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Alfa Romeo 164 164S 1991 1992 1993 Workshop Service Repair Manual
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Basic Information Identification Make: Alfa Romeo Model: 164 Trim Level: 164S Model Years Covered: 1991, 1992, 1993 Introduction Market Position Segment: Executive/Luxury Sedan Competitive Analysis Competitors: BMW 5 Series, Mercedes-Benz...
Type: Cars
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Sku: 425527
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164
Alfa Romeo
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| Basic Information | |
| Identification | |
| Make: | Alfa Romeo |
| Model: | 164 |
| Trim Level: | 164S |
| Model Years Covered: | 1991, 1992, 1993 |
| Introduction | |
| Market Position | |
| Segment: | Executive/Luxury Sedan |
| Competitive Analysis | |
| Competitors: | BMW 5 Series, Mercedes-Benz E-Class, Audi 100/A6, Jaguar XJ. |
| Key Features | |
| Design: | Distinctive Pininfarina styling, front-wheel drive platform shared with Fiat Croma and Lancia Thema. |
| Performance Orientation: | The 'S' designation typically indicates a sportier variant, often with enhanced engine performance and suspension tuning. |
| Manual Details | |
| Coverage Areas | |
| Overall Coverage: | Comprehensive repair and service for Alfa Romeo 164 and 164S models from 1991-1993. |
| Page Count | |
| Total Pages: | 3606 |
| Manual Type | |
| Type: | Workshop Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| File Format: | |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Complete engine disassembly, assembly, repair, and adjustment procedures for all applicable engine variants. |
| Fuel System: | Fuel injection system diagnosis, repair, fuel pump, injectors, fuel lines, and pressure regulator. |
| Ignition System: | Ignition system components, timing, spark plugs, coils, and ECU diagnostics. |
| Cooling System: | Radiator, thermostat, water pump, cooling fan, and coolant flush procedures. |
| Exhaust System: | Exhaust manifold, catalytic converter, mufflers, and pipe replacement. |
| Transmission Manual: | Manual transmission removal, installation, internal component repair, clutch service, and gear linkage adjustment. |
| Transmission Automatic: | Automatic transmission diagnosis, repair, fluid service, and control system checks (if applicable to 164S). |
| Drivetrain: | Front-wheel drive system, driveshafts, CV joints, differential service, and wheel bearings. |
| Suspension Front: | Struts, control arms, ball joints, tie rods, springs, shock absorbers, and alignment procedures. |
| Suspension Rear: | Rear axle, trailing arms, shock absorbers, springs, and rear alignment. |
| Steering System: | Power steering pump, rack and pinion, steering column, and steering wheel replacement. |
| Brake System Front: | Front brake calipers, rotors, pads, hoses, and ABS system components. |
| Brake System Rear: | Rear brake calipers, rotors, pads, hoses, and parking brake system. |
| Electrical System Charging: | Alternator, battery, voltage regulator, and wiring harness diagnosis. |
| Electrical System Starting: | Starter motor, ignition switch, and related circuits. |
| Lighting System: | Headlights, taillights, interior lights, bulb replacement, and wiring. |
| Instrument Panel: | Gauge cluster, warning lights, odometer, tachometer, and speedometer diagnosis. |
| HVAC System: | Heating, ventilation, and air conditioning (HVAC) system components, refrigerant service, blower motor, and controls. |
| Body Exterior: | Body panel removal and installation, doors, hood, trunk lid, bumpers, and glass replacement. |
| Body Interior: | Seat removal, dashboard disassembly, door panel replacement, carpet, and headliner service. |
| Body Chassis: | Chassis components, rust prevention, and structural repair guidance. |
| Safety Systems: | Seat belts, airbags (if equipped), and general vehicle safety precautions. |
| Procedures Included | |
| Maintenance: | Routine maintenance, oil changes, filter replacements, fluid checks, and lubrication. |
| Troubleshooting: | Detailed diagnostic procedures for common and uncommon issues, including symptom-based troubleshooting guides. |
| Repair: | Step-by-step repair instructions for virtually all vehicle components and systems. |
| Disassembly Assembly: | Detailed instructions for removing and reinstalling components in the correct sequence. |
| Adjustment: | Precise adjustment procedures for various systems, including engine timing, idle speed, brakes, and clutch. |
| Diagnostics: | Wiring diagrams, diagnostic codes (if applicable), and testing procedures for electrical and electronic systems. |
| Technical Depth | |
| Depth: | Extremely comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds. |
| Illustrations | |
| Type: | Detailed illustrations, exploded diagrams, drawings, and photographs. |
| Special Tools | |
| Reference: | References to specific Alfa Romeo special service tools and their usage. |
| Specifications | |
| General: | Includes service data, precautions, important points, wear limits, and allowable limits. |
| Manual Specifications | |
| File Format | |
| Quality: | Printable, high-quality PDF suitable for digital viewing and printing of individual pages or the entire document. |
| Print Quality | |
| Printability: | All pages are printable. |
| Binding Type | |
| Type: | Digital Download (not applicable for physical binding) |
| Paper Type | |
| Type: | Not applicable (digital format) |
| Requirements | |
| Software: | Adobe Reader required for viewing. |
| Compatibility | |
| Operating Systems: | Compatible with Windows, Mac, and Linux operating systems. |
| Engine Specifications | |
| Primary Engine | |
| Variant 164S: | Likely a 3.0L V6 (e.g., Busso V6) with potential for increased horsepower and torque compared to standard 164 models. |
| Performance | |
| Horsepower Range: | Estimated 200-230 hp for the 164S, depending on specific market and tuning. |
| Torque Range: | Estimated 245-270 Nm torque for the 164S. |
| Fuel System | |
| Type: | Bosch Motronic electronic fuel injection (EFI). |
| Engine Management | |
| ECU: | ECU controlled ignition and fuel delivery, with diagnostic capabilities. |
| Transmission | |
| Standard | |
| Type: | Likely a 5-speed manual transmission for the 164S, or an optional 4-speed automatic. |
| Optional | |
| Type: | 4-speed automatic transmission. |
| Features | |
| Drive: | Front-wheel drive (FWD). |
| Dimensions | |
| Exterior | |
| Wheelbase: | Approx. 2700 mm (106.3 inches) |
| Length: | Approx. 4740 mm (186.6 inches) |
| Width: | Approx. 1765 mm (69.5 inches) |
| Height: | Approx. 1430 mm (56.3 inches) |
| Weights | |
| Curb Weight: | Approx. 1450-1550 kg (3197-3417 lbs), depending on transmission and equipment. |
| Safety Features | |
| Ratings | |
| Crash Test Data: | Limited publicly available comprehensive crash test data for these specific model years. Advised to consult contemporary automotive publications. |
| Active Features | |
| ABS: | Anti-lock Braking System (ABS) was typically standard or optional on 164 models, especially the 164S. |
| Passive Features | |
| Airbags: | Driver's side airbag was likely optional or standard on later models, check specific vehicle configuration. |
| Seatbelts: | Three-point seatbelts with pre-tensioners for front occupants. Rear seat belts. |
| Technology Features | |
| Infotainment | |
| Audio System: | Factory fitted radio/cassette player, potentially with CD changer option. Speaker system quality varies by trim. |
| Driver Assistance | |
| Cruise Control: | Cruise control was often fitted to higher trims like the 164S. |
| Connectivity | |
| Features: | Limited by modern standards; primarily focused on comfort and luxury features. No integrated Bluetooth or smartphone connectivity. |
| Maintenance | |
| Service Intervals | |
| Oil Change: | Typically every 5,000-7,500 miles or 6-12 months, depending on driving conditions. Consult manual for precise intervals. |
| Timing Belt: | Critical maintenance item for the V6 engine. Interval typically around 30,000-45,000 miles or 3-5 years. **CRITICAL TO FOLLOW.** |
| Fluid Specifications | |
| Engine Oil: | Refer to manual for specific viscosity grade (e.g., 10W-40 or 20W-50, depending on climate and engine wear). Use high-quality synthetic or semi-synthetic oil. |
| Coolant: | Ethylene glycol-based antifreeze/coolant. Specific type and mix ratio as per manual. |
| Brake Fluid: | DOT 3 or DOT 4 brake fluid, as specified. |
| Power Steering Fluid: | Specific hydraulic fluid, likely Dexron II or equivalent. Consult manual. |
| Known Issues | |
| Electrical Gremlins: | Common for Italian cars of this era, including intermittent issues with dashboard lights, sensors, and wiring harness connections. |
| Timing Belt Failure: | Catastrophic engine damage can occur if the timing belt breaks. Regular replacement is paramount. |
| Suspension Wear: | Bushings, ball joints, and tie rod ends can wear over time, affecting handling and requiring replacement. |
| Rust: | Areas prone to rust include wheel arches, sills, and door bottoms, especially in climates with road salt. |
| HVAC Actuators: | Vacuum or electric actuators for HVAC blend doors can fail, leading to poor temperature control. |
| Vehicle History | |
| Brand Heritage | |
| Marque: | Alfa Romeo has a rich history of producing sporty and stylish Italian automobiles, known for their driving dynamics and distinctive engines. |
| Model Evolution | |
| Platform: | The Alfa Romeo 164 was the flagship sedan of Alfa Romeo, based on the Type Four platform, shared with Fiat Croma, Lancia Thema, and Saab 9000. |
| Production | |
| Manufacturing Location: | Produced at the Alfa Romeo plant in Arese, Italy. |
| Production Years: | 1987-1998 (with facelifts in 1992 and 1994). |
| Awards & Recognition | |
| Recognitions | |
| Industry Reviews: | Critically acclaimed for its styling and driving dynamics by automotive journalists of the period. |