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Discussion Starter #1
I know what you are thinking there are billion posts about this subject, the fact of the matter is I my self was searching through these billion posts searching for informational material I can use for my own build but found nothing that was technical. Actually it was very confusing info. So I decided to creat my own post about this matter. I will try to be on point on the things that are important during the build. and I will provide lots of pics which I know you guys like.

Keep in mind there is no easy build.

For some reason I love the transaxle based Alfa’s especially the Alfetta sedans. It is a four door car that looks attractive to the eye. Plus it is a very advanced car for its time.
 

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I’ll try to be on point. For a long time I was looking to buy a Alfetta sedan and finally I came across one. Found this car on Craigslist in Los Angeles and without questions I purchased the car. With original 60000 miles on the odometer. Car was parked in storage for years and needed a rescue. Importantly the car had the original paint and it was in a very untouched condition. You will see later.
 

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So the plan is to convert this car into a V6 Alfa powered machine. Basically modernize the cars drivetrain using a Milano donor car which is common practice. Fortunately I had the car that was going to make the donation, which I also purchased from Craig’s list. To be honest I purchased the Milano just for its LSD to use on my 24valve Gtv6 plus the car had original 90000 miles. This car also ended up being a fresh untouched example. Plus the timing was righ with the Alfetta sedan.

So first thing first was to remove the old drivetrain, suspension from the Alfetta and any component that can later be replace from the more modern Milano. Believe me since then and now the overall chassis has not changed at all.
 

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As you can see this is a very clean car. The engine bay had its original shiny paint and the factory decals which I have decided not to touch and just leave as-is. I made the decision to convert the the car to 5 lug. There are many benefits to this and main reasons are the lighter bigger brakes.
 

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Discussion Starter #5
There is nothing that is really technical about the suspension. Everything is pretty much bolt off bolt on. Even the brake hoses and mounting is identical. You probably know that you cannot use the torsion bars from the Milano since they are too short. This is where you need some spare torsions from a Gtv6. The stabilizer from the Milano mounts at the same exact points as the Alfetta and this is a beefier upgrade.

I was just experimenting with these wheels and offsets and stuff. The first two picks are the original Gtv6 wheels still looks nice. The 5 stars are 16x7 with i think 30 offset. They sit wide and look much nicer. I will post more pics about this later.
 

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Discussion Starter #6
So now mounting the engine. I did a lot of research on the internet and really found nothing that was informative when it came to this. By just visual the V6 engine should just slide into the place of the 4 cyl. engine. Not the case. Yes the V6 engine mounts do sit more forward but by how much? Technically you can use the original body engine mounts from the Alfetta but then your engine mounts are going to be mounted only half way the other half in the air. Best option in my opinion is to use Milano mounts. Yes you will need to do some surgery but at the end you will have a much better product. This is a very important step you need to get right so the engine is positioned correctly. The driveline uses no u joints and has a a very minimal forward backward motion. If your engine is sitting correctly then your rear engine mount should go in its position with ease.
 

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Discussion Starter #7
I must say that the Alfa Romeo V6 “Busso” is a great engine. This was the last true Alfa Romeo engine. Especially with today’s standards it looks and sounds very exotic. So before I pulled the engine out I tried to get it running which I did and it ran great. Out of all the rubble came out this beautiful engine.

Compression was great found no reason to rebuild. Engine was extensively cleaned and everything intake related was replaced to lighten up the look of the engine.
 

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Discussion Starter #8
I know there are many discussions when it comes to the timing belt tensioner. I personally think the best is the original hydraulic unit. The spring loaded tensioners in my opinion are very dangerous. The springs do break and when they do...
 

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Discussion Starter #9
Looks like the engine is ready to go in. If the motor mounts are welded at their correct points there should be no reason to remove the engine again.
 

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I am totally amazed that you would put a Milano engine in an Alfetta Sedan. I bought an Alfetta Sedan new in 1979 and drove it for years until buying a Milano Verde new in 1988. I know you do not live in California where is it illegal to put six cylinder engines in four cylinder cars built after 1976. I am glad to see someone upgrade the Alfetta with the six cylinder engine. I wonder if someone would install the new Giulia engine in an older Alfa.
 

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Discussion Starter #12
I do live in California smog is always a problem. Very cool I remember I was a kid back in 1988 when Milano’s were at the Los Angeles auto show. Beautiful cars.

Thanks
 

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I'm also in Ca - orange county. Smog is a nuisance, but engine swaps can be done legally if done right. Where in LA are you?
 

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Discussion Starter #14
I'm also in Ca - orange county. Smog is a nuisance, but engine swaps can be done legally if done right. Where in LA are you?
i am in Burbank. I will still be installing cataleptic converters only thing I think left for smog would be the charcoal canister not too complex.
 

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Good project.
I ran a 79 Sports Sedan from 1980 to 1998. Turboed the motor, Euro bumpers and Shankle suspension.
This included a stiffer front bar. Slow driving over bumps twisting the bar ripped the metal to where the mounts were secured.
If you do the same it would be a thought to reinforce the metal and then add the mounts.
The same happened to a new Coupe.
So the problem afflicted both models.
:)
 

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Discussion Starter #16
Good project.
I ran a 79 Sports Sedan from 1980 to 1998. Turboed the motor, Euro bumpers and Shankle suspension.
This included a stiffer front bar. Slow driving over bumps twisting the bar ripped the metal to where the mounts were secured.
If you do the same it would be a thought to reinforce the metal and then add the mounts.
The same happened to a new Coupe.
So the problem afflicted both models.
<img src="http://www.alfabb.com/bb/forums/images/smilies/smile.gif" border="0" alt="" title="Smilie" class="inlineimg" />
shankle stabilizers are way too heavy duty, I have had them rip my other cars also. Using the stock Milano ones.
 

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Discussion Starter #18
Van, how is your project coming along? Curious for an update.
going along good thanks I will try to post some more new pics Monday. Working on wiring to try to get the engine started
 

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I almost did the same swap 15 yrs ago. Had a clean but gutted black 78 sport sedan and a gtv6 that was totaled when new with 1400 miles. But my job at Ma Bell was nearly 7 days a week and it just sat. Finally sold everything. Now I’m retired I would love to have it all back!
 
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