I have touched on this briefly in Fenlander's thread on his 156, but thought it was about time our rather less salubrious example had a thread of its own.
I apologise for the rather poor quality of some of the images. They were taken on a phone that I was trying not to cover in grease and oil, hence, holding with fingertips and not exactly achieving a stable shot.
For the past 5 months or so, a couple of like-minded chums and I have been working on a project in our spare time. We acquired a tidy-ish 156 2.5 V6 on eBay as a runner, with tax and test, and more service history than any car I've bought in my entire life, for £300. The downside was a gearbox that was about to grenade itself. Here she is after the 50 mile schlep home from picking her up. The weather was best described as foul, but she completed the trip without incident, despite a noise from the transmission that made us cringe:
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In the boot was a secondhand gearbox that we'd negotiated from the seller for an extra £90 although we only had his "belief" that it was good. We decided to take the chance.
The trip back up the motorway suggested this dl.dropboxusercontent.com/u/13162748/Alfa4.jpg was in good health, running smoothly and at bang on 90 degrees indicated temperature. We couldn't test the power as the 'box would certainly have quit there and then, but the noise these Busso V6s make even at low revs and light throttle are something a bit special. That said, it slurped a visible chunk of the £30 worth of Unleaded we put in to cover those 50 gently driven miles reminding us diesel drivers how frugal our daily drivers are.
The car sat idle for a month or two while we accumulated funds and found the time to start work. First step was definitely to get that gearbox out and install the replacement. We also decided it would be stupid not to put a new clutch in at the same time, and we were very fortuitous to win a new Valeo 3 part clutch kit on eBay for £80 which was duly delivered and sat with the replacement 'box awaiting fitment.
When it came to it, the job, being completely honest, was a total pig. One of the gearbox bolts required us to fabricate a tool to get it out, and the clearance to get the gearbox off the crankshaft and down out of the car is best described as marginal. There were also a whole host of stupid, illogical bits of design that added 20 mins here, 30 mins there, and which explain in a nutshell why professional maintenance on these cars becomes unrealistic in cost terms when they get down to sub £1k in value. It took us a whole Sunday and about 2/3 of the following one to finish it. Here are some pics:
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dl.dropboxusercontent.com/u/13162748/20130413_131646.jpg (much cheering at this one)
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And the new 'box ready to fit:
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Once it was all back together, it was time to gingerly start her up and move her up the drive. To our collective delight, the new clutch felt superb, and the replacement 'box was indeed OK, and worked in silence. After a quick check of levels and fluids, and letting her get up to temperature it was time to take her for a blast around the farm roads where she is currently living:
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Two things struck. That engine is a masterpiece. I've been driving diesels for so long, I'd completely forgotten what it was like to have an engine that climbs on cam and then pulls harder and harder as the revs build. And the noise makes all the hairs on your neck do funny things. Most V6s sound good, but there's a tune to the Alfa engine that is magical. There is significantly more performance on tap than in my 320d, albeit you have to work a bit harder to access it. We also reconfirmed the suspension operated silently, the brakes were shocking (disuse partly to blame), and the steering nice and direct, with little freeplay.
We parked it up for the night happy and retired to the pub for some well earned celebratory beers.
A few days later, my mate had some time free, and thought it would be wise to check the condition of the timing belt, given it was about due for a change. That proved to be the single most fortuitous action of the entire project:
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So, the next job. Full timing belt kit, and a new water pump while we were in there. Alfas suffer from the VAG problem of the penny pinching specification of plastic impeller water pumps. Sure enough, ours was starting to crack. A good aftermarket metal impeller pump was bought, together with a Gates belt kit and a complete set of idlers and tensioners.
On starting this, it was evident that the reason for the shocking state of the belt was caused by the so-called professional mechanic who had fitted it doing the job incorrectly, and with no small amount of bodgery. Instead of locking the cams with the correct tools and tensioning the belt with the pulleys loose, he'd clearly marked the pulleys with paint, and just slipped the belt on "as is". The result was this:
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On the tensioner side, the belt was as tight as a drum. On the other side, it was so slack it didn't even sit on the crank pulley correctly. It had been riding off the idler, and clumping the cover, hence all the tears and cracks.
The whole lot was binned, and the job done correctly with the proper jigs and the new parts. On the plus side we found an immaculate top end which had clearly never wanted for clean oil in its life.
Jigs in place on rear bank: dl.dropboxusercontent.com/u/13162748/988658_597603100284956_1511014018_n.jpg
And front:
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Pulleys off as per correct procedure. Shiny new water pump just visible below.
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And all done with new belt and idlers:
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All back together and she fired first time. Unfortunately, the idle was all over the place which immediately made us panic. Then we discovered we'd forgotten to plug the throttle body wiring connector in. :-) This fixed the issue.
A quick road test, and our faces fell. The engine was fine. Gutsy and powerful as ever. But a metallic rattle appeared which disappeared with the slightest touch of the clutch pedal. Fearing the prospect of having to take the 'box out again, we parked her up in disgrace and went off and sulked for a while.
A few days later, some initial poking about discovered a slight weep from the clutch slave cylinder which we noted was slightly manky looking when we changed the gearbox. £26 netted a Delphi unit from eBay which we fitted, and the noise has gone.
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We also treated her to an oil and filter change which again showed how utterly moronic some aspects of the car's design are. Most notably that air con pipes prohibit both removal of the oil filter from the engine bay, and socket access to the sump plug! The air-con doesn't work anyway, so will be removed as part of the lightening process covered a little later on.
And that, ladies and gentlemen is where we are. I insured her yesterday for the three of us, and my mate is taxing her on the 1st. Then we will use her locally for a few months and make sure she's fit and healthy.
The plan going forward is to strip out everything that isn't necessary and use her as a trackday toy. She owes us about £800 collectively, which isn't a terrific amount of money for a 192 bhp car with a glorious V6 that is now mechanically sound, and which we've already gained a lot of enjoyment from. There is a sense that we've saved her from the crusher, which is pretty much where she was headed. Few people would have been prepared to invest the time or professional labour costs to get her up to scratch, especially as a road car.
A very long post, but it's been a long process so far. I will keep you informed how the first on-road drives go, probably this weekend. Hopefully not from a breakdown truck en route home :-D
Cheers
DP
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