1973-1987 Alfa Romeo Service & Repair Manual

General dimensions and weights Saloon and Sport Sedan Dimensions Overall length (with standard burnpers) ..................................................... Overall length (with irnpact-absorbing burnpers) ...................................... .................................................................................................... Overall width ................................................................................................... Overall height Ground clearance ............................................................................................. W heelbase ........................ .. ............................................................... Front track ............................................................................................. .................................................................... ...................... Rear track .. Weights Kerb weight (full tank): Except N. America ................................................................................... N. America without irnpact-absorbing burnpers ............................... N. America with irnpact-absorbing burnpers ..................................... Maxirnurn towing weight ............................................................................... Coupe and Sprint Veloce Dimensions Overall length ................................................................................................... Overall width .................................................................................................... Overall height ................................................................................................... Ground clearance ............................................................................................. Wheelbase ............................................................................................ Front track ........................ .. ................................................................ Rear track ............................................................................................... Weights Kerb weight (full tank) .................................................................................... Maxirnurn towing weight ............................................................................... 4385 rnrn (1 72.6 in) 4500 rnrn (177.2 in) 1640 rnrn (64.6 in) 1430 rnrn (56.3 in) 152.4 rnrn (6.0 in) 2510 rnrn (98.82 in) 1366 rnrn (53.78 in) 1358 rnrn (53.46 in) l060 kg (2337 I b) 1200 kg (2645 Ib) 1297 kg (2860 Ib) 1200 kg (2645 Ib) 4345 rnrn (171.1 in) 1660 rnrn (65.4 in) 1330 rnrn (52.4 in) 152.4 rnrn (6.0 in) 2400 rnrn (94.49 in) 1360 rnrn (53.54 in) 1358 rnrn (53.46 in) 1232 kg (271 0 Ib) 800 kg (1 763 Ib)

Use of English As this book has been written in England, it uses the appropriate English component names, phrases, and spelling. Some of these differ from those used in America. Normally, these cause no difficulty, but to make sure, a glossary is printed below. In ordering spare parts remember the parts list may use some of these words: English American English American Accelerator Aerial Anti-roll bai Big-end bearing Bonnet (engine cover) Boot (luggage compartment) Bulkhead Bush Cam follower or tappet Carburettor Catc h Chokelventuri Circlip Clearance Crownwheel Damper Disc (brake) Distance piece Drop arm Drop head coupe Dynamo Earth (electrical) Engineer's blue Estate car Exhaust manifold Fault findingldiagnosis Float chamber Free-play Freewheel Gearbox Gearchange Grub screw Gudgeon pin Halfshaft Handbrake Hood Hot spot Indicator Interior light Layshaft (of gearbox) Leading shoe (of brake) Gas pedal Antenna Stabiliser or sway bar Rod bearing Hood Trunk Firewall Bushing Valve lifter or tappet Carburetor Latch Barrel Snap-ring Lash Ring gear (of differential) Shock absorber, shock Rotorldisk Spacer Pitman arm Convertible Generator (DC) Ground Prussian blue Station wagon Header Troubleshooting Float bowl Lash Coast Transmission Shift Setscrew, Allen screw Piston pin or wrist pin Axleshaft Parking brake Soft top Heat riser Turn signal Dome lamp Countershaft Primary shoe Locks Methylated spirit Motorway Number plate Paraffin Petrol Petrol tank 'Pinking' Prise (force apart) Propeller shaft Quarterlight Retread Reverse Rocker cover Saloon Seized Sidelight Silencer Sill panel (beneath doors) Small end, little end Spanner Split cotter (for valve spring cap) Split pin Steering arm Sump Swari Tab washer Tappet Thrust bearing Top gear Torch Trackrod (of steering) Trailing shoe (of brake) Transmission Tyre Van Vice Wheel nut Windscreen Winglmudguard Latches Denatured alcohol Freeway, turnpike etc License plate Kerosene Gasoline (gas) Gas tank 'Pinging' Prv Driveshaft Quarter window Recap Back-up Valve cover Sedan Frozen Parking light Muffler Rocker panel Piston pin or wrist pin Wrench Lock (for valve spring retainer) Cotter pin Spindle arm Oil pan Metal chips or debris Tang or lock Valve lifter Throw-out bearing High Flashlight Tie-rod (or connecting rod) Secondary shoe Whole drive line Tire Panel wagonlvan Vise Lug nut Windshield Fender

Buying spare parts and vehicle identification numbers Buying spare parts ordering spare parts or asking for inforrnation. Spare parts are available from many sources. for example: Alfa A quantity of identification numbers and labels are affixed to the Romeo garages, other garages and accessory shops, and motor car as shown in the diagram, but it is ernphasised that only on North factors. Our advice regarding spare part sources is as follows.: Arnerican vehicles are those rnarked to be found. Officially appointed Alfa Rorneo garages - This is the best source The engine number is starnped on the engine casing on the left- of parts which are peculiar to your vehicle and are otherwise not hand side (photo). generally available (eg complete cylinder heads, interna1 gearbox cornponents. badges, interior trim etc). It is also the only place at which vou should buv Darts if vour car is still under warrantv - non- , , Alfa Rorneo cornponents may invalidate the warranty. To be sure of obtaining the correct parts it will always be necessary to give the storeman your car's engine and chassis number, and if possible, to take the 'old' part along for positive identification. Remember that many parts are available on a factory exchange scheme - any parts returned should always be cleanl It obviously makes good sense to go straight to the specialists on your car for this type of part for they are best equipped to supply you. Other garages and accessory shops - These are often very good places to buy materials and components needed for the maintenance of your car (eg oil filters, spark plugs, bulbs, drivebelts, oils and greases, touch-up paint. filler paste etc). They also sell genera1 accessories, usually have convenient opening hours, charge lower prices and can often be found not far from home. Motor factors - Good factors will stock al1 of the more irnportant cornponents which wear out relatively quickly (eg clutch cornponents. pistons. valves, eaaust system. brake cylinders/pipes/hoses/seals and pads etc). Motor factors will often provide new or reconditioned components on a part exchange basis - this can save a considerable amount of rnoney. Vehicle identification nurnbers It is most important to identify the vehicle accurately when Engine number next to flywheel Plate and sticker locations 1 Vehicle identification 4 Engine nurnber 9 Spark plug data 13. A ir pollution nurnber - engine 5' Exhaust ernission data 10 Fuel requirernent cornpliance certificate cornpartment 6. Loadlseating capacity l1 Paint code 14 Catalytic converter 2. VIN - top of facia 7 Running-in data 12 Exhaust ernission leve1 overheat warning pane1 8 Lubrication data during production North America only 3' DOT certification

Tools and working facilities Introduction A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a considerable expense, offsetting some of the savings made by doing-it- yourself. However, provided that the tools purchased rneet the rele- vant national safety standards and are of good quality, they will last for rnany years and prove an extremely worthwhile investment. To help the average owner to decide which tools are needed to carry out the various tasks detailed in this manual. we have compiled three lists of tools under the following headings: Maintenance and minor repair, Repair and overhaul, and Special. The newcomer to practical rnechanics should start off with the Maintenance and minor repair tool kit and confine himself to the sirnpler jobs around the vehicle. Then, as his confidence and experience grow, he can under- take more difficult tasks, buying extra tools as, and when. they are needed. In this way. a Maintenance and minor repair tool kit can be built-up into a Repair and overhaul tool kit over a considerable period of time without any major cash outlays. The experienced do-it- yourselfer will have a tool kit good enough for most repair and overhaul procedures and will add tools from the Special category when he feels the expense is justified by the arnount of use to which these tools will be put. It is obviously not possible to cover the subject of tools fully here. For those who wish to learn more about tools and their use there is a book entitled How to Choose and Use Car Tools available from the publishers of this rnanual. Maintenance and minor repair t001 kit The tools given in this list should be considered as a rninirnum requirement if routine maintenance, servicing and minor repair oper- ations are to be undertaken. We recomrnend the purchase of combination spanners (ring one end, open-ended the other); although more expensive than open-ended ones, they do give the advantages of both types of spanner. Combination spanners - 10, 1 1, 12, 13, 14 & 1 7 mm Adjustable spanner - 9 inch Spark plug spanner (with rubber insert) Spark plug gap adjustment t001 Set of feeler gauges Brake bleed nipple spanner Screwdriver - 4 in long x ) in dia (flat blade) Screwdriver - 4 in long x ) in dia (cross blade) Combination pliers - 6 inch Hacksaw (junior) Tyre pump Tyre pressure gauge Oil can Fine emery cloth (1 sheet) Wire brush (small) Funnel (medium size) Repair and overhaul t001 kit These tools are virtually essential for anyone undertaking any rnajor repairs to a motor vehicle, and are additional to those given in the Maintenance and minor repair list. Included in this list is a cornprehensive set of sockets. Although these are expensive they will be found invaluable as they are so versatile - particularly if various drives are included in the set. We recornmend the in square-drive type, as this can be used with most proprietary torque wrenches. If you cannot afford a socket set, even bought piecemeal, then inexpensive tubular box spanners are a useful alternative. The tools in this list will occasionally need to be supplemented by tools from the Special list. Sockets (or box spanners) to cover range in previous list Reversible ratchet drive (for use with socketsl Extension piece, 10 inch (for use with sockets) Universal joint (for use with sockets) Torque wrench (for use with sockets) 'Mole' wrench - 8 inch Ball pein hammer Soft-faced hammer, plastic or rubber Screwdriver - 6 in long x a in dia (flat blade) Screwdriver - 2 in long x & in square (flat bladel Screwdriver - 1;. in long x ) in dia (cross blade) Screwdriver - 3 /n long x in dia (electricians) Pliers - electricians side cutters Pliers - needle nosed Pliers - circlip (interna1 and external) Cold chisel - t- inch Scriber Scraper Centre punch Pin punch Hacksaw Valve grinding t001 Steel rulelstraight-edge Allen keys Selection of files Wire brush (large) Axle-stands Jack (strong scissor or hydraulic type) Special tools The tools in this list are those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturers' instructions. Unless relatively difficult rnechanical jobs are undertaken frequently, it will not be economic to buy many of these tools. Where this is the case. you could consider clubbing together with friends (or joining a motorists' club) to make a joint purchase, or borrowing the tools against a deposit from a local garage or tool hire specialist.

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1973-1987 Alfa Romeo Service & Repair Manual

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