a metal undertray from Alfistinet as the one that came off, is so badly damaged again..... This will be the 4th undertray in my ownership!
 

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Discussion Starter #9
Rear bank rocker cover removed. I now know why it was leaking, the front bolts were all loose.

Coolant rubber pipes and the steel pipe under the rad all replaced

New thermostat should be here tomorrow and will pop a new one

Will start the clean up on the engine tomorrow and fit the new rocker cover gasket.

The front wings - the rust is on the surface and not from the inside out as suspected (normal). So I'll get the body shop just to rub them down and repaint and seal the inside.

Some questions!

Any tips on fitting the rocket cover gasket? I noticed when I took the current one off there was a little bead of black silicon under it. Is this needed?

The aircon radiator is pretty badly damaged and caked in oil (when the oil cooler let go I think and a pheasant went through the front grill at 80mph). Worth replacing that? Any tips on how to do that, and where to get the rad from?
 

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Discussion Starter #10
Oh, another question....

Do the fuel injectors just pull out? Is there a seal there that will need replacing when I refit them?

And another.....I presume that is the fuel filter behind the rear bank against the bulkhead? Is it worth replacing?
 

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Discussion Starter #11
Found a new aircon radiator on Alfaworkshop - £177!!!

Anyone know where I can get one cheaper?..er much cheaper?
 

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Great progress so far! :thumbup:
I will try and answer some questions: If you use genuine cam cover gaskets you do not need any silicon except a tiny amount in the sharp corners on either side of the curvature where they go over the cam seal carrier.
The fuel injectors just pull out with a bit of gentle wiggling after you removed the fuel rail. There is an o-ring that seals against the base plates which can be replaced as well as the one on top. You can propably find a set from Mr Injector uk.
I don't know what you're referring to regarding the fuel filter but there is none in the engine bay. The fuel filter is integrated into the pump.

Best regards,
Philipp
 

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Great progress you're making. If your A/C is still holding gas then you'll need to call a mobile fitter who can vacuum the system for you. As you'll see there are just two bolts to undo which hold the high and low pressure pipes in place. One bolt was corroded in place on mine so I drilled it out...no worries of retapping a thread as you'll be using a replacement rad. It's worth sealing the pipes whilst disconnected to avoid introducing moisture into the system. The dryer is part of the rad so where ever you source it from you'll only need the one unit. You may want to replace the o rings...mine were good to go again though.
 

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Discussion Starter #14
Great progress so far! :thumbup:
I will try and answer some questions: If you use genuine cam cover gaskets you do not need any silicon except a tiny amount in the sharp corners on either side of the curvature where they go over the cam seal carrier.
The fuel injectors just pull out with a bit of gentle wiggling after you removed the fuel rail. There is an o-ring that seals against the base plates which can be replaced as well as the one on top. You can propably find a set from Mr Injector uk.
I don't know what you're referring to regarding the fuel filter but there is none in the engine bay. The fuel filter is integrated into the pump.

Best regards,
Philipp
Oh that's good to know that there isn't a fuel filter to change. Not sure what I was looking at then...!

Is there a particular type/brand of silicon to use on the gasket (it is an original one by the way).

thank you!
 

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Discussion Starter #15
Great progress you're making. If your A/C is still holding gas then you'll need to call a mobile fitter who can vacuum the system for you. As you'll see there are just two bolts to undo which hold the high and low pressure pipes in place. One bolt was corroded in place on mine so I drilled it out...no worries of retapping a thread as you'll be using a replacement rad. It's worth sealing the pipes whilst disconnected to avoid introducing moisture into the system. The dryer is part of the rad so where ever you source it from you'll only need the one unit. You may want to replace the o rings...mine were good to go again though.
Thanks for the info. Is it not possible to do this without getting an aircon fitter out though?
 

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Thanks for the info. Is it not possible to do this without getting an aircon fitter out though?
Its highly illegal to just let all the aircon gas out, so thats not recommended. Very bad for the environment.
 

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Discussion Starter #17
Hmm, how do I know if there is any in there......wouldn't want to get someone out to tell me it was empty...! The aircon was just about working when I laid it up.
 

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Hmm, how do I know if there is any in there......wouldn't want to get someone out to tell me it was empty...! The aircon was just about working when I laid it up.
Unless there's a definite leak and it's all escaped (as it did with mine) then I'd want to get it vacuumed. Regardless of how cold the air is, if you can hear the clutch on the compressor engaging (it 'clicks' on and off when you turn it on) then there's still gas in the system. A fail safe prevents the compressor from switching if the system is exhausted of gas. I don't know how many chemicals are in it, but I wouldn't want it in my face when I disconnected the pipes from the rad.
 

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Discussion Starter #19
What's the torque level for the rocker cover bolts? I've seen many different suggestions....

Thanks
 

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Discussion Starter #20 (Edited)
Bit more progress, although work keeps getting in the way grrr.

Wheels back from being powder coated (great service from Hereford Alloy Wheel Solutions btw) - and new centre caps fitted.

Rear brake calipers cleaned up and painted.

Engine started going back together, but now waiting on getting the injectors back (sent away for a service).

New thermostat fitted by my little helper.

New undertray from Alfisti.net just arrived along with some black side indicators (they came with orange LED bulbs - how do stop them flashing so fast....?)

Fuel rails painted.

Now I've got some wheels to get it back on the ground I think I'm going to tackle the inner CV boot next.
 

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