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Alfa Romeo 155 Factory Workshop Repair Manual Suplement

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🏷️ Basic Information Identification Make: Alfa Romeo Model: 155 Type: Sedan Generation: First Generation (1992-1997) Codes Chassis Code: 155 👋 Introduction Market Position Market Segment: Compact Executive Car (D-segment) Brand Philosophy: Sporty, stylish, and driver-focused Italian automobile. Competitive Analysis Key Competitors: BMW 3 Series, Mercedes-Benz C-Class, Audi 80/A4, Volvo S40/V40, Saab 900. Key Features Design Language: Sharply styled by Zagato, often noted for its polarizing front-end design and a blend of Italian flair and German engineering influence (due to some shared platform elements with the Opel Vectra). Driving Dynamics: Renowned for its engaging handling, communicative steering, and potent engine options, particularly the Twin Spark and V6 Busso units. Manual Usefulness Value Proposition: Enables owners and technicians to perform a wide range of maintenance and repair tasks, saving money on labor costs and ensuring proper vehicle upkeep. 📋 Manual Details Coverage Areas Model Years Covered: 1992-1997 Engine Variants Covered: All variants offered for the 155 model range during its production lifecycle, including Twin Spark, V6 Busso, and turbodiesel engines. Page Count Page Count: Not specified, but described as 'complete' and containing 'detailed instructions and step by step diagrams'. Manual Type Manual Type: Factory Workshop Repair Manual Supplement Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals (Twin Spark, V6 Busso, Turbodiesel), fuel system, ignition system, exhaust system, cooling system, lubrication system. Transmission Drivetrain: Manual and automatic transmissions, clutch, differentials, driveshafts, constant velocity joints, transaxle components (where applicable). Suspension Steering: Front and rear suspension components, shock absorbers, springs, anti-roll bars, steering rack, power steering system, wheel alignment. Brakes: Brake system hydraulics, calipers, rotors, pads, ABS system (if equipped), parking brake. Electrical Electronics: Battery, charging system, starter motor, lighting system, wipers, horn, instrumentation, fuse box, ECU diagnostics (OBD I/II dependent on year), body control modules. Body Interior: Body panels, doors, hood, trunk, glass, interior trim, seats, dashboard, HVAC system, body sealing. Procedures Included Maintenance: Routine servicing, oil changes, filter replacements, fluid level checks and changes, spark plug replacement, belt inspection and replacement. Diagnostics: Troubleshooting common issues, diagnostic flowcharts, fault code interpretation (where applicable), component testing. Repair Overhaul: Engine removal and installation, cylinder head service, transmission overhaul, brake caliper rebuild, suspension component replacement, electrical component repair. Disassembly Assembly: Detailed step-by-step instructions for disassembling and reassembling various vehicle components and systems. Technical Depth Depth: Comprehensive, covering from basic maintenance to major component overhauls and advanced diagnostics. 📊 Manual Specifications File Format File Format: PDF Compatibility: All Versions of Windows & Mac Reader Requirement: Adobe PDF Reader Print Quality Print Restriction: Without any restriction Binding Type Binding Type: Digital Download (Printable) Paper Type Paper Type: Not Applicable (Digital) ⚙️ Engine Specifications Primary Engine Twin Spark: 1.8L and 2.0L Twin Spark DOHC 16-valve inline-4. V6 Busso: 2.5L and 3.0L V6 Busso DOHC 24-valve naturally aspirated V6. Turbodiesel: 1.9L and 2.1L Turbodiesel inline-4 (various configurations). Performance Power Output Range: Approximately 115 hp (1.8 TS) to 215 hp (3.0 V6 QV). Torque Output Range: Approximately 160 Nm (1.8 TS) to 270 Nm (3.0 V6 QV). Fuel System Fuel Injection: Electronic multi-point fuel injection (MPI) for petrol engines; direct injection for turbodiesel variants. Maintenance Points Timing Belt Ts: Critical component for Twin Spark engines, requiring regular replacement (typically 60,000-90,000 km or 5-7 years). Oil Type V6: High-quality synthetic oil (e.g., 10W-40 or 15W-50 depending on climate) recommended for the Busso V6 to ensure longevity. 🔧 Transmission Standard Gearbox Options: 5-speed manual transmission, 4-speed automatic transmission (e.g., ZF 4HP18). Optional All Wheel Drive: Q4 variants featured a viscous coupling center differential and Torsen rear differential, offering all-wheel drive capability. Features Clutch Type: Hydraulically operated single dry plate clutch for manual transmissions. Maintenance Transmission Fluid Manual: API GL-4 SAE 75W-90 or 80W-90 gear oil. Transmission Fluid Automatic: Refer to manual for specific ATF type, typically Dexron III or equivalent. 📐 Dimensions Exterior Length: Approximately 4340 mm (170.9 in) Width: Approximately 1715 mm (67.5 in) Height: Approximately 1425 mm (56.1 in) Wheelbase: Approximately 2600 mm (102.4 in) Weights Curb Weight: Approximately 1300-1500 kg (2866-3307 lbs) depending on engine and configuration. Gross Vehicle Weight: Refer to specific model documentation. 🛡️ Safety Features Ratings Crash Test Data: Limited publicly available Euro NCAP or NHTSA data for early models. Later models may have improved safety features. Active Features ABS: Anti-lock Braking System (ABS) available on most models, standard on higher trims and later production years. Traction Control: ASR (Anti-Slip Regulation) or Traction Control System (TCS) available on select performance models. Passive Features Airbags: Driver and front passenger airbags standard on later models, side airbags optional on some trims. Seatbelts: Pre-tensioning front seatbelts. 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette player, with options for CD players on later models. Speaker configurations varied by trim. Climate Control: Manual or optional automatic climate control (HVAC) system. Driver Assistance Cruise Control: Available as...
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Alfa Romeo 155 Factory Workshop Repair Manual Suplement
🏷️ Basic Information
Identification
Make:
Alfa Romeo
Model:
155
Type:
Sedan
Generation:
First Generation (1992-1997)
Codes
Chassis Code:
155
👋 Introduction
Market Position
Market Segment:
Compact Executive Car (D-segment)
Brand Philosophy:
Sporty, stylish, and driver-focused Italian automobile.
Competitive Analysis
Key Competitors:
BMW 3 Series, Mercedes-Benz C-Class, Audi 80/A4, Volvo S40/V40, Saab 900.
Key Features
Design Language:
Sharply styled by Zagato, often noted for its polarizing front-end design and a blend of Italian flair and German engineering influence (due to some shared platform elements with the Opel Vectra).
Driving Dynamics:
Renowned for its engaging handling, communicative steering, and potent engine options, particularly the Twin Spark and V6 Busso units.
Manual Usefulness
Value Proposition:
Enables owners and technicians to perform a wide range of maintenance and repair tasks, saving money on labor costs and ensuring proper vehicle upkeep.
📋 Manual Details
Coverage Areas
Model Years Covered:
1992-1997
Engine Variants Covered:
All variants offered for the 155 model range during its production lifecycle, including Twin Spark, V6 Busso, and turbodiesel engines.
Page Count
Page Count:
Not specified, but described as 'complete' and containing 'detailed instructions and step by step diagrams'.
Manual Type
Manual Type:
Factory Workshop Repair Manual Supplement
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanicals (Twin Spark, V6 Busso, Turbodiesel), fuel system, ignition system, exhaust system, cooling system, lubrication system.
Transmission Drivetrain:
Manual and automatic transmissions, clutch, differentials, driveshafts, constant velocity joints, transaxle components (where applicable).
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, anti-roll bars, steering rack, power steering system, wheel alignment.
Brakes:
Brake system hydraulics, calipers, rotors, pads, ABS system (if equipped), parking brake.
Electrical Electronics:
Battery, charging system, starter motor, lighting system, wipers, horn, instrumentation, fuse box, ECU diagnostics (OBD I/II dependent on year), body control modules.
Body Interior:
Body panels, doors, hood, trunk, glass, interior trim, seats, dashboard, HVAC system, body sealing.
Procedures Included
Maintenance:
Routine servicing, oil changes, filter replacements, fluid level checks and changes, spark plug replacement, belt inspection and replacement.
Diagnostics:
Troubleshooting common issues, diagnostic flowcharts, fault code interpretation (where applicable), component testing.
Repair Overhaul:
Engine removal and installation, cylinder head service, transmission overhaul, brake caliper rebuild, suspension component replacement, electrical component repair.
Disassembly Assembly:
Detailed step-by-step instructions for disassembling and reassembling various vehicle components and systems.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to major component overhauls and advanced diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF
Compatibility:
All Versions of Windows & Mac
Reader Requirement:
Adobe PDF Reader
Print Quality
Print Restriction:
Without any restriction
Binding Type
Binding Type:
Digital Download (Printable)
Paper Type
Paper Type:
Not Applicable (Digital)
⚙️ Engine Specifications
Primary Engine
Twin Spark:
1.8L and 2.0L Twin Spark DOHC 16-valve inline-4.
V6 Busso:
2.5L and 3.0L V6 Busso DOHC 24-valve naturally aspirated V6.
Turbodiesel:
1.9L and 2.1L Turbodiesel inline-4 (various configurations).
Performance
Power Output Range:
Approximately 115 hp (1.8 TS) to 215 hp (3.0 V6 QV).
Torque Output Range:
Approximately 160 Nm (1.8 TS) to 270 Nm (3.0 V6 QV).
Fuel System
Fuel Injection:
Electronic multi-point fuel injection (MPI) for petrol engines; direct injection for turbodiesel variants.
Maintenance Points
Timing Belt Ts:
Critical component for Twin Spark engines, requiring regular replacement (typically 60,000-90,000 km or 5-7 years).
Oil Type V6:
High-quality synthetic oil (e.g., 10W-40 or 15W-50 depending on climate) recommended for the Busso V6 to ensure longevity.
🔧 Transmission
Standard
Gearbox Options:
5-speed manual transmission, 4-speed automatic transmission (e.g., ZF 4HP18).
Optional
All Wheel Drive:
Q4 variants featured a viscous coupling center differential and Torsen rear differential, offering all-wheel drive capability.
Features
Clutch Type:
Hydraulically operated single dry plate clutch for manual transmissions.
Maintenance
Transmission Fluid Manual:
API GL-4 SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
Refer to manual for specific ATF type, typically Dexron III or equivalent.
📐 Dimensions
Exterior
Length:
Approximately 4340 mm (170.9 in)
Width:
Approximately 1715 mm (67.5 in)
Height:
Approximately 1425 mm (56.1 in)
Wheelbase:
Approximately 2600 mm (102.4 in)
Weights
Curb Weight:
Approximately 1300-1500 kg (2866-3307 lbs) depending on engine and configuration.
Gross Vehicle Weight:
Refer to specific model documentation.
🛡️ Safety Features
Ratings
Crash Test Data:
Limited publicly available Euro NCAP or NHTSA data for early models. Later models may have improved safety features.
Active Features
ABS:
Anti-lock Braking System (ABS) available on most models, standard on higher trims and later production years.
Traction Control:
ASR (Anti-Slip Regulation) or Traction Control System (TCS) available on select performance models.
Passive Features
Airbags:
Driver and front passenger airbags standard on later models, side airbags optional on some trims.
Seatbelts:
Pre-tensioning front seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player, with options for CD players on later models. Speaker configurations varied by trim.
Climate Control:
Manual or optional automatic climate control (HVAC) system.
Driver Assistance
Cruise Control:
Available as an option on higher trims or as a dealer-fitted accessory.
Connectivity
Alarm Immobiliser:
Factory fitted alarm and immobiliser systems available on later models.
🔧 Maintenance
Service Intervals
Oil Change Petrol:
Typically every 10,000-15,000 km or 12 months, whichever comes first. Refer to specific engine recommendations in the manual.
Timing Belt Replacement:
Crucial for Twin Spark engines; recommended every 60,000-90,000 km or 5-7 years. Include tensioners and idler pulleys.
Brake Fluid:
Recommend replacement every 2-3 years to maintain optimal braking performance and prevent moisture absorption.
Fluid Specifications
Engine Oil Capacity 2.0 Ts:
Approximately 4.7 liters (5.0 US qts) of SAE 10W-40 or 15W-40 API SG/SH rated oil.
Coolant:
Use a 50/50 mixture of ethylene glycol-based antifreeze and distilled water. Refer to manual for specific antifreeze type.
Power Steering Fluid:
Use genuine Alfa Romeo or Pentosin CHF 11S, or an equivalent synthetic hydraulic fluid.
Known Issues
Twin Spark Issues:
Potential for coil pack failure, spark plug wear (due to four plugs per cylinder), and water ingress in some early engine bays affecting electronics.
V6 Busso Issues:
Can suffer from timing belt tensioner failure (critical), oil leaks, and exhaust manifold cracking. Regular maintenance is paramount.
Rust Corrosion:
Like many European cars of its era, susceptible to rust in wheel arches, sills, and boot floor areas, especially in areas with road salt.
Electrical Gremlins:
Some owners report minor electrical issues, often related to earth points, connectors, or aging wiring harnesses.
📚 Vehicle History
Brand Heritage
Alfa Romeo Legacy:
Alfa Romeo boasts a rich heritage in motorsport and performance car manufacturing, known for its passion, engineering, and distinctive Italian style.
Model Evolution
Development Context:
Developed as a successor to the Alfa Romeo 75, the 155 was built on the Fiat Tipo platform, marking a shift towards greater platform sharing within the Fiat Group, which was met with mixed reactions by purists but aimed to improve economies of scale and market penetration.
Facelift:
Received a significant facelift in 1995 (Series 2), featuring redesigned front and rear styling, improved aerodynamics, and updated interior features.
Production
Production Period:
1992-1997
Manufacturing Location:
Pomigliano d'Arco, Italy.
Motorsport Connection
Dtm Success:
The Alfa Romeo 155 gained significant fame and motorsport credibility through its highly successful DTM (Deutsche Tourenwagen Meisterschaft) campaign, particularly with the 155 V6 TI model driven by legends like Nicola Larini and Alessandro Nannini.
🏆 Awards & Recognition
Recognitions
Motorsport Accolades:
Most notable 'award' is its significant success in touring car racing, particularly winning the 1993 Deutsche Tourenwagen Meisterschaft (DTM) with the 155 V6 TI, a testament to its engineering and racing pedigree.
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