Alfa Romeo Alfetta GTV 1973-1987 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Alfa Romeo Model: Alfetta GTV Model Generation: First Generation Model Designation: GTV (Gran Turismo Veloce) Production Years Covered: 1973-1987 👋 Introduction Market Position Vehicle Class: Compact Sports Coupe / Grand Tourer Target Audience: Enthusiasts seeking to maintain, repair, or restore their Alfetta GTV. Competitive Analysis Key Competitors Era: BMW 3 Series (E21/E30), Porsche 924, Ford Capri, Toyota Celica, Datsun Z-cars. Key Features Design Philosophy: Stylish Italian design, rear-wheel drive, Alfa Romeo's renowned twin-cam engines, innovative transaxle layout. Manual Value Proposition: Comprehensive factory service data, enabling detailed and accurate maintenance and repairs, saving on professional labor costs. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Workshop Manual Language: English Format: PDF Download Availability: Instant Download Licensing: Lifetime Use, No Expiry Dates, No Renewal Fees Device Compatibility: All Windows and MAC Computers, Tablets, Smartphones 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, overhaul, and troubleshooting for all engine variants. Engine Management: Ignition system, fuel injection systems (mechanical and early electronic), carburetor tuning, emission control systems. Transmission Manual: Service, repair, and overhaul of the transaxle (gearbox and differential). Transmission Automatic: Coverage for optional automatic transmissions (if applicable to the model years). Drivetrain: Propeller shaft, driveshafts, universal joints, clutch service and adjustment. Suspension: Front and rear suspension geometry, component replacement (bushings, ball joints, shock absorbers), alignment procedures. Steering: Steering box, linkages, power steering system (if equipped). Brakes: Front and rear brake system maintenance, overhaul, disc and pad replacement, hydraulic system bleeding, parking brake. Electrical System: Wiring diagrams, component testing (alternator, starter, battery), lighting, instrumentation, accessories. Body And Chassis: Body panel removal and installation, door mechanisms, glass, interior trim, chassis lubrication. Heating And Air Conditioning: HVAC system diagnosis and repair (if applicable). Fuel System: Fuel tank, fuel lines, fuel pump, filters, carburetor/injection system specifics. Cooling System: Radiator, water pump, thermostat, hoses, fan operation, coolant specifications. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, fluid level checks, lubrication points. Troubleshooting Diagnostics: Step-by-step diagnostic procedures for common and uncommon problems across all systems. Component Replacement: Detailed instructions for replacing major and minor components. Overhaul Rebuilding: Comprehensive guides for rebuilding engines, transmissions, carburetors, and other major sub-assemblies. Alignment Adjustments: Wheel alignment specifications and adjustment procedures, carburetor and ignition timing adjustments. Electrical Diagnostics: Schematic interpretation, voltage drop testing, continuity testing, fault finding. Technical Depth Depth Of Information: Factory-level detail suitable for professional mechanics and experienced DIY enthusiasts. Illustrations: Hundreds of detailed photos, diagrams, and exploded views for clarity. Torque Specifications: Specific torque values for all critical fasteners and components. Clearances Tolerances: Factory specified clearances and tolerances for engine and drivetrain components. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable within the PDF for efficient information retrieval. Printability: Printable in full or in single pages as per user preference. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Family: Alfa Romeo Twin Cam (DOHC) Common Engine Variants: 1.6L (1570cc), 1.8L (1779cc), 2.0L (1962cc) Petrol Performance 2.0L Approximate: Horsepower: 130-150 hp (depending on fuel injection/carburetion), Torque: 130-150 lb-ft Fuel System Fuel Delivery: Twin Dell'Orto carburetors (e.g., DHLA 40) or Bosch L-Jetronic fuel injection (later models). Fuel Type: Unleaded Gasoline (Octane rating appropriate for the era, 91-98 RON recommended) Engine Codes Common Engine Codes: 105.21 (2.0L), 115.31 (1.6L), 115.18 (1.8L) - Note: Specific codes vary by market and sub-model. 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transaxle (mounted at rear for weight distribution) Optional Transmission Type Optional: 3-speed Automatic (e.g., ZF 3HP12, less common) Features Transaxle Layout: Combined gearbox and differential unit for improved weight distribution and handling. Fluid Specifications Manual Gearbox Oil: GL-4 Gear Oil, SAE 75W-90 or 80W-90 (API GL-4 recommended to protect yellow metals) Automatic Gearbox Fluid: Dexron III/Mercon ATF (or equivalent specified for ZF 3HP12) 📐 Dimensions Exterior Body Style: 2-door Coupe Wheelbase: Approx. 2450 mm (96.5 in) Length: Approx. 4200-4300 mm (165-169 in) Width: Approx. 1670-1700 mm (66-67 in) Height: Approx. 1300-1320 mm (51-52 in) Weights Curb Weight: Approx. 1100-1250 kg (2425-2755 lbs), varies by engine and equipment Wheel Bolt Pattern: 4x108 mm Wheel Offset: ET35 to ET40 (common range, specific to rim size) 🛡️ Safety Features Ratings Crash Test Data: Era-specific safety standards. No modern crash test data available. Focus on passive safety features of the time. Active Features Braking System: Four-wheel disc brakes, often with GTV versions featuring larger discs or ventilated fronts. Passive Features Seatbelts: Standard 3-point front seatbelts, lap belts in rear. Steering Column: Collapsible steering column (designed for impact absorption). 💡 Technology Features Infotainment Audio System: Typically an AM/FM radio, possibly with cassette player in later years. Aftermarket upgrades common. Driver Assistance ABS: Anti-lock Braking System (ABS) was not a standard feature on most early models, and may have been an option on later ones. Connectivity...
Unleaded Gasoline (Octane rating appropriate for the era, 91-98 RON recommended)
Engine Codes
Common Engine Codes:
105.21 (2.0L), 115.31 (1.6L), 115.18 (1.8L) - Note: Specific codes vary by market and sub-model.
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transaxle (mounted at rear for weight distribution)
Optional
Transmission Type Optional:
3-speed Automatic (e.g., ZF 3HP12, less common)
Features
Transaxle Layout:
Combined gearbox and differential unit for improved weight distribution and handling.
Fluid Specifications
Manual Gearbox Oil:
GL-4 Gear Oil, SAE 75W-90 or 80W-90 (API GL-4 recommended to protect yellow metals)
Automatic Gearbox Fluid:
Dexron III/Mercon ATF (or equivalent specified for ZF 3HP12)
📐 Dimensions
Exterior
Body Style:
2-door Coupe
Wheelbase:
Approx. 2450 mm (96.5 in)
Length:
Approx. 4200-4300 mm (165-169 in)
Width:
Approx. 1670-1700 mm (66-67 in)
Height:
Approx. 1300-1320 mm (51-52 in)
Weights
Curb Weight:
Approx. 1100-1250 kg (2425-2755 lbs), varies by engine and equipment
Wheel Bolt Pattern:
4x108 mm
Wheel Offset:
ET35 to ET40 (common range, specific to rim size)
🛡️ Safety Features
Ratings
Crash Test Data:
Era-specific safety standards. No modern crash test data available. Focus on passive safety features of the time.
Active Features
Braking System:
Four-wheel disc brakes, often with GTV versions featuring larger discs or ventilated fronts.
Passive Features
Seatbelts:
Standard 3-point front seatbelts, lap belts in rear.
Steering Column:
Collapsible steering column (designed for impact absorption).
💡 Technology Features
Infotainment
Audio System:
Typically an AM/FM radio, possibly with cassette player in later years. Aftermarket upgrades common.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was not a standard feature on most early models, and may have been an option on later ones.
Connectivity
Modern Connectivity:
N/A (Vehicle is from an era before widespread digital connectivity).
🔧 Maintenance
Service Intervals
Oil Change Interval Engine:
Typically every 5,000-7,500 km (3,000-4,500 miles) or 6-12 months, depending on usage and oil type.
Filter Replacement Oil:
Replace with every oil change.
Spark Plug Service:
Inspect every 15,000-20,000 km (9,000-12,500 miles), replace as needed.
Transmission Service:
Check fluid level regularly. Change fluid and filter (if applicable) every 40,000-60,000 km (25,000-37,000 miles).
Fluid Specifications
Engine Oil Type:
API SF/SG or higher, SAE 10W-40 or 15W-50 recommended for most conditions. Check manual for specific viscosity and API rating.
Engine Oil Capacity:
Approx. 4.5-5.0 liters (4.8-5.3 US quarts) with filter, depending on engine variant.
Coolant Type:
Ethylene Glycol based antifreeze, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 (Check manual for exact specification).
Known Issues
Rust Prone Areas:
Wheel arches, sills, floor pans, rear valence, around windows.
Engine Maintenance Points:
Timing belt (if applicable to variant, though most twin cams used chains), carburetor synchronization, ignition timing, valve adjustments (early models).
Suspension Wear:
Bushings, ball joints, and tie rod ends can wear over time, affecting handling and alignment.
Electrical Gremlins:
Older wiring harnesses can degrade, leading to intermittent electrical issues.