All Major Systems:
Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Clutch, Manual Transmission, Automatic Transmission (if applicable to specific variants), Driveshafts, Rear Axle, Steering System, Front Suspension, Rear Suspension, Brakes (Front and Rear), Electrical System (including wiring diagrams), Bodywork, Interior Trim, Heating and Ventilation, Air Conditioning (if equipped)
Engine Mechanical:
Engine block, cylinder head, crankshaft, connecting rods, pistons, camshafts, valves, timing gear, oil pump, oil seals, gaskets.
Fuel And Emission:
Fuel tank, fuel pump, fuel lines, fuel filters, carburetor(s) overhaul and adjustment, emission control systems (if applicable to specific market versions).
Ignition And Electrical:
Spark plugs, ignition coils, distributors, points, condensers, alternators, starters, batteries, wiring diagrams, lighting systems, gauges, switches.
Transmission And Drivetrain:
Clutch operation, gearbox components, synchronizers, gears, bearings, seals, driveshafts, U-joints, differential, axle shafts.
Suspension And Steering:
Front control arms, ball joints, tie rods, steering rack/box, coil springs, shock absorbers, rear axle location, trailing arms, Panhard rod, springs, shock absorbers, wheel bearings.
Brakes:
Front disc brakes, rear drum brakes (or discs on some models), master cylinder, brake booster (if equipped), wheel cylinders, brake lines, parking brake system.
Body And Chassis:
Body panel repair, rust prevention, door mechanisms, window regulators, hood and trunk latches, sealing components.
Repair And Maintenance:
Routine maintenance, troubleshooting, diagnostic procedures, engine overhaul, transmission repair, brake system servicing, suspension and steering alignment, electrical component testing and repair, body panel repair and alignment, interior component removal and installation
Engine Repair:
Complete engine rebuild, cylinder head removal and reconditioning, piston and ring replacement, crankshaft and bearing service.
Transmission Repair:
Gearbox disassembly and reassembly, clutch replacement, synchronizer ring replacement.
Electrical Troubleshooting:
Fault diagnosis for lighting, ignition, starting, charging, and auxiliary circuits using wiring diagrams.
Suspension And Steering Adjustment:
Wheel alignment specifications, steering system adjustments.
Brake System Maintenance:
Brake pad/shoe replacement, caliper/wheel cylinder overhaul, brake bleeding.
Chassis And Suspension Components:
Inspection, replacement, and adjustment of all wear items including bushings, ball joints, control arms, and shock absorbers.
Interior Trim Removal:
Guidance on removing dashboard panels, door cards, seat upholstery for access to underlying components.
Heater Core And Ventilation:
Maintenance and repair of the heating system, including blower motor and ducting.
Depth:
Comprehensive, step-by-step instructions with detailed illustrations and diagrams suitable for both novice DIY mechanics and experienced technicians.
Diagnostic Procedures:
Includes methods for diagnosing common engine performance issues, electrical faults, and mechanical noises.
Torque Specifications:
Provides crucial torque values for critical fasteners across all major mechanical systems.
Illustrations And Diagrams:
Features detailed exploded views, wiring diagrams, and step-by-step illustrated procedures.
Troubleshooting Guides:
Systematic approaches to diagnose and resolve issues, often organized by symptom.
Specifications And Tolerances:
Detailed mechanical specifications, clearances, and tolerances for engine and transmission rebuilds.
Oil Change:
Every 5,000-7,500 km (3,000-5,000 miles) or annually
Tune Up:
Every 10,000-15,000 km (6,000-9,000 miles)
Spark Plug Replacement:
Every 10,000-15,000 km (6,000-9,000 miles)
Timing Belt Chain Inspection:
Inspect timing chain and tensioner regularly; replace as needed (no fixed interval).
Engine Oil:
SAE 20W-50 (or as recommended by Alfa Romeo; high-zinc content oil recommended for older engines)
Coolant:
50/50 mix of antifreeze and distilled water
Brake Fluid:
DOT 3 or DOT 4 (ensure compatibility with seals)
Transmission Fluid:
GL-4 Gear Oil (e.g., SAE 75W-90 or SAE 80W-90)
Differential Fluid:
GL-5 Gear Oil (e.g., SAE 75W-90 or SAE 80W-90)
Coolant Capacity:
Approximately 6-7 liters
Engine Oil Capacity:
Approximately 4.5-5 liters with filter
Common Problems:
Rust (especially around wheel arches, sills, and floor pans), electrical gremlins, carburetor tuning, timing chain wear, rear axle bushings, front suspension wear.
Ignition System:
Points and condenser maintenance, coil testing.
Cooling System:
Radiator leaks, water pump seals, thermostat issues.
Bodywork Corrosion:
Concentrated inspection needed for sills, floor pans, boot floor, A-pillars, and door bottoms.
Carburetor Performance:
Syncing of twin carbs is critical for smooth operation and power delivery; can be sensitive to adjustment.