🏷️ Basic Information

Make:

Alfa Romeo

Model:

Milano

Production Years Covered:

1985-1989

Chassis Code:

Type 162

👋 Introduction

Positioning:

The Alfa Romeo Milano (also known as the 75 in many markets) was positioned as a sport sedan offering a unique blend of Italian styling, performance, and rear-wheel-drive dynamics, competing with established European sedans of its era.

Competitors:

Competed with models such as the BMW 3 Series (E30), Mercedes-Benz 190E, Audi 80/90, and Volvo 240/740 series.

Vehicle Highlights:

Rear-wheel drive, transaxle layout (improving weight distribution), distinctive Alfa Romeo styling, innovative (for its time) Busso V6 engine options, and a driver-focused cockpit.

Value:

An indispensable resource for owners and mechanics seeking to maintain and repair their Alfa Romeo Milano, providing authoritative, factory-level information that can significantly reduce repair costs and ensure proper vehicle function.

📋 Manual Details

General Information:

Included

Engine Mechanical System:

Included

Engine Electrical System:

Included

Emission Control System:

Included

Fuel System:

Included

Suspension System:

Included

Clutch System:

Included

Manual Transaxle System:

Included

Automatic Transaxle System:

Included

Driveshaft And Axle:

Included

Steering System:

Included

Brake System:

Included

Body Interior And Exterior:

Included

Body Electrical System:

Included

Restraint System:

Included

Estimated Page Count:

Detailed and comprehensive, likely exceeding 1000 pages given the scope.

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF

Delivery Method:

Instant Download

📖 Manual Coverage

Engine And Drivetrain:

Comprehensive coverage of engine mechanicals, lubrication, cooling, fuel delivery (including injection systems common in this era), ignition, emissions control, clutch, manual and automatic transaxles, driveshafts, and axles.

Suspension Steering Brakes:

Detailed information on front and rear suspension components, steering gear, brake system hydraulics, friction materials, and parking brake operation.

Electrical And Body:

Extensive coverage of the vehicle's electrical system, including wiring diagrams, component testing, lighting, starting and charging systems, infotainment (where applicable), and detailed procedures for body panel repair, interior trim, and exterior components. Restraint systems (seatbelts) are also covered.

Maintenance And Tune Up:

Routine maintenance tasks such as oil changes, filter replacements, spark plug service, and belt adjustments.

Diagnostics And Troubleshooting:

Step-by-step diagnostic procedures for identifying common issues and fault finding across all major systems, with a strong emphasis on electrical diagnostics and troubleshooting, aided by wiring schematics.

Repair And Rebuild:

Detailed instructions for the disassembly, inspection, repair, and reassembly of all major vehicle components, from engine internals to body panel replacement.

Wiring Schematics:

Included, crucial for diagnosing and repairing electrical faults. These are typically detailed and system-specific.

Depth:

Comprehensive, suitable for both DIY enthusiasts and professional mechanics. Covers everything from basic maintenance to complete engine and drivetrain rebuilds, including detailed diagnostic strategies and torque specifications.

Illustrations And Diagrams:

Detailed illustrations, diagrams, and wiring schematics are a key feature, facilitating understanding of complex systems and repair procedures.

Instructions Format:

Step-by-step instructions with numbered steps and clear substeps for comprehensive repair guidance.

📊 Manual Specifications

Format:

PDF

Printability:

Fully Printable

Zoom Functionality:

YES (Zoom IN/OUT)

Binding:

Digital Download (Printable PDFs)

Paper Type Analogy:

Equivalent to factory paper-based workshop manuals for durability and clarity.

Software Requirements:

Adobe PDF Reader & WinZip (for unzipping downloaded files).

Operating System Compatibility:

Compatible with All Versions of Windows & Mac.

⚙️ Engine Specifications

Engine Options Common:

Inline-four cylinder (1.6, 1.8, 2.0 liters) and V6 (2.5, 3.0 liters) configurations. Specific engine codes and variants should be cross-referenced within the manual based on exact model year and market. Twin Spark variants were also common for the 4-cylinder engines.

Performance Characteristics:

Known for spirited performance, particularly with the V6 engines. Power output varied significantly by engine displacement and tune, typically ranging from approximately 100 hp for base 4-cylinder models to over 150 hp for early V6 versions and exceeding 180 hp for later 3.0 liter variants.

Fuel Delivery:

Carbureted (e.g., Weber, Solex) on earlier or lower-spec models, transitioning to Bosch L-Jetronic or Motronic fuel injection systems on higher-specification and later models. The manual details the specific fuel system components and diagnostic procedures for each type.

Cooling Type:

Pressurized liquid cooling system with belt-driven water pump and engine-driven fan (or thermostatic fan clutch on some models).

Oil System Type:

Wet sump lubrication system with a mechanically driven oil pump. Critical details on oil capacity, filter part numbers, and recommended oil specifications (viscosity grades like 10W-40 or 20W-50, API classifications) will be found in the manual.

🔧 Transmission

Standard Transmission Type:

5-speed manual transaxle, often featuring a limited-slip differential (LSD) on performance models.

Optional Transmission Type:

3-speed or 4-speed automatic transaxle, depending on market and engine configuration.

Transaxle Layout:

Rear-wheel drive with the transaxle (gearbox and differential combined) mounted at the rear to improve weight distribution and handling characteristics. The manual provides specific procedures for transaxle fluid changes, clutch service, and internal component repairs.

Clutch Type:

Hydraulically actuated dry single-plate clutch.

📐 Dimensions

Body Style:

4-door sedan.

Wheelbase:

Approximately 2510 mm (98.8 inches).

Length:

Approximately 4200 mm (165.4 inches).

Width:

Approximately 1650 mm (65.0 inches).

Height:

Approximately 1370 mm (53.9 inches).

Curb Weight:

Varied by engine and trim, typically ranging from 1150 kg to 1350 kg (2535 lbs to 2976 lbs).

🛡️ Safety Features

Safety Standards:

Designed to meet safety standards of the 1980s. Specific crash test ratings are not readily available in modern formats but structural integrity was a focus. The manual covers seatbelt systems and basic body structure repair.

Active Safety:

Four-wheel disc brakes (often with power assistance), precise steering, and rear-wheel drive bias for handling.

Passive Safety:

Seat belts, padded interior surfaces, and reinforced door beams. The manual details seat belt inspection and adjustment procedures.

💡 Technology Features

Infotainment System:

Basic audio systems (radio, cassette player) were typical for the era. The manual covers wiring and installation/removal procedures for these components.

Driver Assistance Features:

Minimal by modern standards. Focus was on mechanical feel and driver engagement. Features like ABS were becoming available on some later or higher-spec models. The manual details any available ABS systems.

Connectivity Features:

None by modern standards. Vehicle systems were purely mechanical or basic electrical.

🔧 Maintenance

Oil Change Interval:

Typically recommended every 7,500 to 10,000 km (4,500 to 6,000 miles) or 6-12 months, whichever comes first. Consult the manual for exact specifications based on driving conditions.

Timing Belt Replacement:

Crucial for Twin Spark and V6 engines. Recommended replacement every 30,000 to 50,000 km (18,000 to 30,000 miles) or 2-3 years. Failure can cause catastrophic engine damage. The manual details the procedure and specifications.

Engine Oil Specification:

API SG or SF, SAE 10W-40 or 20W-50. The manual will list specific approvals and capacities for different engine variants.

Coolant Specification:

Ethylene glycol-based antifreeze mixed with distilled water (typically 50/50 ratio). Refer to manual for specific Alfa Romeo approved coolant types.

Brake Fluid Specification:

DOT 3 or DOT 4 hydraulic brake fluid. Regular flushing and replacement are recommended.

Common Problems:

Rust in common areas (wheel arches, sills, door bottoms), aging rubber components (hoses, bushings), electrical gremlins (especially in older wiring), ignition system issues (particularly on Twin Spark), and potential head gasket leaks on some V6 engines. The manual is essential for diagnosing and repairing these.

Service Notes On Twin Spark:

Requires careful attention to ignition system maintenance, including spark plug replacement and coil pack integrity. Manual details specific procedures and diagnostic steps.

📚 Vehicle History

Alfa Romeo Legacy:

Alfa Romeo has a long and storied history in motorsport and performance car manufacturing, known for its passion, distinctive engines (like the legendary Busso V6), and engaging driving dynamics.

Milano Development:

The Milano/75 was the successor to the Alfa Romeo Giulietta (Type 116) and was part of Alfa Romeo's strategy to maintain a rear-wheel-drive presence in the compact executive sedan segment. It was notable for its transaxle layout, shared with the Alfetta and Giulietta, and its distinctive 'step' nose design.

Production Period:

1985 to 1992 (though this manual covers up to 1989 models).

Manufacturing Sites:

Primarily manufactured in Italy by Alfa Romeo (at the time, a state-owned enterprise).

🏆 Awards & Recognition

Automotive Journalism Awards:

While specific awards for the Milano might be elusive, it was generally praised for its driving dynamics, styling, and the characterful V6 engines, earning it a dedicated following among enthusiasts.