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2004 Alfa Romeo 156 1.8TS
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Discussion Starter #1
Ever since I bought my '04 1.8TS in January last year, the clutch has been on its last legs - even so, I have done close to 40.000km! I had already started purchasing parts last autumn, including a nice TTV Racing lightweight flywheel. Then I got to talking to a fellow Alfaholic of mine, who's got a few unused 156s sitting around.
The thing is - mine consumes a litre of oil, every 2.000km - and that's running 10W60.. So my friend ended up giving me an offer I had a hard time refusing, on a complete car, with a 2.0TS CF2, that have only done around 75.000km. What's not to like?
Sure, it'll be a heck of a drive-way job, to pull an engine, and I will have to buy an engine crane.. But it should hopefully also mean, that I get my car running for another 4-6 years, at least!

I have created this thread to keep you all updated on the process.
I picked up the car on Thursday afternoon, and started doing a bit of dismantling yesterday. There's still a long way to go, but I'm hoping to have it done, by the end of Easter.
 

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Discussion Starter #3
This is what a solid 8 hours of work got me today. The big 12mm engine mount bolts is going to be an issue - they're well stuck (actually snapped one of them).
Both manifolds removed. Starter removed. Engine turned over by hand - no signs of having sat unused outside for a few years, as it turns over nicely.

Next up, I need to remove the pulley from the power steering pump, but I'm unsure how I block it from spinning whilst loosening the bolts?
Engine hoist and engine stand should arrive next (hopefully all my spare parts as well).
 

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Is your 1.8 TS a CF3 or CF2 model? Bear in mind the blocks are different heights, so bracket from the back of the inlet manifold to the block is specific to the engine, as is the ally casting which holds the ancillaries. If your TS is a CF3, then its likely your manifold & front pipe (twin cats) won't fit the 2.0 engine as they'll sit too close to the sump.

Are you going to use the 2.0 gearbox or 1.8 gearbox?
 

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That's interesting. By the same token, were CF2 manifolds different for 1.8 & 2.0?
2.0 TS CF2 & 2.0 TS CF3 use the same height blocks. But the 1.8 TS CF3 uses a shorter block than the 1.8 TS CF2. I can't remember if 1.8 CF2 & 2.0 CF2 use the same block height or not, so not sure on the manifold. It could be the manifold is the same, the downpipe is different.
 

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2004 Alfa Romeo 156 1.8TS
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Discussion Starter #7 (Edited)
Is your 1.8 TS a CF3 or CF2 model? Bear in mind the blocks are different heights, so bracket from the back of the inlet manifold to the block is specific to the engine, as is the ally casting which holds the ancillaries. If your TS is a CF3, then its likely your manifold & front pipe (twin cats) won't fit the 2.0 engine as they'll sit too close to the sump.

Are you going to use the 2.0 gearbox or 1.8 gearbox?
My 1.8 is a CF3.. The bracket and ally casting is no issue transferring and reusing - but now the exhaust has me worried :(
Where were you when I did my research topic on here a few months back?

I plan on reusing my 1.8 gearbox.

EDIT: You're right on the exhaust. The twin cat section is different for the 1.8 and 2.0. Manifold is the same.
Cheapest option is probably just to modify the manifold and piping from the CF2, as I was planning to do that eventually. Easiest solution is to buy a cheap ebay cat (165£ shipping included)...
 

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Don't buy a cheap ebay cat, they are junk. Is this 2.0 TS donor car you have a CF2 or CF3?
 

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Discussion Starter #9
Don't buy a cheap ebay cat, they are junk. Is this 2.0 TS donor car you have a CF2 or CF3?
The donor is a CF2. So it'll take some modification to fit the manifold and downpipe from that, to my CF3 system. Unless I can just replace the section all the way back to after the cat of the CF2?
 

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The donor is a CF2. So it'll take some modification to fit the manifold and downpipe from that, to my CF3 system. Unless I can just replace the section all the way back to after the cat of the CF2?
I would be tempted to use the CF2 exhaust in its entirety, or at least the manifold, downpipe & mid cat. Although you will have to modify it slightly as your CF3 car needs inputs from 3 lambda sensors, the CF2 only has one lambda boss and it isn't in a position which is useful for you, so you'd need to bung that, and drill into the downpipes in the secondary pipes and weld in two lambda bosses for the primary lambda sensors there. And then after the main cat, you will need to drill and weld in another lambda boss here for your secondary (emissions monitoring) lambda sensor. You will probably need to extend the wiring on the sensor to get it to reach too. It'll run much better without the pre-cats, but you do need to be careful to position the lambda sensors so they are perpendicular to the gas flow and also parallel with the ground.
 

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Discussion Starter #11
I would be tempted to use the CF2 exhaust in its entirety, or at least the manifold, downpipe & mid cat. Although you will have to modify it slightly as your CF3 car needs inputs from 3 lambda sensors, the CF2 only has one lambda boss and it isn't in a position which is useful for you, so you'd need to bung that, and drill into the downpipes in the secondary pipes and weld in two lambda bosses for the primary lambda sensors there. And then after the main cat, you will need to drill and weld in another lambda boss here for your secondary (emissions monitoring) lambda sensor. You will probably need to extend the wiring on the sensor to get it to reach too. It'll run much better without the pre-cats, but you do need to be careful to position the lambda sensors so they are perpendicular to the gas flow and also parallel with the ground.
Thank you, appreciate the advice! Happy to know now, before I get to point of re-assembly, and am unable to make it fit. I will order some bungs and get the exhaust system prepared this week, so it's good to go!
 

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The CF2 set up will produce a bit more noise but I think you may have said you are running a Remus rear silencer. If so, it will be ok but other are a bit loud.

I think O2 sensor bosses are M18x1.5mm.
 

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Discussion Starter #14
The CF2 set up will produce a bit more noise but I think you may have said you are running a Remus rear silencer. If so, it will be ok but other are a bit loud.

I think O2 sensor bosses are M18x1.5mm.
Don't mind the additional noise. It's a quiet car compared to my old Punto with race cat and Ragazzon back box ?

Yes, they are M18*1.5. Have already stopped by a garage on the way home today, to arrange for them to weld it. So just need to drop the exhaust from the car and leave it to them ?
 

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Discussion Starter #15
Not too much progress today, but my engine hoist and engine stand arrived.
Exhaust also removed, so I can drop it off at the workshop tomorrow, for welding.
 

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Discussion Starter #16
Exhaust ready, with new lambda bungs welded in - majority of spare parts arrived today. If all goes well, the donor engine will be on the engine stand tomorrow evening!
 

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Discussion Starter #17
Managed to pull the engine from the donor today. Tomorrow I'll do the belt on it, and prep for install in my car. Then start disassembly and hopefully pull the engine on Tuesday, for this one to go in!
 

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I am in the process of organising engine removal from my 2.0 TS after it ran a big end at a a track day. I was wondering if you had considered dropping the engines with the sub-frame and raising the car body instead of removing from the top?
 

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I am in the process of organising engine removal from my 2.0 TS after it ran a big end at a a track day. I was wondering if you had considered dropping the engines with the sub-frame and raising the car body instead of removing from the top?
I belive that is how it's meant to be done, but to me it'd be a more difficult way, as I'm doing it without access to a lift, in my driveway.
There's not much room to pull it out top, but it's doable.
 
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I've done it both ways and the only way an powertrain is going in from the bottom is with car on a garage ramp.

I'm waiting to see how this works out as I'm considering a CF2 manifold for the JTS to get rid of it's restrictive looking maniverter.
 
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