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Alfa Romeo Alfasud Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Alfa Romeo Model: Alfasud Model Variant: All variants (Saloon, Sprint, Ti, etc.) Codes Chassis Code: Type 901 👋 Introduction Market Position Segment: Compact executive car Unique Selling Proposition: Front-wheel drive, lightweight, sporting handling, unique boxer engine Competitive Analysis Key Competitors: Volkswagen Golf, Ford Escort, Fiat 128, Renault 12 Key Features Design Inspiration: Marcello Gandini (Bertone) Engineering Innovation: Lightweight construction, advanced FWD layout for its time Manual Value Proposition: Enables cost-effective maintenance and repair for enthusiasts 📋 Manual Details Coverage Areas Primary Coverage: Mechanical and electrical systems, bodywork, maintenance, repair Geographic Coverage: Global (designed for all markets) Page Count Estimated Page Count: 500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine: Flat-4 (Boxer) engine overhaul, tuning, diagnosis Engine Specifics: 1.2L, 1.3L, 1.5L, 1.7L boxer engines Cooling System: Radiator, thermostat, coolant pump, fan operation, flush and refill procedures Fuel System: Carburetor (Solex, Dell'Orto) overhaul and adjustment, fuel pump, fuel lines, tank removal and cleaning Ignition System: Spark plugs, ignition coils, distributor, timing adjustment, wiring diagrams Transmission: 5-speed manual transaxle, clutch replacement, gearbox overhaul, fluid changes Drivetrain: Front-wheel drive system, driveshafts, CV joints, differential Suspension: Front independent suspension (MacPherson struts), rear semi-independent torsion bar suspension, shock absorbers, bushings, alignment procedures Steering: Rack and pinion steering system, steering column, linkage, adjustments Brakes: Front disc brakes, rear drum brakes, brake system bleeding, master cylinder, wheel cylinders, brake lines, parking brake Electrical System: 12V electrical system, battery, alternator, starter motor, lighting system, wiring diagrams for all circuits, dashboard instruments, fuses, relays Bodywork: Body panel repair, rust prevention and treatment, door mechanisms, glass replacement, interior trim HVAC: Heating system, ventilation, blower motor, ducting (air conditioning not standard on most models) Procedures Included Maintenance: Oil changes, filter replacements, tune-ups, spark plug replacement, coolant flushes, brake fluid changes, lubrication points Troubleshooting: Diagnostic procedures for common problems, symptom-based fault finding Repair: Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilds, electrical component repairs Special Tools: Identification and use of specific tools required for certain procedures Technical Depth Depth: Comprehensive from basic maintenance to full engine and transmission rebuilds Detail Level: Step-by-step instructions with detailed illustrations and diagrams 📊 Manual Specifications File Format Compatibility: Windows and Mac operating systems Searchability: Likely text-searchable PDF Print Quality Printability: All pages printable Binding Type Binding: Digital Download (no physical binding) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Configuration: Flat-4 (Boxer) Displacement Options: 1186 cc, 1286 cc, 1490 cc, 1712 cc Performance Horsepower Range: 63 hp to 105 hp (depending on engine and tune) Torque Range: 85 Nm to 130 Nm (depending on engine) Fuel System Carburetor Types: Single or twin Solex, Dell'Orto Fuel Type: Unleaded gasoline (later models), Leaded gasoline (early models) Technical Details Cooling Type: Water-cooled Valve Train: SOHC (Single Overhead Camshaft) Bore X Stroke Typical: 80.0 mm x 59.0 mm (1186 cc), 84.0 mm x 58.0 mm (1286 cc), 84.0 mm x 70.0 mm (1490 cc), 86.0 mm x 74.0 mm (1712 cc) 🔧 Transmission Standard Type: 5-speed manual transaxle Optional Type: None (manual only) Features Layout: Front-wheel drive transaxle Clutch Type: Dry single plate Fluid Specifications Gearbox Oil Type: GL-4 SAE 75W/90 or SAE 80W/90 📐 Dimensions Exterior Body Styles: 4-door saloon, 2-door saloon, 3-door hatchback (Sprint), 5-door hatchback (later variants) Wheelbase Typical: 2450 mm (96.5 in) Length Typical: 3990 mm (157.1 in) Width Typical: 1600 mm (63.0 in) Height Typical: 1370 mm (53.9 in) Weights Curb Weight Range: 900 kg - 1050 kg (depending on model) Gross Vehicle Weight: N/A (specific to each model variant) Wheels Tires Wheel Bolt Pattern: 4x98 Typical Tire Sizes: 155 SR 13, 165/70 R13, 175/70 R13 (depending on trim/model) 🛡️ Safety Features Ratings Crash Test Results: Lacking modern crash safety standards due to era of design Active Features Braking System: Front disc, Rear drum Passive Features Seatbelts: Standard front seatbelts, optional rear seatbelts 💡 Technology Features Infotainment Features: Basic AM/FM radio, optional cassette player Driver Assistance Features: None (basic analogue instrumentation) Connectivity Features: None 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6-12 months Tune Up Interval: Every 15,000 - 20,000 km (9,000 - 12,000 miles) Timing Belt Replacement: Not applicable (chain-driven camshafts) Fluid Specifications Engine Oil Type: API SF/CD SAE 20W/50 or 10W/40 (depending on climate) Engine Oil Capacity: Approx. 4.5 liters (with filter) Coolant Type: Ethylene glycol-based antifreeze mixture Brake Fluid Type: DOT 3 or DOT 4 Known Issues Rust Prone Areas: Wheel arches, sills, floor pans, rear quarter panels, door bottoms, strut towers Engine Maintenance: Carburetor tuning and adjustment can be critical; camshaft wear possible Suspension Wear: Bushings, ball joints, and tie rod ends are common wear items Electrical Reliability: Older wiring harnesses can degrade, leading to intermittent faults 📚 Vehicle...
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Alfa Romeo Alfasud Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Alfa Romeo
Model:
Alfasud
Model Variant:
All variants (Saloon, Sprint, Ti, etc.)
Codes
Chassis Code:
Type 901
👋 Introduction
Market Position
Segment:
Compact executive car
Unique Selling Proposition:
Front-wheel drive, lightweight, sporting handling, unique boxer engine
Competitive Analysis
Key Competitors:
Volkswagen Golf, Ford Escort, Fiat 128, Renault 12
Key Features
Design Inspiration:
Marcello Gandini (Bertone)
Engineering Innovation:
Lightweight construction, advanced FWD layout for its time
Manual Value Proposition:
Enables cost-effective maintenance and repair for enthusiasts
📋 Manual Details
Coverage Areas
Primary Coverage:
Mechanical and electrical systems, bodywork, maintenance, repair
Geographic Coverage:
Global (designed for all markets)
Page Count
Estimated Page Count:
500+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Flat-4 (Boxer) engine overhaul, tuning, diagnosis
Engine Specifics:
1.2L, 1.3L, 1.5L, 1.7L boxer engines
Cooling System:
Radiator, thermostat, coolant pump, fan operation, flush and refill procedures
Fuel System:
Carburetor (Solex, Dell'Orto) overhaul and adjustment, fuel pump, fuel lines, tank removal and cleaning
Ignition System:
Spark plugs, ignition coils, distributor, timing adjustment, wiring diagrams
Transmission:
5-speed manual transaxle, clutch replacement, gearbox overhaul, fluid changes
Drivetrain:
Front-wheel drive system, driveshafts, CV joints, differential
Suspension:
Front independent suspension (MacPherson struts), rear semi-independent torsion bar suspension, shock absorbers, bushings, alignment procedures
Steering:
Rack and pinion steering system, steering column, linkage, adjustments
Brakes:
Front disc brakes, rear drum brakes, brake system bleeding, master cylinder, wheel cylinders, brake lines, parking brake
Electrical System:
12V electrical system, battery, alternator, starter motor, lighting system, wiring diagrams for all circuits, dashboard instruments, fuses, relays
Bodywork:
Body panel repair, rust prevention and treatment, door mechanisms, glass replacement, interior trim
HVAC:
Heating system, ventilation, blower motor, ducting (air conditioning not standard on most models)
Procedures Included
Maintenance:
Oil changes, filter replacements, tune-ups, spark plug replacement, coolant flushes, brake fluid changes, lubrication points
Troubleshooting:
Diagnostic procedures for common problems, symptom-based fault finding
Repair:
Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilds, electrical component repairs
Special Tools:
Identification and use of specific tools required for certain procedures
Technical Depth
Depth:
Comprehensive from basic maintenance to full engine and transmission rebuilds
Detail Level:
Step-by-step instructions with detailed illustrations and diagrams
📊 Manual Specifications
File Format
Compatibility:
Windows and Mac operating systems
Searchability:
Likely text-searchable PDF
Print Quality
Printability:
All pages printable
Binding Type
Binding:
Digital Download (no physical binding)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Configuration:
Flat-4 (Boxer)
Displacement Options:
1186 cc, 1286 cc, 1490 cc, 1712 cc
Performance
Horsepower Range:
63 hp to 105 hp (depending on engine and tune)
Torque Range:
85 Nm to 130 Nm (depending on engine)
Fuel System
Carburetor Types:
Single or twin Solex, Dell'Orto
Fuel Type:
Unleaded gasoline (later models), Leaded gasoline (early models)
Technical Details
Cooling Type:
Water-cooled
Valve Train:
SOHC (Single Overhead Camshaft)
Bore X Stroke Typical:
80.0 mm x 59.0 mm (1186 cc), 84.0 mm x 58.0 mm (1286 cc), 84.0 mm x 70.0 mm (1490 cc), 86.0 mm x 74.0 mm (1712 cc)
🔧 Transmission
Standard
Type:
5-speed manual transaxle
Optional
Type:
None (manual only)
Features
Layout:
Front-wheel drive transaxle
Clutch Type:
Dry single plate
Fluid Specifications
Gearbox Oil Type:
GL-4 SAE 75W/90 or SAE 80W/90
📐 Dimensions
Exterior
Body Styles:
4-door saloon, 2-door saloon, 3-door hatchback (Sprint), 5-door hatchback (later variants)
Wheelbase Typical:
2450 mm (96.5 in)
Length Typical:
3990 mm (157.1 in)
Width Typical:
1600 mm (63.0 in)
Height Typical:
1370 mm (53.9 in)
Weights
Curb Weight Range:
900 kg - 1050 kg (depending on model)
Gross Vehicle Weight:
N/A (specific to each model variant)
Wheels Tires
Wheel Bolt Pattern:
4x98
Typical Tire Sizes:
155 SR 13, 165/70 R13, 175/70 R13 (depending on trim/model)
🛡️ Safety Features
Ratings
Crash Test Results:
Lacking modern crash safety standards due to era of design
Active Features
Braking System:
Front disc, Rear drum
Passive Features
Seatbelts:
Standard front seatbelts, optional rear seatbelts
💡 Technology Features
Infotainment
Features:
Basic AM/FM radio, optional cassette player
Driver Assistance
Features:
None (basic analogue instrumentation)
Connectivity
Features:
None
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6-12 months
Tune Up Interval:
Every 15,000 - 20,000 km (9,000 - 12,000 miles)
Timing Belt Replacement:
Not applicable (chain-driven camshafts)
Fluid Specifications
Engine Oil Type:
API SF/CD SAE 20W/50 or 10W/40 (depending on climate)
Engine Oil Capacity:
Approx. 4.5 liters (with filter)
Coolant Type:
Ethylene glycol-based antifreeze mixture
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Rust Prone Areas:
Wheel arches, sills, floor pans, rear quarter panels, door bottoms, strut towers
Engine Maintenance:
Carburetor tuning and adjustment can be critical; camshaft wear possible
Suspension Wear:
Bushings, ball joints, and tie rod ends are common wear items
Electrical Reliability:
Older wiring harnesses can degrade, leading to intermittent faults
📚 Vehicle History
Brand Heritage
Alfa Romeo Legacy:
Renowned for sporting pedigree, beautiful design, and engaging driving dynamics
Model Evolution
Introduction Year:
1972
Facelifts Updates:
Series 1 (1972-1977), Series 2 (1978-1983), Series 3 (1983-1989) with styling and mechanical updates, introduction of Sprint and Ti variants
Discontinuation Year:
1989
Production
Manufacturing Location:
Naples, Italy (and initially also at the Pomigliano d'Arco plant)
Production Volume Estimate:
Over 600,000 units
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