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.
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.
