MICROFICHE INDEX Microfiche 1/14 Presentation - Identification Presentation -step form and are backed up by illustratins aimed to help identify components im- mediately; a detailed series of indexes and references allows the subject desied to be found with ease. {All the information, figures and techn ical specifications inthis manual are revised aund correct at the time of publication. ‘Subsequent variations te technical specifications and characteristic features lied uced between editions of the manval ‘will be published in the “Technical Bulletins” issued by theTechnical Assisia.ie Service when the modifications are put into practis ‘The manufacturers reserve the right at any time and without noiitication to mats ay Changes considered necessary to im- prove of satisly manufacturing or commercial requirements, andfurthermoreslate: that not all models covered by this ‘manuaimay necessarily be avalatle on all markets.P -2 PRESENTATION MANUAL LAYOUT This manual is composed of microtiches, and as for previous manuals, is divided into functional groups. Each group consists of operating procedures and technical data Uniess otherwise indicated, removal and dismantling procedures can be carried out in reverse order when replacing or re-assembling. ‘The procedures described in this manual generally cover complete dismantling, which should only be carried out in cases where it i strictly necessary. Apart from instructing procedures, this manual aiso providesinformative descriptions and data on oper ‘group or subject of technical importance. In particular it must be remembered that gaskets, o-rings and copper washers fitted to joints should always be replaced with new equivalents and never re-used. The procedures and the paragraphs covering Technical Specifications and Notes include descriptions on the use of n for each ‘SPECIAL TOOLSproduced to ensure quick, precise and safe repairs to be carried out, The symbo's used are shown in the first column of each microfiche, affer the indexes. Units or parts must only be substituted with original spares: only in thie way can perfect interchangability and operation of assemblies be ensured,P -3 PRESENTATION Hew TO USSETHE MANUAL MUCRAOFCHE HHEADERS Ezasn wilhe micr-olehes forming the manual has a header shwoni mhe und esor descriptions it covers. a biseuay the mriszliche covering the topic desired can bes sadeted frome tie start.P -4 PRESENTATION INDEXES: = Microfiche Index. OUDOUU0 ‘This is the first chart in each microfiche, which shows its contents and refers to the various column indexes on the top line QUUU000 UUCO000Pp -5 PRESENTATION -Mastuslgeneral index. Thelbfcolows the Microfiche index in the first column, and ‘thang ie contents of all the microfiches in the manual. Resltraites from one microfiche to another are thus mato asor.P -6 PRESENTATION = Column index. Tis Is the first chart in each column and shows the de- tailed index of subjects the column cont Totind the tople desired read: correct column Ie Identified, until the desired chart or charP “7 PRESENTATION 8~wilbOLS 1p aieiteimpler to coneut ha manu special aymbols fmabean ts whieh are aay ml én unr These rst colum mit tho than the tot! symbde used nd selr meaning indore, =a) [=a)P -8 *__ PRESENTATION CHART LAYOUT HEADERS — see 1 ! 1 ! | i ! toa al | | | bei 1 3 = 6 GEARBOX ! ! ! | | 4. Functional unit symbol 2, Functional unit number 3. Chart serial number 4, Functional unit nameP .9 RESENTATION FIGURE AND TEXT | ! | | | | | 1 | ! 1 ! 1 | 1 | ! | I | ! | ! | | | 1 | + Unscrew the acuring muta and rece th right 2 Recover he four Kye | The reterence numbers in the figure foll a r vrsroner a 185/60 R14 82T ‘oad capacty 425 ton ittite oa ination gS 18 Maximum axe presauyee load (kt ~ (o) 800 (castes) oes 18 () oe ‘ Maximum tow. ing weight ca) te 2 Z Minimum steer Seating 243 lock " 500 capacty (rm) Tifa conn ig ines rosrea 03 Le wane? Ty=| 00 -13 COMPLETE CAR 171E ea we Tota allowable welgnt (kp) Coe nS ‘Wheel rims if sipsxte — —_ 4A} ___ 970 ; walght j mmo wr we GJ | sconce Ron ittite | ST cco | talon eS 20 Maximum axle pressures load (kg) CF (oem) ———F (coutires) rn 6% 18 er aaeer bey ou 4.000 fee Minimum Seating sieenglock 800 — = ir | {Ty formestaoa bphapee arity sovare repre DA {0360-300=| 00 - 14 A OMPLETE CAR S171 Sari Total alowablo = 1.398 r Blpxtar woigtt (eg) 6S ‘Whee! rims, “Mt a Ko wai 979 weight (kg) B © I Thot 185/60 R14 82H Load capacity itttt @ 425 — 9) — = 7 we] wasn eo 20 Maximum axle igen’) ——_——— Toad (kg) 900 (cold tires) SR 18 ) Ne Maximum tow 4.000 Pa eeee Minimum a inglock fot 5.500 Seating 243 f Gy? capacity (mmm) " {for snrann hgh tnd dg tae prea O IGT {eabw:30nPoeae 00 ~15 COMPLETE CAR TTB axa 1 7iE at Total aiowable wolght (ko) i Wioot is \ 5 edna Kerb ec wet Tes q vei00 42H ied capachy | as | : _ (kg) faa B00. Inflation eS) 20 Maximum axlo prosavjes load (kg) (glen?) ]} ‘900 {cold tires) 18 = ee) f Maximum tow- tea ing weight (9) = Seating 243 5.500 capacity Ta eases mamaraveowe Ty (03m00 COMPLETE CAR —_— Boxer 10 | tov = |- Boxer 16V.:1) [Boxer 160-16 + 8 16V Boxer 16\i> - S 16Vi> Total allowable wight (kg) ‘as Whoce rims if 5 ledxta 4.000 Thes {| 185/60 R14 82H Load capacity 425 $— a) 800 Intation Gh 20 Maximum axle prose load (ka) (harem [= ce 900 (cold tires) I. ay Ce 18 Maximum tow- 4.100 ing weight (49) Minimum Seating An steering lock 5.500 capactty (om) aE me aarman aT (e030)COMPLETE CAR REALE - a 2 permanent ‘8 16Vs0 Perraanant 4 Total allowable = CIN 1.495 ‘weight (kg) roumrey ‘Wheel rime \f soxrew | sugdnte Korb eaine = —— nore ge; |” Thos 135/80 B14 (2)/185/60 R14 GH {oad copcty fittte 7 = Se 800 Inflation —-_ “0! a Maximum axle proseures a load (kg) ae (giem’) Ge a 18 So be (cold tires) —. “ _ Maximum tow- oS OP] 282) to weight ba) Soe 1.100 Eiaiaaet Minimum ating stooring lock ea 243 = 5.500 (ne) Dizamannge ‘83 301Pa) (8 Vale nar tne we! a Tyaa 00 -18 COMPLETE CAR 4.8 TO! 1,8 TD! Total allowable a 1.405 woight (ka) GO iq S\edxia ~ <_ a 1.040 igh ‘woight (kg) B @ I Thos | 175/70 R13 827 Kana ttttte [| | tes 300 intaion 7D 22 beam a _| presautos 9) (kg/m?) 5 900 (alien) oxy, 18 eee mm [ve | ~ Minimum 3 ing lock j>-<8) Seating 248 ore ing > 5.500 (mm) : {inane tigrapad dng howaatin maven OT (tstu 20\Pa) (Feet re 0ioh u=| 00 -21 CONPLETE CAR 13IE(-141E) 13 4EC) WHEL ()+ 141 LC) ASIEL ()-141EL() es Total allowable ' weit (ka) oe ito Wheel rms i S'hdxis wake Kerb 208 ae a t Tires: 165/70 R13. 79T Toad capacity [ae rm) ititte 800 22 Maximum axle load (xg), | eects te etna 870 J = Oe 6 18 22(2) aeeen (gy CLP 1.000 ear ee eeeen| a8 Minimum, Seating | steeringlock {<2 Sp eas 2 “Rr omy Ge |S eR” TERETE Tes apaliaammasta mona RSeay Pieces ae uo=| 00 - 22 COMPLETE CAR fate axa 9] tate ma) 131 a()- 1418 a0) 5 ~ Total allowable: weight (kg) Cron coe Wheet rims | Stents aire 4 woah a) © 1.025 gy? Ties 165770 R13 79T a ite | S| 0 a) 22 Madame pretojes oad (glen) | oy 70 ae) 18 22) Maximum tow- a — ing weight (kg) ce ca) OO Seating 5500 Seating eas, 243 FTW ETON aNTON BETA ST eae ov= 00 23 COMPLETE CAR 18IE TIE es Tolatslowat>io war SED | | eatine | stents al SMdx tar Keb wary 985 woghitig) B © r = 17570 R13 82T 185/60 R14 62H Smactyo) ttttt @ a > Ss Inflation oS 22 ete o° pease a J (kgiem’) pad 900 tea thes) em 18 2,2(2) inweoia) ue Minimum eae staoring lock 5.500 cinch SED a Ti Fercomnenn ighapeed nog horns pea OOO OOT {Oa Oia) (Far aput ee=| 00 24 COMPLETE CAR 1.816 4x4 1S IE 4x4 Total alowabe = woight eg) ois 1480 | Whatrime if Stedxts 5 ‘pdx 14 Kerb ~ wale 1.095 woight (kg) @ © I Thos 475/70 R13 82T 105180 R14 62H tapcchy tah tittt @ bid Be To | ntaton EB 22 Maxum ace > _| proses oa ¥ {tgen), ——— — Pe ee a 228) (ty oe ae ‘Maximum tow- se: ‘ng weight (ko) enum 1.400 ‘Seating 5.250 capacity oe 243 {Fo common tphapoed Srcg onan ro pane VOTE {23bu201Pa) (3 Fersomen sve 10H17 TTI es Total towable woight (4a) ote uf ‘Whell rims 4 BS Ypuxta Korb sake on weight (9) B 9 r nae {l 105/60 R14 62H ere Oo) ftttt wm ae — ao Intation — @TBI 22 Masqun prossujes {kgiem*) >—— om | oo (cuties), 18 2202 Maximum tow = ing weight (9) caves me 7 Seating 20 5.500 capacty oie ‘ EET Rien seeaae u=| 00 26 COMPLETE CAR, TTIE axa ATE 4x4 Total allowable ¥ art walght (kg) ore 460 S'aaxta Korb weary . 1.095 ‘weight (kg) B T Thos | 485/60 R14 82H Toad apc 09) Hitt @ _ — eS 800 Iatlatton 22 Maximum axle e preseuror load (kg) kg/cm’) pe eee ce ook 800 (cold tres) ete 4,8 22 (2) Maximum tow- Sa ing weight ig) ad ae = Minimum lock f seaing as | ee be 5.50 cepacty aware) tam) Tame ace pa VOB AT pad og (abe 30KPa (2 Forapeen ore Oe= 00 -27 COMPLETE CAR ip 1ev- 164 B16 Total alowable = weight (ko) Com ‘44o Whoo! sme if BYpdxtar Korb ae i 1018 5 ht weight (kg) gE @ t Tiree i 185/60 R14 82H i oad capncty (ho) itttte | + es. fp 0 latlation D 22 Maximum axio * prossujes - toad 9) 000 trae is oo (col tires 2 0 orn 1,8 22 (2) Maximum tow ing woight ko) t109 i = Minimum Seating steering lock fi 5.500 a 243 * Leta (Came SonPay chFarsone sow ihhand 00 28 COMPLETE CAR 1.8 TO! ae ; Tote aioabio = Korb s ? Ares woight (ky) Bp 9 : Thee | 176/70 R13 82T taten—@EBY 22 Maximum axle prasuss load (kg) (kgiom® | re tol ") GR 18° 2,2(2) Maximum tow- ing weight (kg) 7 rs iran, Seating seornglock ge 5280 capacity (mm) {iF com Fah spd dg asap Oa? {23bu-201Pa (Fe soeede sore De| 00 -D compere cAR 33 + VEHICLE IDENTIFICATION AND SERVICE DATA + MODEL IDENTIFICATION VEHICLE IDENTIFICATION AND SERVICE DATA 1 (SPECIFIC FOR 33 MODELS} IDENTIFICATION PLATES eo MODEL IDENTIFICATION (SPECIFIC FOR 33 MODELS) IDENTIFICATION TABLE... 00- 30 IDENTIFICATION PLATE. 0-34 BODY MARKINGS... 0-35 ENGINE MARKING: 00+ 95=| 00 29 COMPLETE CAR VEHICLE IDENTIFICATION AND SERVICE DATA SPECIFIC FUR 33 FKODELS IDENTIFICAZON PLATES: = Engine type and serial number plate M 1. Identificaion and approval plate 2) Vehicle aye and chassis serial number plate=| 00 30 COMPLETE CAR MODEL IDENTIFICATION SPECIFIC FOR 33 MODELS IDENTIFICATION TABLE VERSIONS] 33 IDENTIFICATION 8 3913V so1aVE a BODYSTYLE 5 door saloon DRIVE wo] ork | uk | pH | uh | AR | oud | RH ON IDENTIFICATION 90748 907A 90743 907A2 VEHICLE PLATE: TYPENO. JON AUXILIARY BAY CROSS 907.000 07.000 907,000 907,000 [MEMBER RURIGES eee 39743 from 000001 | 30732 rom 000001 | 30732 rom 000001 | 30734 rom 000001 I00 - 31 IDENTIFICATION TABLE (Continued) COMPLETE CAR VERSIONS) 9131 () So TaTEC) IDENTIFICATION BIEL -s TAIL] SIE oe Seu7ie BODYSTYLE 5 door saloon DRIVE uw pH | un | RH | ud | mH | oun | re ON SO7AZA 907A1 IDENTIFICATION 907898 & SO7AGA a venice [PLATE 907A28 a S07ATA a TYPENO. JON AUXILIARY BAY CROSS 907,000 907,000 907,000 907.090 MEMBER 30750 tom 000001 | 20736 rom 000001 Rie enemies 30753 rom 000001 {30785 rom oon001| 50761 rom 000001 a| 30737 em 000001 a ‘A. Vohicie with catalytic converter (¢) LAW, INJECTION-IGNITION SYSTEM> 00 .32 IDENTIFICATION TABLE (Continued) COMPLETE CAR VERSIONS] ‘33Boxer 16V | 33 Boxer 16 IDENTIFICATION nat S04.7IE Ad 338 10V8 BODYSTYLE door saloon DRIVE wo ]ork [ou | oan | ou [one Toon | an | lon 807A 07A1D 807A1B 80718 IDENTIFICATION} VEHICLE [PLATE SO7ATA A SO7MIE A, 80710 A SO7AIC A TYPE NO. [ON AUXILIARY BAY CROSS 907.000 907.000 907.000 907.000 MEMBER ENGINE TYPE AND SERIAL 30736 from 000001 | 80736 from 000001 | 30746 rom 000001 | 30746 from 000001 NUMBER £30737 trom 000001 a | 90787 trom 000001 a | 30747 rom 000001 a. | 30747 team 000001 a ‘A Vehicle with catalytic convertorhand 00 -33 :__ COMPLETE CAR IDENTIFICATION TABLE (Continued) VERSIONS] _saS t0ve 3370 IDENTIFICATION Pormanent 4 Intercooler BODYSTYLE 5 door saloon oRIVE tH | ona | tH | RH [on SO7AIF IDENTIFICATION 9075 venice [PLATE SO7AIG TYPENO. JON AUXILIARY IBaY CROSS: 907,000 807.000 MEMBER ENGINE TYPE AND SERIAL S2088 For 00000 ga tron coool NUMBER 20747 from o0000% a] ‘A Vohicle witheatalytic converterieee 00 - 34 COMPLETE CAR IDENTIFICATION PLATE ALFA LANCIA INDUSTRIALE S.P.A, —+—1 Approval code —|— 2 Body markings Engine type number Vehicle type and version for spares ordering, identiica- tion of factory of manufacture or assembly and for intro —+—_3 ducing modifications, 6 |, =a 8. Marking of correct smoke ab- sorption coefficient value (only . for diesols Fan shes wee, NS FOR SPARES=| 00 - 35 ‘COMPLETE CAR BODY MAIKENGS (1) Manutacturers ientication code [ZAR [MAAC | + | o8saon21 (2) Vehicto modo! a @ (9) Chassis seriat numbor ENGINE WAR KINGS nae ea (4) Engine type number (6) Engine production serial number “ (5)=| 00-c ne Sport Wagon + VEHICLE IDENTIFICATION AND SERVICE DATA + MODEL IDENTIFICATION VEHICLE IDENTIFICATION AND SERVICE DATA (SPECIFIC FOR SW MODELS) IDENTIFICATION PLATES... 00+ 36 MODEL IDENTIFICATION (SPECIFIC FOR SW MODELS) IDENTIFICATION TABLE. .-00- 37 IDENTIFICATION PLAT 00 - 40 BODY MARKINGS.. ENGINE MARKING: 0- at 0-440a - 36 COMPLETE CAR VEHICLE SIENITIFICATION AND SERVICE DATA SPECIFIC FO.RSW MODELS IDENT HFICATEON PLATES = Engine type uiserial number plate |. Approval anadiéeratification plato 2. Vehicle types aii Chassis serial number platease 00 37 COMPLETE CAR MODEL IDENTIFICATION SPECIFIC FOR SW MODELS . IDENTIFICATION TABLE ‘Sport Wagon 1.31 () Sport Wagon 1416 () VERSIONS} Sport Wagon 1.3 IE L (*) WENTIFICATION ‘Sport Wagon | Sport Wagon 1.3L [Sport Wagon 4x4]. SPort Wagon 14 EL (*) BODYSTYLE five door giardinetta DRIVE uh | pH | ound | RH | LH | RH uy RH lon IDENTIFICATION 90783 90783 907B3A 907838 & VEHICLE PLATE TYPENO. [ON AUXILIARY lBAY CROSS 907.000 907.000 907.000 907.000 MEMBER Ree eee 30782 Mrem | 90782from 000001 0732 from 000001) 30753 rom 00001 ‘A Vehicle with eataiytic converter () LAW. INJECTION-IGNITION SYSTEMhema 00 - 38 COMPLET: CAR IDENTIFICATION TABLE (Continued) Spo Wagat : VERSIONS| “Wicaxa() |-- rt Wagon 151e| "Sport Wagon ey Sport Wogon - Sport Wagon i Sport Wagon 3. IDENTIFICATION Mate art) Sport Wagon 4x¢ BODYSTYLE five door giarinetia DRIVE uw fom ]ou [oan [oun [oan [ou | aa lon 30781 IDENTIFICATION | 907890.4 90782 & 90782 A VEHICLE PLATE: S07B1A & TYPENO. [ON AUXILIARY lBAY CROSS 907.000 907.000 907,000 907,000 MEMBER 30796 rom 000001 wane TPE AND SERIAL —| sores yom oon | 3171 Hemcoote | 0781 ton oto M 30797 tm 000001 ‘A Vohicto with catalytic converter (*) LAW. INJECTION-IGNITION SYSTEM=| 00 39 COMPLETE CAR IDENTIFICATION TABLE (Continued) VERSIONS) Sport Wagon | - Sport Wagon B 16V] Sport Wagon TO IDENTIFICATION 1.71E4x4__| -Sportwagon 16V | Intercooler BODYSTYLE {ive door gardinetta vrve LH | RH uu RH | UH | RH lon 907810 S07B1F IDENTIFICATION 90785 VEHICLE PLATE 907B1E A 907816 & TYPE NO, JON AUXILIARY IBAY CROSS 807.000 907.000 907.000 MEMBER ENGINE TYPE AND SERIAL 20726 rom oo0001] 90748 torn 000001 | aoaoos a [20737 trom 000001 a| 30747 trom 000001 & ‘A Vohiclo with catalytic converter=| 00 - 20 UDENTIFICATION PLATE, 1. Approval code. 2. Body markings. 3. Engine type number. 4. Vehicle type and version. 5. Serial number for units ma tufactured: this Is a reference for spares ordering, identiica- tion of factory of manufacture for assembly and for Intro ducing modifications. + Marking of correct smoke ab- sorption coefficient value (only tor diesels) COMPLETE CAR re ALFA LANCIA INDUSTRIALE S.P.A. 1 FOR SPARES 1 HOTORE-ENGINE + * VERSIONE VERSION a We ER RICAMG! ~00 -41 COMPLETE CAR BONY MARKINGS (1) Manufacturer's identitication code eae) | sorese |e Lessons (2) Vehicle modot H @ ey (9) Chasis soria! number ENGINE MARKINGS 30737 | | 000001 (4) Engine type number (6) Engine production serial number ) 6)=| 00 -F eee - JACKING AND TOWING POINTS - PROGRAMMED MAINTENANCE - FLUIDS AND LUBRICANTS - APPROXIMATE REFILL CAPACITIES JACKING :.ND TOWING APPROXIMATE REFILL POINTS... 7 CAPACITIES PROGRAMMED MAINTENANCE FOR PETAOL ENGINES... LIST OF OPERATIONS TO BE FOR DIESEL ENGINES .... PERFORMED AFTER THE FIRTS 1,500 KMS [AND BEFORE 2,500 KMS.cewsonnennannnnenO0 © 43 ‘CHART SHOWING MAINTENANCE OPERATIONS TO BS CARRIED OUT AT INDICATED KM, FLUIDS AND LUBRICANTS: TABLE rn=| 00 - 42 ae JACKING AND TOWING POINTS FRONT TOWING. HOOK LACKING POINTS EAR TOWING HOOK For Permanent 4 vehicle: n case of towing with two whools raised, turn the ignition key to position 1 (key-operated services excluded).= 0 -43 Pe PROGRAMMED MAINTENANCE LIST OF OPERATIONS TO BE PERFORMED AFTER THE FIRST 1,500 KMS AND BEFORE 2,500 KMS N'] OPERATIONS 1 | Replace engine oll and iter and check lubrication citcuk tightness ‘Check condition and tension of alternator, water pump, air-conditioner compressor, power steering pump drive belt ) ‘Check fuel supply circuit tightness. Check fuel vapour emission contra unt (fora (Chock the sealing ofthe air supply system downstream of the air flow moter (versions with patrol injaction) Check idle speed and ignition advance (petrol engine models, excepting Motronic MLA.1 equipped engine) Chock antifreeze mixture level and verily cooling circuit tightness. Chock condition of protective boots of axle chats, power steering and eleering joint caps 2 3 4 5 [Check exhaust emission carburated (petrol engine models), Check exhaust smoke (Diesel engino models) 6 7 8 8 Check wheel toe-out, 10] Check brake system pipe tightness 1 11 | Check brake and clutch uid le 12 | Check hand brake travet 13| Test vehicleee 00 44 COMPLETE CAR CHART SHOWING MAINTENANCE OPA TIONS TO BE CARRIED OUT AT INDICATED KM Tem x 1000 tr |OPERATIONS ot 20| 40 | 60 | 80 ]100]120] 140] 160] 180] 200 + [Replace engine oll and fitar (at bastowa yoar) and chock wbrcationl «|e lelelelelelelele iret ghtnoss 2 | Replace timing drive bets e e 7g | Check condtion and tension of steonenx, waxter pump, alr conditioning] compressor, powar storing belts 4 | Check airfitereanriage e| fel [el |e 5 [Check fuel fter cartridge (Diesetenghestodals) elelelelolelelojele 6 | Chock fuel iter cartridge (pet! eng midots) e| fel fel fe, fe 7 | Chock exhaust gase axygen sensor (Lawrida probe) ale (models wth catalyst) 1) @ | Chock ignition advance (petroloryine ejxcping MotronieMLa.t modes)! |e] | © ° [Replace spark pugs (oncuding 18 eats) e| fe] fe ° Roplaco spark pligs (16V cataly 20 only ° ° 10 | Check antireoze misture level elelelelelelelelele (1) See *ELECTRICAL-ELECTRONIC DLAGNIOSIS™=| 00 -45 Coen aE w]orcmarons as STS a SS 12] Check gearbox and differential oil level © "[oawaaaeaaae sheets a mT RTS Ts elo | =| oe e| ee stomaaaren Selslabeloialatets =‘To ensure proper operation, folow theta suggestions carol 600 kms (or when refueling) chock: -Engina ol level *“Goolantlevel, “Baka clutch fd aval Tyra pressures “Thapotuiblapresence otwatorinthe elfiterandcean (Diesolongine models onl) -Fludlavellor he scrgen and lamp washer systems Engine oll and iter ‘They must be replacedat te intoralsinkcated ‘Wath low milaages they mustbe replaced once a year Aletiter you habitual deve on duety roads, the more often than indicated. Brake pads (On some vorsions th brake pads woari inicated by th ilumination ofawaming ighton the dashboard. For car with wear indicator forthe front pads, whon waar it inc-ated ‘androplacemant made, the rear pads shouldbe checked a the same time. apencirg onthe use ofthe car, therearpads may notneedimmediata replacement; inthis casa, tis récommended to checkthem again lator {iter should be chocked COMPLETE CAR ‘Brake uldatutch Beaks Muidis hygroscopic o.0.abeorbs water ‘To avold anoinalles during braking the brake fid must be replaced ‘each your, Buttery During het woather, check the oloctrolyte love requonty. ‘Airconditioner i fitod) ‘Once a yaar, prelorably belore warm woathor stats, hava the fitar on tha evaporator) checked by ho Alfa Romeo Sorvice Network. Antifreeze ‘We racommende you to top up with Alla Romae Concantratod Ant toetganeza ti orcripretove texte protcton char Note Underspecaldrivingcondiions(¢.g.onroadssprikiedwithanitroszo tal anclor conouive substances, rough road eurtacos, ot), ofton check the boots of the we shafts and etaering box, and dasn and {uta its, hinges, door catches, bonnet catch, ec. ‘Wha foreado use ue, ubricants and/or ude in general with charac- lortice diforont rom thosaspeciiedby thomenulacturr(inemergen- replace tho fue anc rolaive for athe eariost opportunity. (C1 Matorm star hc vad many dy ron[=| 00 47 COMPLETE CAR FLUIDS AND LUBRICANTS: TABLE : Nemo Type Application | Classification GIP P Others oF Engine - 01 lAPISFCD [Nuovo Sint 2000 |Sintlax Motor O _[SELENIA SPECIAL petrolengines) —|ccMcGs/Po2r04 [SAE tow4o SAE 10W4O ~—FORMULAALFA SAE 10W/40 IROMEO 10Wi40 (1) Engine -01 [API SECO SINT IsINTIAX ISELENIA (turbodiesolongines)CoMC POZ TURBO DIESEL |TURBODIESEL TURBO DIESEL (1) ISAE 1ow4o | rowi40 row4o [Gearbox-13_ |SAE6OW/90 | Rotra MP Pontiax HD TUTELA Diterontiat-17 JAPIGLS SAE sows [SAE coW/s0 Wa0M-DA Fronewne ISAEJ9060 [Roam Pontiax HO suspension 21 JAPIGL-S ISAEsowrse | SAE BOW:90 Rydal GMDEXRON | |DEXRON TT IDEXRON FLUID | TUTELA fieeno-2 | GVA Rare JSAEs05a _ |RovaMP Pontiax HD suspension 25 |APIGLS JSAEeowg0 ‘SAE aoWi90 (1) Product tobe used as an alternative in all couritios oxcopt ITALY. o| 00 - 43 COMPLETE CAR Type ‘Application | Classification Lei) = 1° there Gresve Foot INLGIn. 1 JAutogroase TA lsupply - 04 ~ Engine SECO: Moykote A ligation - 05 = lciuten -12 INGGIn. 3 [Groase33 FD |Autogroase FD INGIn 4 [Gronse 18 JAutogroasoTA | = {iSECO: Mojkote [are NiSECS: Molykote [Pastas Gearbox 13 |NLGIn.o [Groase33FD |Avtogrease FD INLGIn. 1 (Grease 15 JAvtogroaso TR INLGIn. 2 ~~ TISECO: Ergon |Rubber Grease n. 3 ISPCA: Spegraph Drive SAENLGI V2 JAutogreaso iP shat 15, vu— 00 49 COMPLETE CAR Type ‘Application | Classification = = AGP: ° Gearbox «13 7 Dttorontial- 17 UNION CARBIDE [CHEMICALS COM IPANY: Ucon lubri- ae lcant 60 HB 5100 IISECO: Moiykote lBR2 |Diferentiai-17 lISECO: Molykote IVN 2481/6 JOPTIMOL: |Otstamoty 2 LN 584 Front-whool INCGin.3 [Avtoproaso FD UNION CARBIDE CHEMICALS COM- IPANY: Ucon tubri- ant 50 HB §100| 00 -50 COMPLETE CAR Nemo Type Application _____. ne = ‘AaiP P Others [Grease 15 [Autogroase TA [ATE: Bromezyinder = Pasta DBA [Steoring 23 INLGIn.3 fGrease33 FO [AUtogronso FO JUNION CARBIDE ICHEMICALS CoM. PANY: Ucon lubri leant 60 HB 6100 IMILLOIL: Lubricant tor siastomor seals NLGIA.o [Greaue33FO |Auiogreaso FD fiiGin. [Grease 18 [Aviogrease TA JUNION CARBIDE IcHEMICALS COM. IPANY: Ucon tubr- 150 HB $100 FAILLOML: Lubricant or olastomor seals. u| 00 51 COMPLETE CAR AOIP P Others ‘and UNION CARBIDE tyres - 28 CHEMICALS COM. IPANY: Ucon lubri- leant 50 HB 6100 Lubricant Type Application | Classification Grease Flug Engine [Antiveeze extra |Antiiraeze JALFA ROMEO lcooting - 07 ICLIMAFLUID JPERMANENT -40°C kn) JALFA ROMEO JANTIFREEZE (2) [Brakes - 22 [RAKE FLUID JALFA ROMEO [Clutch - 12 ISUPER DOT 4 JBRAKE FLUID [SUPER DOT 4 AUTO FLUID FR DoT 4 (1) Ready -foruae cooling uid (2) Concentrated cooling fluid In countries where the epecitied products are not avaliable and In casos of absolute necessity, other well-known ¥y correspond to the In this case it will be necessary {0 replace the lubricant in the circult 10,000 km.aa 00 - 52 COMPLETE CAR APPROXIMATE FIEFILL CAPACITIES - FoR PETROL ENGINES <= Componente FUEL TANK FUEL RESERVE ; Unit of measurement ig Utros ENGINE Olt. at | 300 | 46 | 463 GEARBOX-DIFFERENTIAL OIL 24 26 REAR DIFFERENTIAL OIL (for 4x4 version) 09 ENGINE COOLING CIRCUIT di 78 QUANTITY OF CONCENTRATED ANTIFREEZE TO BE USE AT fet leona ‘TEMPERATURES UP TO -40°C 5 29 | 4,015 (2) QUANTITY OF ANTIFREEZE READY FOR USE 20 .. 78 | 7.3@) POWER STEERING OIL : 1 BRAKE AND CLUTCH HYDRAULIC CIRCUITS 045 : WINDSCREEN WASHER LIQUID CONTAINER : 60 CONDITIONER FREON 1,150 (1) For 4x4 versions (2) For Sport Wagon 1.7 1E and 4x4eae 00 - 53 COMPLETE CAR APPROXIMATE REFILL CAPACITIES - For DIESEL ENGINES aoa Unit of messurement| = i DIESEL FUEL TANK : 60 DIESEL FUEL RESERVE + [ 65 — ENGINE OIL 525(+ CGEARBOX DIFFERENTIAL OIL 24 26 POWER STEERING OIL : 09 ENGINE COOLING CIRCUIT Z * 68 QUANTITY OF CONCENTRATED ANTIFREEZE TO BE USED AT 4,04 TEMPERATURES UP TO -40°C " QUANTITY OF ANTIFREEZE READY FOR USE 2c * a8 BRAKE AND CLUTCH HYDRAULIC CIRCUITS 0,48 - WINDSCREEN WASHER LIQUID CONTAINER (+) The amount indicated applies o periodic replacementsMICROFICHE INDEX Microfiche 215 Group 00 Maintenance [eae] Group 00 Maintenance ‘TWIN-CARBURETTOR ENGINES ENGINE MAINTENANCE. FUELSISTEN, IGNITION ENGINE MAINTENANCE FUELSYSTEN, IGNITION (continued), COOLING MAINTENANGE waco MAINTENANCE OF MECHANICAL GF&OUPS. TOS, SPECIFIC TOS... ENGINES WITH ELECTRONICIGTZON (LEt-Jotronie) ENGINE MANTENANCE,FUELSISTEM IGNITION . a ENGINE MANTENANCE, FUELSISTEM, IGNITION (continuo. ‘COOLING MAINTENANCE, MAINTENANGE OF NECHANICALGROUPS, TCS, SPECIFIC TOOLS 0 0 ENGINE WITH ELECTRONIICINJEC TION 16 VALU" £3) ENGINE MAINTENANCE, FUEL SYSTEM, IGNITION, ENGINE MAIN-TBIANCE, FUEL SYSTEM, IGNITION (conta), COOLING. MAINTENAICE : MAINTENANCE OF MECHANIGALGGROUPS...... Tes SPECIFIC TOOLS, : : TURGODIESEL ENGINE ENGINE MAINTTENANGES UPPLY., = COOUNG MAINTENANCE, MAINTENANCE OF MECHAANCAL GROUPS... TCS,SPEOFIC TOOLS... . 00 00, 00 00. 00. 00 + 0,COMPLETE CAR TWIN-CARBURETTOR ENGINES - ENGINE MAINTENANCE, FUEL SYSTEM, IGNITION ENGINE MAINTENANCE, FUEL SYSTEM ANDIGNITION REPLACING ENGINE OIL AND FILTER REPLACING TIMING BELTS... TIMING BELTS... : Tonsioning water pump and alternator tive bot. Tansioning ar condoning crive bok Tensioning power steering bel. CHECKING FUEL SUPPLY PRESSURE AND [SEALING .c so CHECKING AIR CLEANER CARTRIDGE=| 00 REPLACING ENGINE OIL ANDFILTER 1 COMPLETE CAR, ‘Thooillwved sould be chackei when the vo hick ison a vel surface. Whtish sub sinces in the oll ise to wakage an. Tonrvhorstayb causset by dituiwith tel 1. When tho orgies. mim, rameve the ciller cap. 2. Withdraw the dpsticc Unscrew the drains lug and tet ihe didiaim out for at least 45 minules. ee + Sh heir he cpa + Replace the file ap, run t about 4. Usieg te appopirt too}, losen thecifitor and romove + Gloan the didinglueg and screw it back onto the sump. + Wipe the gasteton the new filter with oll and screw i into postion by hand + Rofiltha enginewith oil (seo TSN). ne at idle speed for fo rande, wich otine ergo ang waka few mminutas. = Check the cll! zand ensure that there are no leaks.=| 00 -2 aero REPLACING TIMING BELTS 4 4. Disconnoct tho electrical cables from the electric fan, = Rlomove the aternator and water pump drive bet (S00 2 Looson the scraws securing tho oloctifan GROUP oF 3, Romove tho fan by sliding tout of te groove. 4, Remove the timing bel covers. ~ Remove the spark plugs. 5. Remove the camshaft support covers.COMPLETE CAR REPLACING TIMING BELTS (continued) | Remove he tng chet vet ard tum te carkstah 2, Slickan off tans. socuring te bt unsiowrard exer tunetil the piston of ylides mber 1 is at TOC in the pressure on heightening puloys in cid et overcome igration phase. This posioe Is ensured whon tho rolr- thotension onthe beats. Lock the nutsin thibposition. EeeemarkTenholjwesis iniinewih temarkonhe lamar fits a ht-nandtoched bat xian the lo o=arcover. from the canstat ard crankshaft pulleys ahand 00 -4 COMPLETE CAR REPLACING TIMING BELTS (continued) ‘Check engine timing. 2. Rola tho lofhand timing bot unt th tooth and its two adjacont grooves on the fef-hand pulley can be sean throught inspection holon thoroar quaréat etiing i + Rotate the crankshalt until the mark on the engine ‘cover isin line with tha rafarance mark T on thet 1. Whan tho roferonce mark Tis aligned with the mark on ! i * reveal the valves om shiny tre pictos during Yotation {wa the pon of eynder No. tat TDC inthe fron of the camshaft, BREP*LACING TIMING BELTS (continued) 41. Holding thnthafes in thyspsition, thelofthandti ing bo Cary Fiteon the uly without voli the ute of oI, 2. Locoson thobelt tenleatw nut to allow thebell tensioner pul teyto canelreto coratiawith the bal sotath.e tension Go-aitid bythe Spring “erated on the fet Tighten the nt. = Fowate thecanicshatt jah by abou 4S’ oprevert the valvesfrontiting the pion whon the canstaft is being positioned, 8. fowals thi ght-handl_anshaft unt the bath and two ‘gj acint groves on thy ight-hanc pully)can_ be seen Iicough tiohipection Yoeon the rea gual tre tiing pul toy. + floats thevenkshatt all he markora te engine rear coweris inl with thesidbronico rok “onthe flywhoa! (wetthplstordcy linder tk tat TOC inthebntors phaso) 4, Ft tha rigithinc! timiragbat onto thepulins can 00 «5 COMPLETE CARCOMPLETE CAR 1. Loosen the facknut on the righthand bat tensioner 19 allow the bal tencionar pulley to oxo the ores contorted by tho spring ono the be ght the Bolt + Check: the tansion on the timing bots boginning from tho ‘ono onthe righthand side 2, Rotate the crankshaft onthe normal direction of rotation Unt refarenca mark‘ onthe iywhael iin fine with ho tafarence mark onthe engine roar cov. a Inthis position the four cams of the right-hand com jlindors 1 and 3)do not touch their respective valve lappots,| ©0 -7 REPLACING TIRING BELTS (contine ued) 1, Loosen tieight-harnibolt tensionor rut sofa. tensions the timiragtoh, ancl fan tighton tte tho cueet torque, Durhg this opration donot wxeriey Pressure Sul erm cron ihe bel “teint Bouley in Serle mveoioterng the comecinazon iaed, = Turn thes egine onersioluion inth enon die-ectionof totalon “ig iroabe previous pcstignyh thordlr ‘once maak aligneden the engines ty hs), COMPLE TECAR (With ongieve cold) 1G Ni Inthispestion tho four cons of the iet-Rand al (olienders 2und 4}desnotioich their respedivavalwe tappeta, 2, Locsenthe lelthard toe tenslonar nut sothlitensions the loft hancitmingbestt and thenre-ightan tolhecerrect torque. + Once althe oparaiovas have boon cimpbtedchack that the timing rmaiks on the pulleys cones pondia ihe rear holes ofthe tininghett. + Regssemble th vaious components, revarstg the pro- codura followed la dicsassombly andionsionte atorna- ‘or-water punp et=| 00 -8 COMPLETE CAR DRIVE BELTS ‘TENSIONING ALTERNATOR ANO WATER PUMP DRIVE BELT 1.824,018,000 3 (C.2.0131) 1, Free the alternator mounting bots. 2, Move the alternator to tighten or slacken the belt. 3. Restighton the bolts, and with tol N” 1.£24.018.000 {C.2.0131) check that the tension values are within the specitiod tits, within the specified limits,[| 00 ~9 CWPLETECAR DRIVE BELTS (continuod ) TENSTONINGAIR CONDITIONER ORIVEBELT + Leosenthe bolts secsing thecomnprestor. + Move the campressciilighton cer slacker tho bel : sian iho bots snd usigg tool N' 102401 esto (C.2.0131) chockthaaliothe ans ¢on valves aowity aio Soaced hae jervsioning the air conditioning drive bet [Duringrefiting x + Répeat he above open ithe tonsins te ot watin ‘924,o18un AN the specified limits. (C.2.0191)| 00 -10 See DRIVE BELTS (continued) ‘TENSIONING POWER STEERING BELT + Lonsen the bolts securing the powar steering pump, + Move the power steering pump to tighten or slacken tho ote bel 7 ~ Resigtton the bote and ving fol N’ 1.624.018.000 (C.2.0181) chock that the fension values are within the Spectlad mit 1.824,018.000 (€.20131) During refiting |Attor 1000 - 1500 km : the above operations i the tension Isnt within the prescribed limits.=| OO -1 eo CHECKIPAO FUEL SUPPLY PIRESSURE AND SEALING 1. Remove twhaupply hostcomectin eh pump and lt fondcoteanor’ ee 2, Icon aT - want tedwithacuolf aps: neon the pump and the castmottor. 4. Atach a riometerto ttre ond of tehose. [Pump |FIsPA, Punp ‘SAVARA- (GuaRD + Start the engine nd_with 1 down stream jeomatic pre jelivery pressure! 2.18 030 igitn’)| 477 - 20.4kPo (2.177 -0.208 bag | wstip.m. 0.18- 030igin?)| 17.7 20.4? (0.177 -0.29¢ tars ti on thedetiay hose Janomélor closed and allo same .S tho purmp, chock: hatha pump as spectied. = the values menutect ara incortectrepleace thapump.COMPLETE CAR CHECKING AIR CLEANER CARTRIDGE 1. Release the four clips securing the cover ofthe reservoir andrea the cove 2 the four clips securing tl fie andtp ecpoova' the 3. Remove the catidge retaining frame. 4, Remove the cartridge. rdgo retaining franie and cartridge sure comer fromthe side replace the cartridge latic part facing upwards, q filed with the Wich shoud bette witbCOMPLETE CAR TWIN-CARBURETTOR ENGINES « ENGINE MAINTENANCE, FUEL SYSTEM, IGNITION (continues) + COOLING MA!NTENANCE ENGINE MAINTENANCE, FUEL SYSTEM, IGNITION CHECKING AND ADJUSTING IGNITION TIMING, im CHECKING AND ADJUSTING IDLE SPEED AND EXHAUST EMISSIONS (CO%). REPLACING SPARK PLUGS. 0-13 218 18 COOLING MAINTENANCE CHECKING ENGINE COOLANT LEVEL jnnennaensOO* 1 CHECKING SEALING OF ENGINE COOLING SYSTEM... ‘Checking sealing=| 00-13 ene CHECKING AND ADJUSTMENT OF IGNITION TIMING 1. Geom tthe clips of the strobegutic the battery. 2 Comsthe pickupie te hyhiesion cable o! cylinder numba. 8, Comma ean electrons rp.m, courte ead he leads tothe ol i iene ‘Sod he eek thaliitension lead of th cal00 14 COMPLETE CAR CHECKING AND ADJUSTMENT OF IGNITION TIMING (continued) 1. Remove the plastic cover from the engine rear cover, + Startthe engine and runto normal operating temperature, = Using the strobe gun ensure that he timing advanco mark ‘onthe flywhee! lines up with the timing index on the rear ‘cover at 800 r.p.m. 2, Disconnect the vacuum advance pipe from the detribulor and ensure thatthe maximum advance timing markonthe flywheel lines up with the timing index on the ear cover at 41500 p.m. 3. ithe timing marks do not line up, loosen the eistrbutor lock bolt and rotate the dstibutor clockwise to retard or anticlockwise to advance the ting. = Tighten the distributor lock bolt and check that the fed and maximum timing advance satings are correct. = Replace the plastic cover on the engine rear cover. + Insert the vacuum timing advance pi + Wabove adjustment does not alow tho maximum advance to be corrected the distributor must be overhauled or replaced. [Fixed advance angio war [Maximum advance angle 3a"| 00 -15 ere CHECKINGS AND ADJUSTNE INT OF IDLE SPEED AND EXHAUST EMISSIONIS(CO%) = Belorosarking the operations check tat the accelerator = NOTE eda iscor racly adjusted (seo 0422). sis@ the vehicle on allt. . Disconnect the exhaust manos trom the cylinder heads. 3, Insorttlargeas N’ 1.824,008.000|620054) betwoen each flange dhs exhaust mantold andis attachment on the ginger hezads ard then raceme t-ve martod tothe g