🏷️ Basic Information

Make:

Alfa Romeo

Model:

164

Product Type:

Service and Repair Manual

👋 Introduction

Segment:

Executive Sedan

Era:

Late 1980s to mid-1990s

Competitors:

BMW 5 Series, Mercedes-Benz E-Class, Audi 100/A6, Saab 9000, Volvo 900 Series.

Design:

Designed by Pininfarina, known for its sleek, aerodynamic, and timeless styling. Frameless door glass and a distinctive Alfa Romeo grille.

Performance Heritage:

Emphasized Alfa Romeo's reputation for sporty handling and powerful engines, particularly the naturally aspirated and turbocharged V6 Busso engines.

📋 Manual Details

Page Count:

3600

Manual Type:

Comprehensive Service and Repair Manual

Language:

English

Format:

Digital (likely PDF, but not explicitly stated)

📖 Manual Coverage

Engine:

Detailed coverage of all engine variants, including V6 Busso engines (2.0 V6 Turbo, 3.0 V6, 3.0 V6 24v), diagnostics, overhaul procedures, timing belt replacement, fuel injection systems, ignition systems, cooling systems, lubrication systems.

Transmission:

Coverage of manual transmissions (5-speed) and automatic transmissions (e.g., ZF 4HP22), clutch system, torque converter, transmission overhaul, fluid specifications, and shift linkage adjustments.

Brakes:

Complete braking system service, including ABS (Bosch ABS II), hydraulic systems, brake fluid replacement, caliper overhaul, disc and pad replacement, parking brake adjustments, and troubleshooting.

Electrical System:

Extensive coverage of the entire electrical system, including wiring diagrams for all models and years, fuse box layouts, lighting systems, power windows, central locking, climate control electronics, diagnostics for ECUs, ignition switch, starter motor, alternator, battery.

Suspension And Steering:

Front and rear suspension components, shock absorbers, springs, bushings, ball joints, steering rack, power steering system, wheel alignment procedures, and specifications.

Body And Chassis:

Body panel repair, door mechanisms, window regulators, convertible top operation (if applicable to certain trims), frame straightening, structural integrity, and corrosion prevention.

Heating Ventilation And Air Conditioning:

HVAC system diagnostics, refrigerant handling, A/C compressor, condenser, evaporator, heater core, climate control panel operation, and blower motor.

Fuel System:

Fuel tank, fuel pump, fuel filter replacement, fuel injectors, fuel pressure regulator, emissions control systems (catalytic converter, EVAP).

Exhaust System:

Exhaust manifold, catalytic converter, muffler, exhaust pipes, and gasket replacement.

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, spark plug changes, coolant flushes, brake fluid flushes, tire rotations, and belt inspections.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, fault codes explanation, symptom-based troubleshooting guides.

Repair:

Detailed step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilding, and electrical system repairs.

Diagnostics:

Procedures for using diagnostic tools, interpreting sensor data, identifying electrical faults, and performing system checks.

Level:

Expert Level: Covers everything from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics, and electrical system troubleshooting. Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

Digital Format:

Likely PDF. Searchable text is highly probable for a manual of this size and scope.

Clarity:

Expected to be high, with clear diagrams and text, essential for accurate repair work.

Physical Format Assumption:

If printed, likely a professionally bound softcover or hardcover for durability.

Physical Format Assumption:

If printed, would likely be high-quality, durable paper suitable for workshop environments.

⚙️ Engine Specifications

Engine Family:

Alfa Romeo V6 (Busso)

Engine Variant 1:

2.0L V6 Turbo (12-valve)

Engine Variant 2:

3.0L V6 (12-valve)

Engine Variant 3:

3.0L V6 (24-valve)

Power Output 3.0 24V:

Approx. 210-230 hp (depending on market and specific tune)

Torque 3.0 24V:

Approx. 260-280 Nm

Injection Type:

Bosch Motronic electronic fuel injection

Engine Oil Type:

Refer to manual for specific viscosity (e.g., 10W-40, 15W-50 for Busso engines), API service classification

Coolant Type:

Ethylene glycol based coolant, typically a long-life pink or red formulation. Always consult manual for specific type and mixture ratio.

Timing Belt Interval:

Critical! Typically 60,000 km or 4 years. Failure can cause severe engine damage.

🔧 Transmission

Type:

5-speed manual transmission

Type:

4-speed automatic (e.g., ZF 4HP22)

Manual Fluid:

Refer to manual for specific gear oil viscosity and API rating (e.g., GL-4 or GL-5, depending on gearbox design).

Automatic Fluid:

Refer to manual for specific ATF type (e.g., Dexron II/III) and capacity.

📐 Dimensions

Length:

Approx. 4640 mm (182.7 in) for early models, may vary slightly

Width:

Approx. 1765 mm (69.5 in)

Height:

Approx. 1385 mm (54.5 in)

Curb Weight:

Approx. 1450-1550 kg (3197-3417 lbs), depending on engine and features

🛡️ Safety Features

Crash Test Data:

Euro NCAP ratings or equivalent for the period would be referenced in the manual if available; specific official ratings for this older model are less common but it was designed with occupant safety in mind.

ABS:

Bosch ABS II standard on most models, especially later ones.

Airbags:

Driver airbag standard on later models, passenger airbag optional or standard on higher trims.

Seatbelts:

Pre-tensioned seatbelts, potentially front and rear 3-point belts.

Crumple Zones:

Designed with front and rear crumple zones for energy absorption.

💡 Technology Features

Audio System:

Factory fitted radio cassette player, often with a graphic equalizer and CD changer compatibility in later models.

Climate Control:

Automatic climate control system on many models, with electronic sensors and actuators.

Cruise Control:

Electronic cruise control system available on most variants.

Factory Options:

Telephone integration was an option in later years.

🔧 Maintenance

Oil Change:

Typically every 10,000 km or 12 months, but consult manual for specific engine and oil type recommendations.

Air Filter:

Check every 20,000 km, replace as needed or every 40,000 km.

Fuel Filter:

Replace every 40,000 km.

Spark Plugs:

Replace every 60,000 km or as recommended for specific plug type (e.g., copper vs. platinum).

Brake Fluid Type:

DOT 3 or DOT 4, depending on system specification. Consult manual for precise requirement and flush interval.

Power Steering Fluid:

Refer to manual for specific type (e.g., hydraulic fluid or ATF).

Engine:

Timing belt tensioner wear, oil leaks from V6 engines, vacuum hose deterioration, ignition system reliability (especially early models).

Electrical:

Corrosion in connectors, failing door lock actuators, climate control panel issues, intermittent electrical faults.

Body:

Rust in wheel arches, sills, and around windows. Deterioration of rubber seals.

Suspension:

Worn bushings, front strut top mounts.

📚 Vehicle History

Legacy:

Alfa Romeo's long history of performance, sporty sedans, and distinctive Italian design.

Generations:

Type 116, produced from 1987 to 1997. Saw updates including the introduction of the 24-valve V6 and revisions to styling and equipment.

Production Years:

1987 - 1997

Manufacturing Location:

Milan, Italy

🏆 Awards & Recognition

Design Awards:

While specific awards for the 164 are not widely publicized, its Pininfarina design was universally praised and contributed to its desirability.