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peruccy 03-23-2014 07:11 AM

Alfa Romeo 166 V6TB
Hello chaps!

Let me introduce my latest project. It's an Alfa Romeo 166 V6 Turbo '99 with 111000km on the clock. I bought the car for silly money - 600. It has been parked for nearly 5 years, because it had an engine failure. Previous owner said, "it only needs to have the head gaskets replaced". I obviously believed him, how silly of me. All the work on the car will be done by my dad and me. Anyways, here's how she looked when I got her...

First thing I did to her, is to replace the dull velour seats with leather ones I had at home. Also from an AR166

Next thing was to get the engine out, and have a look at the "damage"

Main bearing were all worn. So much for "just a head gasket replacement"...

And of course, the crankshaft was also gone

Luckily the block was OK. So we got a new crankshaft

And got to work. First thing we did, was to enlarge the ports on the heads as much as we could...

Intake port before

Exhaust port before

Intake port after

Exhaust port after

Then the engine was disassembled completely

And after 4hours the bottom end had brand new bearings, o-rings, gaskets, seals exc.

Since we didn't know what has been done to this engine, we decided to also do a major service on the engine. New belts, pulleys, spark plugs exc.

And a "few" other bits ready to go on the car, started to pile up. New radiator, A/C condenser, brake discs + pads front and back, brake cables, brake lines, clutch, gaskets, seals, suspension bushes, cv boots, exc. exc.

New valve guides and bearings for the alternator

3" stainless steel exhaust

To be continued...

Shaggy 03-23-2014 01:44 PM

Wow! Love all the detailed pics. Look forward on following this build. Please keep updating it.

johnnny 03-23-2014 02:51 PM

I'll have to look again when I'm on my pc (now looking from a tablet), but I love what I saw. How come it's a 2 litre turbo, where are you from? I thought only a few markets received those. That's the one I would personally choose for me if the ones I see over here are not mostly wrecked. Like the pictures of basically a complete engine build!

gman2207 03-23-2014 06:02 PM

That looks great, I will own an Alfa myself someday. There's some lovely models over here.

Shaggy 03-24-2014 12:18 AM

What ended up being wrong with the engine? I guess it was more then a head gasket. :)

peruccy 03-24-2014 04:58 PM


@Shaggy: The water pump's propeller broke, which led to overheating, which led to failed head gaskets, which led to crankshaft failure. Furthermore, after owning this car for nearly a year, I realized that the previous owner has not taken care of this car very well. Many many things were broken, half repaired, or not repaired at all - just hidden...

@Johnny: I'm from Slovenia. AFAIK, these 2.0 V6 TB engines were only made for Italian, German and our market. These are getting pretty rare, as not that many "survived". Usually they are dirt cheap to get, because they are neglected by their owners. It's not the cheapest car to maintain, so if you buy it for let's say... 600-800€, and you have to replace the clutch, you're looking at 400€ without labor, so... Drive it as long as it goes, then sell it :-)
But I do agree with you completely. A N/A 3.0 or 3.2 V6 is nice, but sooner or later you get bored with stock HP, and the turbo engine is way better tuning wise. Less effort and money, for more gain. And after owning two AR164 V6TB's and one-of-a-kind AR145 V6 TB (AFAIK, no one else has put this engine in a 145 body), I must admit that I love this engine :-)

I sure miss this car!

Sadly I had to take it apart, because I was unable to register it anymore, because of our stupid laws. What has become of this car? A street race project car, which is still in development at the moment. Here's a sneak preview:
You take one of the lightest stock cars, a standard Trabant which weights only 612kg (mostly out of fiberglass)

You cut the modified front end from a AR145 which can hold a V6 TB engine

And "put" it together :-)

But more on this car some other time...

So... back to the AR166 project...
Rear engine mount was looking shabby, so a new OEM one was ordered

Engine assembling

Replacing gaskets, washers, seals exc. in the engine, gearbox and dif, as we go along. A brand new Valeo clutch was also fitted

Then the engine went in. The second mod to the engine, after head porting, was to fit a bigger intake manifold and intake runners from a 3l. The manifold has 0,5l more capacity, and the intake runners are 7mm bigger. We also replaced CV boots for the half shafts and steering rack.

Brand new OEM lambda probe was fitted, with an adapter which keeps the ECU happy, since there will be no pre-cat or main-cat

Intake runners fitted. AFAIK, no one has yet fitted this manifold or 45mm intake runners (stock are 38mm) on this engine. After that day, I knew why, because it was a pain in the #%! to make them fit...

Since the car sat for so long, all the brakes were seized and shot. So a brand new ATE front 310mm discs and ATE ceramic pads were fitted

And for the rear, we fitted 276mm ATE brake discs and normal ATE pads. (ceramic are not available)

Luckily, this car has no rust at all, since it is zinc-coated. To keep it that way, we added some additional protection

Everything around the engine almost done. Only fluids missing...

Material for a custom home-made exhaust. Stainless steel 3" pipes, hangers, flexi pipe, and a second hand Supersprint backbox

Difference between stock exhaust pipe, and 3" :)

Fluids ready

Just before we started the car, there was a problem. Darn A/C condenser crumbled in my hand as I touched it. So we had to get a new one, together with a new dryer

Looking good next to a shiny new radiator

Home-made middle section of the exhaust

Supersprint mounted. PS: Those orange marks are copper paste :)

After a successful test drive

Both my Alfa's together (I've sold the 164 last year)

Still a lot to come. To be continued...

peruccy 03-30-2014 02:31 AM

Hm... that's strange. I've made a reply a few days ago, but it still hasn't posted on the forum. Was is deleted?

johnnny 03-31-2014 06:20 AM


Originally Posted by peruccy (Post 880805)
Hm... that's strange. I've made a reply a few days ago, but it still hasn't posted on the forum. Was is deleted?

Probably you hit the wrong button, or there was an error. I'm subscribed to the threaad, so it would inform me if the new post was actually posted. If you have put in more images, bad luck...

So, how's the build going? Anything new? Where did you manage to find this car? What state is the turbo in?

peruccy 03-31-2014 02:10 PM

Duplicate post

peruccy 04-02-2014 03:18 PM

I am certain I didn't hit the wrong button, because two days ago, I made a new reply with plenty of new pics. But again, it has not been posted. It said, please wait for the moderator to check your post...

johnnny 04-07-2014 09:34 AM

Hm, in that case I hope that we have a mod checking out this thread and that the post will go live... We want the pics! :)

peruccy 04-13-2014 11:03 AM

Duplicate post

peruccy 04-13-2014 11:09 AM

Yeah, me too! I just made my third and final attempt on replying, and as soon as I add some pictures, again I got the "moderator must check..." message. I just hope that if eventually, someone does allow my posts, that they won't add all three duplicate posts because that would look silly...

johnnny 04-14-2014 11:29 AM

Shaggy pls check this out, we know you want to see the images too!

Shaggy 04-17-2014 01:42 PM

Yea, sorry. For some reason it was moderating your post. You can see them now. Build is looking good peruccy. Keep adding to it!

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