Alfa Romeo 164 1991-1993 Service Repair Workshop Manual
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๐ท๏ธ Basic Information Identification Make: Alfa Romeo Model: 164 Model Generation: Type 116 Production Years Covered: 1991-1993 Chassis Codes: Type 116.26 ๐ Introduction Market Position Positioning: A comprehensive workshop manual for the luxury Italian sedan, Alfa Romeo 164, during its early North American market presence. Competitive Analysis Competitors: Competed against other European executive sedans like the BMW 5 Series, Mercedes-Benz E-Class, and Audi 100/200. Key Features Distinguishing Features: Pininfarina-designed aerodynamic body, advanced front-wheel-drive platform (shared with Fiat Croma, Lancia Thema, Saab 9000), and powerful V6 engines. Manual Value Proposition: Empowers owners and independent mechanics with dealer-level repair and maintenance information, saving significant costs. ๐ Manual Details Coverage Areas Primary Coverage: Service, Repair, and Troubleshooting Diagnostic Coverage: Comprehensive diagnostic procedures, including wiring schematics for fault tracing. Page Count Estimated Page Count: Extensive (Exact count not specified, but implied to be comprehensive for full service/repair). Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF ๐ Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, diagnosis, and repair of engine components. Engine Electrical: Ignition system, starting system, charging system, engine management sensors and actuators. Emission Control: Diagnosis and repair of emission control systems, including catalytic converters and EVAP. Fuel System: Fuel injection system (Bosch Motronic or similar), fuel pump, injectors, fuel pressure regulator. Clutch System: Hydraulic clutch operation, clutch disc, pressure plate, release bearing replacement. Manual Transaxle: Gearbox overhaul, synchromesh, bearings, seals, and lubrication. Automatic Transaxle: Service and repair of the automatic transmission (likely ZF or similar). Drivetrain: Driveshaft, CV joints, and axle components. Suspension: Front and rear suspension components, springs, dampers, bushings, alignment procedures. Steering: Power steering system, steering rack, steering column, tie rods. Brakes: Hydraulic system, ABS (if equipped), brake pads, rotors, calipers, lines, and bleeding procedures. Restraint Systems: Seat belts and airbag systems (if applicable to the specific model year covered). Body Exterior: Body panel repair, trim, doors, windows, bumpers, and glass replacement. Body Interior: Interior trim panels, seating, dashboard, and consoles. Body Electrical: Lighting, power accessories, instruments, dashboard switches, and wiring diagrams. HVAC: Heating, ventilation, and air conditioning system diagnosis, repair, and refrigerant handling. Procedures Included Maintenance: Routine maintenance tasks such as oil changes, filter replacements, spark plug service, and fluid checks. Troubleshooting: Step-by-step troubleshooting guides for common and complex issues across all systems. Repair: Detailed repair procedures for component replacement, adjustment, and overhaul. Diagnosis: Diagnostic steps for identifying the root cause of malfunctions. Installation: Procedures for the installation and removal of various components. Wiring Schematics: Complete wiring diagrams for electrical systems, essential for diagnosis. Technical Depth Depth: Comprehensive, covering basic maintenance to advanced engine and transmission rebuilds. Target Audience: Professional mechanics and knowledgeable DIY enthusiasts. ๐ Manual Specifications File Format Format: PDF Compatibility: All versions of Windows and Mac. Requirements: Adobe PDF Reader. Print Quality Printability: Yes, all pages are printable. Resolution: High resolution for clear viewing and printing. Binding Type Binding: Digital (PDF), allowing for selective printing. Paper Type Paper Type: N/A (Digital format). โ๏ธ Engine Specifications Primary Engine Engine Code Examples: 164 V6 12-valve (Busso V6, e.g., AR0612) and potentially 24-valve variants in later models. Engine Type: Naturally Aspirated V6 (Alfa Romeo Busso V6) Displacement Displacement Liters: 3.0 L (2959 cc) Performance Horsepower Approx: Approx. 184-190 hp for 12-valve, higher for 24-valve variants (specific to market/year). Torque Approx: Approx. 245 Nm (181 lb-ft) for 12-valve. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), likely Bosch Motronic. Timing Valve Actuation: Dual Overhead Camshafts (DOHC), 2 valves per cylinder (for 12V) or 4 valves per cylinder (for 24V). ๐ง Transmission Standard Transmission Type: 5-speed Manual Transaxle Optional Transmission Type: 4-speed Automatic Transaxle (e.g., ZF 4HP-22) Features Drive Layout: Front-Wheel Drive (FWD) ๐ Dimensions Exterior Length Mm: Approx. 4655 mm Width Mm: Approx. 1765 mm Height Mm: Approx. 1380 mm Wheelbase Mm: Approx. 2660 mm Weights Curb Weight Kg Approx: Approx. 1450-1550 kg (depending on engine and equipment) ๐ก๏ธ Safety Features Ratings Crash Test Data Availability: Limited public data available for this era; manual provides repair guidance based on design. Active Features ABS: Anti-lock Braking System (ABS) available on most models. Passive Features Airbags: Driver airbag likely standard for later models in this range, passenger airbag optional or standard on higher trims. ๐ก Technology Features Infotainment Audio System: Factory fitted radio/cassette system, with speaker options and potential for upgraded units. Climate Control: Automatic climate control system with electronic actuators for temperature and air distribution. Covered in HVAC section. Driver Assistance Cruise Control: Electronic cruise control system typically available. Connectivity Diagnostics Port: OBD-I or proprietary diagnostic connector, depending on the exact model year and market. Manual will detail diagnostic access. ๐ง Maintenance Service Intervals Oil Change Interval Km: Typically every 10,000-15,000 km or annually, refer to manual for exact specification based on driving conditions. Timing Belt Interval Km: Crucial maintenance item for the Busso V6, typically recommended...
Dual Overhead Camshafts (DOHC), 2 valves per cylinder (for 12V) or 4 valves per cylinder (for 24V).
๐ง Transmission
Standard
Transmission Type:
5-speed Manual Transaxle
Optional
Transmission Type:
4-speed Automatic Transaxle (e.g., ZF 4HP-22)
Features
Drive Layout:
Front-Wheel Drive (FWD)
๐ Dimensions
Exterior
Length Mm:
Approx. 4655 mm
Width Mm:
Approx. 1765 mm
Height Mm:
Approx. 1380 mm
Wheelbase Mm:
Approx. 2660 mm
Weights
Curb Weight Kg Approx:
Approx. 1450-1550 kg (depending on engine and equipment)
๐ก๏ธ Safety Features
Ratings
Crash Test Data Availability:
Limited public data available for this era; manual provides repair guidance based on design.
Active Features
ABS:
Anti-lock Braking System (ABS) available on most models.
Passive Features
Airbags:
Driver airbag likely standard for later models in this range, passenger airbag optional or standard on higher trims.
๐ก Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette system, with speaker options and potential for upgraded units.
Climate Control:
Automatic climate control system with electronic actuators for temperature and air distribution. Covered in HVAC section.
Driver Assistance
Cruise Control:
Electronic cruise control system typically available.
Connectivity
Diagnostics Port:
OBD-I or proprietary diagnostic connector, depending on the exact model year and market. Manual will detail diagnostic access.
๐ง Maintenance
Service Intervals
Oil Change Interval Km:
Typically every 10,000-15,000 km or annually, refer to manual for exact specification based on driving conditions.
Timing Belt Interval Km:
Crucial maintenance item for the Busso V6, typically recommended every 60,000-90,000 km or 5-7 years due to interference engine design. Manual will specify.
Fluid Specifications
Engine Oil Spec:
Likely API SG/SH or ACEA A2/A3, viscosity typically 10W-40 or 5W-40. Manual will confirm exact specification and capacity.
Coolant Spec:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Manual will specify type and capacity.
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid. Manual will specify.
Transmission Fluid Manual:
Gear oil specification for manual transaxle, e.g., GL-4 or GL-5, viscosity dependent on temperature. Manual will confirm.
Transmission Fluid Automatic:
Dexron-III or equivalent automatic transmission fluid (ATF) for ZF units. Manual will confirm.
Known Issues
Common Wear Items:
Suspension bushings, control arm bushings, exhaust manifold gaskets (Busso V6), aging electrical connectors, climate control flap actuators.
Busso V6 Specifics:
Timing belt maintenance is critical; exhaust manifold leaks can cause noise and performance issues; valve stem seals can wear, leading to oil consumption.
๐ Vehicle History
Brand Heritage
Alfa Romeo Legacy:
Renowned for sporting sedans and innovative engineering, with a focus on driving dynamics and distinctive Italian design.
Model Evolution
164 Development:
Developed as part of the 'Tipo 4' project, sharing its platform with other Fiat Group and Saab vehicles, but with unique Alfa Romeo engineering and styling.
Production
Manufacturing Location:
Italy
๐ Awards & Recognition
Recognitions
Design Awards:
While specific awards for the 1991-1993 models are not widely publicized, the Pininfarina design received critical acclaim for its aerodynamic and elegant lines.