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Alfa Romeo Milano 1985-1992 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Alfa Romeo Model: Milano Nickname Or Alias: 75 Production Years Covered: 1985-1992 Codes Chassis Code: Type 119 👋 Introduction Market Position Market Segment: Compact executive...
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🏷️ Basic Information
Identification
Make:
Alfa Romeo
Model:
Milano
Nickname Or Alias:
75
Production Years Covered:
1985-1992
Codes
Chassis Code:
Type 119
👋 Introduction
Market Position
Market Segment:
Compact executive sedan and estate car
Competitive Analysis
Key Competitors:
BMW 3 Series (E30), Mercedes-Benz W201 (190E), Audi 80/90, Ford Sierra, Peugeot 405
Key Features
Design Philosophy:
Rear-wheel drive, transaxle layout for improved weight distribution, sporty handling, distinctive Italian styling
Performance Orientation:
Emphasis on driver engagement, sharp steering, and responsive engines, particularly in performance variants
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive workshop service and repair for Alfa Romeo Milano (75) models
Page Count
Page Count:
898
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, assembly, inspection, repair, timing, valve adjustments, piston/ring replacement, cylinder head service, block machining
Engine Management:
Fuel injection systems (Bosch L-Jetronic, Motronic), ignition systems, sensors, actuators, troubleshooting fuel and ignition faults, ECU diagnostics
Cooling System:
Radiator, thermostat, water pump, hoses, fan operation, coolant specifications, diagnosis of overheating
Lubrication System:
Oil pump, oil pan, oil filter, oil passages, oil specifications, oil pressure testing
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes, gaskets, hangers, emissions control
Transmission Manual:
Gearbox disassembly, assembly, clutch operation, synchromesh, differential, gearbox oil specifications, repair procedures
Transmission Automatic:
Automatic transmission service, fluid specifications, torque converter, control pressure testing, repair procedures (if applicable to covered models)
Drivetrain:
Propeller shaft, universal joints, rear axle assembly, drive shafts, bearings, lubrication
Suspension Front:
MacPherson struts, control arms, anti-roll bar, bushings, wheel bearings, alignment procedures
Suspension Rear:
Transaxle mounted suspension, trailing arms, shock absorbers, springs, bushings, wheel bearings, alignment procedures
Brakes Hydraulic:
Brake master cylinder, brake lines, brake fluid specifications, bleeding procedures, brake booster
Brakes Disc:
Front and rear brake calipers, brake pads, brake discs, rotor replacement, caliper overhaul
Brakes Parking:
Parking brake mechanism, cables, adjustment
Steering:
Steering rack, power steering pump, hoses, fluid specifications, steering column, U-joints, troubleshooting steering issues
Electrical System Overview:
Wiring diagrams, electrical component locations, fuse box layouts, relay functions
Battery Charging:
Alternator, voltage regulator, battery maintenance, testing, replacement
Lighting:
Headlights, taillights, interior lights, signal lights, bulb types, troubleshooting
Instruments Gauges:
Speedometer, tachometer, fuel gauge, temperature gauge, warning lights, diagnostic procedures
Wiper Washer:
Wiper motor, blades, linkage, washer pump, fluid reservoir, operation
Heating Ventilation Ac:
HVAC controls, blower motor, heater core, evaporator, refrigerant charging, leak detection, system diagnosis
Body Exterior:
Body panel removal/installation, doors, hood, trunk, bumpers, glass, seals, trim
Body Interior:
Dashboard removal, seats, door panels, carpeting, headliner, interior trim components
Frame Chassis:
Structural components, rust repair, corrosion protection (general guidance)
Procedures Included
Maintenance Basic:
Oil change, filter replacement, fluid checks and top-offs, tire rotation, spark plug replacement, air filter replacement
Maintenance Scheduled:
Detailed periodic maintenance charts and schedules
Troubleshooting:
Systematic diagnostic procedures for common issues across all major vehicle systems
Repair Engine:
Complete engine overhaul, head gasket replacement, timing belt replacement, component rebuilds
Repair Transmission:
Manual and automatic transmission rebuilds, clutch replacement, driveshaft and axle repair
Repair Brakes:
Brake pad and rotor replacement, caliper overhaul, master cylinder replacement, brake line repair
Repair Suspension:
Strut and shock absorber replacement, control arm bushing replacement, ball joint replacement, wheel bearing replacement
Repair Electrical:
Component testing and replacement (alternator, starter, sensors), wiring harness repair, light repair
Installation Removal:
Step-by-step instructions for removing and installing major components and sub-assemblies
Adjustment:
Precise adjustment procedures for various systems including ignition timing, carburetor/throttle body, clutch, brakes, and suspension alignment
Engine Performance Tuning:
Includes information on adjustments and specifications relevant to optimal engine performance and tuning
Safety Precautions:
Includes specific notes on DANGER, CAUTION, and NOTE for safety-critical procedures
Technical Depth
Depth:
Highly detailed, 'bumper-to-bumper' coverage suitable for professional mechanics and experienced DIY enthusiasts
Detail Level:
Includes pictorial diagrams, exploded views, and detailed explanations for complex procedures
Special Tools:
References specific Alfa Romeo special service tools (SSTs) and their part numbers where applicable
Specifications:
Provides critical service data, factory specifications, allowable limits, and tightening torques for all major components
Illustrations:
Detailed illustrations, exploded diagrams, and photographs supporting repair procedures.
Wear Limits:
Provides specific wear limits for various components to ensure correct repair and rebuild tolerances
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Yes, all pages are printable
Page Quality:
High-resolution, clear text and diagrams
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Requirements
Software Requirement:
Adobe Reader
Os Compatibility:
Windows, Mac, Linux OS
⚙️ Engine Specifications
Primary Engine
Engine Options Typical:
Inline-4 (1.6L, 1.8L, 2.0L), V6 (2.5L, 3.0L) - Carbureted and Fuel Injected variants
Performance
Hp Range:
Approx. 95 hp (1.6L) to 190+ hp (3.0L V6 Quadrifoglio)
Torque Range:
Approx. 130 Nm to 260+ Nm depending on engine
Fuel System
Fuel Delivery:
Carburetor (Solex, Weber) and Electronic Fuel Injection (Bosch L-Jetronic, Motronic)
Engine Layout
Layout:
Front-engine, RWD (transaxle)
Engine Codes
Common Engine Codes:
AR06124 (2.0L Twin Cam), AR06212 (2.0L Twin Spark), AR06410 (2.5L V6)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual
Optional
Optional Transmission:
3-speed or 4-speed Automatic (ZF)
Features
Transaxle Layout:
Integrated transaxle (gearbox and differential) in the rear for 50/50 weight distribution
📐 Dimensions
Exterior
Body Styles:
4-door Sedan, 5-door Estate (Sportwagon)
Weights
Curb Weight Range:
Approx. 1150 kg - 1350 kg depending on engine and body style
🛡️ Safety Features
Ratings
Crash Safety Era:
Reflects safety standards of the 1980s and early 1990s; modern safety features were limited
Active Features
Active Safety Features:
Four-wheel disc brakes, responsive steering
Passive Features
Passive Safety Features:
Seat belts, crumple zones, steel safety cage
💡 Technology Features
Infotainment
Infotainment System:
Basic analog gauges, radio/cassette player. Modern aftermarket options are common.
Driver Assistance
Driver Assistance Features:
None from the factory; advanced driver assistance systems (ADAS) are not present.
Connectivity
Connectivity Options:
None from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500-10,000 km or 6-12 months, depending on driving conditions and oil type
Timing Belt Replacement:
Critical for Twin Cam and V6 engines; typically every 50,000-80,000 km or 5 years. Consult manual for specific engine variant.
Fluid Specifications
Engine Oil Type:
Multi-grade API SG/CD or higher (e.g., 10W-40, 15W-50 depending on climate and engine). Consult manual for precise specifications.
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for confirmation)
Transmission Fluid Manual:
GL-4 or GL-5 gear oil (SAE 75W-90 or 80W-90). Consult manual for specific type and capacity.
Transmission Fluid Automatic:
Dexron II or equivalent (ZF ATFs). Consult manual for specific type and capacity.
Power Steering Fluid:
ATF Dexron II or manufacturer-specified fluid
Known Issues
Rust Corrosion:
Prone to rust, especially in wheel arches, sills, and around windows. Regular inspection and treatment are essential.
Transaxle Clutch Slave Cylinder:
Can be prone to leaks and premature wear; requires specific bleeding procedure.
Electrical Gremlins:
Aging wiring looms and connectors can lead to intermittent electrical issues.
Engine Mounts:
V6 engine mounts can degrade over time, leading to vibration.
Suspension Bushings:
Rubber bushings in suspension and steering components can perish, affecting handling and ride quality.
📚 Vehicle History
Brand Heritage
Brand Focus:
Italian manufacturer known for performance, passion, and distinctive styling
Model Evolution
Design Inspiration:
Successor to the Alfa Romeo Giulietta (Type 116), retaining rear-wheel drive and transaxle layout, with updated styling and engineering
Production
Production Period:
1985 - 1992
Manufacturing Locations:
Italy (Milan/Arese)
🏆 Awards & Recognition
Recognitions
Awards General:
While specific awards for the Milano are not widely publicized as a single entity, it was generally well-regarded for its handling and driving dynamics within its class at the time of its release.