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Alfa Romeo 75 MILANO Service Repair Workshop Manual

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The 75 Milano, also known as the 75 or Giulietta (Type 116), is a sport sedan produced from 1985 to 1992. Renowned for its rear-wheel-drive layout, near-perfect weight distribution, and...
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Alfa Romeo 75 MILANO Service Repair Workshop Manual
The 75 Milano, also known as the 75 or Giulietta (Type 116), is a sport sedan produced from 1985 to 1992. Renowned for its rear-wheel-drive layout, near-perfect weight distribution, and distinctive Italian styling, the 75 Milano offered engaging driving dynamics and was positioned as a more modern competitor to established European sport sedans of its era, such as the BMW 3 Series. Unique selling points included the availability of the sonorous Busso V6 engine and an advanced transaxle layout that further optimized handling. This model represents a significant chapter in heritage, emphasizing performance and driver involvement. This comprehensive service repair workshop manual provides detailed information for all models and engine variants of the 75 Milano. It covers essential areas including scheduled maintenance, diagnostic procedures, step-by-step repair instructions for all major mechanical and electrical components, and rebuilding procedures. The manual is designed to assist owners, mechanics, and technicians in maintaining and repairing the vehicle, ensuring its optimal performance and longevity. With hundreds of pages of expert guidance, it serves as an indispensable resource for anyone working on this classic Italian automobile.
🏷️ Basic Information
Identification
Make:
Alfa Romeo
Model:
75 Milano
Alternative Model Designations:
Alfa Romeo 75, Alfa Romeo Giulietta (Type 116)
👋 Introduction
Market Position
Positioning:
A enthusiast-focused, sport sedan offering distinctive Italian design and engaging driving dynamics.
Competitive Analysis
Key Competitors:
BMW 3 Series (E30), Mercedes-Benz 190E (W201), Audi 80/90, Ford Sierra
Key Features
Design Philosophy:
Rear-wheel drive, near-perfect weight distribution, distinctive Alfa Romeo styling, advanced (for its time) engineering.
Unique Selling Points:
Busso V6 engine variants, advanced Transaxle layout, sporty handling characteristics.
Manual Value Proposition
Benefit To Owner:
Empowers owners to perform maintenance and repairs, saving costs and ensuring proper care of a classic Italian automobile.
📋 Manual Details
Coverage Areas
Languages:
English (assumed, based on product description emphasizing completeness and repair)
Model Variants Covered:
All models and engine variants of the Alfa Romeo 75 Milano
Page Count
Estimated Page Count:
Hundreds of pages (as stated in description)
Manual Type
Type:
Service Repair Workshop Manual
Format
Digital Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system
Transmission:
Manual and Automatic transmission repair, clutch, driveline, driveshafts
Chassis And Suspension:
Front and rear suspension, steering system, wheels and tires
Brakes:
Hydraulic brake system, parking brake, ABS (if applicable)
Electrical System:
Battery, charging system, starting system, lighting, instruments, wiring diagrams, fuses and relays
Body And Interior:
Body panels, doors, windows, interior trim, seats, HVAC system, body electrical components
Procedures Included
Maintenance:
Scheduled maintenance, lubrication, fluid changes, filter replacements, inspections
Diagnostics:
Troubleshooting guides, fault finding procedures, diagnostic trouble codes (DTCs) interpretation (where applicable)
Repair:
Step-by-step repair instructions for all major mechanical and electrical components
Rebuilding:
Detailed procedures for engine, transmission, and component rebuilds
Refurbishing:
Procedures for restoring worn or damaged components
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds)
📊 Manual Specifications
File Format
Compatibility:
Universal PDF reader compatibility
Print Quality
Quality:
High-resolution, printable pages
Binding Type
Type:
Digital Download (N/A for physical binding)
Paper Type
Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Examples:
AR01634 (2.0L Twin Spark), AR06122 (3.0L V6)
Engine Configurations:
Inline-4 (Twin Spark), V6
Displacement Options:
1.6L, 1.8L, 2.0L (Twin Spark), 2.5L V6, 3.0L V6
Performance
Horsepower Range:
Approximately 110 hp (1.6L) to 200 hp (3.0L V6 Quadrifoglio)
Torque Range:
Varies significantly by engine, e.g., ~180 Nm (2.0 TS) to ~250 Nm (3.0 V6)
Fuel System
Induction Type:
Carburetor (early models), Bosch L-Jetronic/Motronic Fuel Injection (later Twin Spark and V6)
Technical Details
Valve Train:
DOHC 8v (Inline-4), DOHC 12v (V6), DOHC 16v (later Twin Spark)
Bore Stroke Examples:
2.0L Twin Spark: 83.0 mm x 91.0 mm; 3.0L V6: 88.0 mm x 82.0 mm
Compression Ratio Examples:
2.0L Twin Spark: 9.3:1; 3.0L V6: 9.0:1
🔧 Transmission
Standard
Type:
5-speed manual transaxle
Optional
Type:
3-speed automatic (e.g., ZF 3HP22)
Features
Transaxle Layout:
Rear-mounted gearbox and differential (transaxle) for optimized weight distribution.
Fluid Type Examples
Manual Transmission Fluid:
SAE 75W-90 GL-4 or GL-5 (check specific manual for exact spec)
Automatic Transmission Fluid:
Dexron II (for ZF 3HP22)
📐 Dimensions
Exterior
Length:
Approximately 4350 mm (171.3 in)
Width:
Approximately 1680 mm (66.1 in)
Height:
Approximately 1370 mm (53.9 in)
Wheelbase:
Approximately 2610 mm (102.8 in)
Weights
Curb Weight Range:
Approximately 1150 kg - 1300 kg (2535 lbs - 2866 lbs)
Gross Vehicle Weight Rating:
Refer to vehicle plate; typically around 1600-1700 kg
Cargo
Trunk Volume:
Moderately sized trunk, typical for its class, influenced by transaxle placement.
🛡️ Safety Features
Ratings
Crash Test Data:
Limited formal crash test data available compared to modern standards; designed with period-appropriate safety features.
Active Features
Braking System:
Hydraulic disc brakes on all four wheels (often ventilated front), often with servo assistance.
ABS:
Optional on some later models
Passive Features
Seatbelts:
Three-point seatbelts (front), two-point (rear, early models), three-point (rear, later models)
Steering Column:
Collapsible steering column
Body Structure:
Reinforced safety cell with crumple zones
💡 Technology Features
Infotainment
Audio System:
Period-appropriate radio cassette players, often with basic speaker systems. Aftermarket upgrades common.
Dashboard Instruments:
Comprehensive array of analog gauges including tachometer, speedometer, oil pressure, temperature, and fuel level.
Driver Assistance
Features:
Limited to ABS on later models. Focus is on driver engagement rather than electronic aids.
Connectivity
Features:
None (pre-digital age connectivity).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or 12 months (approximate, consult manual)
Timing Belt Interval:
Every 40,000 - 60,000 km (25,000 - 37,000 miles) or 3-5 years for Twin Spark engines. V6 timing chains require less frequent attention but checking is crucial.
Spark Plug Replacement:
Typically every 20,000 - 40,000 km, depending on type (e.g., Twin Spark requires regular attention).
Fluid Specifications
Engine Oil Type Examples:
API SG/SH, ACEA A2/A3, SAE 10W-40 or 10W-50 (depending on climate and engine wear)
Coolant Type:
Ethylene glycol-based antifreeze (e.g., Paraflu UP) mixed with distilled water in a 50:50 ratio.
Brake Fluid Type:
DOT 4
Power Steering Fluid Type:
Typically ATF Dexron II or specific Alfa Romeo fluid.
Known Issues
Rust Susceptibility:
Prone to rust in wheel arches, sills, and around window seals. Thorough inspection is vital.
Twin Spark Ignition:
Twin Spark engines require meticulous maintenance of the dual spark plug system for optimal performance and longevity.
Electrical Gremlins:
Aging wiring looms and connectors can lead to intermittent electrical faults.
Transaxle Clutch Actuation:
Hydraulic clutch actuation system can be a source of leaks or poor operation if not maintained.
Maintenance Philosophy
Importance Of Prevention:
Proactive maintenance is key to preserving the character and reliability of these Italian classics.
📚 Vehicle History
Brand Heritage
Founding Principles:
Emphasis on performance, sporting heritage, and innovative engineering since its founding in 1910.
Model Evolution
Predecessor:
Alfa Romeo Giulietta (Type 116, superseded)
Successor:
Alfa Romeo 155
Development Inspiration:
Designed to be a more modern and competitive successor to the Alfetta and Giulietta.
Production
Production Years:
1985-1992
Manufacturing Locations:
Milan, Italy; also assembled in other Fiat Group facilities.
Total Production Numbers:
Over 379,000 units across all variants.
🏆 Awards & Recognition
Recognitions
Automotive Journalism:
Frequently praised for its driving dynamics and handling, particularly the V6 models, by contemporary automotive press.
Classic Car Status:
Recognized as a future classic and a notable example of 1980s Italian automotive design and engineering.
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