Gbinsb - GTV V6 TB project

[gbinsb 22]

Hi,

 

I will start my project topic by showing some of the mods that we have done on the TB so far.

 

- Installed pressure gauge instead of the clock.

- Painted center console

- Phase 2 black leather interior

- Brembo big brake calipers from a alfa 166

- 147 GTA rear brake disk modification

- Bilstein B6 & Eibach pro springs

- HKS SSQV dump valve

- 200 cell sports cat

- Quad exhaust (home build) + ragazzon mini silencer

- RF remote control with original alarm system

- GT cloverleaf 18" wheels

- interior ceiling refinished with alcantara

- cleaned engine bay

- Alfa 155 2.5 v6 camshafts

- Magnecor KV85 HT leads + Denso Iridium sparkplugs

- squadra chips

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

We did many more things like general maintenance, clutch replacement and stuff like that. My new things to modify I will describe on this topic. At the moment a engine rebuild

 

 

 

[Paso 239]

Park this beauty in our virtual garage as well!

[Damgreg 94]

147 rear brake disc modification? Tell us more about that!

I was on the go to adapt the 166 rear brake calipers with 159 rear brake discs...

[Thanos 193]

I think the easier and cheapest way is to use the 295mm brake disks from a Fiat Ulysse with the OEM gtv rear caliper.

An adapter is very simple to make..

[kunev 131]

Great car and modifications  !

What discs did you use for front brake upgrade?

I see gearbox picture, but no any related info?

[charlee 314]

Great work so far. Love it   Is that a VDO gauge? Did you get those 155 cams new?

 

 

I think the easier and cheapest way is to use the 295mm brake disks from a Fiat Ulysse with the OEM gtv rear caliper.

An adapter is very simple to make..

 

Sounds like an idea Those discs are not vented?

[Thanos 193]

not vented..

They are 10mm thick and they have a bolt pattern of 5x98. 

Almost plug and play...

[charlee 314]

Well, yeah. What about adaptors? Has anyone done this?

[Joris 136]

Yes Fabian did them on my Spider

[charlee 314]

Oh, great. Do you miss your Spider?

[gbinsb 22]

147 rear brake disc modification? Tell us more about that!

I was on the go to adapt the 166 rear brake calipers with 159 rear brake discs...

 

A dutch guy made some adapters for the OEM brake calipers to get a bigger offset. I used the 147 GTA rear brake discs. just for the looks

 

 

 

 

 

 

 

 

 

Great car and modifications  !

What discs did you use for front brake upgrade?

I see gearbox picture, but no any related info?

 

Front brakes are Brembo GT sport 305mm discs from a GTV 3.0 24V. The gearbox has been opened up to replace some synchomess rings.

 

Great work so far. Love it   Is that a VDO gauge? Did you get those 155 cams new?

 

Yes its a VDO gauge, pain in the ass to install in a P1.. The 155 cams are not new, but over 20 years old but they look like new and after measurements they are within specs!

 

Yes Fabian did them on my Spider

 

Fabian is a very adaptive guy, he can adapt almost anything

[gbinsb 22]

We started the disassembly couple of weeks ago. The crankshaft has been damaged a little bit. So this has been send to a specialist, just like the heads and cylinders.

 

 

 

 

 

 

 

 

 

 

 

after this we have cleaned the engine

 

 

[gbinsb 22]

So we proceeded to rebuild the engine with the refurbished parts. we cleaned the engine pretty good

 

 

no sludge left.

 

 

Cleaned the pistons and rods, and installed new piston rings.

 

 

new valve guides, reseated the valves and flattened the gasket surface.

 

 

Honed the cylinders.

 

 

The crankshaft was polished and didn't need special oversized bearings, but..

 

 

The rods in my engine have oil sprayers in the rods.

 

 

The new original bearings don't have the oil hole anymore.. It seems that Alfa revised the rods in the 90's and leave out the oil spraying hole. So also the new bearing don't have the hole anymore.

 

 

I then bough the Glyco after marked bearings, they still have the hole SO now I can still use this function.

 

 

Installed the cylinders with pistons.

 

 

When we installed the main bearing caps, I was a bit confused. The engine overhaul manual wrote 25nm and 79 degrease angle torque. The alfa repair manual wrote 84 - 93 nm and talked about lock nuts with 25 nm. When I disassembled the engine I didn't see any extra lock nuts, but my 2 middle bearings where not round but eclipse shape. so that was not good, probably the nuts where not tightened properly because of the confusion with a previous rebuild.

 

I found out that alfa used lock nuts in the past on the 164 v6 engine, but started using the angle torque on all new engines and leave the lock nuts. So that is what I did, 25 nm and 79 degrees. I measured roughly about 122 - 136 nm.

 

 

I started also cleaning the auxiliary parts so that we can fit the heads with nice clean parts.

 

 

[Paso 239]

Great work on rear breaks! Keep us posted!

[jonalfaspider 107]

wow proper hardcore, fantastic work well done

 

i am replacing my headliner, is it fairly straight forward or do i have to remove anything like the rear parcel shelf?

[charlee 314]

You don't need to remove the shelf, only the A-pillar covers

[gbinsb 22]

0Finally after 8 years of abandoning this project, the beginning of this year I continued. It’s driving again and has MoT. I also did a A/C delete, walboro 255l fuel pump, TD05 with 16G conversion turbo, FMIC, bigger radiator, Q2 diff with enforced clutch and a AFM to MAF conversion. Now I have to dial in the bigger turbo

 

 

[kunev 131]

This is really a good update to be read , especially from performance fanatic perspective ! Everything look very clean, not only the engine and car .

 

Why did you delete the AC ? For me personally, AC is one of the most significant option a car can have (speaking from point of almost all my driving experience done in warm months in non-working AC environment ). I associate intentional AC delete with very seriously modified car likely intended for racing. On my other car, which have been very seriously modified, I insisted on restoring of AC system, which have missed and cut parts.

I see also likely aftermarket wastegate actuator, blow-off valve and oil cooler 

What is intercooler's core size? What is this clutch? It is just stronger pressure plate or something more special?

TD05 from earlier 164 TB I guess? Do you know 16G compressor wheel dimensions? I prefer upgrading with something more modern, but that is much easier, if you source everything needed from 164 TB.

I wish you sooner completion and waiting for updates and impressions  

[gbinsb 22]

Hello Kunev,

 

Initially I figured that my AC lines and pump were in the way of the inter cooler and bigger radiator. So I removed the lines and all AC stuff. Replaced the AC pulley with a bigger pulley for the steering pump and fabricated the new steering pump support. I can use the standard aux belt. Afterwords I might have saved the AC, or rerouted the lines like I did with the steeringpump line. I made some room for the radiator by adjusting the support. So maybe in the future.. 

 

I actually don’t remember the core size of my intercooler, tube is 57mm diameter. But much bigger won’t fit nice imo.

 

the TD05 was from the earlier 164 correct. I had most parts, so it fitted on the stock support and 60mm downpipe exhaust. That is pretty convenient. Only thing I had to adjust was oil return pipe. Connection on the oil carter was different from my GTV and 164 engine. I rebuilded it to the 16G big compressor. Unfortunately I didn’t choose for the billet compressor wheel at that time, but that’s ok for now. Turbo is good, for at least 300hp. I used kinugawa actuator, this works perfectly, the original was gone already on my Garrett turbo. I had to fabricate my own bracket to fit the 16G compressor housing.

 

The blowoff valve is from HKS, and doing a perfect job. Much better than the Forge crap. And I used a Mocal oil cooler as a replacement for the Stock rusted one.

 

For the clutch, all I know it holds 35% more than stock. See pictures below for the difference. It has been over 8 years that I purchased it, so i don’t know the fine details anymore 

[Carlo 32]

Great you made good progress this year!

 

I installed exactly the same intercooler: core is L550mm x H180mm and I think 65mm thick with indeed 57mm connecting pipes.

 

I used D55x1,5mm stainless pipes and bents together with 54mm silicon hoses.

 

I klocked the exit from the compressor much more downwards so that the intercooler pipe goes under the airco compressor and its pipes.

The pressure hose from the steeeing pump rerouted in front of the coolers (in the front bumper) to save some space.

[kunev 131]

So now you use bigger pulley for power steering pump i.e. less rpm of it per same engine rpm, right?

That big 16G compressor wheel is significantly bigger in size than original one looking at dimensions, which you provide.

TD05 turbine wheel also must be bigger than original TB25. After quick search I found some wheel dimensions for TD05H 49/55,6mm and for T25 41,7/53mm (exducer/inducer), but not sure if they are representative and accurate for particular turbos here. Earlier 164 TB with Mitsubishi TD05H-12B must drive very differently from later ones with Garrett TB2538