Alfa Romeo 155 1992-1998 Workshop Service Manual for Repair
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๐ท๏ธ Basic Information Identification Make: Alfa Romeo Model: 155 Production Years: 1992-1998 Codes Platform: Type 167 ๐ Introduction Market Position Segment: Compact executive car Reputation: Known for sporting dynamics and distinctive Italian styling. Competitive Analysis Key Competitors: BMW 3 Series (E36), Mercedes-Benz C-Class (W202), Audi A4 (B5), Volvo S40/V40. Key Features Design Philosophy: Emphasis on driver engagement and performance, typical of Alfa Romeo. Platform Sharing: Shared platform with Fiat Tempra, but with significant chassis and suspension tuning. ๐ Manual Details Coverage Areas Scope: Comprehensive repair and maintenance for all Alfa Romeo 155 models from 1992-1998. Page Count Count: Over 1000 pages Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF (Digital Download) ๐ Manual Coverage Systems Covered Engine: Detailed coverage of all engine variants (e.g., Twin Spark, V6 Busso), including disassembly, assembly, diagnostics, and tuning. Transmission: Manual and automatic transmission service, repair, and adjustment procedures. Suspension And Steering: Front and rear suspension, steering rack, power steering system repair and adjustment. Brakes: Brake system overhaul, including ABS (where applicable), fluid replacement, component diagnosis, and repair. Electrical System: Wiring diagrams, component testing, fuse box layout, lighting, ignition, and electronic control unit (ECU) diagnosis. Bodywork And Chassis: Body panel repair, door mechanisms, glass replacement, structural integrity checks. Heating Ventilation Air Conditioning: HVAC system servicing, refrigerant handling, component replacement, and diagnostics. Fuel System: Fuel pump, injectors, fuel tank, lines, and emissions control system repair and testing. Procedures Included Maintenance: Routine scheduled maintenance, fluid changes, filter replacements, spark plug service. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, guided by symptoms. Repair: Detailed step-by-step instructions for component repair and replacement. Disassembly Assembly: Comprehensive instructions for dismantling and reassembling all major vehicle components. Adjustments: Precise instructions for adjustments, including valve clearances, timing, and emissions controls. Technical Depth Depth: Highly detailed, covering everything from basic servicing to complete engine and transmission rebuilds, including electrical system diagnosis. Special Tools: Identifies and illustrates required special service tools for specific repair operations. Specifications: Includes crucial service data, torque specifications, wear limits, and factory tolerances. ๐ Manual Specifications File Format Format: PDF Compatibility: Windows, macOS, Linux OS Print Quality Printable: Yes, all pages are printable. Readability: Clear text, detailed diagrams, and photographs. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Software Requirement Reader: Adobe Reader required โ๏ธ Engine Specifications Primary Engine Twin Spark: Twin Spark engines (e.g., 1.8L, 2.0L) known for their twin-spark plug per cylinder technology for improved combustion efficiency and performance. V6 Busso: Optional V6 Busso engines (e.g., 2.5L, 3.0L) renowned for their distinctive sound and smooth power delivery. Performance Horsepower Range: Approximately 120 hp to 230 hp depending on engine variant and specification. Torque Range: Approximately 165 Nm to 280 Nm. Fuel System Injection Type: Electronic fuel injection (EFI) across most variants. Emissions Control: Catalytic converters and onboard diagnostics (OBD) systems introduced during the production run. ๐ง Transmission Standard Type: 5-speed manual transmission was standard on most models. Optional Type: Optional 4-speed automatic transmission was available on some variants. Features All Wheel Drive: Certain performance variants, notably the 155 Q4 and 155 GTA, featured permanent all-wheel drive systems. ๐ Dimensions Exterior Length: Approx. 4440 mm Width: Approx. 1715 mm Height: Approx. 1420 mm Weights Curb Weight: Varies by engine and trim, typically between 1300-1500 kg. ๐ก๏ธ Safety Features Ratings Crash Test Data: Limited standardized crash test data available from the era, but generally built with safety as a consideration for its class. Active Features ABS: Anti-lock Braking System (ABS) was available as an option or standard on higher trims. Traction Control: Traction control systems (ASR) were available on certain performance models. Passive Features Airbags: Driver airbag became standard during the production run, passenger airbag was an option. ๐ก Technology Features Infotainment Audio System: Factory fitted Clarion or Blaupunkt radio/cassette players, with optional CD changers. Driver Assistance Cruise Control: Available on higher trim levels or as an aftermarket option. ๐ง Maintenance Service Intervals Oil Change: Typically recommended every 10,000-15,000 km or 12 months, depending on usage and oil type. Timing Belt: Critical for Twin Spark engines: Timing belt replacement typically every 60,000-80,000 km or 5 years, due to interference engine design. Fluid Specifications Engine Oil: API SG/SH or ACEA A2/A3, viscosity typically 10W-40 or 10W-50 (refer to specific engine for exact spec). For V6, 10W-60 may be recommended for spirited driving. Coolant: Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. Brake Fluid: DOT 3 or DOT 4 brake fluid. Transmission Fluid Manual: API GL-4, SAE 75W-90 or 80W-90 gear oil. Transmission Fluid Automatic: Dexron III or equivalent ATF. Known Issues Engine Noise: Twin Spark engines can develop 'diesel noise' from tappets if oil changes are neglected or incorrect oil is used. Rust: Prone to rust in common areas like wheel arches, sills,...
Systematic diagnostic procedures for common and uncommon faults, guided by symptoms.
Repair:
Detailed step-by-step instructions for component repair and replacement.
Disassembly Assembly:
Comprehensive instructions for dismantling and reassembling all major vehicle components.
Adjustments:
Precise instructions for adjustments, including valve clearances, timing, and emissions controls.
Technical Depth
Depth:
Highly detailed, covering everything from basic servicing to complete engine and transmission rebuilds, including electrical system diagnosis.
Special Tools:
Identifies and illustrates required special service tools for specific repair operations.
Specifications:
Includes crucial service data, torque specifications, wear limits, and factory tolerances.
๐ Manual Specifications
File Format
Format:
PDF
Compatibility:
Windows, macOS, Linux OS
Print Quality
Printable:
Yes, all pages are printable.
Readability:
Clear text, detailed diagrams, and photographs.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Software Requirement
Reader:
Adobe Reader required
โ๏ธ Engine Specifications
Primary Engine
Twin Spark:
Twin Spark engines (e.g., 1.8L, 2.0L) known for their twin-spark plug per cylinder technology for improved combustion efficiency and performance.
V6 Busso:
Optional V6 Busso engines (e.g., 2.5L, 3.0L) renowned for their distinctive sound and smooth power delivery.
Performance
Horsepower Range:
Approximately 120 hp to 230 hp depending on engine variant and specification.
Torque Range:
Approximately 165 Nm to 280 Nm.
Fuel System
Injection Type:
Electronic fuel injection (EFI) across most variants.
Emissions Control:
Catalytic converters and onboard diagnostics (OBD) systems introduced during the production run.
๐ง Transmission
Standard
Type:
5-speed manual transmission was standard on most models.
Optional
Type:
Optional 4-speed automatic transmission was available on some variants.
Features
All Wheel Drive:
Certain performance variants, notably the 155 Q4 and 155 GTA, featured permanent all-wheel drive systems.
๐ Dimensions
Exterior
Length:
Approx. 4440 mm
Width:
Approx. 1715 mm
Height:
Approx. 1420 mm
Weights
Curb Weight:
Varies by engine and trim, typically between 1300-1500 kg.
๐ก๏ธ Safety Features
Ratings
Crash Test Data:
Limited standardized crash test data available from the era, but generally built with safety as a consideration for its class.
Active Features
ABS:
Anti-lock Braking System (ABS) was available as an option or standard on higher trims.
Traction Control:
Traction control systems (ASR) were available on certain performance models.
Passive Features
Airbags:
Driver airbag became standard during the production run, passenger airbag was an option.
๐ก Technology Features
Infotainment
Audio System:
Factory fitted Clarion or Blaupunkt radio/cassette players, with optional CD changers.
Driver Assistance
Cruise Control:
Available on higher trim levels or as an aftermarket option.
๐ง Maintenance
Service Intervals
Oil Change:
Typically recommended every 10,000-15,000 km or 12 months, depending on usage and oil type.
Timing Belt:
Critical for Twin Spark engines: Timing belt replacement typically every 60,000-80,000 km or 5 years, due to interference engine design.
Fluid Specifications
Engine Oil:
API SG/SH or ACEA A2/A3, viscosity typically 10W-40 or 10W-50 (refer to specific engine for exact spec). For V6, 10W-60 may be recommended for spirited driving.
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
Dexron III or equivalent ATF.
Known Issues
Engine Noise:
Twin Spark engines can develop 'diesel noise' from tappets if oil changes are neglected or incorrect oil is used.
Rust:
Prone to rust in common areas like wheel arches, sills, and around the windscreen, especially in regions with harsh winters.
Electrical Gremlins:
Older Italian cars can sometimes suffer from minor electrical faults, often related to wiring insulation degradation or connector issues.
Suspension Wear:
Bushings and ball joints can wear over time, affecting handling and ride quality.
๐ Vehicle History
Brand Heritage
Heritage:
Alfa Romeo has a long history of producing sporty and engaging cars with a strong motorsport pedigree.
Model Evolution
Introduction:
Launched in 1992 as a successor to the Alfa Romeo 75 (Milano), aiming for a more modern and globally competitive platform.
Facelift:
Received a significant facelift in 1996, with revised styling (including a more integrated grille) and updated features.
Production
Manufacturing:
Primarily manufactured in Italy.
๐ Awards & Recognition
Recognitions
Motorsport Heritage:
The 155 chassis was successful in various touring car championships, most notably the DTM and BTCC, highlighting its performance potential.