1992-1998 Alfa Romeo 155 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Alfa Romeo Model: 155 Model Code: 167 Series Year: 1992-1998 Generation Generation: First Generation 👋 Introduction Market Position Market Position: The Alfa Romeo 155 was positioned as a compact executive sports sedan, aiming to blend Italian flair and performance with practicality for the European market. It competed with rivals like the BMW 3 Series, Mercedes-Benz C-Class, and Audi A4. Competitive Analysis Competitive Analysis: The 155 offered a more characterful driving experience and distinctive styling compared to many German competitors. Its independent front suspension (derived from the Fiat Tipo) and multi-link rear suspension (on some models) provided a good balance of ride comfort and handling, though some critics noted a less engaging chassis compared to its predecessor, the 75. Key Features Key Features: Distinctive Italian design, a range of potent engines (including Twin Spark and V6 variants), available Q4 all-wheel-drive system, advanced chassis technology for its time, and a driver-focused interior. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive coverage for the Alfa Romeo 155 produced between 1992 and 1998, encompassing all major mechanical, electrical, and body systems. Page Count Page Count: Estimated 1000+ pages (typical for factory service manuals of this era and scope) Manual Type Manual Type: Factory Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) Completeness Completeness: 100% complete and intact, providing factory-level detail across all vehicle systems for the specified model years. Target Audience Target Audience: Designed for both DIY owners seeking to maintain and repair their vehicles, and professional mechanics requiring accurate factory data. 📖 Manual Coverage Systems Covered Systems Covered: Engine Mechanical, Engine Electrical, Fuel System, Ignition System, Cooling System, Exhaust System, Lubrication System, Clutch, Transmission (Manual & Automatic), Drive Axles, Suspension (Front & Rear), Steering System, Brakes (Hydraulic & ABS), Electrical System (Wiring Diagrams, ECUs, Lighting, Accessories), Body & Chassis, Climate Control, Body Electronics. Procedures Included Procedures Included: Detailed step-by-step repair and maintenance procedures, diagnostics, troubleshooting guides, component removal and installation, overhaul instructions, specifications, torque values, electrical testing, component testing. Technical Depth Technical Depth: Factory-level technical depth, suitable for both experienced professional mechanics and advanced DIY enthusiasts. Includes detailed illustrations, diagrams, and schematics for complete disassembly and reassembly of all major vehicle components. Troubleshooting Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for common drivability, electrical, and mechanical issues. Includes troubleshooting for ABS, fuel injection, and ignition systems. Wiring Diagrams Wiring Diagrams: Detailed electrical wiring diagrams for all major systems, including engine control, lighting, instruments, power windows, central locking, and ABS. Torque Specifications Torque Specifications: Comprehensive list of torque specifications for all critical fasteners, including engine components, suspension, brakes, and chassis fasteners. Component Removal Installation Component Removal Installation: Step-by-step instructions with accompanying illustrations for the removal and installation of components such as engines, transmissions, suspension arms, steering racks, brake calipers, body panels, and interior trim. Engine Overhaul Engine Overhaul: Detailed procedures for engine rebuilds, including piston ring replacement, bearing clearance checks, valve seat grinding, cylinder head gasket replacement, and timing component replacement. Body And Chassis Body And Chassis: Information on body panel repair, rust prevention, door mechanisms, glass replacement, chassis alignment, and welding procedures. Specifications Specifications: All essential technical specifications, including engine bore and stroke, compression ratios, valve clearances (if applicable), and tire pressure recommendations. Chassis And Suspension Chassis And Suspension: Detailed diagrams and procedures for front MacPherson struts and rear multi-link suspension systems, including component replacement and alignment specifications. Steering System Steering System: Hydraulic power steering system, including pump, rack, and fluid maintenance procedures. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution scans ensuring clarity of text, diagrams, and illustrations, suitable for printing. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Primary Engine: 1.8L Twin Spark (1756 cc) DOHC 16-valve inline-4. Engine Variants Engine Variants: Available engines included the 1.8L Twin Spark (129 hp), 2.0L Twin Spark (144 hp), 2.0L V6 Turbo (177 hp), 2.5L V6 24V (190 hp), 1.9L TD (75 hp), 2.5L TD (125 hp). This manual likely covers the most prevalent petrol Twin Spark and V6 variants. Performance Performance: Varies by engine. The 1.8 Twin Spark typically offered 0-60 mph in around 9.5 seconds. The V6 variants provided significantly stronger performance, with the 2.5 V6 reaching 60 mph in under 7 seconds. Fuel System Fuel System: Electronic Fuel Injection (EFI) with Bosch Motronic or similar engine management systems. Ignition System Ignition System: Distributorless Ignition System (DIS) or distributor-based systems depending on specific engine and model year. Cooling System Cooling System: Pressurized liquid-cooled system with belt-driven water pump and engine-driven fan or viscous fan clutch. Cylinder Head Cylinder Head: DOHC (Double Overhead Camshaft), 4 valves per cylinder for Twin Spark engines. Engine Management Engine Management: Bosch Motronic or equivalent electronic engine control unit (ECU) managing...
The Alfa Romeo 155 was positioned as a compact executive sports sedan, aiming to blend Italian flair and performance with practicality for the European market. It competed with rivals like the BMW 3 Series, Mercedes-Benz C-Class, and Audi A4.
Competitive Analysis
Competitive Analysis:
The 155 offered a more characterful driving experience and distinctive styling compared to many German competitors. Its independent front suspension (derived from the Fiat Tipo) and multi-link rear suspension (on some models) provided a good balance of ride comfort and handling, though some critics noted a less engaging chassis compared to its predecessor, the 75.
Key Features
Key Features:
Distinctive Italian design, a range of potent engines (including Twin Spark and V6 variants), available Q4 all-wheel-drive system, advanced chassis technology for its time, and a driver-focused interior.
📋 Manual Details
Coverage Areas
Coverage Areas:
Comprehensive coverage for the Alfa Romeo 155 produced between 1992 and 1998, encompassing all major mechanical, electrical, and body systems.
Page Count
Page Count:
Estimated 1000+ pages (typical for factory service manuals of this era and scope)
Manual Type
Manual Type:
Factory Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
Completeness
Completeness:
100% complete and intact, providing factory-level detail across all vehicle systems for the specified model years.
Target Audience
Target Audience:
Designed for both DIY owners seeking to maintain and repair their vehicles, and professional mechanics requiring accurate factory data.
Factory-level technical depth, suitable for both experienced professional mechanics and advanced DIY enthusiasts. Includes detailed illustrations, diagrams, and schematics for complete disassembly and reassembly of all major vehicle components.
Troubleshooting
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common drivability, electrical, and mechanical issues. Includes troubleshooting for ABS, fuel injection, and ignition systems.
Wiring Diagrams
Wiring Diagrams:
Detailed electrical wiring diagrams for all major systems, including engine control, lighting, instruments, power windows, central locking, and ABS.
Torque Specifications
Torque Specifications:
Comprehensive list of torque specifications for all critical fasteners, including engine components, suspension, brakes, and chassis fasteners.
Component Removal Installation
Component Removal Installation:
Step-by-step instructions with accompanying illustrations for the removal and installation of components such as engines, transmissions, suspension arms, steering racks, brake calipers, body panels, and interior trim.
Engine Overhaul
Engine Overhaul:
Detailed procedures for engine rebuilds, including piston ring replacement, bearing clearance checks, valve seat grinding, cylinder head gasket replacement, and timing component replacement.
Body And Chassis
Body And Chassis:
Information on body panel repair, rust prevention, door mechanisms, glass replacement, chassis alignment, and welding procedures.
Specifications
Specifications:
All essential technical specifications, including engine bore and stroke, compression ratios, valve clearances (if applicable), and tire pressure recommendations.
Chassis And Suspension
Chassis And Suspension:
Detailed diagrams and procedures for front MacPherson struts and rear multi-link suspension systems, including component replacement and alignment specifications.
Steering System
Steering System:
Hydraulic power steering system, including pump, rack, and fluid maintenance procedures.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution scans ensuring clarity of text, diagrams, and illustrations, suitable for printing.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Primary Engine:
1.8L Twin Spark (1756 cc) DOHC 16-valve inline-4.
Engine Variants
Engine Variants:
Available engines included the 1.8L Twin Spark (129 hp), 2.0L Twin Spark (144 hp), 2.0L V6 Turbo (177 hp), 2.5L V6 24V (190 hp), 1.9L TD (75 hp), 2.5L TD (125 hp). This manual likely covers the most prevalent petrol Twin Spark and V6 variants.
Performance
Performance:
Varies by engine. The 1.8 Twin Spark typically offered 0-60 mph in around 9.5 seconds. The V6 variants provided significantly stronger performance, with the 2.5 V6 reaching 60 mph in under 7 seconds.
Fuel System
Fuel System:
Electronic Fuel Injection (EFI) with Bosch Motronic or similar engine management systems.
Ignition System
Ignition System:
Distributorless Ignition System (DIS) or distributor-based systems depending on specific engine and model year.
Cooling System
Cooling System:
Pressurized liquid-cooled system with belt-driven water pump and engine-driven fan or viscous fan clutch.
Cylinder Head
Cylinder Head:
DOHC (Double Overhead Camshaft), 4 valves per cylinder for Twin Spark engines.
Engine Management
Engine Management:
Bosch Motronic or equivalent electronic engine control unit (ECU) managing fuel injection and ignition timing.
🔧 Transmission
Standard
Standard:
5-speed manual transmission.
Optional
Optional:
4-speed automatic transmission (common on V6 models).
Q4 System
Q4 System:
Viscous coupling all-wheel-drive system (Q4) available on select performance models, primarily featuring a Torsen center differential and limited-slip rear differential.
Clutch Type
Clutch Type:
Hydraulically actuated single dry plate clutch.
Gear Ratios
Gear Ratios:
Specific gear ratios for each transmission variant will be detailed in the manual, crucial for understanding performance characteristics.
📐 Dimensions
Exterior Length
Exterior Length:
Approximately 4300-4360 mm (169.3-171.7 inches) depending on model variant.
Exterior Width
Exterior Width:
Approximately 1700-1710 mm (66.9-67.3 inches).
Exterior Height
Exterior Height:
Approximately 1410-1420 mm (55.5-55.9 inches).
Wheelbase
Wheelbase:
Approximately 2550 mm (100.4 inches).
Weight Curb
Weight Curb:
Around 1250-1450 kg (2756-3197 lbs) depending on engine and equipment.
Wheelbase Q4
Wheelbase Q4:
The Q4 model may have slightly different dimensions or weight distribution due to the AWD system.
🛡️ Safety Features
Ratings
Ratings:
NCAP or equivalent safety ratings for this period are limited, but the 155 featured standard safety equipment for its era.
Active Features
Active Features:
Anti-lock Braking System (ABS) was optional or standard on higher trims and later models. Ventilated front disc brakes and solid rear discs.
Passive Features
Passive Features:
Three-point seat belts, driver and passenger airbags (optional on early models, standard on later ones), crumple zones, side impact protection.
Brake System Description
Brake System Description:
Front: Ventilated discs. Rear: Solid discs. ABS system with proportioning valves.
💡 Technology Features
Infotainment
Infotainment:
Basic infotainment systems for the era, typically featuring an AM/FM radio, cassette player, and optional CD player. Analog gauges and a driver-focused dashboard layout.
Driver Assistance
Driver Assistance:
Limited driver assistance features by modern standards. ABS was the primary advanced safety technology available.
Connectivity
Connectivity:
No modern connectivity features such as Bluetooth or USB. Basic wiring for optional external devices may be present.
Instrument Cluster
Instrument Cluster:
Analog tachometer, speedometer, fuel gauge, coolant temperature gauge, and warning lights. Trip computer on some higher trims.
🔧 Maintenance
Service Intervals
Service Intervals:
Typical intervals: Oil and filter change every 7,500-10,000 miles (12,000-15,000 km) or 12 months. Spark plug replacement every 30,000-60,000 miles depending on type. Timing belt replacement on Twin Spark engines is critical, typically every 30,000-60,000 miles or 5 years. V6 models usually have a timing chain. Refer to the manual for specific intervals.
Fluid Specifications
Fluid Specifications:
Engine Oil: Typically 10W-40 or 15W-40 API SJ or higher. Coolant: Ethylene glycol based antifreeze. Brake Fluid: DOT 3 or DOT 4. Power Steering Fluid: ATF Dexron II or equivalent. Transmission Fluid: Manual - GL-4 SAE 75W-90 or 80W-90. Automatic - ATF Dexron II or III.
Known Issues
Known Issues:
Rust on sills, wheel arches, and rear quarters. Aging electrical components, including wiring harnesses and sensors. Twin Spark engines require diligent timing belt maintenance to prevent catastrophic failure. Wear on suspension bushings and ball joints. Alfa Romeo V6 engines are generally robust but require regular oil changes.
Spark Plug Part Number
Spark Plug Part Number:
For 1.8L Twin Spark (e.g., AR671), common spark plug sets include NGK BKR6EKC or equivalent. Note the two spark plugs per cylinder design.
Engine Oil Capacity
Engine Oil Capacity:
Approximately 4.5-5.0 liters (4.8-5.3 US quarts) for most 4-cylinder Twin Spark engines. V6 variants may require slightly more.
Timing Belt Replacement Interval
Timing Belt Replacement Interval:
Crucial interval of 50,000-60,000 km (30,000-37,000 miles) or 4-5 years for Twin Spark engines. The manual will detail this critical maintenance.
Coolant Type
Coolant Type:
Ethylene glycol based antifreeze with corrosion inhibitors, typically a pink or red color.
Brake Fluid Capacity
Brake Fluid Capacity:
Approximately 1 liter (1.05 US quarts) for the brake system.
Transmission Fluid Capacity Manual
Transmission Fluid Capacity Manual:
Approximately 1.5-1.8 liters (1.6-1.9 US quarts) for 5-speed manual transmissions.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Alfa Romeo has a long and storied history in motorsport and the production of sporting sedans, known for their passion, performance, and distinctive Italian character.
Model Evolution
Model Evolution:
The 155 was launched in 1992 to replace the Alfa Romeo 75. It was a significant departure in design and platform, sharing its underpinnings with the Fiat Tipo. It underwent a facelift in 1995, introducing revised styling and updated engines.
Production
Production:
Produced from 1992 to 1998. Significant motorsport success, particularly in touring car championships (DTM, BTCC), contributed to its image. The 155 was succeeded by the Alfa Romeo 156.
Platform Sharing
Platform Sharing:
Based on the Fiat Tipo/Tempra platform, offering a modern chassis design for its time.
🏆 Awards & Recognition
Recognitions
Recognitions:
While not receiving specific annual 'car of the year' awards, the Alfa Romeo 155 achieved significant motorsport success, particularly in touring car racing, which bolstered its performance credentials and brand image.
Motorsport Success
Motorsport Success:
The 155 V6 Ti 'DTM' variant, driven by drivers like Nicola Larini and Alessandro Nannini, was highly successful in the Deutsche Tourenwagen Meisterschaft (DTM) championship, winning titles in the early to mid-1990s.
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