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Alfa Romeo ALFETTA Service Repair Manual 1973-1987

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The Alfetta, produced from 1973 to 1987, represents a significant chapter in the brand's history, embodying dedication to performance, distinctive Italian styling, and driver engagement. Available in sedan (Berlina) and...
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SKU: 136676
Alfa Romeo ALFETTA Service Repair Manual 1973-1987
The Alfetta, produced from 1973 to 1987, represents a significant chapter in the brand's history, embodying dedication to performance, distinctive Italian styling, and driver engagement. Available in sedan (Berlina) and coupe (GT, GTV, GTV6) variants, the Alfetta is characterized by its iconic Bertone-designed coupe bodies and classic Italian sedan proportions. A key engineering innovation was its transaxle layout, integrating the gearbox and differential at the rear axle to achieve superior weight distribution and enhanced handling dynamics. This, coupled with its sporty engine options, including the renowned Twin Cam and the powerful 2.5L V6 Busso engine in the GTV6, cemented its reputation as a driver-focused automobile that competed effectively with contemporary European executive cars. This comprehensive service repair workshop manual provides in-depth guidance for the maintenance, repair, and restoration of your Alfetta. It covers all major systems, including engine mechanicals, fuel and ignition systems, transmission and drivetrain, suspension, steering, brakes, and electrical systems, as well as body and chassis components. Detailed procedures for regular maintenance, troubleshooting common and uncommon faults, component repair, and even complete rebuilding and restoration are included. With its professional technician-level information, this manual is an indispensable resource for owners, mechanics, and technicians aiming to preserve the performance, reliability, and classic character of their Alfetta.
🏷️ Basic Information
Identification
Make:
Alfa Romeo
Model:
Alfetta
Model Variants:
Berlina (Sedan), GT (Coupe), GTV (Coupe), GT Veloce (Coupe), GTV6 (Coupe)
Production Years Covered:
1973-1987
👋 Introduction
Market Position
Vehicle Segment:
Compact executive car / Sports sedan/coupe
Brand Philosophy:
Alfa Romeo's focus on performance, distinctive styling, and driver engagement.
Competitive Analysis
Key Competitors:
BMW 3 Series, Mercedes-Benz W123/W201, Audi 80/100, Ford Sierra, Lancia Beta.
Key Features
Design Language:
Iconic Bertone styling for coupe variants, classic Italian sedan proportions.
Engineering Layout:
Transaxle design (gearbox and differential at rear) for improved weight distribution and handling.
Performance Orientation:
Emphasis on sporty handling and engine responsiveness.
Manual Value Proposition
Cost Savings:
Enables DIY repairs and maintenance, significantly reducing labor costs.
Accessibility:
Provided in an easy-to-use PDF format, accessible on PC and MAC.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Workshop Manual
Language:
English (Assumed, based on product description)
Format:
PDF Download
Page Count
Page Count:
Undisclosed (PDF manual, page count can vary by specific content)
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical (including assembly, disassembly, inspection, repair of all components), fuel system (carburetor/injection, fuel pumps, lines), ignition system, cooling system, lubrication system, exhaust system.
Transmission:
Manual Transmission (gearbox, clutch, driveshafts, transaxle configuration), Automatic Transmission (if applicable to specific models/years covered).
Drivetrain:
Rear-wheel drive system, differential, axle shafts.
Suspension:
Front and rear suspension systems (independent/transaxle specific), shock absorbers, springs, control arms, bushings, anti-roll bars.
Steering:
Steering system components, steering rack, power steering system (if equipped).
Brakes:
Front and rear brake systems (disc brakes), brake calipers, master cylinder, brake lines, parking brake system.
Electrical:
Wiring diagrams, charging system (alternator, battery), starting system (starter motor), lighting system (headlights, taillights, interior lights), instrument panel and gauges, ignition switch, fuses, relays, horn.
Body And Chassis:
Body panel removal and installation, interior trim, doors, windows, seats, bumpers, frame/unibody structure, corrosion prevention.
Heating And Air Conditioning:
HVAC system components, blower motor, heater core, evaporator, refrigerant system (if applicable).
Procedures Included
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, lubrication points, tire rotation, brake inspection.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, identification of electrical and mechanical issues.
Repair:
Detailed step-by-step repair instructions for all covered systems, including component removal, overhaul, and reassembly.
Rebuilding:
Comprehensive guidance on engine rebuilds, transmission overhauls, and other major component restorations.
Refurbishment:
Procedures for restoring worn or damaged components and systems.
Restoration:
Detailed instructions applicable to classic car restoration projects, including bodywork, interior, and mechanical aspects.
Technical Depth
Depth Level:
Comprehensive (A-Z coverage, professional technician level information)
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text (implied by PDF format)
Print Quality
Printability:
Printable pages for individual repair tasks or complete sections.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Family:
Alfa Romeo Twin Cam (Nord engine variants)
Engine Variants
Engine Displacement Options:
1.6L, 1.8L, 2.0L (Twin Cam), 2.5L V6 (Busso V6 for GTV6)
Performance
Horsepower Range:
Approximately 109 hp (1.8L) to 158 hp (2.0L) for Twin Cam; 158 hp to 180 hp for GTV6 variants (depending on specific tuning and year).
Torque Range:
Varies by displacement and tuning, typically in the range of 150-200 Nm for Twin Cam variants.
Fuel System
Carburetion:
Often equipped with twin downdraft Weber or Dell'Orto carburetors (e.g., 40 DCNF, 45 DCOE).
Fuel Injection:
Later models, particularly GTV6, may feature Bosch L-Jetronic or similar fuel injection systems.
Cooling System
Cooling Type:
Liquid-cooled, front-mounted radiator.
Lubrication System
Oil Type Recommendation:
Typically SAE 10W-40 or 10W-50, API SG or equivalent (specific grades to be confirmed in manual).
Engine Codes
Common Engine Codes:
AR00540 (1.6), AR00530 (1.8), AR105.06 (2.0 Twin Cam), AR115.01 (2.5 V6 GTV6)
🔧 Transmission
Standard
Gearbox Type:
5-speed manual transaxle.
Optional
Automatic Transmission:
Less common, but some export markets or specific models might have offered an automatic option (details to be verified).
Features
Transaxle Design:
Integrated gearbox and differential unit located at the rear axle for optimal weight distribution.
Fluid Specifications
Transmission Fluid Type:
GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90, specific viscosity depends on ambient temperature and manufacturer recommendation).
Clutch System
Clutch Type:
Hydraulically operated single dry-plate clutch.
📐 Dimensions
Exterior
Wheelbase Range:
Approximately 2500-2530 mm (98.4-99.6 in) depending on sedan/coupe variants.
Length Range:
Sedan: ~4300-4360 mm (169.3-171.7 in); Coupe: ~4200-4250 mm (165.4-167.3 in).
Width Range:
Approximately 1660-1700 mm (65.4-66.9 in).
Height Range:
Approximately 1370-1380 mm (53.9-54.3 in) for coupes, slightly higher for sedans.
Weights
Curb Weight Range:
Approximately 1100-1300 kg (2425-2866 lbs) depending on model and equipment.
Gross Vehicle Weight Rating:
To be confirmed in the manual, typically around 1500-1600 kg.
Towing Capacity:
Not typically specified or recommended for this type of sporty vehicle.
🛡️ Safety Features
Ratings
Crash Test Results:
Limited official crash test data available from the era; designed to contemporary European standards.
Active Features
Braking System:
Four-wheel disc brakes (standard on most models from launch) for superior stopping power compared to contemporary drums.
Handling Dynamics:
Transaxle layout and near 50/50 weight distribution contribute to excellent handling characteristics.
Passive Features
Seat Belts:
Three-point seat belts for front occupants, lap belts for rear (standard fitment evolved through production years).
Body Structure:
Reinforced passenger cell and crumple zones, typical of European design principles of the period.
💡 Technology Features
Infotainment
Radio System:
Factory fitted radios were typically AM/FM, often Blaupunkt or Becker, with manual tuning and basic speaker systems.
Speakers:
Typically two or four speaker configurations.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was not a standard feature on most Alfettas of this era, becoming more common in later iterations or optional for some.
Connectivity
Connectivity Features:
No modern connectivity features (Bluetooth, USB, etc.) were available on original models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 8,000-10,000 km (5,000-6,000 miles) or annually, whichever comes first. Manual will provide precise recommendations.
Filter Replacement:
Air filter, oil filter, fuel filter replacement at recommended intervals, usually coinciding with oil changes or every ~15,000-20,000 km.
Timing Belt Replacement:
For Twin Cam engines, timing belts require replacement at specified intervals (e.g., 50,000-80,000 km or 5 years). For V6, chain or belt specifics apply. Manual is critical here.
Tune Up Frequency:
Regular tune-ups including spark plug replacement, ignition timing adjustment, carburetor adjustment (if applicable) recommended every 15,000-25,000 km.
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze mixture, typically 50/50 with distilled water. Manual will specify approved types.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual will confirm specific requirement.
Power Steering Fluid:
If equipped, typically ATF Dexron II or equivalent. Manual will specify.
Known Issues
Rust Prone Areas:
Sills, wheel arches, floor pans, boot floor, door bottoms are common areas for rust due to age and material.
Carburetor Tuning:
Twin Weber/Dell'Orto carburetors can require frequent adjustment and maintenance for optimal performance and fuel economy.
Electrical Gremlins:
Aging wiring looms, grounds, and components can lead to intermittent electrical issues.
Transaxle Clutch Wear:
Clutch wear and potential rear-mounted gearbox issues are common maintenance points.
Engine Oil Leaks:
Seals and gaskets in the Twin Cam and V6 engines can degrade over time, leading to oil leaks.
📚 Vehicle History
Brand Heritage
Alfa Romeo Legacy:
Renowned for motorsport heritage and a long tradition of producing engaging driver's cars.
Model Evolution
Initial Launch:
Introduced in 1972 for the 1973 model year, designed as a modern compact executive car.
Key Development:
The Alfetta platform was a departure with its rear transaxle and de Dion rear suspension (on some variants), setting it apart from earlier Alfa Romeos.
Gnostic Variant:
The GTV6, introduced in 1980, is considered a performance icon, featuring the potent 2.5L V6 'Busso' engine.
Production
Manufacturing Location:
Primary manufacturing at Alfa Romeo's Portello plant in Milan, Italy.
Production End Year:
1987
🏆 Awards & Recognition
Recognitions
European Car Of The Year Nomination:
The Alfetta was nominated for European Car of the Year in 1973, finishing as runner-up.
Automotive Press Reviews:
Consistently praised for its handling, engine performance (especially the V6), and styling by automotive journalists of the period.
Certifications
Industry Standards:
Built to comply with European automotive safety and emissions standards of the respective production years.
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