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Alfa Romeo 75 2.5 V6 Milano 1985-1989 Service Repair Manual

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🏷️ Basic Information Identification Make: Alfa Romeo Model: 75 (Tipo 162) Trim: 2.5 V6 Milano Years Covered: 1985-1989 Codes Chassis Code: Tipo 162 👋 Introduction Market Position Segment: Compact Executive Sedan Brand Philosophy: Sporty, driver-focused Italian performance and design Competitive Analysis Key Competitors: BMW 3 Series, Mercedes-Benz 190E, Audi 80/90, Ford Sierra, Volvo 240 Key Features Design: Distinctive wedge shape, distinctive Alfa Romeo grille, advanced transaxle layout for weight distribution Drivetrain: Rear-wheel drive, optional limited-slip differential (LSD) Engine Layout: Front-engine, rear-wheel drive Purpose Of Manual Target Audience: DIY enthusiasts and professional mechanics 📋 Manual Details Coverage Areas Primary Coverage: Complete Factory Service Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Repair, Wiring Diagrams, Emission Control Page Count Estimated Page Count: Varies, typically 500+ pages for comprehensive factory manuals Manual Type Type: Workshop Service Repair Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system Chassis: Suspension (front and rear), steering system, braking system, wheels and tires Electrical: Starting and charging system, lighting system, instruments and gauges, ignition, body electrical components, wiring diagrams Body: Body panels, doors, windows, interior trim, heating and ventilation Procedures Included Maintenance: Periodic maintenance schedules, fluid checks and changes, filter replacements, lubrication Repair: Step-by-step repair procedures for all major vehicle systems, including detailed disassembly and reassembly instructions Troubleshooting: Diagnostic charts, symptom-based troubleshooting guides, common problem identification Technical Depth Depth: Comprehensive, covering everything from basic adjustments to major component overhauls Diagrams Illustrations: High-quality diagrams, exploded views, and illustrations for clarity 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text within the PDF Print Quality Printability: Printable without restriction Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper: N/A (Digital Download) Requirements Software Requirement: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Code: AR06112 (Busso V6) Configuration: 60-degree V6 Displacement: 2492 cc (2.5 liters) Performance Horsepower: Approximately 156 PS (154 hp) at 5400 rpm (European spec) Torque: Approximately 210 Nm (155 lb-ft) at 4000 rpm (European spec) Fuel System Induction: Bosch L-Jetronic fuel injection Fuel Type: Unleaded gasoline (RON 95 or higher recommended) Engine Management Ignition System: Electronic ignition (e.g., Bosch Motronic variant) Cooling System Type: Liquid-cooled Lubrication System Oil Capacity: Approximately 5.0 liters (5.3 US quarts) with filter change Engine Construction Block Material: Aluminum alloy Cylinder Head Material: Aluminum alloy 🔧 Transmission Standard Type: 5-speed manual transaxle (e.g., ZF S5-24/3) Optional Type: 3-speed automatic (e.g., ZF 3HP22) Features Layout: Transaxle (gearbox and differential combined in a single unit at the rear axle) Fluid Type Manual Transmission Fluid: GL-4 SAE 75W-90 or GL-4 SAE 75W-80 (specifics to be confirmed in manual) Automatic Transmission Fluid: ZF TE-ML 11A or equivalent ATF (specifics to be confirmed in manual) 📐 Dimensions Exterior Wheelbase: Approx. 2500 mm (98.4 in) Length: Approx. 4340 mm (170.9 in) Width: Approx. 1680 mm (66.1 in) Height: Approx. 1370 mm (53.9 in) Weights Curb Weight: Approx. 1250-1350 kg (2755-2976 lbs) Wheels Tires Standard Wheel Size: 14-inch or 15-inch alloy wheels Standard Tire Size: e.g., 195/60VR14 or 195/55VR15 Bolt Pattern: 4x108 🛡️ Safety Features Ratings Crash Test Data: Limited data available for this era, but generally designed to contemporary European standards. Active Features Brakes: Front: Ventilated discs; Rear: Discs ABS: Optional on some models/markets during this period. Passive Features Seatbelts: Standard front seatbelts, rear seatbelts may vary by market. Headrests: Front and rear headrests. 💡 Technology Features Infotainment Audio System: Factory fitted radio cassette player, often with integrated amplifier. Speakers: Typically 4-6 speakers. Driver Assistance Cruise Control: Available as an option on some higher-trim models. Connectivity Early Systems: No modern connectivity features like Bluetooth or USB. 🔧 Maintenance Service Intervals Oil Change: Every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on usage. (Consult manual for precise intervals). Spark Plugs: Check/replace as per manual, typically around 20,000-40,000 km (12,000-24,000 miles). Timing Belt: CRITICAL: Replacement interval typically every 40,000-60,000 km (25,000-37,000 miles) or 4-5 years. Failure can cause catastrophic engine damage. Fluid Specifications Engine Oil Viscosity: SAE 10W-40 or SAE 15W-50 (API SG/SH or equivalent) - check manual for specific recommendation. Coolant: Ethylene glycol-based antifreeze, mixed 50/50 with distilled water. Refer to manual for specific type and capacity. Brake Fluid: DOT 3 or DOT 4 (check manual for confirmation) Known Issues Rust Corrosion: Prone to rust in wheel arches, sills, and around window seals, especially in humid climates. Electrical Gremlins: Can suffer from aging wiring looms, brittle connectors, and minor electrical faults, particularly after many years. Engine Management Aging: Fuel injection and ignition system components (e.g., airflow meter, injectors, coil packs) can wear out. Transaxle Clunk: Some models may develop a 'clunk' from the rear transaxle under acceleration/deceleration due to worn U-joints or differential mounts. 📚 Vehicle History Brand Heritage Founding Principles: Founded on racing heritage, engineering excellence, and passionate Italian...
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Alfa Romeo 75 2.5 V6 Milano 1985-1989 Service Repair ManualAlfa Romeo 75 2.5 V6 Milano 1985-1989 Service Repair ManualAlfa Romeo 75 2.5 V6 Milano 1985-1989 Service Repair ManualAlfa Romeo 75 2.5 V6 Milano 1985-1989 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Alfa Romeo
Model:
75 (Tipo 162)
Trim:
2.5 V6 Milano
Years Covered:
1985-1989
Codes
Chassis Code:
Tipo 162
👋 Introduction
Market Position
Segment:
Compact Executive Sedan
Brand Philosophy:
Sporty, driver-focused Italian performance and design
Competitive Analysis
Key Competitors:
BMW 3 Series, Mercedes-Benz 190E, Audi 80/90, Ford Sierra, Volvo 240
Key Features
Design:
Distinctive wedge shape, distinctive Alfa Romeo grille, advanced transaxle layout for weight distribution
Drivetrain:
Rear-wheel drive, optional limited-slip differential (LSD)
Engine Layout:
Front-engine, rear-wheel drive
Purpose Of Manual
Target Audience:
DIY enthusiasts and professional mechanics
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Factory Service Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Repair, Wiring Diagrams, Emission Control
Page Count
Estimated Page Count:
Varies, typically 500+ pages for comprehensive factory manuals
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system
Chassis:
Suspension (front and rear), steering system, braking system, wheels and tires
Electrical:
Starting and charging system, lighting system, instruments and gauges, ignition, body electrical components, wiring diagrams
Body:
Body panels, doors, windows, interior trim, heating and ventilation
Procedures Included
Maintenance:
Periodic maintenance schedules, fluid checks and changes, filter replacements, lubrication
Repair:
Step-by-step repair procedures for all major vehicle systems, including detailed disassembly and reassembly instructions
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting guides, common problem identification
Technical Depth
Depth:
Comprehensive, covering everything from basic adjustments to major component overhauls
Diagrams Illustrations:
High-quality diagrams, exploded views, and illustrations for clarity
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text within the PDF
Print Quality
Printability:
Printable without restriction
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Paper:
N/A (Digital Download)
Requirements
Software Requirement:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Code:
AR06112 (Busso V6)
Configuration:
60-degree V6
Displacement:
2492 cc (2.5 liters)
Performance
Horsepower:
Approximately 156 PS (154 hp) at 5400 rpm (European spec)
Torque:
Approximately 210 Nm (155 lb-ft) at 4000 rpm (European spec)
Fuel System
Induction:
Bosch L-Jetronic fuel injection
Fuel Type:
Unleaded gasoline (RON 95 or higher recommended)
Engine Management
Ignition System:
Electronic ignition (e.g., Bosch Motronic variant)
Cooling System
Type:
Liquid-cooled
Lubrication System
Oil Capacity:
Approximately 5.0 liters (5.3 US quarts) with filter change
Engine Construction
Block Material:
Aluminum alloy
Cylinder Head Material:
Aluminum alloy
🔧 Transmission
Standard
Type:
5-speed manual transaxle (e.g., ZF S5-24/3)
Optional
Type:
3-speed automatic (e.g., ZF 3HP22)
Features
Layout:
Transaxle (gearbox and differential combined in a single unit at the rear axle)
Fluid Type
Manual Transmission Fluid:
GL-4 SAE 75W-90 or GL-4 SAE 75W-80 (specifics to be confirmed in manual)
Automatic Transmission Fluid:
ZF TE-ML 11A or equivalent ATF (specifics to be confirmed in manual)
📐 Dimensions
Exterior
Wheelbase:
Approx. 2500 mm (98.4 in)
Length:
Approx. 4340 mm (170.9 in)
Width:
Approx. 1680 mm (66.1 in)
Height:
Approx. 1370 mm (53.9 in)
Weights
Curb Weight:
Approx. 1250-1350 kg (2755-2976 lbs)
Wheels Tires
Standard Wheel Size:
14-inch or 15-inch alloy wheels
Standard Tire Size:
e.g., 195/60VR14 or 195/55VR15
Bolt Pattern:
4x108
🛡️ Safety Features
Ratings
Crash Test Data:
Limited data available for this era, but generally designed to contemporary European standards.
Active Features
Brakes:
Front: Ventilated discs; Rear: Discs
ABS:
Optional on some models/markets during this period.
Passive Features
Seatbelts:
Standard front seatbelts, rear seatbelts may vary by market.
Headrests:
Front and rear headrests.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio cassette player, often with integrated amplifier.
Speakers:
Typically 4-6 speakers.
Driver Assistance
Cruise Control:
Available as an option on some higher-trim models.
Connectivity
Early Systems:
No modern connectivity features like Bluetooth or USB.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on usage. (Consult manual for precise intervals).
Spark Plugs:
Check/replace as per manual, typically around 20,000-40,000 km (12,000-24,000 miles).
Timing Belt:
CRITICAL: Replacement interval typically every 40,000-60,000 km (25,000-37,000 miles) or 4-5 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Viscosity:
SAE 10W-40 or SAE 15W-50 (API SG/SH or equivalent) - check manual for specific recommendation.
Coolant:
Ethylene glycol-based antifreeze, mixed 50/50 with distilled water. Refer to manual for specific type and capacity.
Brake Fluid:
DOT 3 or DOT 4 (check manual for confirmation)
Known Issues
Rust Corrosion:
Prone to rust in wheel arches, sills, and around window seals, especially in humid climates.
Electrical Gremlins:
Can suffer from aging wiring looms, brittle connectors, and minor electrical faults, particularly after many years.
Engine Management Aging:
Fuel injection and ignition system components (e.g., airflow meter, injectors, coil packs) can wear out.
Transaxle Clunk:
Some models may develop a 'clunk' from the rear transaxle under acceleration/deceleration due to worn U-joints or differential mounts.
📚 Vehicle History
Brand Heritage
Founding Principles:
Founded on racing heritage, engineering excellence, and passionate Italian design.
Model Evolution
Predecessor:
Alfa Romeo Giulietta (Nuova Giulietta)
Successor:
Alfa Romeo 155
Production
Production Period:
1985-1992
Manufacturing Plant:
Alfa Romeo's plants in Italy (primarily Pomigliano d'Arco and Arese)
Model Name Origin
Meaning:
Named after Milan, Italy (Milano) and its founding year (1860), referencing the company's origins.
🏆 Awards & Recognition
Recognitions
Automotive Press:
Generally well-received by the automotive press for its handling, engine performance, and distinctive styling.
Ratings
Performance Handling:
Often praised for its balanced chassis and engaging driving dynamics, a hallmark of Alfa Romeo.
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