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Alfa Romeo 75 MILANO 2.5 3 V6 Digital Workshop Repair Manual

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The Alfa Romeo 75, also known by its nickname Milano, is a compact executive sedan produced from 1984 to 1992. This rear-wheel-drive vehicle is distinguished by its renowned Italian design,...
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Alfa Romeo 75 MILANO 2.5 3 V6 Digital Workshop Repair Manual
The Alfa Romeo 75, also known by its nickname Milano, is a compact executive sedan produced from 1984 to 1992. This rear-wheel-drive vehicle is distinguished by its renowned Italian design, penned by Giugiaro, and its potent Alfa Romeo Busso V6 engine, celebrated for its distinctive sound and performance. Its chassis layout, featuring a rear transaxle, contributes to optimal weight distribution and exceptional handling characteristics, making it a favored choice among driving enthusiasts. The 75's angular styling and unique "kamm-tail" rear are hallmarks of its era, setting it apart from competitors like the BMW 3 Series and Mercedes-Benz 190 E. This digital workshop repair manual provides comprehensive diagnostic, repair, maintenance, and rebuild procedures for the Alfa Romeo 75 Milano 2.5 V6 (Type 119). It covers all major vehicle systems, including the engine, transmission, brakes, suspension, steering, electrical components, body, and HVAC. The manual details routine maintenance tasks, troubleshooting guides, and step-by-step instructions for component removal, installation, and overhaul, offering professional-level depth with detailed specifications and torque values. High-quality photos, illustrations, and diagrams are included to facilitate understanding, ensuring owners and technicians can effectively maintain and repair the vehicle.
🏷️ Basic Information
Identification
Make:
Alfa Romeo
Model:
75
Nickname:
Milano
Engine Variant:
2.5 V6
Powertrain Configuration:
Rear-wheel Drive (RWD) with Transaxle
Product Type:
Digital Workshop Repair Manual
Codes
Chassis Code:
Type 119
👋 Introduction
Market Position
Segment:
Compact Executive Sedan / Sports Sedan
Unique Selling Proposition:
Renowned Italian design, potent V6 engine, rear-wheel drive dynamics, and distinctive Alfa Romeo character.
Competitive Analysis
Key Competitors:
BMW 3 Series, Mercedes-Benz 190 E, Audi 80/90, Ford Sierra, Peugeot 405.
Key Features
Design:
Giugiaro-designed exterior, distinctive 'kamm-tail' rear, angular styling.
Powertrain:
Alfa Romeo Busso V6 engine known for its distinctive sound and performance.
Chassis Layout:
Rear transaxle layout for optimal weight distribution and handling.
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive diagnostic, repair, maintenance, and rebuild procedures for the Alfa Romeo 75 Milano 2.5 V6.
Page Count
Estimated Page Count:
Likely exceeds 1000 pages (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Repair Manual
Language
Language:
English (assumed from product description)
Format
Digital Format:
Digital (Viewable and Printable PDF-like format)
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical (assembly, disassembly, inspection), lubrication system, cooling system, fuel system (including injection), ignition system, exhaust system, engine management.
Transmission:
Manual and Automatic Transaxle (gearbox and differential), clutch, driveshafts, propeller shaft.
Brakes:
Hydraulic system, brake calipers, brake discs, brake pads, parking brake, ABS system (if equipped).
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, anti-roll bars, steering linkage.
Steering:
Steering rack, power steering system, steering column.
Electrical:
Battery, charging system, starting system, lighting system, dashboard instruments, engine control unit (ECU) wiring, body electricals, power accessories, fuse box diagrams.
Body:
Body panels, doors, windows, locks, hinges, interior trim, bumpers, glass replacement.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system components and service.
Procedures Included
Maintenance:
Routine service, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement.
Diagnostics:
Troubleshooting guides for common problems, symptom-based diagnostics, fault code interpretation (if applicable to the era).
Repair:
Component removal, installation, adjustment, and overhaul for all major vehicle systems.
Rebuild:
Detailed engine rebuild, transmission overhaul, and suspension component rebuilding instructions.
Installation:
Procedures for replacing or installing various parts and accessories.
Technical Depth
Depth:
Professional level, covering detailed specifications, tolerances, torque values, and step-by-step instructions for complex tasks.
📊 Manual Specifications
File Format
Compatibility:
Windows 95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7; Compatible with Mac computers.
Print Quality
Visuals:
High-quality photos, illustrations, and diagrams.
Binding Type
Binding:
Not Applicable (Digital Format)
Paper Type
Paper Quality:
Not Applicable (Digital Format)
Features
Searchability:
Likely searchable text content for efficient information retrieval.
Usability:
Easy to use, printable for workshop convenience.
⚙️ Engine Specifications
Primary Engine
Engine Code:
AR06157 (for 2.5 V6)
Configuration:
90-degree V6, DOHC (Dual Overhead Camshafts)
Displacement:
2492 cc (2.5 Liters)
Bore X Stroke:
84.0 mm x 74.5 mm
Compression Ratio:
9.3:1 (typical for 2.5 V6)
Performance
Horsepower:
155 hp (115 kW) @ 5800 rpm (approximate for Euro specs)
Torque:
210 Nm (155 lb-ft) @ 4000 rpm (approximate for Euro specs)
Fuel System
Injection System:
Bosch L-Jetronic or Motronic (depending on market and year)
Fuel Type:
Unleaded Gasoline (Petrol)
Lubrication
Oil Capacity:
Approximately 5.5 liters (5.8 US quarts) with filter
Cooling
Coolant Capacity:
Approximately 8.0 liters (8.5 US quarts)
🔧 Transmission
Standard
Type:
5-speed Manual Transaxle
Optional
Type:
3-speed Automatic Transaxle (e.g., ZF 4HP22)
Features
Layout:
Rear-mounted transaxle (gearbox and differential combined)
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5 SAE 75W-90 or 80W-90 (verify with manual for specific Alfa Romeo recommendation)
Automatic Transmission Fluid:
Dexron III or equivalent (verify with manual)
📐 Dimensions
Exterior
Length:
4360 mm (171.7 in)
Width:
1680 mm (66.1 in)
Height:
1370 mm (53.9 in)
Wheelbase:
2510 mm (98.8 in)
Weights
Curb Weight:
Approx. 1250-1350 kg (2756-2976 lbs) depending on equipment
🛡️ Safety Features
Ratings
Crash Test Performance:
No standardized global crash ratings available from that era (e.g., Euro NCAP did not exist in its current form).
Active Features
Brakes:
Front: Ventilated Discs, Rear: Discs (often with inboard rear discs for reduced unsprung weight)
ABS:
Optional (typically Bosch ABS)
Passive Features
Seatbelts:
3-point front and rear seatbelts
Chassis Reinforcement:
Designed with structural integrity for its time.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player (brand varies, e.g., Blaupunkt, Clarion), often with amplifier system.
Dashboard:
Analog gauges for tachometer, speedometer, oil pressure, temperature, fuel; warning lights for critical systems.
Driver Assistance
ABS:
Optional, as mentioned in safety features.
Connectivity
Features:
Primarily focused on mechanical and electrical systems; no modern connectivity features like Bluetooth or USB.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually (recommended)
Timing Belt Replacement:
Every 60,000 km (37,000 miles) or 3-4 years (CRITICAL for V6 engines)
Fluid Specifications
Engine Oil:
API SG/SH or higher, SAE 10W-40 or 15W-40 (verify with manual, synthetic options recommended for Busso V6)
Coolant:
Ethylene glycol-based antifreeze with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid:
DOT 3 or DOT 4.
Known Issues
Engine Wear:
Timing belt tensioner failure (hence critical interval), potential for oil leaks, carburetor/injection system tuning issues.
Electrical:
Aging wiring harnesses, corrosion in connectors, issues with dashboard electronics.
Rust:
Susceptible to rust in wheel arches, sills, and door bottoms.
Suspension:
Wear in control arm bushings and ball joints.
📚 Vehicle History
Brand Heritage
Heritage:
Alfa Romeo has a long history of producing sporting cars with a focus on driving pleasure and distinctive Italian style.
Model Evolution
Predecessor:
Alfa Romeo Alfetta
Successor:
Alfa Romeo 155
Production
Production Years:
1984-1992
Manufacturing Location:
Milan, Italy (and other Fiat Group facilities)
🏆 Awards & Recognition
Recognitions
Market Perception:
Highly regarded by enthusiasts for its driving dynamics, unique engine, and Italian flair. Often considered a 'driver's car'.
Ratings
Performance Reviews:
Praised for sharp handling and a sonorous V6 engine in contemporary automotive press.
Certifications
Manual Quality:
Recognized for its comprehensive coverage and detail, suitable for professional technicians and dedicated enthusiasts.
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