Alfa Romeo ALFETTA Service Repair Manual 1973-1987
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🏷️ Basic Information Identification Make: Alfa Romeo Model: Alfetta Model Variants: Berlina (Sedan), GT (Coupe), GTV (Coupe), GT Veloce (Coupe), GTV6 (Coupe) Production Years Covered: 1973-1987 👋 Introduction Market Position Vehicle Segment: Compact executive car / Sports sedan/coupe Brand Philosophy: Alfa Romeo's focus on performance, distinctive styling, and driver engagement. Competitive Analysis Key Competitors: BMW 3 Series, Mercedes-Benz W123/W201, Audi 80/100, Ford Sierra, Lancia Beta. Key Features Design Language: Iconic Bertone styling for coupe variants, classic Italian sedan proportions. Engineering Layout: Transaxle design (gearbox and differential at rear) for improved weight distribution and handling. Performance Orientation: Emphasis on sporty handling and engine responsiveness. Manual Value Proposition Cost Savings: Enables DIY repairs and maintenance, significantly reducing labor costs. Accessibility: Provided in an easy-to-use PDF format, accessible on PC and MAC. 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English (Assumed, based on product description) Format: PDF Download Page Count Page Count: Undisclosed (PDF manual, page count can vary by specific content) 📖 Manual Coverage Systems Covered Engine: Engine mechanical (including assembly, disassembly, inspection, repair of all components), fuel system (carburetor/injection, fuel pumps, lines), ignition system, cooling system, lubrication system, exhaust system. Transmission: Manual Transmission (gearbox, clutch, driveshafts, transaxle configuration), Automatic Transmission (if applicable to specific models/years covered). Drivetrain: Rear-wheel drive system, differential, axle shafts. Suspension: Front and rear suspension systems (independent/transaxle specific), shock absorbers, springs, control arms, bushings, anti-roll bars. Steering: Steering system components, steering rack, power steering system (if equipped). Brakes: Front and rear brake systems (disc brakes), brake calipers, master cylinder, brake lines, parking brake system. Electrical: Wiring diagrams, charging system (alternator, battery), starting system (starter motor), lighting system (headlights, taillights, interior lights), instrument panel and gauges, ignition switch, fuses, relays, horn. Body And Chassis: Body panel removal and installation, interior trim, doors, windows, seats, bumpers, frame/unibody structure, corrosion prevention. Heating And Air Conditioning: HVAC system components, blower motor, heater core, evaporator, refrigerant system (if applicable). Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, lubrication points, tire rotation, brake inspection. Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, identification of electrical and mechanical issues. Repair: Detailed step-by-step repair instructions for all covered systems, including component removal, overhaul, and reassembly. Rebuilding: Comprehensive guidance on engine rebuilds, transmission overhauls, and other major component restorations. Refurbishment: Procedures for restoring worn or damaged components and systems. Restoration: Detailed instructions applicable to classic car restoration projects, including bodywork, interior, and mechanical aspects. Technical Depth Depth Level: Comprehensive (A-Z coverage, professional technician level information) 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text (implied by PDF format) Print Quality Printability: Printable pages for individual repair tasks or complete sections. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Family: Alfa Romeo Twin Cam (Nord engine variants) Engine Variants Engine Displacement Options: 1.6L, 1.8L, 2.0L (Twin Cam), 2.5L V6 (Busso V6 for GTV6) Performance Horsepower Range: Approximately 109 hp (1.8L) to 158 hp (2.0L) for Twin Cam; 158 hp to 180 hp for GTV6 variants (depending on specific tuning and year). Torque Range: Varies by displacement and tuning, typically in the range of 150-200 Nm for Twin Cam variants. Fuel System Carburetion: Often equipped with twin downdraft Weber or Dell'Orto carburetors (e.g., 40 DCNF, 45 DCOE). Fuel Injection: Later models, particularly GTV6, may feature Bosch L-Jetronic or similar fuel injection systems. Cooling System Cooling Type: Liquid-cooled, front-mounted radiator. Lubrication System Oil Type Recommendation: Typically SAE 10W-40 or 10W-50, API SG or equivalent (specific grades to be confirmed in manual). Engine Codes Common Engine Codes: AR00540 (1.6), AR00530 (1.8), AR105.06 (2.0 Twin Cam), AR115.01 (2.5 V6 GTV6) 🔧 Transmission Standard Gearbox Type: 5-speed manual transaxle. Optional Automatic Transmission: Less common, but some export markets or specific models might have offered an automatic option (details to be verified). Features Transaxle Design: Integrated gearbox and differential unit located at the rear axle for optimal weight distribution. Fluid Specifications Transmission Fluid Type: GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90, specific viscosity depends on ambient temperature and manufacturer recommendation). Clutch System Clutch Type: Hydraulically operated single dry-plate clutch. 📐 Dimensions Exterior Wheelbase Range: Approximately 2500-2530 mm (98.4-99.6 in) depending on sedan/coupe variants. Length Range: Sedan: ~4300-4360 mm (169.3-171.7 in); Coupe: ~4200-4250 mm (165.4-167.3 in). Width Range: Approximately 1660-1700 mm (65.4-66.9 in). Height Range: Approximately 1370-1380 mm (53.9-54.3 in) for coupes, slightly higher for sedans. Weights Curb Weight Range: Approximately 1100-1300 kg (2425-2866 lbs) depending on model and equipment. Gross Vehicle Weight Rating: To be confirmed in the manual, typically around 1500-1600 kg. Towing Capacity: Not typically specified or recommended for this type of sporty vehicle. 🛡️ Safety Features Ratings Crash Test Results: Limited official crash test data available from the era; designed to contemporary...
Less common, but some export markets or specific models might have offered an automatic option (details to be verified).
Features
Transaxle Design:
Integrated gearbox and differential unit located at the rear axle for optimal weight distribution.
Fluid Specifications
Transmission Fluid Type:
GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90, specific viscosity depends on ambient temperature and manufacturer recommendation).
Clutch System
Clutch Type:
Hydraulically operated single dry-plate clutch.
📐 Dimensions
Exterior
Wheelbase Range:
Approximately 2500-2530 mm (98.4-99.6 in) depending on sedan/coupe variants.
Length Range:
Sedan: ~4300-4360 mm (169.3-171.7 in); Coupe: ~4200-4250 mm (165.4-167.3 in).
Width Range:
Approximately 1660-1700 mm (65.4-66.9 in).
Height Range:
Approximately 1370-1380 mm (53.9-54.3 in) for coupes, slightly higher for sedans.
Weights
Curb Weight Range:
Approximately 1100-1300 kg (2425-2866 lbs) depending on model and equipment.
Gross Vehicle Weight Rating:
To be confirmed in the manual, typically around 1500-1600 kg.
Towing Capacity:
Not typically specified or recommended for this type of sporty vehicle.
🛡️ Safety Features
Ratings
Crash Test Results:
Limited official crash test data available from the era; designed to contemporary European standards.
Active Features
Braking System:
Four-wheel disc brakes (standard on most models from launch) for superior stopping power compared to contemporary drums.
Handling Dynamics:
Transaxle layout and near 50/50 weight distribution contribute to excellent handling characteristics.
Passive Features
Seat Belts:
Three-point seat belts for front occupants, lap belts for rear (standard fitment evolved through production years).
Body Structure:
Reinforced passenger cell and crumple zones, typical of European design principles of the period.
💡 Technology Features
Infotainment
Radio System:
Factory fitted radios were typically AM/FM, often Blaupunkt or Becker, with manual tuning and basic speaker systems.
Speakers:
Typically two or four speaker configurations.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was not a standard feature on most Alfettas of this era, becoming more common in later iterations or optional for some.
Connectivity
Connectivity Features:
No modern connectivity features (Bluetooth, USB, etc.) were available on original models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 8,000-10,000 km (5,000-6,000 miles) or annually, whichever comes first. Manual will provide precise recommendations.
Filter Replacement:
Air filter, oil filter, fuel filter replacement at recommended intervals, usually coinciding with oil changes or every ~15,000-20,000 km.
Timing Belt Replacement:
For Twin Cam engines, timing belts require replacement at specified intervals (e.g., 50,000-80,000 km or 5 years). For V6, chain or belt specifics apply. Manual is critical here.
Tune Up Frequency:
Regular tune-ups including spark plug replacement, ignition timing adjustment, carburetor adjustment (if applicable) recommended every 15,000-25,000 km.
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze mixture, typically 50/50 with distilled water. Manual will specify approved types.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual will confirm specific requirement.
Power Steering Fluid:
If equipped, typically ATF Dexron II or equivalent. Manual will specify.
Known Issues
Rust Prone Areas:
Sills, wheel arches, floor pans, boot floor, door bottoms are common areas for rust due to age and material.
Carburetor Tuning:
Twin Weber/Dell'Orto carburetors can require frequent adjustment and maintenance for optimal performance and fuel economy.
Electrical Gremlins:
Aging wiring looms, grounds, and components can lead to intermittent electrical issues.
Transaxle Clutch Wear:
Clutch wear and potential rear-mounted gearbox issues are common maintenance points.
Engine Oil Leaks:
Seals and gaskets in the Twin Cam and V6 engines can degrade over time, leading to oil leaks.
📚 Vehicle History
Brand Heritage
Alfa Romeo Legacy:
Renowned for motorsport heritage and a long tradition of producing engaging driver's cars.
Model Evolution
Initial Launch:
Introduced in 1972 for the 1973 model year, designed as a modern compact executive car.
Key Development:
The Alfetta platform was a departure with its rear transaxle and de Dion rear suspension (on some variants), setting it apart from earlier Alfa Romeos.
Gnostic Variant:
The GTV6, introduced in 1980, is considered a performance icon, featuring the potent 2.5L V6 'Busso' engine.
Production
Manufacturing Location:
Primary manufacturing at Alfa Romeo's Portello plant in Milan, Italy.
Production End Year:
1987
🏆 Awards & Recognition
Recognitions
European Car Of The Year Nomination:
The Alfetta was nominated for European Car of the Year in 1973, finishing as runner-up.
Automotive Press Reviews:
Consistently praised for its handling, engine performance (especially the V6), and styling by automotive journalists of the period.
Certifications
Industry Standards:
Built to comply with European automotive safety and emissions standards of the respective production years.