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Alfa Romeo Alfasud Maintenance Service Repair Manual

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🏷️ Basic Information Identification Make: Alfa Romeo Model: Alfasud Codes Chassis Codes: Type 901, Type 902, Type 904 👋 Introduction Market Position Target Audience: Alfa Romeo Alfasud owners, independent repair...
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Sku: 192404
Alfa Romeo Alfasud Maintenance Service Repair Manual
🏷️ Basic Information
Identification
Make:
Alfa Romeo
Model:
Alfasud
Codes
Chassis Codes:
Type 901, Type 902, Type 904
👋 Introduction
Market Position
Target Audience:
Alfa Romeo Alfasud owners, independent repair shops, classic car enthusiasts, professional mechanics
Competitive Analysis
Value Proposition:
Provides in-depth, professional-level repair and maintenance information, bridging the gap between owner's manuals and specialized service bulletins, crucial for preserving and maintaining a classic Italian automobile.
Key Features
Diagnostic Capability:
Extensive diagnostic information and troubleshooting guides are essential for the Alfasud's unique engineering and electrical systems.
Completeness:
Covers all facets of vehicle maintenance and repair, from routine servicing to complete engine and transmission rebuilds.
📋 Manual Details
Coverage Areas
Coverage Scope:
All models and variants of the Alfa Romeo Alfasud
Page Count
Estimated Page Count:
Estimated 700+ pages (typical for comprehensive workshop manuals)
Manual Type
Manual Type:
Workshop Manual / Service Manual / Repair Manual / Parts Catalog
Language
Language:
English
Format
Format:
Digital (likely PDF, compatible with Windows, Mac, Linux)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, diagnostics, tuning, lubrication, cooling, fuel delivery (carburetor and early injection systems), emissions control
Transmission Drivetrain:
Transaxle (gearbox and differential) overhaul, clutch service, driveshafts, maintenance
Steering Suspension:
Steering rack and linkage overhaul, power steering (if applicable), front and rear suspension component service, alignment specifications
Brakes TCS:
Brake system diagnostics, hydraulic components (master cylinder, calipers, wheel cylinders), disc and drum brake service, parking brake, TCS (Traction Control System) diagnostics and repair (for applicable models)
Body Chassis:
Body repair, panel replacement, interior trim, doors, windows, structural information, jacking points
Electrical Systems:
Wiring diagrams, component testing, starter, alternator, ignition system, lighting, instrumentation, fuse/relay identification and troubleshooting
Climate Control:
Heating, ventilation, and air conditioning (HVAC) system service and repair
Parts Information:
Detailed parts catalog with diagrams and identification
Procedures Included
Diagnostic Procedures:
Troubleshooting guides for common and complex issues, diagnostic flowcharts
Maintenance Procedures:
Scheduled maintenance tasks, fluid changes, filter replacements, belt adjustments, tune-up procedures
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul of all major systems
Technical Specifications:
Detailed torque specifications, clearances, tolerances, electrical specifications, fluid capacities
Technical Depth
Depth Of Coverage:
Comprehensive, professional-level diagnostics and repair procedures suitable for experienced mechanics and advanced DIY enthusiasts
📊 Manual Specifications
File Format
Digital Format:
PDF (likely, offering searchability and bookmarking)
Print Quality
Diagram Quality:
High-quality, detailed diagrams and illustrations used by Alfa Romeo repair mechanics
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Horizontally-opposed (boxer) four-cylinder, SOHC
Engine Type Variants
Displacement Variants:
1.2L (1286 cc), 1.3L (1290 cc), 1.5L (1490 cc), 1.7L (1719 cc)
Performance
Horsepower Range:
63 hp to 105 hp (depending on engine variant and market)
Torque Range:
95 Nm to 132 Nm (depending on engine variant)
Fuel System
Fuel Delivery:
Twin-choke downdraft carburetors (e.g., Solex, Weber) and early Bosch L-Jetronic fuel injection on later models
Ignition System
Ignition Type:
Distributor-based, electronic ignition on later models
Cooling System
Cooling Type:
Water-cooled, front-mounted radiator
Lubrication
Oil Capacity:
Approx. 4.0 - 4.5 liters (check manual for specific engine)
Engine Codes
Common Engine Codes:
e.g., 115, 116, 135, 170 (specific to Alfa Romeo's internal coding)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transaxle
Optional
Automatic Transmission:
Rarely offered, not a common feature
Features
Drive Layout:
Front-wheel drive
Fluid Specifications
Gearbox Oil:
API GL-4 SAE 75W-90 or SAE 80W-90 (verify specific viscosity for climate)
📐 Dimensions
Exterior
Body Styles:
4-door Sedan, 5-door Hatchback (Sud Giardinetta), 2-door Coupe (Sud Sprint)
Wheelbase:
Approx. 2,510 mm (98.8 inches)
Weights
Curb Weight Range:
Approx. 950 - 1100 kg (2094 - 2425 lbs)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official modern crash test data available for this era; focus on structural integrity and passive safety features of the period.
Active Features
Braking System:
Front ventilated discs, rear drums (standard); later models and performance variants may have 4-wheel discs. Diagonal split braking system.
Passive Features
Seatbelts:
Standard seatbelt anchorage points
💡 Technology Features
Infotainment
Original Features:
Basic radio with analog tuning, cassette player (optional). Focus is on mechanicals rather than advanced electronics.
Driver Assistance
ABS Availability:
ABS was not a standard feature and was rare or absent on most Alfasud models.
TCS Availability:
Traction Control System (TCS) was very uncommon or not available on most Alfasud variants, though the manual covers it if present.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 - 7,500 km (3,000 - 4,500 miles) or annually, whichever comes first (refer to manual for precise recommendations).
Timing Belt Interval:
Highly recommended to replace every 40,000 - 60,000 km (25,000 - 37,000 miles) or every 3-4 years due to potential for catastrophic engine damage.
Fluid Specifications
Engine Oil Spec:
API SG/SH, ACEA A2/A3, SAE 10W-40 or 15W-50 (depending on climate, check manual).
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4.
Known Issues
Rust Susceptibility:
Significant rust issues, particularly in sills, wheel arches, and floor pans. Requires vigilant inspection and maintenance.
Electrical Gremlins:
Older wiring harnesses can degrade, leading to intermittent electrical faults. The manual's wiring diagrams are invaluable.
Carburetor Tuning:
Carburetors (Weber, Solex) require periodic adjustment for optimal performance and emissions.
Transaxle Clutch:
Clutch wear and transaxle synchromesh issues can occur with high mileage.
📚 Vehicle History
Brand Heritage
Brand Focus:
Alfa Romeo is renowned for sporty, driver-focused cars with distinctive Italian styling and engineering.
Model Evolution
Introduction Year:
1972
Production End Year:
1989
Production
Manufacturing Location:
Pomigliano d'Arco, Naples, Italy
Key Designers:
Marcello Gandini (Bertone) for the Sprint Coupe, Pininfarina for the sedan and estate variants.
🏆 Awards & Recognition
Recognitions
Historical Acclaim:
Voted European Car of the Year 1972. Praised for its innovative FWD layout, handling, and sporty driving characteristics for its era.
Ratings
Performance Reviews:
Widely lauded by automotive press for its excellent roadholding, agile chassis, and responsive engines, despite some early reliability concerns.
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