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Alfa Romeo 155 DIY Workshop Service Repair Manual

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$133.00
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$133.00
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🏷️ Basic Information Identification Make: Alfa Romeo Model: 155 Production Years: 1992-1998 Codes Chassis Codes: 167 👋 Introduction Market Position Positioning: The Alfa Romeo 155 was positioned as a compact executive car, known for its sporting character, distinctive Italian styling, and front-wheel-drive (or optional Q4 all-wheel-drive) platform. Competitive Analysis Competitors: Competed against vehicles like the BMW 3 Series, Mercedes-Benz C-Class, Audi 80/A4, and Volvo S40 during its production run. Key Features Styling: Designed by Ercole Spada, featuring a wedge-shaped profile and a distinctive front grille. Later models featured improved aerodynamics and styling updates. Drivetrain Options: Offered in front-wheel drive (FWD) and the acclaimed Q4 all-wheel drive (AWD) configurations, which featured a viscous coupling and a Torsen differential. 📋 Manual Details Coverage Areas Covered Years: 1992, 1993, 1994, 1995, 1996, 1997, 1998 Page Count Estimated Pages: Extensive (Typical of full workshop manuals, likely 1000+ pages when compiled) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures for engine blocks, cylinder heads, pistons, crankshafts, camshafts, valve trains, etc. Engine Control System: Diagnosis and repair of ECU, sensors (knock, camshaft position, speed sensors), actuators, and emission control systems. Fuel System: Fuel pump, injectors, throttle body, fuel tank, charcoal canister, fuel pressure regulation, and EFI system. Cooling System: Radiator, water pump, thermostat, cooling fan system, coolant types, and bleeding procedures. Lubrication System: Oil pump, oil filter, lubrication passages, and oil specifications. Ignition System: Spark plugs, ignition coils, distributors (if applicable), and ignition timing. Exhaust System: Exhaust pipes, mufflers, catalytic converters, and emission control systems. Transmission Manual: Manual transaxle assembly, clutch system (master cylinder, slave cylinder, clutch unit, pedal), torque converter clutch, and fluid specifications. Transmission Automatic: Automatic transaxle assembly, valve body, control cables, fluid specifications, and diagnosis. Drive Train: Front drive shafts, output shafts, differential case, and associated seals. Chassis: General chassis structure and repair procedures. Suspension Front: Front suspension arms, shock absorbers, coil springs, stabilizer bar, and wheel alignment. Suspension Rear: Rear suspension systems, shock absorbers, coil springs, and rear wheel alignment. Steering System: Steering system, steering column, steering sensors, power steering link, and steering gear box. Brakes System: Brake system, front and rear brakes, brake master cylinder, booster, fluid specifications, parking brake, and skid control sensors. Wheel And Tire System: Tire and wheel specifications, mounting, and maintenance. Lighting System: Headlamps, tail lamps, turn signals, license plate lamps, and interior lighting. Electrical System: Wiring diagrams, wire harness repair, starter system, generator/charging system, battery, and electrical component diagnosis. Safety Systems: Supplemental Restraint System (SRS), airbags (front, side, curtain), seat belt warning system, shift lock system, and yaw rate sensors. Body Repair: Body panel repair, glass replacement (windshield, quarter, back door), weatherstripping, door frames, bumpers, and roof headlining. Interior Systems: Seats, seat belts, instrument panel, audio-visual system, air conditioning, heater, power window control, power door locks, and sunroof systems. Wipers And Washers: Wiper motors, blades, washer systems, nozzles, and switches. Procedures Included Maintenance: Regular maintenance, fluid changes, filter replacements, inspections, and lubrication. Troubleshooting: Diagnostic procedures, common fault finding, and symptom-based repair guidance. Repair: Detailed step-by-step repair instructions for all major vehicle systems, including component disassembly and reassembly. Wiring Diagrams: Comprehensive wiring diagrams for all electrical circuits. Torque Specifications: All necessary torque specifications for fasteners during repair and assembly. Engine Rebuild: Detailed procedures for engine disassembly, inspection, repair, and reassembly, including piston ring gap, bearing clearances, and cylinder head resurfacing. Transmission Rebuild: Step-by-step instructions for overhauling both manual and automatic transmissions. Suspension And Steering Geometry: Includes specifications and procedures for alignment adjustments of both front and rear suspensions. Diagnostic Charts: Troubleshooting charts to help diagnose common problems based on symptoms. Technical Depth Depth: Full factory-level diagnostic and repair coverage, suitable for professional technicians and experienced DIY enthusiasts. Diagnostic Tools: While the manual itself is not a diagnostic tool, it provides the necessary information to interpret data from specialized diagnostic equipment used by technicians. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely searchable text for easy navigation and information retrieval. Print Quality Quality: High resolution, clear text and diagrams suitable for printing. Binding Type Binding: N/A (Digital) Paper Type Paper Type: N/A (Digital) Completeness Scope: Comprehensive, covering all aspects of maintenance, repair, troubleshooting, and diagnostics as used by dealership technicians. ⚙️ Engine Specifications Primary Engine Engine Options: Varied widely including 1.7L, 1.8L, 2.0L (Twin Spark), 2.5L V6, and 2.0L Turbo 4-cylinder engines for the Q4 models. Performance Typical Horsepower Range: Approximately 115 hp to 190 hp, depending on the engine variant and market. Engine Technology: Featured Alfa Romeo's Twin Spark ignition system for enhanced combustion efficiency and performance in many gasoline engines. Fuel System Injection Type: Multi-point fuel injection (MPI) was standard across most gasoline engines. Fuel Recommendation: Unleaded gasoline, octane rating typically 95 RON (Premium Unleaded). 🔧 Transmission...
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Alfa Romeo 155 DIY Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Alfa Romeo
Model:
155
Production Years:
1992-1998
Codes
Chassis Codes:
167
👋 Introduction
Market Position
Positioning:
The Alfa Romeo 155 was positioned as a compact executive car, known for its sporting character, distinctive Italian styling, and front-wheel-drive (or optional Q4 all-wheel-drive) platform.
Competitive Analysis
Competitors:
Competed against vehicles like the BMW 3 Series, Mercedes-Benz C-Class, Audi 80/A4, and Volvo S40 during its production run.
Key Features
Styling:
Designed by Ercole Spada, featuring a wedge-shaped profile and a distinctive front grille. Later models featured improved aerodynamics and styling updates.
Drivetrain Options:
Offered in front-wheel drive (FWD) and the acclaimed Q4 all-wheel drive (AWD) configurations, which featured a viscous coupling and a Torsen differential.
📋 Manual Details
Coverage Areas
Covered Years:
1992, 1993, 1994, 1995, 1996, 1997, 1998
Page Count
Estimated Pages:
Extensive (Typical of full workshop manuals, likely 1000+ pages when compiled)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul procedures for engine blocks, cylinder heads, pistons, crankshafts, camshafts, valve trains, etc.
Engine Control System:
Diagnosis and repair of ECU, sensors (knock, camshaft position, speed sensors), actuators, and emission control systems.
Fuel System:
Fuel pump, injectors, throttle body, fuel tank, charcoal canister, fuel pressure regulation, and EFI system.
Cooling System:
Radiator, water pump, thermostat, cooling fan system, coolant types, and bleeding procedures.
Lubrication System:
Oil pump, oil filter, lubrication passages, and oil specifications.
Ignition System:
Spark plugs, ignition coils, distributors (if applicable), and ignition timing.
Exhaust System:
Exhaust pipes, mufflers, catalytic converters, and emission control systems.
Transmission Manual:
Manual transaxle assembly, clutch system (master cylinder, slave cylinder, clutch unit, pedal), torque converter clutch, and fluid specifications.
Transmission Automatic:
Automatic transaxle assembly, valve body, control cables, fluid specifications, and diagnosis.
Drive Train:
Front drive shafts, output shafts, differential case, and associated seals.
Chassis:
General chassis structure and repair procedures.
Suspension Front:
Front suspension arms, shock absorbers, coil springs, stabilizer bar, and wheel alignment.
Suspension Rear:
Rear suspension systems, shock absorbers, coil springs, and rear wheel alignment.
Steering System:
Steering system, steering column, steering sensors, power steering link, and steering gear box.
Brakes System:
Brake system, front and rear brakes, brake master cylinder, booster, fluid specifications, parking brake, and skid control sensors.
Wheel And Tire System:
Tire and wheel specifications, mounting, and maintenance.
Lighting System:
Headlamps, tail lamps, turn signals, license plate lamps, and interior lighting.
Electrical System:
Wiring diagrams, wire harness repair, starter system, generator/charging system, battery, and electrical component diagnosis.
Safety Systems:
Supplemental Restraint System (SRS), airbags (front, side, curtain), seat belt warning system, shift lock system, and yaw rate sensors.
Body Repair:
Body panel repair, glass replacement (windshield, quarter, back door), weatherstripping, door frames, bumpers, and roof headlining.
Interior Systems:
Seats, seat belts, instrument panel, audio-visual system, air conditioning, heater, power window control, power door locks, and sunroof systems.
Wipers And Washers:
Wiper motors, blades, washer systems, nozzles, and switches.
Procedures Included
Maintenance:
Regular maintenance, fluid changes, filter replacements, inspections, and lubrication.
Troubleshooting:
Diagnostic procedures, common fault finding, and symptom-based repair guidance.
Repair:
Detailed step-by-step repair instructions for all major vehicle systems, including component disassembly and reassembly.
Wiring Diagrams:
Comprehensive wiring diagrams for all electrical circuits.
Torque Specifications:
All necessary torque specifications for fasteners during repair and assembly.
Engine Rebuild:
Detailed procedures for engine disassembly, inspection, repair, and reassembly, including piston ring gap, bearing clearances, and cylinder head resurfacing.
Transmission Rebuild:
Step-by-step instructions for overhauling both manual and automatic transmissions.
Suspension And Steering Geometry:
Includes specifications and procedures for alignment adjustments of both front and rear suspensions.
Diagnostic Charts:
Troubleshooting charts to help diagnose common problems based on symptoms.
Technical Depth
Depth:
Full factory-level diagnostic and repair coverage, suitable for professional technicians and experienced DIY enthusiasts.
Diagnostic Tools:
While the manual itself is not a diagnostic tool, it provides the necessary information to interpret data from specialized diagnostic equipment used by technicians.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Likely searchable text for easy navigation and information retrieval.
Print Quality
Quality:
High resolution, clear text and diagrams suitable for printing.
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
Completeness
Scope:
Comprehensive, covering all aspects of maintenance, repair, troubleshooting, and diagnostics as used by dealership technicians.
⚙️ Engine Specifications
Primary Engine
Engine Options:
Varied widely including 1.7L, 1.8L, 2.0L (Twin Spark), 2.5L V6, and 2.0L Turbo 4-cylinder engines for the Q4 models.
Performance
Typical Horsepower Range:
Approximately 115 hp to 190 hp, depending on the engine variant and market.
Engine Technology:
Featured Alfa Romeo's Twin Spark ignition system for enhanced combustion efficiency and performance in many gasoline engines.
Fuel System
Injection Type:
Multi-point fuel injection (MPI) was standard across most gasoline engines.
Fuel Recommendation:
Unleaded gasoline, octane rating typically 95 RON (Premium Unleaded).
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transaxle
Optional
Optional Transmission:
4-speed automatic transmission (available on some variants)
Features
Q4 Drivetrain:
The Q4 model featured a permanent all-wheel-drive system with a 3-differential setup (front, center, and rear) for superior traction and handling.
📐 Dimensions
Exterior
Length:
Approximately 4,285 mm (168.7 inches)
Width:
Approximately 1,700 mm (66.9 inches)
Height:
Approximately 1,420 mm (55.9 inches)
Weights
Curb Weight:
Approximately 1,250 kg - 1,450 kg (2,755 lbs - 3,197 lbs), depending on engine and configuration.
Wheelbase:
Approximately 2,550 mm (100.4 inches)
🛡️ Safety Features
Ratings
Crash Test Results:
Specific official ratings from organizations like Euro NCAP for this period are less common, but the vehicle was equipped with safety features for its era.
Active Features
ABS:
Anti-lock Braking System (ABS) was available as standard or optional depending on the trim level and year.
Traction Control:
Traction control (ASR) was often available on higher-trim or Q4 models.
Passive Features
Airbags:
Driver airbag was standard on most models. Passenger, side, and curtain airbags were introduced in later production years or on higher trims.
Seat Belts:
Pre-tensioning front seat belts and three-point rear seat belts were standard.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD players, often with speaker systems in doors and rear parcel shelf. Manual covers removal and installation of audio components.
Driver Assistance
ABS And Traction Control:
ABS and ASR systems are detailed for diagnosis and repair, including sensor function and hydraulic unit operation.
Connectivity
Wiring Diagrams Utility:
The inclusion of detailed wiring diagrams is crucial for diagnosing and repairing any issues within the vehicle's electrical system, including sensors, control modules, and actuators.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 - 15,000 km (6,000 - 9,000 miles) or annually, whichever comes first.
Timing Belt Replacement:
Crucial for Twin Spark and V6 engines. Intervals vary but are often around 60,000 - 100,000 km (37,000 - 62,000 miles) or 5-7 years. This manual would detail the exact procedure and associated parts.
Fluid Specifications
Engine Oil:
Typically SAE 10W-40 or 15W-40 (API SG/SH or higher), but specific recommendations depend on engine and climate. Check the manual for precise ACEA or manufacturer specifications.
Coolant:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. Manual will specify Alfa Romeo approved coolant or equivalent.
Brake Fluid:
DOT 3 or DOT 4 brake fluid. Manual will specify the exact requirement and change interval.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil with appropriate viscosity (e.g., 75W-90). Specific grade is critical.
Transmission Fluid Automatic:
Specific ATF fluid (e.g., Dexron-III or equivalent). The manual will detail the exact type and capacity.
Known Issues
Common Problems:
Rust on body panels (wheel arches, sills), aging electrical components, potential issues with timing belts and water pumps on Twin Spark engines, and wear on suspension bushings.
Diagnosis Tips:
The manual provides essential diagnostic trees for electrical faults, engine performance issues, and mechanical problems. Understanding sensor readings and error codes is key.
📚 Vehicle History
Brand Heritage
Alfa Romeo Legacy:
Alfa Romeo has a rich heritage in motorsport and performance-oriented vehicles, known for its engaging driving dynamics and Italian design flair.
Model Evolution
Generations:
The 155 represents a significant step for Alfa Romeo in the compact executive segment, succeeding the 75 and preceding the 156. It saw design refreshes and powertrain updates throughout its lifecycle.
Production
Manufacturing Location:
Primarily manufactured in Italy.
Motorsport Success:
The 155 achieved considerable success in touring car racing, most notably in the DTM (Deutsche Tourenwagen Meisterschaft) with its Q4-based silhouette, driven by legendary drivers like Nicola Larini and Alessandro Nannini.
🏆 Awards & Recognition
Recognitions
Motorsport Accolades:
Significant success in touring car championships, including the DTM, which enhanced the model's performance image.
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