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1994-2001 Alfa Romeo 145 146 Workshop Service Repair Manual

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Basic Information Identification Make: Alfa Romeo Model: 145 / 146 Product Name: 1994-2001 Alfa Romeo 145 146 Workshop Service Repair Manual Codes Chassis Codes: 930 (145), 930 (146) Introduction Market...
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1994-2001 Alfa Romeo 145 146 Workshop Service Repair Manual
Basic Information
Identification
Make: Alfa Romeo
Model: 145 / 146
Product Name: 1994-2001 Alfa Romeo 145 146 Workshop Service Repair Manual
Codes
Chassis Codes: 930 (145), 930 (146)
Introduction
Market Position
Positioning: The Alfa Romeo 145 and 146 were positioned as compact hatchbacks within Alfa Romeo's lineup, known for their distinctive styling and engaging driving dynamics, often appealing to enthusiasts seeking an alternative to more mainstream European offerings.
Competitive Analysis
Competitors: Competed against models like the Volkswagen Golf, Ford Focus, Opel/Vauxhall Astra, Fiat Bravo/Brava, and Renault Mégane of the era.
Key Features
Design: Stylish Italian design, characteristic Alfa Romeo grille, engaging handling, often praised for interior ergonomics and materials for its class.
Target Audience: Enthusiast drivers, individuals seeking a stylish and sporty compact car, those who appreciate Italian automotive heritage.
Manual Utility
Utility: Indispensable resource for DIY owners and professional mechanics to maintain, diagnose, and repair the Alfa Romeo 145/146, ensuring longevity and optimal performance.
Manual Details
Coverage Areas
Years Covered: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001
Models Covered: Alfa Romeo 145, Alfa Romeo 146
Page Count
Estimated Pages: Varies (typically 800-1200+ pages for comprehensive factory manuals)
Manual Type
Type: Workshop Service Repair Manual
Language
Language: English (assumed based on typical sales and product description)
Format
Format: Digital (likely PDF, printable)
Manual Coverage
Systems Covered
Powertrain: Engine Mechanical, Engine Electrical, Fuel System, Exhaust System, Cooling System, Lubrication System, Ignition System
Drivetrain: Transmission (Manual, Automatic), Clutch, Driveshafts, Differential
Chassis: Suspension (Front & Rear), Steering System, Brakes (Front & Rear, ABS), Wheels & Tires
Body: Body Panels, Doors, Hood, Trunk, Glass, Interior Trim, Seating
Electrical: Wiring Diagrams, Lighting System, Instrumentation, Power Accessories, Battery & Charging System, ECU Diagnostics
Procedures Included
Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Tune-ups, Fluid Checks & Replacements
Repair: Engine Overhaul, Transmission Repair, Brake System Repair, Suspension Component Replacement, Electrical Component Diagnosis & Repair
Troubleshooting: Diagnostic Procedures, Symptom-based Troubleshooting Guides, Fault Code Interpretation
Diagnostics: OBD-II (On-Board Diagnostics II) Systems, Sensor Testing, Actuator Testing, Wiring Harness Checks
Bodywork: Panel Replacement, Dent Repair, Rust Prevention, Seam Sealing
Technical Depth
Depth: Comprehensive factory-level detail, suitable for full vehicle disassembly and reassembly. Includes diagnostic procedures, torque specifications, and wiring diagrams.
Manual Specifications
File Format
Format Details: Likely PDF, allowing for digital searching, printing of specific pages, and accessibility on various devices. Searchable text functionality is highly desirable.
Print Quality
Quality: High-quality text and diagrams as described in the product information, essential for accurate repair and maintenance.
Binding Type
Binding: N/A (Digital Format)
Paper Type
Paper: N/A (Digital Format)
Engine Specifications
Primary Engine
Engine Family: Alfa Romeo Twin Spark (TS)
Engine Variants: 1.3L (1356cc), 1.4L (1370cc), 1.6L (1598cc), 1.8L (1747cc), 2.0L (1995cc) Twin Spark 8v and 16v
Cylinder Configuration: Inline 4-cylinder
Performance
Horsepower Range: Approx. 90 PS (1.3) to 155 PS (2.0 V6, though V6 was less common in 145/146 variants covered by typical manuals, focus is on TS)
Torque Range: Approx. 112 Nm (1.3) to 187 Nm (2.0 TS)
Fuel System
Injection Type: Bosch Motronic Electronic Fuel Injection (EFI)
Fuel Type: Unleaded Petrol (Octane rating typically 95 RON)
Technical Details
Valve Train: DOHC (Double Overhead Camshaft), 4 valves per cylinder (Twin Spark system has two spark plugs per cylinder)
Bore X Stroke: Varies by engine displacement (e.g., 1.8L TS: 83.0 mm x 82.7 mm)
Compression Ratio: Typically 9.5:1 to 10.3:1 depending on engine variant
Engine Management: ECU controlled ignition and fuel injection, often with distributorless ignition.
Transmission
Standard
Type: 5-speed Manual Transmission
Optional
Type: 4-speed Automatic Transmission (optional on some variants)
Features
Clutch Type: Hydraulically operated single dry plate clutch
Gear Ratios: Specific ratios detailed in manual for each engine/transmission combination.
Fluid Specifications
Manual Transmission Fluid: API GL-4, SAE 75W-90 or 80W-90 gear oil (specific part numbers/grades to be confirmed in manual).
Automatic Transmission Fluid: Dexron II or equivalent (specific grades to be confirmed in manual).
Dimensions
Exterior
Body Styles: 3-door hatchback (145), 5-door hatchback (146)
Length: Approx. 4,050 - 4,150 mm (varies slightly by model and year)
Width: Approx. 1,700 mm
Height: Approx. 1,400 - 1,430 mm
Weights
Curb Weight: Approx. 1,100 - 1,300 kg (depending on engine and equipment)
Safety Features
Ratings
Crash Test Results: Euro NCAP ratings were not standard for this era. Specific test data may be limited and vary by testing organization.
Active Features
Braking System: Front ventilated discs, rear solid discs (standard). ABS (Anti-lock Braking System) was optional on many models.
Passive Features
Airbags: Driver airbag (standard or optional depending on market and trim level), passenger airbag less common in early models.
Seatbelts: Pre-tensioner seatbelts for front occupants.
Body Structure: Designed with crumple zones and a reinforced passenger cell for occupant protection.
Technology Features
Infotainment
Audio System: Factory fitted radio/cassette player, with optional CD player. Basic speaker systems.
Climate Control: Manual air conditioning and heating controls were common, with optional automatic climate control on higher trim levels.
Driver Assistance
ABS: Anti-lock Braking System (ABS) was an optional feature, not standard on all models.
Traction Control: Traction control was not a widely available feature on these models during their production run.
Connectivity
Connectivity Features: No modern connectivity features like Bluetooth or USB ports. Systems are basic for the era.
Maintenance
Service Intervals
Oil Change: Typically every 10,000 - 15,000 km or 12 months, whichever comes first (refer to manual for exact intervals based on driving conditions).
Timing Belt: Critical maintenance item for Twin Spark engines. Replacement interval typically around 60,000 - 80,000 km or 4-5 years. Failure can cause severe engine damage.
Spark Plugs: Twin Spark engines utilize two spark plugs per cylinder. Intervals vary, but typically around 40,000 - 60,000 km for replacement. Specific plug types are crucial.
Fluid Specifications
Engine Oil: API SJ/SL, ACEA A3/B3, SAE 10W-40 or 5W-40 (depending on climate and manufacturer recommendation; consult manual for precise grade).
Coolant: Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Fiat/Alfa Romeo specific coolant types may be recommended.
Brake Fluid: DOT 3 or DOT 4 (consult manual for specific recommendation).
Known Issues
Common Wear Items: Wheel bearings, suspension bushings, exhaust components, clutch wear.
Electrical Concerns: Wiring harness issues, sensor failures (e.g., crank sensor, MAF sensor), aging ECUs can be points of failure.
Engine Specific: Oil leaks from valve cover gaskets, wear on camshafts in high-mileage Twin Spark engines, potential for oil consumption in some units. Correct timing belt maintenance is paramount.
Rust: Can be susceptible to rust in common areas like wheel arches, sills, and rear suspension mounts, particularly in humid climates or areas with road salt.
Vehicle History
Brand Heritage
Heritage: Alfa Romeo has a long and storied history in motorsport and automotive manufacturing, renowned for sporty handling, distinctive Italian styling, and a passionate following.
Model Evolution
Development: The 145 and 146 replaced the 33 series and were designed to offer a more modern and competitive package in the compact segment. They shared a common platform and mechanicals but differed in body style (3-door vs. 5-door).
Production
Production Years: 1994 - 2001
Manufacturing Location: Italy
Awards & Recognition
Recognitions
Awards Achievements: While specific awards for the 145/146 are not as prominent as some other Alfa Romeo models, they were generally well-regarded for their driving dynamics and styling within their segment. The Twin Spark engine technology itself received recognition over the years.
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