Alfa Romeo 164 Twinspark Super

[Spinakerr]

With winter drawing in and the garage being used for non-vehicle storage, I took the only logical course of action for the 164 in autumn: purchase a new interior.

The car came with a smart black interior in great condition, but it never felt quite right - seatbelts occasionally snagged, the sides rubbed against the transmission tunnel at extremes and it sat too high, with my hair brushing the ceiling. This was particularly irksome for my girlfriend, who loves driving the car but couldn't comfortably reach the pedals.

I was looking to make modifications and treat the leather to ensure it aged gracefully, but when a 164 interior in great condition came up I contacted the fellow owner and a deal was struck.

Here was the previous interior, note the manual controls:

IMAG4107_zps0szpbijz by James Vincent, on Flickr

One small issue was the location - Yorkshire is quite a stretch and as the Alfa hadn't turned a wheel in three weeks I was worried it might not make it without an issue. The first frost of the year and the car being caked in sand from a neighbour's inconsiderate (and non-notified) sandblasting added to my trepidation.

IMAG4106_zps9knsing1 by James Vincent, on Flickr

Seaside effect in central London. Thanks next door, much appreciated!

IMAG4108_zps81afwhin by James Vincent, on Flickr

I gritted my teeth, cleaned the glass and wipers to prevent scratches and turned the key at 9am. Clearly the 164 wanted to get going, and we were in Yorkshire 3.5 hours later. Fantastic variety of scenery:

IMAG4115_zpsiy3m6nck by James Vincent, on Flickr

IMAG4117_zpssmtp5hmc by James Vincent, on Flickr

The seller was a great chap and true Alfa fanatic, with two 164s. Luckily, he had agreed to help me fit the seats on the driveway. Perforated leather, fully electric, with lumbar support and the all-important Alfa logo on the seat backs:

IMAG4120_zpsw7zu56vq by James Vincent, on Flickr

There are even heated seat controls - a challenge for a another day.

IMAG4121_zpsxclbcllm by James Vincent, on Flickr

The seller identified my existing set as a 166 set, hence a similar design and the matching bolt patterns. Mystery solved, but my previous 'disposable' notion had just flipped to 'irreplaceable Alfa part awaiting another fanatic'.

Four 6mm allen bolts for the front seats, though one required some persuasion:

IMAG4125_zpsblzp7ir3 by James Vincent, on Flickr

The rears were similarly easy - two 10mm bolts, three screws and two pairs of hands made it easy work. The seller had also done this many times, so this was but a few minutes:

IMAG4126_zps0yhf1sx8 by James Vincent, on Flickr

Twenty years of junk underneath the seats. Hopefully the weight saving here will offset the motors in the new seats.

IMAG4127_zpsokefsgsy by James Vincent, on Flickr

You can see at the bottom of this picture the existing connectors for the electric motors. Unfortunately, no plugs for the heater elements could be found so we'll have to pick that up later.

IMAG4128_zps7fwc0dpi by James Vincent, on Flickr

Getting the seats in, we found the passenger recline button was only working one way, but fortunately disassembling the controls and removing some sand (coincidentally in the new set) freed up the contacts and we soon had full functionality.

IMAG4129_zpsxs6svspu by James Vincent, on Flickr

IMAG4130_zpsgllokjrg by James Vincent, on Flickr

Bolts in, perfect fit. With the light fading, a decision had to be made about the 166 set. It transpires you can actually fit two sets in a single 164 (apologies for blurry photo):

IMAG4134_zpsjkje9iw1 by James Vincent, on Flickr

Lumbar support and the electric adjustments finally got the comfort level correct for the 4 hour return trip.

Almost 400 miles in one day, and the 164 didn't miss a beat. Surely some further rewards are in order for such reliability!

IMAG4137_zps7fbo9tb0 by James Vincent, on Flickr

Hopefully I can find a good home for the old set in short order, as space is at premium.

Edited by Spinakerr on Sunday 6th November 22:25

Edited by Spinakerr on Sunday 16th July 15:56

[Spinakerr]

As the first owners were an Alfa dealer and then the dealer's son, I suspect it was swapped for a 166 set early on - certainly the main owner, who had it for 12 years, had no idea they were incorrect.

Had the day off today for DIY so took the 164 out and about in the daylight - here's some proper photos of the new set, with just enough patina to ensure they fit the car.





Right, best get back to the plans for proper rust proofing and mechanical work. Idle is still irregular, for those that are following it; the seats unfortunately had no effect.

[Spinakerr]

Minor update today - I found some spare fuses for the (handily illuminated) fusebox, and checked all the others for good measure:

IMAG4247_zpsj3sbiz4d by James Vincent, on Flickr

I then cleaned a number of contacts and wiggled a few connectors, rewarded by an amber beacon of joy:

IMAG4248_zps31danmfu by James Vincent, on Flickr

Working heated seats! They're not cycling perfectly, but a revelation for the posterior nonetheless.

Also experienced a 'high idle' for 5 minutes, which might be a further symptom of the erratic idle culprit - the throttle position sensor, as the idle control valve is working correctly.

Edited by Spinakerr on Sunday 16th July 15:57

[Spinakerr]

GrantB5 said:

If you do need anything give me a message and I can have a word with one of the guys if its of any use.

Thanks! Currently trying to track down cam cover gaskets and the correct Bosch alternator.

164s in Madiera? Sounds like an excuse to visit a warmer climate! I'm glad they survived the 2010 floods.

This is the first car I've had with heated seats that actually work, so it's definitely my preferred winter transport. All this city driving it showing on the elderly clutch though, so that's the next item to be changed. It never ends...

[Spinakerr]

Thank you both - have PMed you Grant and I have managed to track down a reconditioned alternator - looks like many Bosch variants will fit, just need to match the bolt positions and output.

The 164 got me safely to Somerset today, with a bootfull of accumulated trinkets and gifts. For the Alfa. Also some presents for the family.

Hopefully the next few days will afford me some tinkering time in daylight.

[Spinakerr]

First of the new additions today - Bosch TPS. A potential culprit for the uneven idle as it bolts on to the Dellorto butterfly at the top of the intake manifold, and if not at 100% could be causing the feedback loop. A quick test revealed its maximum voltage opening to actually be only marginally off spec, not bad for 20 years.

Luckily for Bosch components the part number is stamped clearly, and 0 280 122 001 was also used in the Punto GT, so an unused replacement was sourced for a few pounds.

Post turkey and pudding, I swapped a Christmas sunset walk for a TPS swap. Awkward access 7mm bolts required all the socket set accessories:

20161225_164857_zpsltgvebrz by James Vincent, on Flickr

Old and new part. Again tested them side by side, only a slight difference in operation but I put the new one in any way:

20161225_170236_zpsftmwpna4 by James Vincent, on Flickr

Of course, no difference to the idle, but I now have a spare.

Discussing the matter with my dad and he said on any older car it sounds like a stuck valve, especially at the exhaust end, with a pattern of 1-2 1-2 1-2 1 putters, always an odd number. But with a modern engine this could be a number of items in the loop given the ECU and all the items mentioned earlier in the thread.

Injector number 2 seems to have evidence now of fuel leakage, in addition to the trademark blackening of leaking exhaust gases and oil up the engine:

20161225_163740_zpsysnnqswt by James Vincent, on Flickr

More to follow tomorrow.

Edited by Spinakerr on Sunday 16th July 15:59

[Spinakerr]

A whole day, good weather and a working kettle gave me perfect conditions for the long-planned injector, inlet and fuel line refresh.

Firstly, a before pic of the fueling situation. In evidence are the probable leaking injectors and manifold rubbers, 110k EV1 Bosch injectors that are slightly loose and original fuel lines cracked with age.

20161226_100956_zpsqlgttcdn by James Vincent, on Flickr

Injectors unclipped, earths unbolted and the idle control valve moved carefully to one side:

20161226_101736_zpsrqsadacm by James Vincent, on Flickr

Fortunately the EV1s were easily pulled out once three bolts holding the fuel rail were removed:

20161226_104621_zpstosmcnac by James Vincent, on Flickr

The all came out intact, though the O rings were very tough and some evidence of fuel making it past them at the bottom. A recurring bane of mine, the 'single fit' clamps, were removed with great satisfaction and the rail came free. Rags soaked up the resultant fuel.

Next, the plastic intake manifold. Various breathers and hoses were disconnected, and then I removed the main 'S' intake and used a 6mm hex attachment to remove the Dellorto. Time to clean this side of the butterfly:

20161226_114753_zpsxo37iilj by James Vincent, on Flickr

The intake was in generally good order:

20161226_114801_zpsb60cuzni by James Vincent, on Flickr

Twenty years of use evident on the rubber, and yet more of my nemesis: the unadjustable hose clips:

20161226_122432_zps76hdwufc by James Vincent, on Flickr

Here's the end-of-life fuel line:

20161226_140552_zpsxhxuspr6 by James Vincent, on Flickr

The most troublesome bolts were the two 17mm item only accessible from below. Some blind socket-setting later, and reflex-testing catches of the bolts, allowed the intake to pull up and and out of the 'manicottos':

20161226_142533_zps3mzxfn0b by James Vincent, on Flickr

Pretty grimy but entirely in one piece and no cracks:

20161226_142812_zpsjlhrnwlx by James Vincent, on Flickr

Some correct 7.5mm SAE30R9 fuel hose was cut to replace the accessible sections, and new hose clamps added:

20161226_153512_zpsqcesnkaj by James Vincent, on Flickr

Fitted:

20161226_154541_zpshr3coo8k by James Vincent, on Flickr

After a few months of searching with the number 60593553 embedded in my retina, I finally sourced some new old stock from Italy:

20161226_162721_zpsgmm3pjt3 by James Vincent, on Flickr

The new 'manicottos' in place with some mikalor clamps, and the intake carefully cleaned before refitting:
20161226_165535_zpssephbd2j by James Vincent, on Flickr

Right, that was the straightforward replacement section completed. The injectors required more research and preparation. There are endless reports on replacement injectors and upgrades, but the one written on an Alfa board by a 164 owner replacing early 90s Bosch single-outlet items (EV1) with later Bosch quad-outlet items (EV6) was my main reference point. This was born out of owners in countries using E85 fuel keeping their cars running, but many others have seen other benefits.

If carefully matched to a slight increase vs the original output, these should give slight benefits in economy and performance without any other modification as they are the same size and fitment. I'll let you google the rest and grab a pitchfork if you wish for the endless discussion on it. The replacement for my units, yellow topped 0 280 150 702 were 0 280 155 746/702/712, going from 150cc per minute to 200. I ended up finding the 712 (blue) variant from a Vauxhall Omega, and had them refurbished.
20161226_104621_zpstosmcnac by James Vincent, on Flickr

Injector outputs clearly visible here:

20161226_104630_zpsilmlnhun by James Vincent, on Flickr

Everything went back together in short order, and after checking, double checking and triple checking the fuel lines I tentatively put the key in at ignition stage and let the pumps refuel the rail and prime for a few minutes. No leaks. Phew. I turned the key and - success! The twinspark burst into life with a customary growl, and settled into its warm-up idle.

As I'm due to do a few hundred miles this week, I thought it prudent to take it for a local amble before dinner. My dad came with me. 'Do I need hat and gloves?' 'No Dad, I got the heated seats working' I chuckled.

Winding our way through Somerset roads, the car was driving well and warming up to temperature when the idle could be checked. It seems to be smoother when letting off the accelerator, but nothing earth-shattering. As I approached a roundabout and came to a stop, the engine died. The heady perfume of super unleaded (circa 2016) permeated the cabin. Luckily the engine restarted and I gently nudged it, as 50% power, to a nearby petrol station.

Opening the bonnet revealed petrol all over the hot engine. Not ideal, so we let it cool down and ensured everything was off. From the spray pattern on the bonnet and the position of the offside injector it is clear it had come free at the top of the rail. In the below photo you should be able to see some metal as the bottom of the injector:

20161226_181057_zpslmopevot by James Vincent, on Flickr

My dad said he should have brought his hat and gloves, as it was cold. As always, he was right.

Backup arrived in a warm Mondeo laden with tools and torches (and hats and gloves). We mopped up the petrol and unclipped the injectors, then deduced from comparison with the original photos that one of the top clips to the rail was on incorrectly, allowing the injector to work free and leak with engine vibration. We put the clips in correctly, let the pumps prime again and turned the key - once again the engine leapt into life and we made worked it through the rev range to ensure it was all secure - done.

Slightly later than expected I parked up and listened. Smooth. Quiet. No hiccups or odd-numbered pops at the exhaust with the engine fully warmed. Could I finally have cured the uneven idle? Perhaps I was just delusional from a day in the cold and too much tea.

Dinner beckoned so better pictures, confirmation of the success and cosmetic finishing to follow tomorrow.

Edited by Spinakerr on Sunday 16th July 16:08

[Spinakerr]

Thanks guys - I'm glad this running restoration is of interest to some! It's strange how this car has completely captured my attention, time and budget. The challenge and the exhaust note has done its work.

A frostier morning made me glad I stuck it out yesterday, and unfortunately I didn't get time to tidy the wiring loom:

20161227_094821_001_zpsvpf8v7va by James Vincent, on Flickr

For reference, the injectors should clip in securely as below. I had them on incorrectly, leading to the near-immolation yesterday evening, so I heavily recommend taking 'before' photos to refer to.

20161227_145948_zpsxatbfdow by James Vincent, on Flickr

I couldn't resist taking some carb cleaner to the engine now that it was all back together:

20161227_122231_zpsuj2aluft by James Vincent, on Flickr

Next stop - the New Forest, 100 miles away. The A303 was holding its traditional 'festive soltice' of a gigantic traffic jam, so I chose a non-A road route criss-crossing the countryside.

The B3081 with no traffic is a joy - great scenery, hairpin climbs, good visibility and relatively good road surface. I had to stop as a pink sunset spilled across the sky and the stars came out.

20161227_162129_zpsd4yrnpby by James Vincent, on Flickr

Don't worry, I only use the fog lights to flash oncoming motorists with their fog lights on (Partridge style).

20161227_162149_zps7a2v449r by James Vincent, on Flickr

The Alfa felt quite a bit more responsive but noticeably much smoother when letting my foot off the accelerator. I think there must have been problems with the previous injectors/hoses as I wasn't expecting this much of an improvement!

Most importantly, the route gave dozens of stopping places at junctions and roundabouts. At every stage - smooth idle. No hiccups, no uneveness or searching - just a smooth, quiet idle. Fantastic, I may have finally done it!

Of course, the Doubt Centre in my brain has grown from the shed in twenties to a thriving metroplis in my early thirties, so I'll keep driving and see how it goes...

Edited by Spinakerr on Sunday 16th July 16:10

[Spinakerr]

The Alfa continues to march imperiously through the winter, a delightfully smooth idle and heated seats making each journey a little more enjoyable.

Last weekend it shrugged off an impressive frost shell to start without drama:

20161229_112735_zpsim0valwa by James Vincent, on Flickr

Heated wing mirrors have also decided to start working, which on any other car would be unexpected. I'm sure they will stop again soon.

Typical countryside motoring entails a dashboard of green/amber vehicular hieroglyphics:

20170120_210622_zpsdlaenpn2 by James Vincent, on Flickr

And when there's a tube strike, the skeletal clutch just about holds me through London traffic to evening events in the centre:

20170115_180010_zpse66ng7zu by James Vincent, on Flickr

Next up for Feb - new brake lines, an oil change and an MOT. I'm sure it will be fine.

Edited by Spinakerr on Sunday 16th July 16:12

[Spinakerr]

MrMoonyMan said:

On my 9000 I have the optional heated washer fluid (which provides a satisfying steam when sprayed on cold mornings) as well as heated seats and mirrors. Makes for a lovely cross country trip to work on these frosty mornings.

Heated washer jets? Goodness the Trolls got it right with the 9000. Most comfortable seats in existence, let's keep these Type 4's going.

MJK 24 said:

Your parts sourcing ingenuity reminds me of trying to run a 1985 Alfa Sprint in the late 90's. Parts could be rather difficult to source for what was then only a 12 year old car based on the very common Alfasud that sold in vastly higher volumes than the 164.

Indeed, it's all part of the Alfa experience. I saw a Sprint with a 24v V6 in it this evening, the emotions of which I am still trying to process. Will take pictures tomorrow for the PH opinion.

Paul S4 said:

I would be very tempted to get that alloy cam cover polished up, then maybe get the exhaust manifolds nickel/chrome plated...!!

Manifold powder coating should be coming free of charge from a friend, the rest I like to keep clean and close to original at present. We'll see.

Yesterday I thought I would replace the perished top engine mounts. One small bush in the engine, a larger horizontal bush to the bodyshell.

20170131_155810_zpso5pldnj2 by James Vincent, on Flickr

Bolts came out with a bit of penetrating spray and a whispered swear:

But then I get to the issue of the small bush - it's stuck fast, and there is limited access for a hacksaw, and a Dremel might just implode given the volume of metal:
20170131_160120_zpsjkvt45h8 by James Vincent, on Flickr

Can anyone suggest methods of removal with the engine in situ? I don't want to apply too much heat given everything attached to the engine lump. Some sort of G-clamp/bolt contraption perhaps?

Edited by Spinakerr on Sunday 16th July 16:14

[Spinakerr]

Thanks for your messages, I'm glad the 164 is of interest to others - I haven't had too many people recount horror stories of ownership, just that parts availability wasn't very good even when new. Plenty of work left to do this year, I think these updates will increase as I might aim to take it on a European tour instead of our indestructible Rover 75 Tourer.

JMF894 said:

You realise you can NEVER sell it now don't you?

At a subconscious level it's recalcitrant resistance to improvements, and the absence of 'easy fixes' for maintenance, is what keeps me going.

Chris-34nmw said:

I have a twin spark into my 105 GTV and converted it to jenveys and an emerald so I have a bag full of injection bits and a spare couple of coils if you can make use of them for spares. Free to a home as good as this!

Also for an alternator in my 105 I use a converted Suzuki Swift item - high output and lighter - Alfaholics sell a kit. Not sure that's an option for you if you're going the strictly stock route.

Happen to have a spare set of forged internals for one of these motors on eBay at present too.

Thanks Chris - for the moment the engine is in good health and I need to put some hours into the suspension, gearbox and brakes to get everything mechanically healthy. Then I'll get back to the engine, but happy to talk over PM about this and other experiences with the twinspark 8V.

Firstly, MOT was passed on Friday with no extra expense, though the handbrake will need some further maintenance as it was ok'd by a raised eyebrow rather than full effectiveness. The tester apparently commented on 'better than new' emissions levels, so I allowed myself a smile after all the injector/fuel line/intake work last year.

Here is is a miserable photo of the 24v V6 Sprint. Bodywork will need some serious effort, so I wish the new owner well:

20170203_193748_zpsvskhoyfo by James Vincent, on Flickr

Early candidate for 'worst engine photo of 2017':
20170203_193813_zpsxywxhzdu by James Vincent, on Flickr

My mechanic was also throwing out some old parts, and gifted me a new downpipe. Very nice of him, and I will likely mate this to a stainless system once my immediate mechanical concerns are dealt with.

20170203_200614_zps0hvclxhb by James Vincent, on Flickr

Then it was on to Somerset in the rain and wind, heated seat and new stereo drowning out both the inclement environment and my muttered swearings at the M3 closures.

This morning my mother volunteered the garage that work on her Puma to help press out the engine mount bushes.

99t said:

In my experience, that sort of steel sleeved bush in an alloy part will need quite an extreme amount of force to remove intact - it was a tight interference fit when new and now corrosion between the alloy and steel has had some time to take effect, it will be well and truly in there!

How much work would it be to remove the alloy "arm" from the engine and get it pressed out?

Yes, thank you for this and the other suggestions. Bolts out:

20170204_101847_zpsbytina8m by James Vincent, on Flickr

Alloy mount off:
20170204_102119_zpsnaqj4zis by James Vincent, on Flickr

The helpful press:
20170204_102454_zpsvtqghed7 by James Vincent, on Flickr

The steel-sleeved larger bush was extracted without too much trouble, but as expected the corroded smaller bush in the alloy arm would not budge. Heads we scratches, various chemicals were deployed. Ultimately, working it from each side work, but it cracked the alloy arm:

20170204_103558_zpsjcfckrtw by James Vincent, on Flickr

Very frustrating, but the garage were very helpful and have thrown in some chemical metal and tried not to take anything for their time - H&M Motors in Somerton - thank you!

Time thus far for the entire operation - about 20 minutes.
20170204_105246_zpsiknoo0pq by James Vincent, on Flickr

Simply reassemble, right? Of course not. The wider 'shoulders' of the new bushes just made things...difficult. At this stage I was in the above garage's parking space, nearing their closure time and having to borrow their tools, with my mother as the only help. Luckily she took to the socket set and spanners with gusto. The engine needed to be 'rocked' forward to line up some bolts, and the arm was wound in and out to get items in place. Being a Londoner, I expected the garage owners to reclaim their tools and tow me off the premises, but fortunately my faith in humanity (well, Somerset) was restored as all the mechanics came out to help over the next 30 minutes, and it all finally went back together.

20170204_120707_zps3adv5yyz by James Vincent, on Flickr

I don't look forward to doing that again when I source a new alloy arm. Careful driving and potholes will be given an even wider berth for the time being.

Next up - new brake lines, discs, pads and brake cylinders. A complete refresh for safety - I've chanced it for too long and want to stop a little less alarmingly. Even with a full refresh I'm sure the handbrake will still be truculent.

Edited by Spinakerr on Sunday 16th July 16:20

[Spinakerr]

Whilst I usually check the PH frontpage with metronomic regularity in the evening, due to recent 164-propelled travels I completely missed Reader's Car Of The Week. Thank you to the PH team and to everyone for their messages & advice - great to read through the Alfa Experiences.

Twoshoe said:

I can’t remember the last time I saw a 164 on the road. However, I did see a Cloverleaf Q4 at a classic car show in Martock, Somerset, last summer – surely the rarest of all, 4-wheel drive, 6 speed box and lhd only. Wouldn’t be surprised if it’s the only one in the UK. Anyway, I digress.

Yes that Q4 is well-known, and I think it was painted/restored at an Alfa-sympathiser in Martock who I have yet to uncover. I'm very keen to get a 6 speed 166 TS box into mine, but alas have not found anyone to take on the project - anyone know somebody with a gleam in their eye for such an endeavour? Personal 3D printers might be a way off, but I can see owner's clubs buying them and issuing parts in the near future for members to keep cars on the road. Let's hope!

rxe said:

When I saw that Sprint, I wondered how on earth it would fit - the one I had in the late 80s was a boxer, and there's no way you'd stuff a v6 in without huge amounts of chassis welding - but of course they made "normal" 4 cylinder versions towards the end. One day I'm going to find a Nissan Cherry Europa and stuff a quad cam boxer in it - would make a cracking sleeper.

Was the idle fix the injectors or the rubber? Across 7 Alfas, I've never had a sniff of a problem with injectors, loads of problems with rubber bits though....!

I suspect that crack will be fine for quite some time - certainly allowing you to get the right part at your leisure, and replacing it will be a lot easier at home with less pressure. Heat normally works on ally bits like that - MAPP or oxy. Burn the bush out, get it nice and warm over a few cycles. Probably safest to burn the bush and weaken the shell with a hacksaw.

I must update my GTA thread - progress has been made, mechanically it is now spot on, we are nearing the wallet busting session in the body shop. I've also picked up a 10V diesel 156 sport wagon for £380, which I have utterly fallen in love with.

The sprint has some 'girders' underneath, but really the whole project needs stripping back and reassembling with some time, money and careful thought. Not one for me at present.

I suspect the idle gremlin was a combination of items, all tired/loose/out of kilter. If I send the injectors away for refurbishment that would tell me for sure, but for the moment I'm enjoying smooth power delivery and over 30mpg.

I know of a few 164s that have their alloy 'arm in good nick so will acquire one and patiently saw it out. Being on a garage's forecourt expedited a solution, next time I will take my time. Likely with the aforementioned pint in a pub somewhere. Do add the GTA thread, that car must be healthy now! £380 for a sport wagon is also a bargain. I doubt my girlfriend will ever part from her Rover 75 Tourer, but if she did that would be on the list.

freeform said:

Back home, there were few replacement 75s about so I bought a 1989 164 V6. It was a lovely car, handled very well for a large front-wheel-driver and survived the following year's French road trip.

Good, so it can be done - this car needs to tour Europe this year. That's the goal.

Right, back to discs, brake pipes, gearboxes and suspension items. It never ends...

[Spinakerr]

Nano-update while some bigger items are shipped/haggles/crafted by albinos in a parallel Alfa dimension:

The X1/9 oil filler cap looked ok, but soon started to corrode and lose its seal after a few months. Luck afforded me a genuine fiat item from 1996, still in its packaging. Old and new:

20170219_184109_zpsytxr7x00 by James Vincent, on Flickr

And mounted, with a much more convincing tightness:

20170219_184303_zpsg55ikf1c by James Vincent, on Flickr

Phew.

Edited by Spinakerr on Sunday 16th July 18:24

[Spinakerr]

The 164 hadn't had an oil change in a while, and the first instance was a swearworthy cocktail of rusted-on filters, troublesome sump plugs (with a 12mm Allen socket set) and Bovril purging.

Fortunately, my prep last time brought it down to a few minutes. I even sprayed the filter the night before.

Engine warmed, gentle jacked up and allen socket removal:

20170305_131350_zps7pxgyhqv by James Vincent, on Flickr

FRAM 9105 off:

20170305_133137_zpsawbefie2 by James Vincent, on Flickr

New FRAM 9105 on, and some proper oil for the first time ever on this machine:

20170305_133445_zpsvoleqaz7 by James Vincent, on Flickr

This car always needs a top up (more in than out, inexplicably, ciao etc), so I did another 1/2 litre after the first drive.

Then off to Somerset in today's glorious sun. London background:
20170305_160547_zpsgj1m2nyl by James Vincent, on Flickr

Fortunately, a clear A303:
20170325_162220_zps2scfvrut by James Vincent, on Flickr

Didn't miss a beat.

Edited by Spinakerr on Sunday 16th July 19:40

[Spinakerr]

Thanks - it's becoming pleasureable to drive, and parts have started arriving for more serious work this Spring.

I say didn't miss a beat, but actually the seat belt casing tryptiched itself, so I raided the parent's solvent cupboard and let it cure overnight.

20170325_220736_zpsiuc5xfcu by James Vincent, on Flickr

Almost:

20170326_105052_zpssfw4dv06 by James Vincent, on Flickr

I give it a week:

20170326_105651_zpscuc4b0wm by James Vincent, on Flickr

As it's Mother's Day, I did the only decent thing - fix some issues with a door card.

The leatherette trim clips had been dislodged over the years and I neglected to reaffix them properly when fixing both the tweeter and door release cable. It clattered and flapped and needed to be fixed:

20170326_105656_zpsx9en9nod by James Vincent, on Flickr

20170326_105714_zpsu59ab2kv by James Vincent, on Flickr

Some door cards are easy, some area horror. I would say the 164 rates as 'bothersome', and requires either a support or another pair of hands for safe removal. Various allen bolts in the cubby hole, behind the handle and behind the electric window switch:

20170326_110310_zpsrl7oq9v1 by James Vincent, on Flickr

Plus screws along the bottom, behind the door edge light, and the vent, and anywhere a screw might be:

20170326_110520_zpsnpmyuft3 by James Vincent, on Flickr

Then it was a case of pull outward to release the two yellow push-fitters, and up slightly to clear the central locking rod.

20170326_111546_zpsd5y0mfox by James Vincent, on Flickr

Not too far though, as the tweeter and door cable are still attached.

20170326_111548_zpspmjyhhwl by James Vincent, on Flickr

My luck then was rekindled as five retaining clips for the leatherette trim dropped out of the bottom, bypassing the need for some improvisation. With my dad holding the door card I reattached it as securely as possible, and hopefully it will hold for a while.

20170326_114309_zps8fxix0z5 by James Vincent, on Flickr

Of course, this all needs to come off again when I paint the speaker grill and replace the main speakers, but I now know what to do.

Edited by Spinakerr on Saturday 22 July 12:56

[Spinakerr]

Fixed another long-term issue last night - the cabin boot release switch. It had never worked, and had to be operated from the rear by a key, which is always annoying if you are trying to drop someone off at a station or some such.

The light on the switch was operating, the fuse was in place and I could hear the solenoid, so it must be at the hatch end.

Trim removed, it looked obvious:

20170326_125911_zpsfab9kk0e by James Vincent, on Flickr

20170326_130130_zpsevjhf45x by James Vincent, on Flickr

Simply reattach the arm and... nope, still didn't work. In operation it didn't pull the release far enough, due to wear, so I shortened the arm with some careful bends:

20170326_132218_zpszsoce2hj by James Vincent, on Flickr

The pushed it into the bush:

20170326_153247_zpsytbzeyiv by James Vincent, on Flickr

Finally! The last switch in the cabin that needed rectifying now works!

Edited by Spinakerr on Saturday 22 July 12:58

[Spinakerr]

The 164 came with a smattering of dents at purchase, to be expected on a London car spending most of its life on the street.

A year into my ownership, an unsightly crease appeared on the bonnet, so today I finally took the car to a dent repair specialist. Martin (aka Dentman) had a workshop about 60 seconds from my house, so I spent a happy few hours with him improving the bodywork.

The bonnet, rear and passenger door before:

20170401_135935_zpsxifqt21m by James Vincent, on Flickr

20170318_124109_zpsgtbgtrqb by James Vincent, on Flickr

20170318_123902_zpsa4yswsrn by James Vincent, on Flickr

I had seen wonders worked, but this was another level. The metal was prodded, poked, massaged and reasoned with to minimise the dents:

20170401_143021_zps6nnpp8g6 by James Vincent, on Flickr
20170401_165451_zpsmxlaibeh by James Vincent, on Flickr

Immensely satisfied with the result, and Martin kindly rectified some other minor dings around the car. The Alfa just needs a proper wash and polish to show off those Pinanfarina lines now...

Edited by Spinakerr on Monday 3rd April 19:58

Edited by Spinakerr on Saturday 22 July 13:14

[Spinakerr]

911F said:

Great to see this - brings back a lot of childhood memories, my Father bought a brand new 164 T Spark Super from Alfa Romeo Baker Street in 1995. Two tone White over Grey.

It would be great if you could source the correct polished wheels it would have come with

Having one from new must have been wonderful, especially in the two tone combination - do let me know if he saved any parts or manuals!

The Super wheels are very hard to find in the four bolt twinspark configuration:

http://www.automobilesreview.com/img/alfa-romeo-16...

I have lead on another set of speedlines that need to be saved, but am always on the lookout for some of the original phase 1 Zender Sports. I have no idea why I like them.

[Spinakerr]

In a fantastic example of 'If it isn't broken, don't fix it', the new polybush top engine mounts had made the ride too firm, with many items vibrating noisily at idle. Unnervingly, due to the 'shoulders' of the larger yellow mount, you may recall me having to wind the control arm back significantly. This resulted in a number of new clonks and groans travelling over bumps, my theory being the engine is now out of alignment and by firming up on corner the lower (original) mounts are having an issue.

Luckily, an Alfa contact sent me a new alloy arm, as the original was cracked in the rebushing experiment, so I got underway.

Bolts out:

20170401_181136_zpsomnf0htj by James Vincent, on Flickr

Here you can see how fully wound the mount was:

20170401_181538_zpsbr6yymqc by James Vincent, on Flickr

Looking at the angles, I decided to remove the troublesome shoulders before buying new mounts. Two hanksaw blades later:

20170401_184707_zpshgtdsnzk by James Vincent, on Flickr

20170401_185749_zpsylotmrxb by James Vincent, on Flickr

Alloy arm replacement with out crack of chemical metal:

20170401_190040_zpsurmbimyw by James Vincent, on Flickr

All done, with the arm now able to be wound out a bit

20170401_191959_zpsnwces6dj by James Vincent, on Flickr

This has definitely cured the idle vibrations, though clonk remain when the left front hit bumps and holes. Suspension is due a refresh after 20 years, so will keep tinkering.

Also gave it a good clean this weekend:

20170401_194509_zpsrrkdjdet by James Vincent, on Flickr

Edited by Spinakerr on Saturday 22 July 13:22

[Spinakerr]

The 164 had a proper run down to Goodwood recently - my partner was having a flying lesson so we took a fantastically scenic drive from London through the South Downs early in the morning. No traffic, sunshine aplenty and the exhaust singing joyfully through the greenery.

Obligatory Goodwood tunnel shot:
20170408_093025_zpsxullgfg8 by James Vincent, on Flickr

The new Aerodrome building, as yet unopened:
20170408_093214_zpsksvvopng by James Vincent, on Flickr

A largely deserted airfield at this time in the morning allowed for some trouble-free Spitfire photography:

20170408_093940_zpszoxav8xy by James Vincent, on Flickr

Plus seemingly empty skies to boot:

20170408_103748_zpsfw2sdirm by James Vincent, on Flickr

In the paddock I couldn't resist parking next to a fellow thoroughbred racing Italian, especially as the Jaguar/BMW/Astons started showing up:

20170408_110833_zpswykd4hw5 by James Vincent, on Flickr

This Aston was especially striking amongst those being driven:

20170408_112032_zpsautjd6qc by James Vincent, on Flickr

Just time for some Art Deco posing to pretend we are Miami Vice villains, sadly ruined by needless orange fencing:
20170408_114850_zpsp81bdek7 by James Vincent, on Flickr

We then took a prime parking position at our retreat for the evening:

20170422_112447_zpszpywrcxq by James Vincent, on Flickr

The drive home was almost as fun the next day, with the Alfa again performing well but clonking at potholes and sharp bends.

Once safely back in the capital, we were greeted by long-planned parcels of joy to be fitted. More updates to follow as the refurb continues, and the suspension is analysed:
20170414_095608_zpsve4g31dt by James Vincent, on Flickr

Edited by Spinakerr on Saturday 22 July 13:26