🏷️ Basic Information

Make:

Alfa Romeo

Model:

75

Trim Level:

Milano

Engine Variant:

2.5 V6

Chassis Code:

Type 119

Engine Code Prefix:

AR0615

👋 Introduction

Market Segment:

Compact executive sports sedan.

Design Philosophy:

Rear-wheel drive, front-engine layout with a balanced chassis and powerful V6 engine, embodying Alfa Romeo's sporty heritage.

Key Competitors:

BMW 3 Series (E30), Mercedes-Benz 190E, Audi 80/90, Ford Sierra XR4i.

Engine Layout:

Front-engine, rear-wheel drive (transaxle layout for weight distribution).

Suspension Design:

Innovative De Dion rear suspension for improved handling and unsprung weight.

Styling:

Distinctive Franco Scaglione-penned wedge shape with signature Alfa Romeo 'Scudetto' grille.

📋 Manual Details

Systems Covered:

Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Clutch, Transmission, Drive Shaft, Rear Axle, Suspension (Front & Rear), Steering System, Braking System, Electrical System, Air Conditioning, Bodywork, Interior Trim, Troubleshooting

Page Count:

Hundreds of Pages (estimated 800-1200 pages)

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Complete overhaul and repair of the Alfa Romeo Busso V6 engine, including cylinder head, pistons, crankshaft, camshafts, timing components, and oil pump.

Fuel System:

Bosch L-Jetronic fuel injection system, fuel pump, injectors, fuel pressure regulator, fuel filter, and fuel tank servicing.

Ignition System:

Electronic ignition system, distributor, ignition coil, spark plugs, and ignition timing procedures.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan system, and coolant capacity.

Lubrication System:

Oil pump, oil filter, oil pan, oil pressure testing, and recommended oil specifications.

Transmission Manual:

Overhaul and repair of the 5-speed manual transaxle, clutch assembly, and gearbox internals.

Drive Shaft And Rear Axle:

Propeller shaft, universal joints, rear axle assembly, differential, and axle bearings.

Suspension Front:

Independent front suspension, MacPherson struts, control arms, anti-roll bar, and wheel alignment specifications.

Suspension Rear:

De Dion rear axle system, Watt's linkage, trailing arms, shock absorbers, springs, and wheel alignment specifications.

Steering System:

Rack and pinion steering, steering column, power steering pump, and steering linkage.

Braking System:

Front ventilated discs, rear inboard discs, brake calipers, master cylinder, brake fluid specifications, bleeding procedures, and parking brake system.

Electrical System:

Wiring diagrams, starter motor, alternator, battery, lighting system, fuses, relays, and instrument cluster diagnostics.

Air Conditioning:

Refrigerant types, system components, servicing, and troubleshooting of the HVAC system.

Bodywork And Trim:

Body panel removal and installation, door mechanisms, window regulators, interior trim components, and sealant application.

Basic Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, brake pad inspection and replacement, fluid level checks, and tire pressure.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults, including fault codes (if applicable) and symptom-based diagnostics.

Engine Rebuild:

Detailed step-by-step instructions for complete engine disassembly, inspection, component replacement, and reassembly, including torque specifications and clearances.

Transmission Overhaul:

Complete guide to disassembling, inspecting, repairing, and reassembling the manual transaxle, including gear selection and synchromesh inspection.

Suspension And Steering Repair:

Replacement of ball joints, tie rod ends, bushings, wheel bearings, shock absorbers, and power steering pump.

Brake System Overhaul:

Disc and caliper servicing, master cylinder replacement, brake line repair, and bleeding procedures for both front and rear systems.

Electrical Diagnostics:

Using wiring diagrams to diagnose electrical faults, testing components such as relays, solenoids, and sensors.

Timing Belt Replacement:

Precise instructions for timing belt removal and installation, including camshaft and crankshaft timing marks, and tensioner adjustment.

Fuel Injector Testing:

Procedures for testing fuel injector spray patterns, flow rates, and electrical resistance.

Clutch Replacement:

Step-by-step guide for clutch disc, pressure plate, and release bearing replacement.

Depth:

Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Yes (typically for scanned PDFs with OCR)

Print Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Naturally Aspirated V6, SOHC (initially) / DOHC (later variants, but 2.5L typically SOHC for this model designation)

Displacement:

2492 cc (2.5 Liters)

Bore X Stroke:

88.0 mm x 68.2 mm

Compression Ratio:

9.0:1 (typical)

Cylinder Head Material:

Aluminum Alloy

Block Material:

Cast Iron

Horsepower:

155 hp (DIN) @ 5800 rpm

Torque:

224 Nm (165 lb-ft) @ 3000 rpm

Fuel Delivery:

Bosch L-Jetronic (Lambda controlled)

Fuel Type:

Unleaded Petrol (Octane rating 95 RON recommended)

Ignition Type:

Electronic Ignition with distributor

Cooling Medium:

Water-glycol mixture (50/50)

Oil Capacity:

Approx. 5.5 Liters (with filter)

Recommended Oil Viscosity:

SAE 10W-40 or 15W-50 (API SG/SH)

🔧 Transmission

Transmission Type:

5-Speed Manual Transaxle

Transmission Type:

3-Speed Automatic (e.g., ZF 3HP22)

Layout:

Rear-mounted transaxle (engine front, gearbox/differential rear) for 50/50 weight distribution.

Gear Ratios Manual Example:

1st: 3.45, 2nd: 2.10, 3rd: 1.38, 4th: 1.00, 5th: 0.79 (Typical for 2.5L)

Differential Type:

Limited Slip Differential (Optional on some models, standard on higher trims)

Manual Transmission Fluid:

API GL-4 SAE 75W-90 or 80W-90

📐 Dimensions

Length:

Approx. 4350 mm (171.3 in)

Width:

Approx. 1680 mm (66.1 in)

Height:

Approx. 1370 mm (53.9 in)

Wheelbase:

Approx. 2510 mm (98.8 in)

Front Track:

Approx. 1410 mm (55.5 in)

Rear Track:

Approx. 1390 mm (54.7 in)

Curb Weight:

Approx. 1260 - 1340 kg (2778 - 2954 lbs)

Gross Vehicle Weight:

Approx. 1700 kg (3748 lbs)

Max Payload:

Approx. 440 kg (970 lbs)

Fuel Tank Capacity:

Approx. 52 Liters (13.7 US gallons)

🛡️ Safety Features

Crash Test Data:

Limited official crash test data available for this era of vehicle. Expect performance typical of its time.

Brakes:

Front Ventilated Discs, Rear Inboard Discs, Power Assisted.

Steering Assistance:

Recirculating ball or Rack and pinion with power assist (depending on market/spec).

Seat Belts:

Three-point front seat belts, two-point rear seat belts (early models) / three-point rear seat belts (later models).

Body Structure:

Reinforced safety cage, crumple zones.

Headlights:

Halogen headlamps.

💡 Technology Features

Radio System:

Factory fitted AM/FM radio with cassette player (optional).

Speaker System:

Basic 2 or 4 speaker system.

ABS:

Optional ABS (Anti-lock Braking System) available on later models or higher trims.

Connectivity Features:

None by modern standards; analogue systems.

🔧 Maintenance

Oil And Filter Change:

Every 10,000 - 15,000 km (6,000 - 9,000 miles) or 12 months.

Air Filter Replacement:

Every 20,000 - 30,000 km (12,000 - 18,000 miles).

Spark Plug Replacement:

Every 20,000 - 30,000 km (12,000 - 18,000 miles) for standard plugs.

Timing Belt Replacement:

Every 40,000 - 60,000 km (25,000 - 37,000 miles) or 4-5 years, whichever comes first. Crucial for engine integrity.

Coolant Flush And Replace:

Every 2-3 years.

Brake Fluid:

DOT 4 (ISO Class 6).

Power Steering Fluid:

ATF Dexron II or equivalent.

Rust And Corrosion:

Common issue, especially in sills, wheel arches, and rear suspension mounting points. Thorough inspection required.

Electrical Gremlins:

Aging wiring looms and connectors can lead to intermittent faults. Fuel injection and ignition systems are particularly susceptible.

Cooling System Leaks:

Degradation of hoses, radiator, and water pump seals can cause coolant leaks. Regular checks are essential.

Clutch Actuation Issues:

The clutch slave cylinder, located at the gearbox, can be prone to leaks or failure. The clutch pedal assembly can also wear.

De Dion Axle Bushings:

Wear in the bushings for the De Dion axle and its locating links can cause imprecise rear-end handling.

📚 Vehicle History

Alfa Romeo Legacy:

Long history of producing sporting and engaging vehicles, known for performance-oriented engines and distinctive Italian styling.

Predecessor:

Alfa Romeo Giulietta (Type 116).

Successor:

Alfa Romeo 155.

Development Goals:

To create a more modern and competitive successor to the Giulietta, incorporating advanced engineering and improved handling characteristics.

Production Years:

1985 - 1992

Manufacturing Location:

Milan, Italy.

Engine Origin:

The renowned Alfa Romeo 'Busso' V6 engine, first introduced in the Alfa 6.

🏆 Awards & Recognition

Automotive Press Reviews:

Generally praised for its engaging handling, spirited V6 engine, and distinctive Italian styling, although criticized for its electrical reliability and potential for rust.