Manual Coverage
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Systems Covered
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Engine Systems:
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Detailed coverage of Boxer (1351, 1596, 1712 16v), Twin Spark (TS 1370, 1598, 1747, 1970 16v), and JTD Turbo Diesel (TD 1910) engines. Includes removal/refitting, operations in vehicle, ignition-injection systems (I.A.W, Motronic, Rochester), fuel supply, air supply, exhaust systems, cooling systems, and engine control units.
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Transmission And Drivetrain:
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Clutch system (removal/refitting, operations), Gearbox (removal/refitting, operations), Front Axle, Steering system.
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Brakes And Suspension:
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Brake system (components, operation, service), Front Suspension, Rear Suspension, Wheels and Tyres, Wheel Characteristic Angles.
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Electrical System:
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Comprehensive coverage of ignition, starting, and charging systems for all engine variants. Includes lighting, miscellaneous devices (fusebox, wipers, etc.), check panel, control units (power window, antitheft, climate control, injection, ABS, Air-Bag, EGR), power supply, and wiring diagrams.
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Bodywork And Interior:
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Bodyshell introduction, moving components, fixed components, straightening, doors, lids, interior trim, interior fittings, and exterior fittings. Includes specific sections for 97' variants and lids.
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Comfort And Climate:
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Heating and Ventilation systems for TD, Boxer, and T.Spark engines, including manually controlled and automatic systems. Air Conditioning system coverage with pressure sensor calibration and compressor details.
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Procedures Included
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Maintenance Procedures:
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Scheduled maintenance operations for each engine type, fluid and lubricant specifications, supply quantities, lifting points, towing points, torque wrench settings, and specific tool requirements.
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Repair Procedures:
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Detailed step-by-step procedures for removal, refitting, and in-vehicle operations for major mechanical and electrical components, including engine rebuilds, gearbox servicing, suspension and brake repairs, and bodywork procedures.
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Troubleshooting Diagnostics:
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Implicitly covered through detailed system descriptions and component specifications. Specific diagnostic sections for electrical systems (e.g., 146 Electric System Diagnoses) are mentioned.
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Technical Data And Specifications:
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Extensive technical data including model identification, ID plate positioning, dimensions, weights and loads, engine technical features, cooling system details, fuel and air feeding systems, electrical component specifications, torque settings, and protection product applications.
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Technical Depth
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Depth Of Information:
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Comprehensive and detailed, covering from basic maintenance and fluid changes to complete engine overhaul, gearbox repair, electrical system diagnostics, and bodywork straightening. Suitable for professional mechanics and advanced DIY enthusiasts.
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Engine Specifications
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Primary Engine
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Engine Families Covered:
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Alfa Romeo Boxer (1.3L, 1.6L, 1.7L 16V), Alfa Romeo Twin Spark (TS) 16V (1.4L, 1.6L, 1.8L, 2.0L), and JTD Turbo Diesel (1.9L).
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Performance
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Performance Details:
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Specific horsepower and torque figures for each engine variant are detailed within the manual, enabling precise performance tuning and diagnosis.
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Fuel System
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Fuel Delivery Systems:
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Covers various fuel injection systems including I.A.W., Motronic (MP3.1, M2.10.3, M2.10.4, M1.5.5), Rochester, and JTD Common Rail injection systems. Includes fuel supply system components, injectors, fuel pumps, and filters.
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Ignition System
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Ignition Components:
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Detailed information on ignition systems for all engine types, including ignition coils, spark plugs, distributors (for Boxer), and electronic ignition control units.
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Cooling System
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Cooling System Components:
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Comprehensive coverage of cooling systems, including radiators, coolant hoses, thermostats, water pumps, and cooling fans, with specific procedures for removal and refitting.
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Maintenance
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Service Intervals
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Typical Service Schedule:
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The manual includes 'Maintenance Operations' sections for each engine type, detailing recommended service intervals for oil changes, filter replacements, timing belt/chain checks, fluid checks, and more, typically based on mileage or time.
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Fluid Specifications
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Recommended Fluids:
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Detailed specifications for engine oil (viscosity grades like 10W-40, 15W-40), coolant type and mixture, brake fluid (DOT 3/4), power steering fluid, and gearbox oil are provided. Supply quantities are also listed.
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Known Issues
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Common Wear Items:
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While the manual focuses on repair procedures, it implicitly covers common wear items such as suspension components (bushings, ball joints), brake pads and discs, clutch components, and exhaust systems.
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Torque Settings
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Critical Torque Values:
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Specific torque settings for engine components (head bolts, manifold bolts), suspension fasteners, wheel nuts, and other critical areas are listed, crucial for preventing damage and ensuring safety.
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