Alfa Romeo 75 MILANO 2 5 3 V6 Service Repair Manual
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🏷️ Basic Information Identification Make: Alfa Romeo Model: 75 Trim Level: Milano Engine Variant: 2.5 V6 Codes Chassis Code: Type 119 Engine Code Prefix: AR0615 👋 Introduction Market Position 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. Competitive Analysis Key Competitors: BMW 3 Series (E30), Mercedes-Benz 190E, Audi 80/90, Ford Sierra XR4i. Key Features 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 Coverage Areas 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 Page Count: Hundreds of Pages (estimated 800-1200 pages) Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered 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. Procedures Included 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. Technical Depth Depth: Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Yes (typically for scanned PDFs with OCR) Print Quality Print Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine 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 Performance Horsepower: 155 hp (DIN) @ 5800 rpm Torque: 224 Nm (165 lb-ft) @ 3000 rpm Fuel System Fuel Delivery: Bosch L-Jetronic (Lambda controlled) Fuel Type: Unleaded Petrol (Octane rating 95 RON recommended) Ignition System Ignition Type: Electronic Ignition with distributor Cooling System Cooling Medium: Water-glycol mixture (50/50) Lubrication System Oil Capacity: Approx. 5.5 Liters (with filter) Recommended Oil Viscosity: SAE 10W-40 or 15W-50 (API SG/SH) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transaxle Optional Transmission Type: 3-Speed Automatic (e.g., ZF 3HP22) Features Layout: Rear-mounted transaxle (engine front, gearbox/differential rear) for 50/50 weight...
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.
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.
Procedures Included
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.
Technical Depth
Depth:
Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications.
📊 Manual Specifications
File Format
File Format:
PDF
Searchable Text:
Yes (typically for scanned PDFs with OCR)
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
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
Performance
Horsepower:
155 hp (DIN) @ 5800 rpm
Torque:
224 Nm (165 lb-ft) @ 3000 rpm
Fuel System
Fuel Delivery:
Bosch L-Jetronic (Lambda controlled)
Fuel Type:
Unleaded Petrol (Octane rating 95 RON recommended)
Ignition System
Ignition Type:
Electronic Ignition with distributor
Cooling System
Cooling Medium:
Water-glycol mixture (50/50)
Lubrication System
Oil Capacity:
Approx. 5.5 Liters (with filter)
Recommended Oil Viscosity:
SAE 10W-40 or 15W-50 (API SG/SH)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transaxle
Optional
Transmission Type:
3-Speed Automatic (e.g., ZF 3HP22)
Features
Layout:
Rear-mounted transaxle (engine front, gearbox/differential rear) for 50/50 weight distribution.
Factory fitted AM/FM radio with cassette player (optional).
Speaker System:
Basic 2 or 4 speaker system.
Driver Assistance
ABS:
Optional ABS (Anti-lock Braking System) available on later models or higher trims.
Connectivity
Connectivity Features:
None by modern standards; analogue systems.
🔧 Maintenance
Service Intervals
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.
Fluid Specifications
Brake Fluid:
DOT 4 (ISO Class 6).
Power Steering Fluid:
ATF Dexron II or equivalent.
Known Issues
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
Brand Heritage
Alfa Romeo Legacy:
Long history of producing sporting and engaging vehicles, known for performance-oriented engines and distinctive Italian styling.
Model Evolution
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
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
Recognitions
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.
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