WORKSHOP ¥f milano (# MANIAL = “* m™ilanc ; ASSISTENZA TECNICAFOREWORD This manual ie intended for use by workshops belonging to the ALFA ROMEO Service Organization. It contains aif neces sary instructions for tune up, repair and overhaul of the units and systems with which the ALFA ROMEO cars are equipped. It includes procedures conceraing removal and installation, disassembly end assembly, checks and! inspections as well as instructions tor effective trouble diagnosis. Al operations are extensively illustrated so thet the part or unit iavoived. as well as the proper toof 10 be used, are exsly identified. All dete, figures and technical specifications herein contained are up to date at tiie of publication. Any subsequent charige In values or technicel specifications occurring between reprints, wil be included in the Technical Bulletins issued by the Service Department as changes take place: The manufacturer reserves.the right to make - at any time and without notice - all thase changes that it deerms necessary to Improve the vehicle or arising out of manufacturing or commercial requirements. tt further advises that not all models mentioned in this manual will be availeble in all countries. HOW TO USE THE MANUAL This manual is designed as # guide Yor personne! assigned to provide effective service to the mechanical urvits Conceited. The instructions herein contained aré in general common to alt different madels of the same group, when. they are meant for ane partieulsr model, 1 is previously inaicated with a specific detailed reference to be found in the CONTENTS and in the text Alt instructions given for the purpose of restoring faulty components to proper working conditions, do nat necessarily reflect manufacturer's directives: at regards service, but they must just the same be complied with. Furthermore, since most given instructions concern complete disassembly of Components; they should be followed in their entirety only when itis strictly necestary. For easier consultation of the manual, read the CONTENTS carefully. The following chapters are of the utmost importance — SERVICE DATA AND SPECIFICATIONS to be complied with when tuning up and repaicing the vehicle. The specifi ‘ations have been subdivided into four different items: Technical Data, Generat Specifications, Checks and Adjustments and Tightening Torques; — TROUBLE DIAGNOSIS AND CORRECTIONS where Hikely couses of trouble, as well as the relevant recommended corrective actian, are listed; — SPECIAL SERVICE TOOLS designed to allow quick, acourete andi sate repsirs Messurements given in this manual are expréssed in the International System of Units (Si) as well as in the yard/pound systemand in the metric system. Captians CAUTION and WARNING emphasize steps ther must be followed with extreme care to avoid personal injury and/or damage to the vehicle or part of it. Remember to keep the manual up-to-date with the dats supplied by the “Technical Bulletin” periodically sued by the Service Department, PABBASUOO00000 in Marcn 1986eT — WORKSHOP INSTRUCTIONS ° Disassembly and assembly operations should be always carried out using proper tools (general purpose as well as special service tools) since makeshift tools will damage the parts involved. To loosen tight fitting cast iron pars, just lightly strike shem with 2 lead or aluuninium hemmer; use @ wooden or plastic mallet 10 toosen light alloy parts Separate one by one the parts making up each unit and partially tigh ten nuts onto relevant studs or screws, On.dfsessembly, check if parts that should be marked do in fact have the relevant number or reference stamped on it. Hf any previously replaced part is found to be in properly marked, it should be stamped accordingly. Before washing, clean all parts with @ brush and cloth removing most dirt (thus avoiding needless dirtying of the weshing Huid)z then wash them with detergent or special compound, Rernove any residual dirt with a jet of carnpressed air. Dry al! parts immediately after washing to prevent them from rusting. Thoraughiy wash parts: that have been ground or lapped and blow them with a jet of compressed air to remove al! residiaes. Reassembly, clean all parts (especially those that have been ground) with a jet of compressed air or @ clean brush. On assembly also suitably lubricate parts (except settlubricating bushes) to prevent seizure during their running: period, To apply lubricant, use-2 clean brush as well as-clean of! Keeping them eviey from dust and dirt at all times and using them only Far this special purpose. Suitably protect with adhesive tape or clean cloths al! engine parts that after disassembly show orifices or drilling which are likely t0 fet in dust or Foreign matter On assembly, replace all geskets, seal rings, spring washers-and lock rings in-adalition to all. worn or damaged parts. IMPORTANT NOTICE Ver" replacing units or parts the-eo?, be sure.to use only genuine spare parts to ensure intérchangeabil ty as well as proper performance. When ordering, remember to show the part number raked from the Spare Parts Catalogue or from the microfiches Service quality varies according to procedures used, personnel skill, and available tools and parts. March 1986 Iv PA384500000000