Alfa Romeo 75 MILANO Service Repair Workshop Manual
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๐ท๏ธ Basic Information Identification Make: Alfa Romeo Model: 75 Milano Alternative Model Designations: Alfa Romeo 75, Alfa Romeo Giulietta (Type 116) ๐ Introduction Market Position Positioning: A enthusiast-focused, sport sedan offering distinctive Italian design and engaging driving dynamics. Competitive Analysis Key Competitors: BMW 3 Series (E30), Mercedes-Benz 190E (W201), Audi 80/90, Ford Sierra Key Features Design Philosophy: Rear-wheel drive, near-perfect weight distribution, distinctive Alfa Romeo styling, advanced (for its time) engineering. Unique Selling Points: Busso V6 engine variants, advanced Transaxle layout, sporty handling characteristics. Manual Value Proposition Benefit To Owner: Empowers owners to perform maintenance and repairs, saving costs and ensuring proper care of a classic Italian automobile. ๐ Manual Details Coverage Areas Languages: English (assumed, based on product description emphasizing completeness and repair) Model Variants Covered: All models and engine variants of the Alfa Romeo 75 Milano Page Count Estimated Page Count: Hundreds of pages (as stated in description) Manual Type Type: Service Repair Workshop Manual Format Digital Format: PDF Download ๐ Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system Transmission: Manual and Automatic transmission repair, clutch, driveline, driveshafts Chassis And Suspension: Front and rear suspension, steering system, wheels and tires Brakes: Hydraulic brake system, parking brake, ABS (if applicable) Electrical System: Battery, charging system, starting system, lighting, instruments, wiring diagrams, fuses and relays Body And Interior: Body panels, doors, windows, interior trim, seats, HVAC system, body electrical components Procedures Included Maintenance: Scheduled maintenance, lubrication, fluid changes, filter replacements, inspections Diagnostics: Troubleshooting guides, fault finding procedures, diagnostic trouble codes (DTCs) interpretation (where applicable) Repair: Step-by-step repair instructions for all major mechanical and electrical components Rebuilding: Detailed procedures for engine, transmission, and component rebuilds Refurbishing: Procedures for restoring worn or damaged components Technical Depth Depth: Comprehensive (from basic maintenance to complete engine/transmission rebuilds) ๐ Manual Specifications File Format Compatibility: Universal PDF reader compatibility Print Quality Quality: High-resolution, printable pages Binding Type Type: Digital Download (N/A for physical binding) Paper Type Type: N/A (Digital Format) โ๏ธ Engine Specifications Primary Engine Engine Code Examples: AR01634 (2.0L Twin Spark), AR06122 (3.0L V6) Engine Configurations: Inline-4 (Twin Spark), V6 Displacement Options: 1.6L, 1.8L, 2.0L (Twin Spark), 2.5L V6, 3.0L V6 Performance Horsepower Range: Approximately 110 hp (1.6L) to 200 hp (3.0L V6 Quadrifoglio) Torque Range: Varies significantly by engine, e.g., ~180 Nm (2.0 TS) to ~250 Nm (3.0 V6) Fuel System Induction Type: Carburetor (early models), Bosch L-Jetronic/Motronic Fuel Injection (later Twin Spark and V6) Technical Details Valve Train: DOHC 8v (Inline-4), DOHC 12v (V6), DOHC 16v (later Twin Spark) Bore Stroke Examples: 2.0L Twin Spark: 83.0 mm x 91.0 mm; 3.0L V6: 88.0 mm x 82.0 mm Compression Ratio Examples: 2.0L Twin Spark: 9.3:1; 3.0L V6: 9.0:1 ๐ง Transmission Standard Type: 5-speed manual transaxle Optional Type: 3-speed automatic (e.g., ZF 3HP22) Features Transaxle Layout: Rear-mounted gearbox and differential (transaxle) for optimized weight distribution. Fluid Type Examples Manual Transmission Fluid: SAE 75W-90 GL-4 or GL-5 (check specific manual for exact spec) Automatic Transmission Fluid: Dexron II (for ZF 3HP22) ๐ Dimensions Exterior Length: Approximately 4350 mm (171.3 in) Width: Approximately 1680 mm (66.1 in) Height: Approximately 1370 mm (53.9 in) Wheelbase: Approximately 2610 mm (102.8 in) Weights Curb Weight Range: Approximately 1150 kg - 1300 kg (2535 lbs - 2866 lbs) Gross Vehicle Weight Rating: Refer to vehicle plate; typically around 1600-1700 kg Cargo Trunk Volume: Moderately sized trunk, typical for its class, influenced by transaxle placement. ๐ก๏ธ Safety Features Ratings Crash Test Data: Limited formal crash test data available compared to modern standards; designed with period-appropriate safety features. Active Features Braking System: Hydraulic disc brakes on all four wheels (often ventilated front), often with servo assistance. ABS: Optional on some later models Passive Features Seatbelts: Three-point seatbelts (front), two-point (rear, early models), three-point (rear, later models) Steering Column: Collapsible steering column Body Structure: Reinforced safety cell with crumple zones ๐ก Technology Features Infotainment Audio System: Period-appropriate radio cassette players, often with basic speaker systems. Aftermarket upgrades common. Dashboard Instruments: Comprehensive array of analog gauges including tachometer, speedometer, oil pressure, temperature, and fuel level. Driver Assistance Features: Limited to ABS on later models. Focus is on driver engagement rather than electronic aids. Connectivity Features: None (pre-digital age connectivity). ๐ง Maintenance Service Intervals Oil Change Interval: Every 10,000 km (6,000 miles) or 12 months (approximate, consult manual) Timing Belt Interval: Every 40,000 - 60,000 km (25,000 - 37,000 miles) or 3-5 years for Twin Spark engines. V6 timing chains require less frequent attention but checking is crucial. Spark Plug Replacement: Typically every 20,000 - 40,000 km, depending on type (e.g., Twin Spark requires regular attention). Fluid Specifications Engine Oil Type Examples: API SG/SH, ACEA A2/A3, SAE 10W-40 or 10W-50 (depending on climate and engine wear) Coolant Type: Ethylene glycol-based antifreeze (e.g., Paraflu UP) mixed with distilled...
2.0L Twin Spark: 83.0 mm x 91.0 mm; 3.0L V6: 88.0 mm x 82.0 mm
Compression Ratio Examples:
2.0L Twin Spark: 9.3:1; 3.0L V6: 9.0:1
๐ง Transmission
Standard
Type:
5-speed manual transaxle
Optional
Type:
3-speed automatic (e.g., ZF 3HP22)
Features
Transaxle Layout:
Rear-mounted gearbox and differential (transaxle) for optimized weight distribution.
Fluid Type Examples
Manual Transmission Fluid:
SAE 75W-90 GL-4 or GL-5 (check specific manual for exact spec)
Automatic Transmission Fluid:
Dexron II (for ZF 3HP22)
๐ Dimensions
Exterior
Length:
Approximately 4350 mm (171.3 in)
Width:
Approximately 1680 mm (66.1 in)
Height:
Approximately 1370 mm (53.9 in)
Wheelbase:
Approximately 2610 mm (102.8 in)
Weights
Curb Weight Range:
Approximately 1150 kg - 1300 kg (2535 lbs - 2866 lbs)
Gross Vehicle Weight Rating:
Refer to vehicle plate; typically around 1600-1700 kg
Cargo
Trunk Volume:
Moderately sized trunk, typical for its class, influenced by transaxle placement.
๐ก๏ธ Safety Features
Ratings
Crash Test Data:
Limited formal crash test data available compared to modern standards; designed with period-appropriate safety features.
Active Features
Braking System:
Hydraulic disc brakes on all four wheels (often ventilated front), often with servo assistance.
ABS:
Optional on some later models
Passive Features
Seatbelts:
Three-point seatbelts (front), two-point (rear, early models), three-point (rear, later models)
Steering Column:
Collapsible steering column
Body Structure:
Reinforced safety cell with crumple zones
๐ก Technology Features
Infotainment
Audio System:
Period-appropriate radio cassette players, often with basic speaker systems. Aftermarket upgrades common.
Dashboard Instruments:
Comprehensive array of analog gauges including tachometer, speedometer, oil pressure, temperature, and fuel level.
Driver Assistance
Features:
Limited to ABS on later models. Focus is on driver engagement rather than electronic aids.
Connectivity
Features:
None (pre-digital age connectivity).
๐ง Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or 12 months (approximate, consult manual)
Timing Belt Interval:
Every 40,000 - 60,000 km (25,000 - 37,000 miles) or 3-5 years for Twin Spark engines. V6 timing chains require less frequent attention but checking is crucial.
Spark Plug Replacement:
Typically every 20,000 - 40,000 km, depending on type (e.g., Twin Spark requires regular attention).
Fluid Specifications
Engine Oil Type Examples:
API SG/SH, ACEA A2/A3, SAE 10W-40 or 10W-50 (depending on climate and engine wear)
Coolant Type:
Ethylene glycol-based antifreeze (e.g., Paraflu UP) mixed with distilled water in a 50:50 ratio.
Brake Fluid Type:
DOT 4
Power Steering Fluid Type:
Typically ATF Dexron II or specific Alfa Romeo fluid.
Known Issues
Rust Susceptibility:
Prone to rust in wheel arches, sills, and around window seals. Thorough inspection is vital.
Twin Spark Ignition:
Twin Spark engines require meticulous maintenance of the dual spark plug system for optimal performance and longevity.
Electrical Gremlins:
Aging wiring looms and connectors can lead to intermittent electrical faults.
Transaxle Clutch Actuation:
Hydraulic clutch actuation system can be a source of leaks or poor operation if not maintained.
Maintenance Philosophy
Importance Of Prevention:
Proactive maintenance is key to preserving the character and reliability of these Italian classics.
๐ Vehicle History
Brand Heritage
Founding Principles:
Emphasis on performance, sporting heritage, and innovative engineering since its founding in 1910.
Model Evolution
Predecessor:
Alfa Romeo Giulietta (Type 116, superseded)
Successor:
Alfa Romeo 155
Development Inspiration:
Designed to be a more modern and competitive successor to the Alfetta and Giulietta.
Production
Production Years:
1985-1992
Manufacturing Locations:
Milan, Italy; also assembled in other Fiat Group facilities.
Total Production Numbers:
Over 379,000 units across all variants.
๐ Awards & Recognition
Recognitions
Automotive Journalism:
Frequently praised for its driving dynamics and handling, particularly the V6 models, by contemporary automotive press.
Classic Car Status:
Recognized as a future classic and a notable example of 1980s Italian automotive design and engineering.