DIREZIONE ASSISTENZA
Alfawiki.nl

CONTENTS...G .’.-.

..

GENERAL VIEWS . . , . . . . . . . . . . . . . .OO-2

APPROXIMATE REFILL CAPACITIES. 00-24

Dimensions and weights. . . . . . . . . . . OO-2

ENGINE MAINTENANCE . . . . . . . . . . .OO-24

MODEL VARIATION . . . . . . . . . . . . . . . OO-3

Basic mechanical system . . . . . . . . . . 00-24

IDENTIFICATION DATA . . . . . . . . . . . .OO-5

Ignition and fuel system. . . . . . . . . . . 00-28

LIFTING POINTS AND

Checking CO% . . . . . . . . . . . . . . . . . . OO-29

TOWING . . . . . . . . . . . . . . . . u., . . . . . .OO-6

TROUBLE DIAGNOSIS AND

Pantograph jack . . . . . . . . . . . . . . . . . 00-6

CORRECTIONS . . . . . . . . . . . . . . . . . . . .OO-32

Garage jack and safety stands. . . . . . . 00-7

CHASSIS AND BODY MA!NTENANCE. 00-39

Towing. . . . . . . . . . . . . . . . . . . . . . . , OO-7

Checking fuel and exhaust system . _ . 00-39

SPECIAL SERVICE TOOLS., . . . . . . . . .OO-8

Clutch . . . . . . . . . . . . . . . . . . . . . . . . OO-39

INSTRUCTIONS FOR PRE-DELIVERY

Gearbox-differential . . . . . . . . . . . . . . 00-39

INSPECTION AND PERIODICAL

Assembly drive shaft . . . . . . . . . . . . . 00-39

MAINTENANCE COUPONS. . . . ; . . . . . . OO-8

Front axle and front suspension. . . . . 00-39

Pre-delivery . . . . . . . . . . . . . . u . . . . . 00-8

Rear axle and rear suspension. . . . . . . 00-40

Checking level . . . . . . . . . . . . . . . . . . 00-8

Checking suspension heights . . . . . . . 00-40

Functional tests . . . . ; . . . . . . . . . . . . . 00-8

Wheel alignment. . . . . . . . . . . . . . . . . 00-42

Cleaning and finishing inspection. . _ _ 00-8

Brake system . . . . . . . . . . . . . . . . . . . OO-43

Maintenance. . . , . . . . _ ........... 00-10

Steering system . . . . . . . . . . . . . . . . . 00-45

MAINTENANCE SCHEDULE. . . . . . . . . . 00-l 1

Body . . . . . . . . . . . . . . . . . . . . . . . ..OO-4 5:,--FLUIDS AND LUBRICANTS CHART . . 00-19

SERVICE DATA AND*. RECCOMMENDED FUEL AND

SPECIFICATIONS. . . . . . . . . . . . . . . . . . OO-45

LUBRICANTS . . . . . . . . . . . . . . . . . . . . -00-20

Engine maintenance . . . . . . . . . . . . . . .OO-45

Fuel..........................OO-2 0

Chassis and body maintenance. . . . . . 00-47

Fluids and lubricants . . . . . . . . . . . . . 00-21

SPECIAL SERVICE TOOLS . . . . . . . . . :OO-48 .

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May 1983

COMPLETE CAR

GENERAL VIEWS.; . 1DIMENSIONS AND WEIGHTS
Model

1200

1350

1500

identification number

905.00905.02905.04 - 905.05

405.03905.06 - 905.07

Wheelbase
Track

P
Front

Ca

Rear

CP

Front

Sa

Rear

SP

Overall length
Overhang

LLI

m m( i n )m m (in)m m (in)mm (in)2 4 5 5 (96.651
1392 (54.8)
1359 (53.5)
4015(158.07)800 (31.5)760 (29.921

Overall widthLam m (in)1612 (63.46)

Height (unladen)Hm m (in1

1305 (51.38)

Ground clearancem m (in)

121 (4.76)

Min. steering radius

mm (in)4700 (185.04)

Kerb weight

kg

(lb)

890 (1962.1)

Max. allowed aross weiaht

ks

(lb)

1 3 1 5 (2899)

kg

(lb)

PayloadMax. allowed axle gross weight

Front
Rear

Max. towing gross weight
Seating capacity

kg

(lb)

kg

(lb)

725 (1598.31
1000 (2204.6)
2

Front
Rear

425 (936.91
725 (1598.31‘\ ‘\

May 1 9 8 3Alfawiki.nl

3

-...

.:

IT

COMPLETE CAR

MODEL VARIATION(Except Switzerland, Sweden, Australia)

I

1200

Model
Body

1500

1350

1500

WADRIFOGLIO

5 - door saloon

5 -door saloon
-r

Drive

Left

qight

Left

Right

Left

Right

Left

Right

905.02905.03905.04905.OE

905.06905.07- on certification
Identification

No.
- on identificationlabel- on identification
labelType approval No.

- on intermediate
bulkhead label

Serial NO.

905 A

-

905 A00

905 Al905 A2905 A2905 Al 0

906 A20905A20- on intermediate

from

from

bulkhead label

05.001 .OO’

05.001 .OOl

Type and serial No.

from

0 5 . 0 0 1 .OOl
305.04305.02
from
000.000.1

from
000.000.1

Tire dimensions

165170 SR 13165170 SR 13165170 SR 13

5J x 13 H2

5Jx13H2
or

5Jx 13H2

Rim dimensions

5 ‘/2J x 13 CH

5 ‘/ml x 13 CH

Alfawiki.nl
00-3

Or

May 1983

COMPLETE CARIDENTIFICATION DATAIDENTIFICATION LABELS(Except Switzerland, Sweden, Australia)

5 - Door Saloon 1200 - .I350 - 1500

Certification and identification label(Identification No. and Type approval No.)Intermediate bulkhead label-(Type approval
No. and serial No.)
Cylinder block label (Engine No.)
Lubrication data label (see “Fluids and Lubricants”
of each grouplllubrication data)
Paint label (This label indicates the productused for the first paintl(Paint)

VEHICLE IDENTIFICATION(AND SERVICE) DATAVEHICLE IDENTIFICATIONCODESA) Chassis numberingz A I? 9 0 5 A00 0 5 . 0 0 2 . 4 5 8
(I)

(3)

(2)

(1) Manufacturer identification letters.

(2) Serial
number:progressively
assigned by Production.
(3) “Type approval number”: notfor service identification use; forused as vehicle service identification
number. This number consists of five
figure numbers, divided as follows:4a) Basic type number: it is assigned
to all vehicles having a common

service purposes, use the “typenumber” whichiS
stamped on

design concept (Ex.: 905: Saloon).

identification label along with the“type approval number”.

fies, within the basic type, those

The following is an example of suchlabel.

4b) Type variant number: it identivehicles that differ because of somevariant that alters their features (Ex.:905.02 5-door Saloon).

(4) Identification number: to be

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00-S

May 1983

COMPLETE CAR

B) Engine numbering

II

ALFA ROMEO AUTO SPA

It consists of two sets of figures,
namely:I II

305.0000045 12(I)

(2)(I) Type number: ir is assigned tos

all engines having common generaltechnical
characteristics(Ex.: 305.02: 1350 engine with
twin carburetor).

(2) S e r i a l n u m b e r : p r o g r e s s i v e l yassigned by production.

LIFTING POINTS AND TOWINGPANTOGRAPH JACKWARNING:a. Never get under the vehicle
while it is supported only by the
iack. Always use safety stands tosupport frame when you have to
*,-+,

- ?’

b.

work under the vehicle.
Place wheel chocks at both front
and back of the wheels diagonally opposite the jack’s position.

Fit pantograph jack, supplied withthe vehicle, to safety points shown infigure.

May 1983

00-B

Alfawiki.nl

COMPLETE CARGARAGE JACK AND SAFETY STANDSTOWINGWARNING:a. When raising vehicle with garage

Closely follow Motor Vehicle Fiegu-

jack, be sure to support it withlations r e g a r d i n g v e h i c l e t o w i n g .

b.

front (in back) of the front(rear) wheels.

CAUTION:
When raising the vehicle, always
place a wooden block under vehicle’s
lifting points.
Position garage jack and safety stands‘
in a safe manner under the points
shown in the figure.

Set ignition key to “GAR” anddo not withdraw it from switch;otherwise antitheft device could
become engaged.

safety stands.
When jacking up the rear (front)of the vehicle, place chocks ind.

CAUTION:Use proper towing equipment toavoid possible damage to thevehicle.
Before towing, make sure thatfront and rear axes as well as
steering system are in goodworking condition; contrarywise
use a dolly.
If vehicle must be towed with its

e. Release parking brake and set
gearshaft lever to “neutral” bef.

fore starting to tow the vehicle.
Do not apply lateral forces totowing hook. Keep towing bar
or similar devices always inline with the vehicle.

g. Remember that when vehicle isbeing towed, there is no vacuum
in servobrake;
consequently,
when braking, greater pressure

rear wheels raised, front wheels

must be applied onto brakem u s t b e p l a c e d o n a towing
dolly.

pedal.

Alfawiki.nl
00-7

May 1983

COMPLETE CAR

SPECIAL SERVICE TOOLSSpecial service tools play a very
important role in a vehicle’s majnte-

expressly on the manufacturer’s
design, needed for overhauling, main-

A.O.OOOO
c.0.0000

nance since they are essential toensure accurate, reliable and quick
service. To this effect, it must be
remembered that times taken relevant to the various maintenancetenance and repair of models are

u.0.0000

Special Service Tool
TesterReamerlisted and illustrated in this manual.
The identification number is determined by the relevant ordering part

Order of the listed tools by theauthorized workshop, must be per-operations are computed assuming

number and consists of *a letter
followed by a five figure numberthat said special tools are being used.

according to the following schedule:

formed according to the usual
systems alretidy followed by each
Service - net.

A l l special; s e r v i c e t o o l s , m a d e

INSTRUCTIONS FOR PRE-DELIVERY INSPECTION
AND PERIODICAL MAINTENANCE COUPONSIn this chapter are listed anddescribed all pre-delivery and maintenance
operations
required by
AI-FA 33 models.

is required, proceed accordingly;
such operation will be considered aspart of pre-delivery inspection. In
case damages or malfunctions otherAs far as technical specifications
regarding each operation are concerned,

than those herein described areencountered, they will have to betaken care of repair or adjust accord-t o p up w i t h s p e c i f i e d f l u i dtions” chapter.

ing to current technical and administrative procedures. As each operation
is being carried out, the relevant card
must be filled out and then filed

sealed and opened only when
ready to use..

together with the sold vehicle’s otherdocuments; also the pre-delivery
card included in the Instruction

tion with utmost care andcleanliness.

r e f e r t o e a c h s e c t i o n ’s
relevant “Service Data and Specifica-

PRE-DELIVERY
Pi-e-delivery inspection of a newvehicle, prior to customer delivery,
consists in carrying out all checking
operations
andhereafter
tests
described in order to detect and thus
eliminate any damage or malfunction.
It goes without saying, however, thatwhen Dealer personnel picks-up thevehicle should perform a visual checkin order to:
make sure that vehicle is innormal driving condition, especially as regards level of fluids-

and controls in generaldetect any dents or scratcheson-

body or other damage to thevehicle’s interior (upholstery)make sure nothing is missing,
especially factory supplied ac-r

cessories, spare tire and any
parts that are to be fitted on
vehicle only prior to customer
delivery.

Book supplied to the customer must
be duly filled out as demostration ofstrictly

execution of pre-delivery

oil level reaches the filler loweredge. If required, top up withspecified oil and fit cap back.
Brake and clutch fluid-

Check if level in the reservoir is
up to max. mark. If required,remembering that tins must be

Be sure to perform this opera-

Battery electrolyte-

Check and make sure electrolyte
covers the plate upper edge by 5checks.

mm (0,2 in); contrarywise, top
up with distilled water.

CHECKING LEVEL
Coolant- When engine is cold, check levelin expansion reservoir. If required, top up to specified max.

Windshield washer fluid
Check if relevant reservoir is full;
if required, top up with specified
solution.
Tire pressure-level.
Engine oil- Check if level is up to MAX.
mark on dipstick (carry out thisoperation after having parked
the vehicle on an even surface
and after the engine has been off
for a few minutes). If required,
top up with specified oil.

Check tire pressure and, if
required, restore to specified
values. Use higher p.s.i. for spare
tire.

FUNCTIONAL TESTSEngine starting and idling- Check if engine starts properly.

If checking operations show that

Gearbox and Differential oil

When engine is warm, checktopping up -as foreseen by this text -- Remove filler cap and check if

specified idle-rpm.

May 198300-a

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COMPLETE CAR

Engine controls- Check and make sure starter
control knob works freely,
without sticking; further checkthat when this knob is pushed
in, respective device is not at all-

Heating system
Check proper working conditionof levers controlling heater andDoors and bonnets- Visually check all weather-outlets for admission of air into
the vehicle (open and close).
- Check if electric fan works

sure they are not damaged, outof shape or dirty.
-y See if doors and bonnets areproperly at different speeds andaligned and centered with rele-

if relevant warning light on thevant openings.

engaged on carburetor.
Check accelerator pedal andmake sure it does not stick; alsoboard lights up.
Seats, seat belt and ac!essory equip-

check that when pedal is pushed
down all the way, throttle valve
is fully open.

Lights, signal,
equipment

electricalaccessoryment- After having removed relevant- With ignition key set to “M A R ”

protecting covers, inspect seatscheck if lights outside and insidechecking if they slide freely on

the vehicle, as well as relevant
warning lights, go on: front

tracks without sticking andinitial stroke - it comes without

and rear parking lights, number

working condition of seat andelasticity.
Also check if parking brakeand emergency flasher, stop

Brake, clutch and gearbox controls- With engine running, push brake
pedal and check if ” after the-

stripping for tight fit and makeplate lights, direction indicators
high and low beamlights,headlights, headlights flasher,reverse gear lights, rear fog lights

control lever works properly.
With engine running, push clutch
pedal down and make sure thatall gearbox speeds engage easily,

inside ceiling lamp (throughwithout sticking and noiselessly.

manual as well as door switch),
instrument cluster light.

Tightening wheel screws
Use a spanner and check if wheelscrews, are properly tightened.

-

Also check if screws, are incompliance with vehicle and rim
type, as shown in the Spare Parts
Catalogue.

-

Check if seat belts and relevant
retractors are in good working

condition.
inside- Checkandoutsiderear-view mirrors making sureCheck proper working conditionof following warning lights:
alternator, fuel reserve, oil pressure, brake fluid level, parking
brake on, starter on, defroster

visors, ashtrays, glove compartment and any other accessory.

on, cooling water temperature.
Check proper operation of horns

Windshield and rear window wiper
and washer- After having installed wiper
blades, check if windshield wiper
works properly at both speeds asly (needles are moving): rpm
indicator, oil pressure gauge,
water temperature gauge, fuellevel indicator, and clock.

head-rest adjusting devices.
-

they swing easily and stay firmly
in place when set; also checks n a p switch on m i r r o r f o r
day/night driving.
- Check maneuverability of sun-and cigarette lighter.
Dashboard instruments- While starting up the engine,
check if all electrically controlled instruments work proper-

noiselessly. Also check proper

CLEANING AND
FINISHINGINSPECTION

well as it is set to intermittent

Exterior cleaning
If required, dewax the vehicle

operation.
- Operate the windshield washer

using suitable products andprocedures; wash the vehicle’s

System circuits tightness
Visually check circuits of follow-

and check if sprayer jets are

exterior with a solution of

normal and properly directedwater and shampoo, rinse it

ing systems for leaks or evidence

toward the windshield’s higher

thereof: fuel, brake, clutch, andsection.

thoroughly and dry it.
Finish up cleaning by removing-

engine cooling.
Check engine, gearbox and differential for evidence of oil

Locks, hinges, windows
Check proper working condition

any stubborn spots by means ofsuitable compounds.

of all door locks (close, lock,open from inside and outside).

Paint
Visually and thoroughly check

Engine cooling electric fan

Check in the same manner also

all painted surfaces and remove- Connect and short-circuit wiresof radiator thermal contact andlocks of engine and back door.

accidental orleaks.

check if fan starts and works- Check door and bonnet hinges
for smooth noiseless operation.

properly.
Also make sure that wires are-properly and securely connectedto thermal contact.

manufacturing

flaws, if any.

Check if windows can be opened

Exterior/Interior mouldings and fit-and closed all the way withouttings- Visually check all vehicle’s out-

sticking and noiselessly.

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00-9

May 1983

COMPLETE CAR

side parts: bumpers, mouldings,

MAINTENANCE

grills, headlight rims, letters andemblems making sure they are
securely fitted, and *have n o

Coupons will have to be stamped by
the Service Organisation Agency to

Maintenance operations consist in
checking and restoring proper work-

show that specified maintenance
operations have been carried out.

spots or dents.
Verify all upholsteries (roof,

ing condition of some parts of theJust as for pre-delivery inspection,

vehicle which are most likely toshould topping UP or change of fluids
and lubricants - as described in the

carpets, panels etc ..) removing
possible stains or scratches.
Factory issued accessory equipment- Check if following items are in
their proper place in the vehicle:
tool kit, spare tire, jack, Instruction Book and Service Book.

May 1983

become worn or out-of-adjustment asa consequence o f t h e v e h i c l e ’s
normal use.
A list of various operations to be
performed at different intervals, as
shown in the chart that follows, isincluded in the coupons of theService Book which accompanies
each vehicle.

00-10
Alfawiki.nl

text - become necessary, they will beconsidered as part of maintenanceo p e r a t i o n s . .In case damages ormalfunctions other than those listed
are encountered, they will be takencare of repair of adjust according tocurrent technical and administrative
procedures.

COMPLETE. CAR

MAINTENANCE SCHEDULE(Except Switzerland, Sweden, Australia)

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00-11

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COMPLETE CAR(Except Switzerland, Sweden, Australia)

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Alfawiki.nl

COMPLETE CAR

MAINTENANCE SCHEDULE(Swiss version)
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00-14

Alfawiki.nl

COMPLETE CAR

MAINTENANCE SCHEDULE
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Alfawiki.nl

00-15

May 1983

COMPLETE CAR

MAINTENANCE SCHEDULE(Australia version)
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00-I 7

May 1983

COMPLETE CAR

FLUIDS AND LUBRICANTS CHART

Alfawiki.nl

May 1983

COMPLETE CARRECOMMENDED FUEL AND -LUBRICANTS
FUEL
To ensure proper engine operation,use petrol with a 2 98 Octane Rating(R.M.) and a G 1 1 s e n s i t i v i t y (I).
(1) Difference between Research Method
Oct%ne Rating and Motor Method Octane
Rating.

Alfawiki.nl

COMPLETE CAR

FLUIDS AND LUBRICANTS

-

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-

Alfawiki.nl
00-2 1

May 1983

COMPLETE CAR

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May 1983

Alfawiki.nl

COMPLETE CARi

APPROXIMATE REFILL CAPACITIESREFILL CA P A C I T I E S

APPROXIMATEkg (lb)II

1 (Imp gal 1

FUEL TANK

50 (11)

FUEL RESERVE-

6.5 (I ,431

COOLANT-

7.3 (I ,611

With filter

3.6 (7.94)

Without filter

3.15 (6.94)

ENGINE OIL SUMPGEARBOX-DIFFERENTIALOILCONCENTRATE ANTI FREEZE QUANTITY
DEPENDING ON TEMPERATURE

ANTIFREEZE QUANTITY READY FOR USE

E-

2.3 + 2.4 (5.1 + 5.3)--

2.6 (0.57)

IO”2 (14°F)

1.8 (0.40)- 2 0 ° C (-4’F)- 35°C (-31°F)- - 20°C(4’F)

3.65 (0.80)
I-I

7.3 (1.61)

CAM SHAFT SUPPORT SUMPS 01 L Kg 0.250 (lb 0.55) FOR EACH
SUPPORT (REFILL T O B E C A R R I E D OUT I N C A S E O F DISASSEMBLIES

0.5 (1.1)

ONLY-COMPLETELY DRY SUPPORTS

ENGINE MAINTENANCE
BASIC MECHANICALSYSTEMCHECK AND POSSIBLE
ADJUSTMENT OF VALVE
CLEARANCE

2. Insert the key A . 5 0 1 9 3 i n t oproper hole on camshaft,
3. Further rotate crankshaft so thatcamshaft hole is in line with theadjusting screw on the cup.
4. Suitably rotate the cup involved

Following operations must be performed while engine is cold.

in the adjusting operation as well as
the one next to it so that relevant
cavities will face each other.

1. Disassemble spark plugs, remove
camshaft support cover and, bymeans of a syringe, suck oil from

5. Introduce tool A.2.0278 forretaining of valve cups in order totank.
2. Using the feeler gauge C.6.0168
check clearance between cam resting

prevent rotation of cups during

radius and cup crown making sure it
is within specified value.

prevent axial sliding).

clearance adjustment (tool does not

Valve clearance (cold engine)

In case clearance is not within theIntake0.35 + 0.40 mm (0.014 + 0.016 in)prescribed values, carry out adjust-Exhaustment operating as follows:
1. Rotate crankshaft till piston is in

0.45 + 0.50 mm (0.018 + 0.020 in)

its compression stroke (valve closed).

May 1983

00-24
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COMPLETE CAR

1 Bolt2 Bolt3 Screw

Replacing timing belts withengine on car
6.

Interpose tool C.6.0168 between

tapper bucket upper part and cam
minimum radius and, by means ofwrench A.5.0193, operate until theprescribed clearance is obtained.
.
7 . For better security check clearance after having removed previously
inserted cup locking pin.

1 Mark on rear cover
2 T - shaped reference markREMOVAL

1. Disconnect electric fan wiring,loosen relevant screws 0 andremove fan from radiator throughlower channel 0.

6. Loosen
idler
lock
pulleysnuts 1andthen press idler
p u l l e y s @ so a s t o o v e r c o m etension load on belts. Tighten

0

nuts

8. Repeat the procedure for eachvalve of the two heads.

0

while in this position.

9. At the end of operation, restore
the tank oil level and reassemble
cover and spark plugs.

CHECKING, REPLACING
AND ADJUSTING DRIVE
BELTS
Alternator and water pumpcontrol belt
Inspect belt for cracks or damage.

2w
2 Channel

Replace it if necessary. Push on belt
longest section, located between

1 Screw

engine pulley and alternator pulley,
applying an 79 N (8 kg; 3.63 lb) loadand verify relevant deflection whichshould be of 15 mm (0.59 in);contrarywise proceed to adjust belttension as follows.

2. Remove spark plugs, alternatorand water pump control belt.

Loosen bolts
7.
well as screws

8

1 and 0 as
3 that secure
alternator support bracket to theengine’s front cover.

2. Move the alternator so as toeither stretch or slacken the belt andthen tighter&gain bolt 0.
3. Check again belt tension andthen tighten all previously loosenedbolts.

1 Lock nur

2 Idler pulley

7. Now remote first the right hand
cogged belt and then the left handbelt from camshaft and crakshaft

3. Remove camshaft belts plastic
covers.

pulleys.

4. Remove camshaft support covers.

ASSEMBLY

5. Remove timing plastic coverlocated on cylinder block rear cover,

CAUTION:
Check again engine timing proceed-

and rotate crankshaft till piston ining as per step Sabove.

no. 1 cylinder is set in top deadcenter on its combustion -stroke.
Such correct position is achieved
reference
when theT-shaped

1. Rotate camshafts till referencemark @ on flywheel is in line withmarks stamped on same are in linewith those stamped on relevant

the mark on rear cover 1

support.

0.

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00-25

May 1983

COMPLETE CAR

3. Check again engine timing.
4. Fit back camshaft support covers, alternator and water pumpcontrol belt, electric fan and spark
plugs.
5. Start engine and warm it up tonormal running temperature, thenremove again camshaft support covers. Working on one cylinder head at
the time, proceed as follows: bringrelevant camshaft in neutral position,loosen and then tighten again idler
pulley lock nut thus giving the belt in
its final tension load.

2 . Key camshaft control belts. onto
crankshaft and camshaft pulleys
starting with the one of the left handcylinder head.
(1) Belt keying must take place
while belt pulling section (opposite
the idler pulleys) is fully stretched.
(2) Loosen idler pulleys lock nuts all
the way and then tighten them again.
(3) Let driving shaft rotate in thefunctioning direction so as to allow
belt to set on pulleys.
(4) Set, one by one, the camshafts
to the neutral position, then unloosen nuts securing backstand, press a
few times on them and secure nuts tothe prescribed torque.
(5) Rotate crankshaft a few times in
its working direction so that belts
may take up their final position.

Rotate camshafts till they are inneutral position: loosen idler pulleys
lock nuts pressing idler pulleys a few
times, and then tighten relevant nuts
according to specified torque.
Rotate crankshaft a few times in its
working direction thus allowing belts
to settle on pulleys, and then repeat
above described tension checking
operation while positioning camshafts one at the time - with cups
disengaged.

.

.

@ : Tightening torqueIdler pulley lock nut(warm engine)
29+35 N - m

A milky oil indicates the presence of cooling water.
Identify the cause and takecorrective measures.
An oil with extremely low
viscosity indicates dilution withpetrol.

2 . Using an oil filter wrench,
remove oil filter.

(3 + 3.6 k g - m
2 1 . 3 8 f 2 5 . 8 ft.lb)

6. Fit back camshaft support covers and timing belts covers.

CHANGING ENGINE OIL
ANQ REPLACING OIL
FILTER
1. With engine warm, remove oil
filler cap and oil pan drain plugletting oil drain completely into asuitable container (wait at least 15
minutes).

3. When engine oil is completely
drained, clean oil pan drain plug andscrew it back into place.
4. Moisten the gasket of the newoil filter and then install the filter
tightening it all the way.
5 . Refill engine with specified new
oil referring to LUBRICANTS &hart.
Check oil level with dipstick.

ENGINE OIL QUANTITY

1kg

1 (lb)Camshaft support sumps (*I 0.25 (0.55)
Engine oil sump
Sump capacity
Filter capacity@ : Tightening torqueIdler pulley lock nut(cold engine)
37+46 N-m
(3.8 + 4.7 k g - m(*I27.49 + 33.98 ft-lb)

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00-26

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3.60 (7.94)
3 . 1 5 (6.94)
0 . 4 5 (1 .OO)

Refill to be carried out, far each sump.
in case of disassembly only.

COMPLETE CAR

6. Fit oil filler cap back and start
the engine letting it idle for about 2
minutes.
7. Now check following items forany oil leaks: filter, pan, seal rings,
oil pressure transmitter, gaskets ofcylinder block and cylider head
covers, and cylinder head gaskets. If
necessary, tighten or replace items
that are not oil tight.
8. Turn the engine off and wait a
few minutes.
9. Take out dipstick and clean it;
fit dipstick back, take it out again
and check oil level making sure it
reaches the MAX reference mark.

Refill radiator through relevant filler
according to following instructions:

1 Coolant drain plugs

3. Fill cooling system with recommended anti-incrustator following
relevant instructions for use.
Recommended anti-incrustator:
NALCO 1006
INTERPROIND Jal Auto
Stand. No. 3681-69955
4. Remove again drain plugs fromcylinder block bottom and let
anti-incrutiator drain completely.
5. Thoroughly flush the systemwith running water.
6. Fit drain plugs back to cylinder
block and fill the radiator.

System refill

CAUTION:
When checking oil level, park the car
on a level surFace.

After having drained the coolingsystem, refill it with the kind andquantity of coolant as shown in
the following chart.

Sunimertime

COOLING SYSTEM

Drinkable waterI

1. While engine is cold, remove
radiator filler cap.
remove drain
and2. L o o s e nplugs 0, located on bottom ofcylinder block, let coolant draincompletely and then fit plugs backon cylinder block bottom andtighten them.

Checking the system’
1. Check coolant level in radiatormaking sure it is within MAX andMIN level marks.
2. Check hoses and unions for leaks
making sure they are not in any way
damaged.
3. Check filler cap making sure
relevant spring, gasket and valves arein good working condition.
4. Test the electric fan as follows:(1) Disconnect thermostat wires andshort-circuit them.
(2) Turn ignition key and check ifelectric fan-starts up.
5. Check radiator as per instructions contained in Group 07 - Radiator.
6. If top-up requires an abnormallylarge amount of coolant, check entire
cooling system for leaks and eliminate them.

7.3(Imp Gal ) (1.61)

System flushingThis operation should be performed
only if plain water is used as engine
coolant in summertime.

1. Refill the system till max. levelmark in expansion reservoir isreached.
2. Start the engine and warm it up
to normal running temperature thus
allowing the thermostat to open andto expel any air that was left over inthe system.
3. When engine is cold, top up
cooling system till max. level mark in
expansion reservoir is reached.
4. Fit filler cap back and.tighten it.

Radiator cap pressure test
Minimum out- C
side temperature (S- IO -20(14) (- 4)Concentrated antifreeze Std. No.
368 I-69956 I(Imp Gal )1.8
2.6(0.40 (0.57)

3.65(0.80)

Diluting drinkablewater(Imp Gal !

5.5
4.7
Il.211 (I .03)

3.65
(0.80)

Ready-to-use antifreeze Std. No.
3681-69958 I(Imp Gal 1

Alfawiki.nl

00-27

7.3
(1.61)

1. Fit union @ onto tester andthen insert it on expansion reservoir
cap.
2. Apply pressure to the cap andcheck tester to make sure that when
specified pressure reading is reached,‘the relief valve opens up.

Radiator filler cap relief pressure:68.6 kPa (0.69 bar;
0 . 7 kg/cm’; 9.96 p.s;i.l

May 1983

COMPLETE CARCHECKING CYLINDERCOMPRESSION

or between cylinder liners andpistons.

When diagnostic poor engine performance because power is not up to

REPLACING AIR CLEANERCARTRIDGE

normal, it is advisable to test cylinder
compression using relevant tester(MOTOMETER) and according tofollowing procedure:
1. Start rhe engine and warm it up
t o n o r m a l running temperature.
2. Remove spark plugs.
3. Disconnect distributor’s highvoltage cable.

I.

Unfasten air cleaner cover retain-

ing spring clips 0.
2. Lift cover 0

andremovecartridge.
3. Thoroughly clean cartridge by
blowing low pressure compressed air
from within.
If necessary, replace cartridge.

4. Apply compression tester onto
the seat of one spark plug.

3 Filler cap

1 Tester
2 Union

5. _ Crank the engine briefly keeping

Cooling system pressure test
1.

Remove expansion reservoir cap.

2. Tighten tester onto expansion
reservoir filler.
3. Apply pressure to the coolingsystem and check tester to make surethat pressure remains within specified value.
Coolingsystem testing pressure:107.9 kPa (I.08 bar;

1.1 kg/cm’; 15.65 p.s.i.1

the accelerator pedal fully pressed sothat carburetor throttle valve is fully

1 Cover2

Air cleaner cover retaining spring clip

open.
6. Verify that compression pressure
is above min. value (make sure there
are no leaks from tester’s union).
Min. compression pressure1030 kPa (IO.3 bar;
10.5 kg/cm2 ; 149.34 p.s.i.1
Repeat the test to check com7.
pression in other cylinders, being
careful to reset the tester eachtime. Compare the readings andmake sure that max. difference
between the various cylinder pressure
measurements does not exceed specified value.

IGNITION AND FUELSYSTEMCHECKING AND REPLACINGSPARK PLUGS
1.

Disconnect spark plug wires with

relevant protecting boots.
2. Remove spark plugs with spark
plug wrench.
3.

Clean electrodes and check insu-

lation for cracks and chips.
Max. compression difference
between cylinders
98 kPa (0.98 bar;
1 kg/cm’; 14.22 p.s.i.1

If electrodes are excessively worn,
replace the spark plugs.
S p a r k p l u g t y p e : L O D G E 2 5 HL
4.

When replacing spark plugs, coatplug thread with specified grease andIf picked up values are not within
specified ones, look for the trouble’s
cause in poor tightness of the valves

May 1983

00-28
Alfawiki.nl

then fit them in relevant seat tightening them according to specified
torque.

COMPLETE CAR

Spark plug thread:
ISECO Grease: Molykote A - Std.
No.4500-18304@ : Tightening torqueSpark plugs
25+34 N-m
(2.5+ 3.5 kg-m
18.08 + 25.31 ft.lb)

CHECKING CO%CHECKING THE
DISTRIBUTOR
Visual check
1. Remove distributor cap androtor @ and check them for cracks
or chips.
2. Make sure that distributor cap
carbon is securely kept in place in its
seat by the relevant spring and that it
moves freely thus ensuring proper
constant adherence to distributor
rotor.
3. Apply a coating of engine oil tofelt inside rotor control shaft and acoating of specified grease to cam.

5. Connect spark plug wires and fit
back relevant protecting boots according to following sequence: I - 3 2 - 4.

CHECKING AND ADJUSTING
IGNITION TIMING,
IDLE-RPM AND COY..

I. Connect stroboscopic flash lamp
feed clamps to the battery and the
pickup to the high voltage cable ofcylinder no. 1.
2. Connect an electronic tachometer to the engine by fitting feed
clamps to the ignition coil’s feeding
and the pickup to the coil’s highvoltage cable.

CHECKING IGNITIONWIRING
1. Visually check ignition wiringfor cracks, burns and loose terminals.
2. Measure resistance of high voltage cable by connecting an ohmmeter between the cable’s terminal andthe corresponding electrode on theignition coil.

.

P

Alfawiki.nl
oo-‘2 9May 1983

COMPLETE CAR

3. Remove the small plastic covet
located on the engine rear cover.

CHECKING AND ADJUSTING
IDLE-RPM AND CO%

Preliminary inspection:a.
Clean or replace air cleaner.
b.

Inspect ignition system making
sure following parts are in goodworking condition: spark plugs,

CAUTION:If during engine tune up there is no
extra cooling fan available, keep
checking indicator pump and thewater temperature gauge on dashboard and immediately suspend
testing if temperature goes up,
meaning that engine is overheating.

cables, distributor cap, rotorarm, (refer to: Group 05 - IgniC.

d.

tion System).
Check ignition timing.
Check adjustment of acceleratar
control (see: Group 04 - Accelerator Control).

Check idle-rpm and overall CO% as
follows:
1. Insert CO-tester probe @ into
the tail pipe 0.
2. Connect an electronic tachometer to the engine.

1 Advance hose
2 Ignition timing check hole

4.

Start the engine and warm it up

to normal

running temperature.
5. Using the stroboscopic flash
lamp, check if - with engine runningat g 900 r.p.m. - the mark on theengine rear cover is in line with thefixed advance notch on flywheel.

Fixed advance
8% 1”
6. Disconnect the vacuum advancehose from distributor and verify thatwhen engine at 4500 r.p.m. the markon the engine rear cover is in linewith the max. advance notch on
flywheel.

Max. advance36”+ 1”
7.

If specified alignment does nottake place, loosen the distributor
retaining bolt and rotate distributor
either clockwise to retard or anticlockwise to advance.
8. Tighten the distributor retaining
bolt and check fixed and max.
advance to make sure they arewithin specified values.
9. Fit the small plastic cover backonto engine rear cover.
10. Fit vacuum advance hose backonto distributor.
If above described adjustment does
not succeed in correcting max.
advance, overhaul or replace the

1 Tail pipe

distributor.

May 198300-30
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2 CO-tester probe

COMPLETE CAR

3. Start the workshop’s gas exhauster.
4. Srart the engine and warm it up
to normal running temperature.
5. Now check if engine rpm iswithin specified value.

Sweden, Australia) idling speed isreached.
(5) Act on mixture meteringscrew @ till the smoothest possible
engine running is obtained, while
keeping CO% within the prescribedvalves.

Idle-rpm
900 + 1000 r.p.m.
850 + 950 r.p.m. ( l )Switzerland,(“1 (for
Australia)..

CO%< 3.5% total
0 . 7 + 2 . 4 % (*)
Sweden,

6. If not within specified value,
adjust idle-r-pm just by turning
relevant idle-adjusting screw @which makes it possible to change
rpm without changing CO percentage(Carbon monoxide).
7. Verify that CO percentage
picked up by tester corresponds tospecified value and that engine
runs smoothly.

(“) for Switzerland, Sweden, Australia(6) Fit back into place mixture
metering and throttle valve screw
seals,(7) ff further optimizing of idle-rpm
is desired, just act on.relevant idling
adjusting screw 0.

Ajlowed CO %< 3.5 % total
If not within specified value or incase of engine tune up after engine
overhauling or after having cleanedor replaced the carburetor, anadjustment involving also mixture
metering screw @) and throttle
valve screw @) is required. In thisinstance, proceed as follows:(1) Remove seals from mixture
metering screw 0 and from throttle valve screw 0.
(2) Tighten idling screw @ all theway.
( 3 ) N o w act on throttle valve
screw 03 and on mixture meteringscrew @ till following conditions arepresent:
Rpm
850
8 0 0 (*)
C O %
0.5 + 1% total(“) for Switzerland, Sweden,
Australia(4) Loosen
idlingadjustingscrew @ till a 900 + 1000 rpm(850 + 950 rpm for Switzerland,

1
2
3

medium rpm, the vapors going up theoil filler go through the flame trap
located in the hose @ connecting
oil filler to air cleaner; from here
then they go through the min. rpm
blow-by hose @ and, downstream
from throttle valve, are distributed
onto intake manifold @ _Since when the accelerator ‘is fully
depressed the vacuum generated by
the engine is not sufficient to completely suck exhaust gases solely
through the min. rpm hose, gases arealso conveyed inside air cleaner,
upstream from carburetor, by meansof the max. rpm blow-by hose 0.

CHECKING HOSES AND
UNIONS
1. Inspect hoses and unions tomake sure they are not in any way
damaged and that are no leaks.
2. Disconnect all hoses and clean
them blowing a jet of compressed air
through them.
Replace any damaged hose.
3. Remove flame trap located inmain blow-by hose near the oil filler;
wash it with suitable cleaner, blow itwith compressed air and, then fit
it into place.

Idling mixture metering screw
Idling adjusting screw
Throttle valve adjusting screw

EMISSION CONTROLSYSTEM
Recycling of exhaust gas and oilvapors, generating in the cylinder
block and then burned in the cylinders, is achieved through a series ofblow-by hoses.
At any rpm, the vacuum created in
the carburetor is sufficient to convey
gas and vapors into intake duct andfrom here into cylinders for final
combustion.
When engine is idling or running at

Alfawiki.nl
00-3 1

Air cleaner
Max. rpm blow-by hose
Main blow-by hose
Oil filter
Min. rpm blow-by hose
Carburetor
Intake manifold
Cvlinder block

May 1 9 8 3

COMPLETE CARCARBURETOR

CLEANINGJETS/

REPLACING FUEL FILTER
as well as idle jets.
b.

If necessary, clean carburetor jetsand blow-by hoses as follows:a. Remove air cleaner, carburetor
cover, and then remove main jets

Clean jets with compressed air(do not use any metal tool) andthen fit them back onto carburetor; also fit cover and air cleaner.

Loosen hose clamps and remove thefilter. Install a new filter paying
special attention to the fuel flowing
direction as indicated on filter body.
Tighten hose clamps.

TROUBLE DIAGNOSIS AND CORRECTIONS
Condition

CANNOT CRANK ENGINEOR SLOW CRANKING

Corrective action

Probable causelDead battery

Recharge and check recharge systemlFaulty battery

ReplacelOxidized battery terminals

Clean terminalslLoose wiring connections inCorrect

starting circuitlFaulty starter switch

ReplacelFaulty starter

Repair or replace(Starting circuit trouble-shooting procedure)Turn on starter while lights are on (set switch to “ON”).
If lights go off or dim considerably:a. Check battery’b. Clean battery terminals
If lights stay bright and starter does not work:a.

Check wiring connection between battery and starterb. Check starter switch
c. Check starter

ENGINE CRANKS NORMALLY BUT WILL NOT START
In most cases the trouble lies either in the ignition system or in the fuel system.
-

Trouble in ignition system
Trouble in fuel system-

Valves do not work properly- Low compression(Trouble-shooting procedure)First of all check spark plugs as follows:
Disconnect high voltage cable from one spark plug and hold it about 10 mm (0.39 in) from any engine metal partand let the starter run.

CAUTION
Above test must be performed with uttermost care.

May 198300-32

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ENGINE MAIN MECHANICAL UNIT

.DRlVE UNIT REMOVAL AND INSTALLATIONREMOVAL
Drive u n i t s u p p o r t s

DETAIL A

040 c4s(4.1 + 5
29.6 f 36.2)

DETAIL 6
DETAIL C

(kg.m
ftlb)

Drive unit central support
Central supporr to body fixing bolt
Rear support pin
Rear support to body fixing screws
Gearbox casing
Engine unit
Engine front support to crossmember fixing screw
Engine front support
Detail A
Detail 6
Detail C

May 1983

Central support
Rear support
Front support

01-2
Alfawiki.nl

ENGINE MAIN MECHANICAL UNIT

Enginecompartment - Electrlc w i r e s dlsconnectlons

Ignition inductor cable
ignition distributor
Cooling temperature transmitter cable
Coil high voltage cable
Tachometer and coil low voltage cables
Alternator and alternator warning light supply cable
Head lamps cables
Electric fan thermal switch cables
Foglamps cables

10
11
12
13
14
15
16
17

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01-3

Horn cables
Electric fan supply cable
Windshield and rear window washers pump cables
Water temperature thermal contact cable
Oil pressure manual contact cableStarter supply cables
Energization cable
Earth cable on engine coverMay 1983

ENGINE MAIN MECHANICAL UNIT

E n g i n e c o m p a r t m e n t - Plplng r e l e a s e

1 Fuel pipe
2 Clutch oil supply pipe
3 Expansion tank plug
4 Air bleeder into crankcase
5 Sleeve for water return from radiator
6 Sleeve for water delivery to radiator
7 Servobrake vacuum pipe
6 Hot water to heater supply pipe
9 Heater warer return pipe

May 1983

01-4

Alfawiki.nl

ENGINE MAIN MECHANICAL UNIT

During engine removal from car, it isnecessary to remove engine andgearbox - differential as single
unit.
Put the vehicle on the auto lift andengage first gear.

Great care is required when dealing~~tY~~~~~ngine~j

1. Operating from passenger compartment inside withdraw knob ofgearbox lever, then remove thetwo lever bellows.
2. Remove the hood (refer to:Group 56 - Hoods).
3. Working from inside the engine
compartment, disconnect the battery
earth cab le.
4. Disassemble the air filter asfollo\lvs:(1) Disconnect the corrugated air
intake pipes from the air filter bytaking off the fixing clamps.
(2) Disconnect the blow-by pipes.
Then remove the filter (Refer to:Group 04 Air Filter - Removal).
accelerator
and
5. Disconnect
starter controls as follows:(1) Extract the retaining ring 0,
slip the return spring @ off its
clamps and take off the slotteda d j u s t e r @ from the throttle
control lever.
(2) Release accelerator cable together with bracket @ unscrewing
the two securing screws located on
intake manifold.
(3) Disconnect hose and sheath ofstarter control of operating on sheath
securing screw @ and on starter
control lever screw 0.

6. With reference to the figure on
page 01-3 disconnect the following
electric cables, preferably as indicated :. earth cable @I, from theengine rear cover. high voltage cable @, from thecoil. low voltage and tachometer
cables @ from coil
. alternator and warning light
supply cable @, from thealternatorlwater temperature thermal contact cable @, from the thermal
contact on the right hand head.
electric fan supply cable 0 ,from the fan.
windshield and rear window
washers pump cables @ fromthe pump
lstarter motor supply I@ andenergization @ cables fromthe starter motor.
oil pressure switch cable @ ,from manual contact on the rearcover.
electric fan thermal contact
cable @, from the thermal
contact on radiator.
fog lamp supply cables @,from fog lamp connectorslhead lamp supply cables 0,
from the headlamps.
horn supply cables @I , fromthe horns.
water temperature transmitter
cable @ , from the transmitteron the intake manifoldlignition
inductor
electronic
cable a from distributor.
ignition
distributor
removecap 2 together with spark plug
cables.
oil level sensor cable, from levelrod (for models fitted withcheck control, only)

0

CAUTION:
Unfix the electrical cables from theirclamps, separate them from the drive
unit so as not to impede its removal.

1
2

Bracketscrew

4
5

SpringRetaining ring

3

Screw

6

Adjuster

May 1983

7. Unscrew and remove the coolant
expansion tank plug.
8. Raise the car and from beneathremove the right hand drain plug 3
and then the left hand drain plug 4under the cylinder block and drain
off the coolant; screw the plugs again

801-6
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after draining.
9. Depending on what is to bedone, drain the oil from the oil sumpby removing the plug @ and, if
necessary, drain the oil from thegearbox by removing
the drainplug 0. Screw the plugs again afterdraining.

1

2
3
4

Gearbox oil drain plug
Engine oil drain plug
Right head coolant drain plug
Left head coolant drain Plug

10. Lower the vehicle and withreference to figure of page 01-4,
disconnect the following pipes andcouplings, preferably as indicated:
hot water to heater delivery
pipe @, from the supply manifold
heaterreturnwater
frompipe @, from the water pumpintakedelivery pipe @ to block fromthe water pump intake
water delivery coupling @, toradiatorradiator water return coupling 0, from the water pumpintakefuel inlet line 0, from supply
pumpclutch oil delivery hose 0,
from pipe union (properly plug
the hose)
intakeservobrakevacuumpipe 0, from the suction manifold.
11. Loosen bolt 0 securing engine
central support @ to body.

ENGINE MAIN MECHANICAL UNIT

INSTALLATION

1 Central support
2 Central support securing bolt

6 Bolt securing gearbox rear support
7 Exhaust pipe
8 Engine cross member securing screw
9 Engine support cross member
10 Front elastic support

3 Rear support
4 Pin
5 Rear support securing screw

CAUTION:

3. Remove the lifter and unloose

Drive unit assembly must be performed in such a way that thethe lower bolt @ securing the

gearbox rear support and the engine

gearbox to the rear support.
4. Put the rod @ in thefront support are not respectively

support 0, positioning it on its

upwards

body clamping points and screw up

a n d l o n g i t u d i n a l l y pre-loaded.
Referring to preceding illustration,
follow as indicated.
1. Raise the drive unit with thecolumn lifter used for disassembly
until the centre support axis @ is at
about the halfway point of the
body slot and tighten the relevantbolt-@,-+’
Connect the left strut to the engine
support cross member and fasten the
cross member in position to the bodywith the screws @.

rearillustration put the side rod @ in
the support @ on the right sidefirst,
thentighten,rail @
screw @, second, screw 0.

0.

the screws 5
5. Screw up the drive shafts todifferential shafts joint screws in oilwith the prescribed torque.

0: Tightening torque
Drive shafts to differential
shafts connection screws
33 f 36 N-m(3.4 + 3.7 k g - m
24.58 + 26.75 ft-lb)

2.
Fasten the front support @ in
position to the cross member tighten-

6. Assemble the exhaust pipe 0.
7. Clamp the lower bolt @ securing the rear support to the gearbox.

2

ing the correct screws.

8. With reference to the following

3 Support

May 1983

01-8
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1

Right cylinder
head
Right side rail

45
6Side rod
Screw
Screw

ENGINE MAIN MECHANICAL UNIT

9. Complete the unit assemble

prescribed oil:carrying out the disassembly operations in reverse order, with particularEngine oil
AGIP Sint 2000 lOW50

attention to the following steps.
(I) By means of a spanner, tighten
to the prescribed indicative torque,the union connecting hose to clutch

I P S u p e r M o t o r O i l lOW50
Gearbox oil differential:
AGIP Fl Rotra HP SAE SOW90
IP Pontiax HD SOW90

control pipe.
0: Tightening indicative torquerelevant to hose union to pipe.
15 + 19 N.m

SummerPotable water

Antifreeze
(See
Unit
General Directives)

07-(5) Adjust the accelerator cable (SeeUnit 04 Accelerator Wire Adjust-(3) Bleed the clutch hydraulicsystem (See Unit 12 - H y d r a u l i cmerit).
(6) With the engine at running heat,

System Bleeding) and if necessary

check its idling. For any tuning up(1.5 + 1.9 kg-m

top up the oil level to the MAX mark10.84 + 13.78 ft.lb)

on the tank with the prescribed fluid

required, see
Maintenance -(AGIP Fl Brake Fluid Super HD or(2)

WinterCheck

The

engineoil

levelc&responds to the MAX mark on thedipstick, and the gearbox oil level

Unit
00
EngineIgnition and Feed

System.

IP Auto Fluid FR).
(4) Top up the coolant with theprescribed liquid.

reaches the lower edge of the filler
hole. If necessary, top up with the

SEPARATION AND ASSEMBLY OF THE UNITSASSEMBLYSEPARATIONWith the drive unit on the rotatory
stand fitted with suitable supporting
equipment, separate the engine unit
from the gearbox unit for the purpose of replacement or overhaul of
the two units and of the clutch, as

2. Remove the lower cover @protecting the engine flywheel after
disassembling the screws and washers 2 securing the lower cover to0

1. Lubricate the direct drive shaft
working seat with the prescribedgrease (Grease Molykote paste G).
2. Perform assembly operations in
the reverse order to the separation,tightening connecting nuts and bolts

and washers @ from the starter
motor 0 securing screws 0
and remove the starter motor fromthe engine unit.

the engine rear cover and to thegearbox.
3. Unscrew and remove the remaining nuts and washers @ and complete the separation of the two units.
Withdraw the thrust beating from its
support on the gearbox so as not to

two units
39 + 48 N-m(4 + 4.9 kg-m
28.92 + 35.43 ft.lb)

1
2

1
2

follows:
1. Unscrew and take off the nuts

Nut and washer
Screw

3

Starter motor

Lower cover3
Screw and washer

to the prescribed torque.
0: Tightening torqueNuts and bolts connecting the

Nut and washer

0 1 - Q
Alfawiki.nl

M a y 1983

ENGINE MAIN MECHANICAL UNIT

ENGINE DISASSEMBLY
@xl

May

1983

Alfawiki.nl

ENGINE MAIN MECHANICAL UNIT

(6.7 + 7.4
48.4 + 53.5)

@ N.m
(kwm
fr-lb)

5.8 f 7.2)

1
2
3
4
5
6
7
8
9
10
11
12

May 1983

Main bearings
Woodroff key
Thrust half-ring
Oil pump gear
Bush
Seal ring
Rear cover
Oil plug
Flywheel
WasherLock ring
Fin

13
14
15
16
17
18
19
20
21
22
23

01-12
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Compression rings
Oil scraper ring
Oil pump
Oil sump
Engine oil drain plug
Main bearing caps
PistonConnecting rod
Connecting rod bearings
Connecting rod cap
Crankshaft

ENGINE MAIN MECHANICAL UNITPRELIMINARIES

6. Unscrew and remove screws @fixing union 0 to block, thenremove the union.

I. R e m o v e d r i v e u n i t f r o m c a r
according to procedures: Drive Unit

Removal and Installation.
2.

Remove gearbox unit and clutch
according toengineunit from

Separation and Asprocedures:
sembly of the units.

ENGINE UNIT
1. Sequentially remove following
parts:- Oil filter @ u s i n g p r o p e rspanner-

Dipstick 0.
- P r e s s u r e s w i t c h @ for minimum oil pressure check--

1 Vacuum advance pipe
2 Distributor securing nut
1 Pipe union

Remove alternator.
4.
(1) Loosen securing bolts @ fixing

Remove carburettor
7.
(1) Unscrew the four nuts withalternator @ and remove driving

securing washers carburettor to intake manifold.

belt.

Thermal contact @ for watertemperature check from right(2) Complete bolts 0 removal andtake out alternator @ _(3) Unscrews screws @ and re-cylinder head.

move bracket @.

1 Bolts
2 Alternator

5.
1 Oil filter
2 Pressure switch

3 Dipstick
4 Thermal contact

2 Screws(2) Remove the accelerator cablereturn spring securing bracket, carburettor, relevant gaskets and spacer.

3 Screws
4 Bracket

Remove pipings.

(1) Loosen screws of clamps andremove fuel supply pipe 0.
( 2 ) L o o s e n s c r e w s @ of water
system coupling @ clamp @ andremove coupling.

8. Remove thermostat(1) Unscrew screws 0, r e m o v ecover @ and thermostat.
(2) Unscrew nuts 2 and remove
thermostat housing8 1 from intake
manifold @.

2. Remove sparking plugs using
proper box spanner.
3. Remove distributor assembly.
advancevacuum(1) Disconnect
pipe 0 from carburettor.
(2) Loosen distributor securing
nut 0 and withdraw distributor
from rear cover.

1 Fuel pipe

3 Coupling

2 Clamp

Alfawiki.nl
01-13

1 Thermostat
housing
2 Nuts3 Screws
4 Intake manifold
5 Cover

May 7983

ENGINE MAIN MECHANICAL UNIT

9. Remove intake manifold(1) Unscrew nuts 0, remove engine lifting bracket @ and manifold 0.
(2) Remove water temperaturetransmitter from intake manifold.

(2) Unscrew right belt stretcher @securing nut and press on jockey
pulley @ to overcome belts tensionload; lock nut by fixing belt stretcher
in the “loose belt” position.

1 Belt stretcher

2 Spring

14.
14. Remove camshaft driving belts
rear covers.
15. Remove water pump assembly.
(I)(1) Unscrew screws 1 with wash- . .
ers
ers securing
securing pulleypulleyto waterwater
8 22 topump hub and* remove pump driving
pulley.
1 Jockey pulley

1 Intake manifold 3 Nuts
2 Bracket

10. Remove fuel pump assembly(1) Unscrew nuts with washers securing fuel pump to block rear cover 4 .
(2) Remove pump 0, spacer 2
and pump control push rod 1 .

08

2 Belt stretcher(3) Withdraw belt from pulley on
camshaft and on driving shaft,respectively.
(4) Repeat procedure for left headcamshaft driving belt.

1 Screws

1 Push rod

3 Pump2 Spacer

4 Cover

12. Unscrew screws securing pulleys
to camshafts preventing their rotation by toothed spanner A.5.0195,
then remove pulleys.

2 Pulley(2) Unscrew screws @ securing
w a t e r p u m p @ to block andremove pump with gasket.
16. Unscrew nut @ and remove
right jockey pulley.

11. Remove
camshaftdriving
toothed belts.
(I) Loosen securing screws andremove two camshaft driving front
belts guards.

13. Unscrew securing nut and re-

May 1983

move right belt stretcher @ and1 Nut

spring @ _2 screws

01-14
Alfawiki.nl

3 Water pump

ENGINE MAIN MECHANICAL UNIT

17. Lock flywheel by tool A.2.0378.

(2) Suck oil from camshaft supports(2) Withdraw upward pump from18. Unscrew screws 0 and @,tanks with a suitable syringe.

block.

remove guard @and engine front( 3 ) U n s c r e w s c r e w s @ and @support 4

securing cylinder heads to block;0.

remove heads with relevant gaskets.

24. Remove block front cover.
( I ) Unscrew screws @ and nuts
with washers @ securing cover @and remove cover with relevant
gasket.
(2) Remove front oil retaining
ring @ from cover by lever with ascrewdriver.
Replace ring at assembly.

1 Screw
2 Guard

3 Screw
4 Front support

1 Screws

2 Screws

19. Remove pulleys from crankshaft.
(1) Unscrew nut 0.
(2) Sequentially remove washer @22. Remove oil sump.

a n d s p a c e r 0, water pump a.nd

seal gasket.
(3) If required remove sealant marks
on sump and block.

alternator driving pulley @, righthead camshaft drive toothed pul-

(1) Unscrew screws with washers 0
1 securing oil sump to block.
(2) Remove oil sump and relevant

1 Screws
2 Nutsley 0, spacer @, left head camshaft drive toothed pulley @ andpilot belt washer @.

3 Block front cover
4 Oil retaining ring

25. Remove pistons and connecting
rods.
(1) Fit to flywheel a tool whichallows crankshaft rotation.

1 Screws
I N u t2 Washer3 Spacer
4 Pulley

5 Toothed pulley
6 Spacer
7 Toothed pulley
8 Washer

20. Remove flywheel locking tool,
previously fitted.
21. Remove cylinder heads.
(1) Unscrew screws @ fixing COV-

2 Oil sump

23. Remove oil sump assembly.
(1) Unscrew screws with washers 0
1 securing oil pump @ toblock rear cover.

0

ers 2 to camshaft supports; remove
covers with relevant gaskets.

(2) Turn crankshaft to permit accessto screws securing connecting rod
caps.
(3) Unscrew and remove screws @and connecting rod caps 0.
1 Screws

2 Cover

1 Screws

2 Oil pump

Alfawiki.nl
01-15

May 1983

ENGINE MAIN MECHANICAL UNIT

8. Acting on lever A.3.0324 compress springs and withdraw valve
stem totters using a screwdriver.
9. Sequentially remove upper caps,
outer and inner springs, boots fromintake valves, washers and lower
cups.
10. Repeat removal procedure foreach valve.

1 Camshaft

5.

2 cupsW ithdraw front oil retaining ringfrom its seat on camshaft support
using a screwdriver.

11. Withdraw yoke from head support tool and take out valves fromhead lower side.

CYLINDER HEADS
1. Secure head to support standfork
connected to
A.2.0195
A.2.0226 previously clamped in avice,
2. Unscrew screws 2 securingc a m s h a f t r e a r c o v e8r 3 t o support 0; remove cover with seal
gasket.
3. Loosen and remove screws 4
with washers fixing camshaft support
to cylinder head; remove support
with relevant gasket.

0

CRANKSHAFT

6 . F i t t o o l s A . 3 . 0 3 2 1 , A.3.0324
a n d A.3.010316, used for valves
removal, to head.
7. If not already done, insert valvesr e t a i n i n g y o k e 0 into cylinder
head support tool A.2.0195.

1 . Clamp cranksahft in vice.
2. Secure puller A.3.0402 to shaft
and withdraw rear guide bushingfrom crankshaft.
n3.

yA.3.0402

W ithdraw oil pump and distribu-

tor control gear by using proper plate

and press.
A.2.0:7$$7=

1 Support
2 Screws

3 Cover
4 Screws

4. Remove cups @ from housing
on support, then camshaft @ withdrawing from rear side.

1 YokeAlfawiki.nl
0147

May 1983

ENGINE MAIN MECHAN1CA.L UNIT

grinding, in order to ensure exact
guide/seat perpendicularity as well

Valve

Engine12(N) 1 3 5 0 1 5 0 0

as proper valve working position.
Valve seat

outer

VALVE SEATS

diameter
mm (in)1.

Check valve seats for any scores,
cracks or burrs and make sure they

38.875 + 38.9
(1.5305 + 1.5315)
33.375 + 33.4
(1.3140~1.3150)

are properly fitted in their respective

Diameter

38.8 + 38.825

recess on the cylinder head.

of valve

II .5276 + 1.5285)

2.
If necessary, mount the head on
tool A.2.0226 and regrind the valve

Seat recess

33.3 + 33.325

mm (in)(1.3110+1.3120)

seats using the proper tool.
This operation may be performed aslong as there is sufficient grinding
allowance that will permit eliminating the existing flaws while keeping
the specified profile; contrarywise,
valve seats will have to be replaced.
For relevant procedure see paragraph:“Valve Seat Replacement”.

= intake valvei.

e. = exhaustvalve0
1 Valve seat

2 Original profile

3 Profile after max.

regrrdrng(4) Having completed all machining,lap valve seats with proper tool.

(1) Regrind valve contact face till allevidence of wear has been removed
and following taper is obtained :3.

Oven preheat the head at 140°C(284°F).
4. Fit new valve seats using theproper tool.

Checking valve tightness
When replacing guides, after regrinding and lapping of seats, it is advis-

p = 90” t 90” 30’able to test valve tightness - withvalves and sparkplugs duly mounted -of dimension “a” on the “0”reference diameter.

according to the following procedure:
1.
Mount
the
head
on
tool
A.2.0226 and A.2.0195 previously

0 Reference diameter:
Intake = 37.3 mm (1.4685 in)
Exhaust = 31.9 mm (1.2559 in)“a” dimension at max. regrinding

secured in a vice.
2. Fill the combustion chambercavity with gasoline.
3. Let some low-pressure air into
the intake ducts and check forpresence of air bubbles in the gaso-

limit:
2.9 mm (0.1142 in)(2) Machine the valve seat upper
face still the 6 reference diameter
position obtained through the pre-line.

vious operation is reached, attaining
the specified CL taper.
Taper of valve seat upper facea=120°(3) Machine the seat inner face till
dimension “b” of the valve contact
face is restored, attaining the specified y taper.
Height of inner face:
Intake: b = 1.07 + 1.37 mm(0.0421 + 0.0539 in)Exhaust: b = 1.26 + 1.56 mm( 0 . 0 4 9 6 + 0.0614 i n )Taper of valve seat lower face:
I n t a k e : y = 50”
Exhaust: y = 30”

For seat lapping use the propercompound(SIPALlapping
AREXONS Carbosilicium for valves Std. no. 4100-31502).

Valve seat replacement
Remove worn valve seats using1.
the proper tool.
2. With a set of new valve seats

4. Follow the same procedure andcheck tightness of the exhaust valves
by letting low pressure air into theexhaust valve ducts.
5. Should there be some leaks,
ascertain that valves are properly
fitted in their seats and then repeat
above tightness tests; if the results
are negative, valve seats will needverify that dimensions shown in therelappin,g as indicated in paragraph:
Checks and Inspections - Cylinder

following table are complied with:

Heads and Valves - ‘Valve Seats.

Alfawiki.nl
01-19

May 1983

ENGINE MAIN MECHANICAL UNITSPRINGS
Visually check the springs for cracks
and make sure they are not out-ofsquare if the evidenced flaws suggest
it, check the technical data of theinner and outer springs and then witha dynamometer verify that theirlenght under load falls within thevalues shown in the following table:

425.32 + 452.76(43.4 + 46.2 :Load N95.68 + 101.85)(kg ; lb)

194.53 + 208.25

cup’s nut is intact and that the cup
has retained its original punchingposition.
CAUTION:
Do not remove the valve clearance
adjusting screw from the cup.

VALVES
Check and make sure that valves do
not show any scores, burns orevidence of sticking with theircorresponding cylinder head seats(forming a step); if they do, replacethem.

(19.85+21.25;

Lengthunderload
mm (in)

0.

i.

=

=

I

I

I

I

0.
i.
1

43.76 + 46.85)

CAMSHAFT SUPPORT

25.25 (0.9941)

1. Visually check the seats ofcamshaft cups and journals for scoresand for any evidence of pitting or
abnormal wear.
(1) Reset reamer to testing dimension.

23.25 (0.9153)

outer spring
inner spring

Diameter of camshaft bearings
Front = 35.015 + 35.040 mm(1.3785 + 1.3795 in)Centre = 46.500 + 46.525 mm(I.8307 + 1.6317 in)Rear = 47.000 + 47.025 mm(1.8504 + 1.8514 in)(3) Following the same procedure,measure the diameter of the four cup
seats and determine the relevant
fitting play.
Diameter of cup seats
36.00 + 36.025 m m(1.4173 + 1.4183 in)Max. cup-to-seat play
0.1 mm (0.0039 in)

CAMSHAFT
1. Carefully examine working surfaces of cams and of camshaft
journals making sure that there
are no scores, no evidence of seizure,
S overheating or abnormal wear.
2. With a micrometer measure thediameter of camshaft journals.

CUPS
Check that the outer surface of thecups as well as the upper surface on
which cams work, show no scores, noevidence of pitting or Abnormal wear.
Further verify that- calking of- theMay 1983(2) Measure the diameter of camshaft bearings.

0 l-20
Alfawiki.nl

ENGINE MAIN MECHANICAL UNIT

MAIN
AND CONNECTING
ROD BEARINGS

micrometer. For relevant dimensions
and tolerances see: Service Data andSpecifications - “Piston” chart.

Thoroughly clean the main andconnecting rod bearings and visuallycheck them for scores as well as forany evidence of seizure.
In case of excess wear, replace all
bearings. When fitting connecting rod
bearings to the crankshaft, be sure touse matching parts, i.e. belonging to
the same size class; for this purpose
they are identified by same colour

4. In case the connecting rod

dots on the side of the half-bearing

piston assembly has been disassem-

and on the relevant crank pin of thebled, check the piston pin seats

shaft. Applicable dimensions andon the connecting rod small end as

tolerances are shown in: Service Data

well as on the piston pin bosses for

and Specifications “Connecting rod
bearings” and“Main bearings”

5.

charts.

excess wear.
Should parts not be replaced andSurface grinding must be performed

therefore used again, remember thatworking surfaces - especially that ofthe piston pin seat on the piston must be totally free of any scores,

flatness and. parallelism tolerances
shown in the above chart.

even the slightest one.

The piston pin must always be
replaced.

in accordance with the roughness,

CYLINDER BLOCK
1. Visually check cylinder blockfor cracks or excess wear of sliding
surfaces.
2.

PISTONS AND
CONNECTING RODS
1. Visually check pistons and connecting rods for cracks, scores andevidence of excess wear.
2. Measure the play between therings and their seats in the piston.
For relevant dimensions and tolerances see: Service Data and Specifications - “Pistons” and “Piston
Rings” charts.

FLYWHEEL
1. Verify that teeth of gear are notin any way chipped or- show any
evidence of pitting; contrarywise,
replace the flywheel.
2. Check the clutch driven plateMax. allowed roughness of cylinder‘
wall surface
0.5 + 1 pm (20,10*” + 39.10m6 in)
3.

See

to

which

size

class

the

contact surface on the flywheel forcylinder walls refer to and thenproceed to check them by measuring

any scores,

chips or evidence ofthem. CylintJer walls are selected

overheating. Before doing so, how-according to their inner diameter andare divided into five different classes:

ever, make sure that the contact
surface has not been previously
ground and that the amount ofmaterial. available for removal isgoing to be sufficient for eliminationof the existing flaws.
For this purpose, verify that dimension “b” shown in the chart is greaterthan the min. specified limit and thatthe removable stock will allow
surfacing as required.

Min. limit of dimension “b”
20.95 mm (0.8248 in)
3. Check piston diameter with a

May 1983

Check cylinder walls surfaces forroughness.

01-22
Alfawiki.nl

A, B, C, D, and E. The class identifying letters are stamped on thecylinder block upper surface next toeach wall location.

ENGINE MAIN MECHANICAL UNIT

Dimensions relevant to each class areshown in: Service Data and Specifications “Cylinder block” chart.
(1) Reset the reamer by means of a

Cylinder wall max. taper:
A - B = 0.02 mm (0.00079 in)
Cylinder wall max. out-of-round:
X - Y = 0.02 mm (0.00079 in)

PISTON - CYLINDERWALL FIT(3) Compare actual values D withthey will be selected by matchingeach cylinder wall identification

1.

micrometer.
nominal ones C of each size class andthen determine the cylinders walls
max. wear.

Cylinder wall max. wear:
C - D = 0.04 mm (0.00157 in)

When original parts are involved,

letter that is stamped on cylinder
block upper surface to the pistonthat has the same letter stamped on
its head or a coloured dot painted on
the inside of its crown, according to
the following schedule:

4. If the dimensions thus established are not within tolerance,cylinders walls must be reboredkeeping in mind that three different
oversize pistons are available as spareparts; this means that the diameter ofEnginePistonidentifying
letter andcolourWall 8identifying
letterwalls will have to be in accordancewith the tolerances shown in: Service
Data and Specifications “Cylinder
block” chart.

1200
1350

C - green(1) Mount main bearing caps on thecylinder block and tighten screws as
specified in: “Engine assembly -1500

D - yellow

A - blueB - pinkE- w h i t eEngine unit”.
Then proceed to bore cylinder walls
so as to stay within the tolerances
shown in: Service Data and Speci-(2) Measure the diameter at therecommeded depth and then determine taper and out-of-round of

fications - “Cylinder block” chart.

If the letter stamped on the cylinder

Lapping must be performed so thattool marks cross each other at anangle of 9CP + 1203

block has been previously erased,
matching will take place according to
the identification letter stamped on
the piston that needs replacing; in(2) If wear does not exceed thethis instance, it is advisable to make adouble check and measure thecylinders walls.
specified limit but pistons and spring
rings need replacing because of someflaws or damage, cylinders walls
will need at least to be lapped; in thiscase measure the diameter of thewails in order to identify the newsize class to which they belong
and that will have to be kept in mind
during piston fit operations, regardless of the letter stamped on thecylinder block. Should lapping cause

cylinder wall diameter.
2. When oversize walls are used,
they will be matched to the relevant
completely

assembled

pistons,

namely with compression rings andoil scraper ring, which are available as
spare parts according to the following oversize scale: G.2 - 0.4 - 0.6 mm(0.0078 - 0.0157 - 0.0236 in).

a size class change, cylinder wall will
no longer be identifiable through theletter stamped on the cylinder block
which, therefore, must be erased inorder to avoid mistakes during future
operations_

01-23
Alfawiki.nl

May 1983

ENGINE MAIN MECHANICAL UNIT

Cylinder wall to piston playStandard 0.03 + 0.05 mm(0.0012+ 0.0020 in)
Oversize 0.03 + 0.06 mm(0.0012 + 0.0024 in)
2. Apply engine oil to piston pin,to the connecting rod small end, andto the piston pin supports.
3. Fit the connecting rod‘small end
between the piston pin supports
ensuring that holes are perfectlyaligned in order to allow proper
piston pin fit.
4. Fit the piston pin @ into thepiston @ and connecting rod 0,
and then lock it with two spring
rings 0.
a. PoSition pistons so that thearrow stamped on their cr0w.n
points in the direction of engine
rotation, namely: upward forthe right head pistons and”
downward for the left headpistons.
b. Fit connecting rods in thepistons so that the position ofmatching identification numbers
and arrows corresponds to thatshown in the below Figure.

them with oil. Select bearings according to the diameter of crankshaft
journals.

-(2) Fit thrust half-rings on therelevant seat obtained in the third
main bearings support.
Make sure that these half-rings are
fitted with oil channels facing the
crankshaft shoulders.

CRANKSHAFT
1. Fit rear bushing and oil pumpdrive gear on the crankshaft.
(1) Fit the crankshaft rear bushing 0 by means of tool A.3.0450.
(2) Heat the oil pump and distributor drive gear to 150°C (302°F).
(3) Shrink the gear @ on the
crankshaft positioning it so that theaxis of the flywheel centering dowel
and the front surface of one of
the gear’s form the specified angle.
Positioning of crankshaft rear geara = 22°+2~oConnecting rod
Piston pin
Spring ring
Left head piston (No. 2 and 4)
Right head piston (No. 1 and 3)

1 Bush(3) Place crankshaft on main bearing
supports.
2. Fit main bearing caps on cylinder block,(1) Fit main bearings to main
bearing caps and lubricate them withoil.

2 Pump drive gear

With the help of a suitablespecial pliers, fit piston rings in thepiston seat making sure that themarking stamped on the flat surfaceof the rings faces upwards.

a

MARKINGENGINE UNIT
1. Fit crankshaft on cylinder block.
(1) Fit main bearings on relevant
main bearings supports and lubricate

Alfawiki.nl
01-25(2) Fit main bearing caps: front @(see markings), centre @, andrear 0, fitted with relevant bearings, on cylinder block supports.
Coat supports with engine oil andtighten oiled screws without fully
locking them.
(3) Tighten screws securing the main
bearing caps to the relevant cylinder
block supports in two or three
May 1983

ENGINE MAIN MECHANICAL UNIT

successive steps, according to specified torque and sequence (from A

block having the gauge’s indicating
finger touch the crankshaft parallel-4.

to F).

wise to the shaft’s axis.

cover.

0: Tightening torqueCaps to cylinder supports securing screws:

6 6 + 73 N - m(6.7 + 7.4 k g - m
46.4 + 53.5 ft-lb)

Fit seal ring in the main oil

gallery of the cylinder block rear

(2) Using a screwdriver, move thecrankshaft along its axis and checkthe gauge’s reading to ensure that“g” end play is within specified
values.
Crankshaft end play

0.35 mm (0.0137 in)

5. Fit rear cover, with relevant
gasket, on t h e c y l i n d e r b l o c k .
(4) Subsequentially tighten screws

Tighten all cover retaining screws

securing the main bearing caps to thecylinder block in two or threesuccessive steps, according to specified torque and sequence (from A

according to specified torque.
@ : Tightening torque
Rear cover retaining screws
19+24N-m(1.9 + 2.4 k g - m

to F).
0: Tightening torqueCaps to cylinder block s u p ports securing screws
40+49 N - m(4.1 + 5 kgam
29.6 + 36.2 ft.lb)

13.7 + 17.4 ft.lb)(3) If the shaft has not been previously reground and therefore thevalue established as per step above isgreater than the specified value, it ispossible to regrind the shoulders of
the rear journal till its “c” iength issuch that it will allow fitting of theoversize thrust half-rings available as
spare parts.

Having completed tightening of allscrews, apply engine oil ‘to t h esupports and rotate the crankshaft
by hand.

6.

3. Check crankshaft end play.

tool A-3.0337.
a. Apply engine oil to the ring’s

Rear journal “c” length

Fit crankshaft oil seal ring using(1) Attach a centesimal dial gauge

2 8 . 7 6 4 + 28.804 m m .

sealing lip, its external surface aswith magnetic base to the cylinder(1.1324 + 1.1340 in)

well as to its working seat.

May 1983

01-26
Alfawiki.nl

ENGINE MAIN MECHANICAL UNIT

13. Fit crankshaft front pulleys.
(1) Key the below mentioned parts
according to the indicated sequence:
the belt guide washer @, the left

0: Tightening torqueScrews securing water pump
1 9 +24 Nam(I .9 + 2.4 kg-m

head camshaft drive toothed pul-13.7 + 17.4 ft.lb)

ley 0, the spacer @, the righthead camshaft drive toothed pulley 0, the water pump and alternator drive pulley @, the spacer 0,
and the washer 0.

10. Fit front cover, with proper
gasket, to cylinder block and tighten
screws and nuts according to specified torque.
0: Tightening torque
Front cover to cylinder block
retaining screws:
19 + 24 N - m(1.9 + 2.4 kg-m
13.7 + 17.4 ft.lb)
11. Fit the engine front support @and the pulley’s lower guard @ to

1
2
3
4

Nut
WasherSpacerPulley5678Toothed pulleySpacerToothed pulley
Washer3 Screw

15. Fit cylinder heads.
(2) After having suitably locked(I) Turn crankshaft till the piston in

flywheel rotation, tighten pulleyNo. 1 cylinder is set at Top Deadretaining nut according to specified

Center in the compression stroke;
this correct positioning is further

torque.

the cover.

1 Gasket
2 Pumpensured by the ‘7” notch 0 on theTightening torque
Pulleys to cylinder block retaining nut:
118 + 144 N-m

flywheel matching with the reference 0
2 o n The r e a r c o v e r 0.

(12 + 14.7 kg-m
86.8 + 106.3 ft.lb)

1 Pulley’s guard

2 Front support

12. Fit crankshaft oil seal front ringusing tool A.3.8338. Before doing so,
apply a coating of engine oil to thering’s sealing lip and work surface.

14. Fit the water pump.
(1) Fit new gasket @ on pump.
(2) Fit pump 0, without pulley,
on cylinder block.
(3) Fit screws @ with washers andtighten them to specified torquevalue.

May 1983

01-28
Alfawiki.nl

1 Notch
2 Reference

3 Cylinder block
rear cover(2) Align the references shown on
the camshaft rear journal and on the
support rear side panel.

ENGINE MAIN MECHANICAL UNIT

for torque spanner with 400 mm(15.748 in) lever arm
62+67 N.m
(6.3 + 6.8 k&m
45.6 + 49.2 ft.lb)
16. Fit camshaft belts rear covers.
17. Fit belt tensioner assemblies on
the cylinder block pins according tothe(3) Fit cylinder heads, with relevant
gaskets, o n t h e c y l i n d e r b l o c k .
By extremely careful during thisassembly operation in order to avoid
that opened valves, projecting above
the head surface, might strike theFylinder block surface and thus bedamaged.

following

sequence:

sup-ports 0,5spring @, washers @( 2 ) V e r i f y t h a t t h e c r a n k s h a f t ’s

and washers 0. Lock belt jockey
relevant
pulleyassemblies withangular position corresponds to thenuts 0 after having pre-loaded belt
jockey pulley in order to allow foras previously mentioned for heads

belt passage.

Top Dead Center of cylinder No.1,
assembly.
(3) Rotate camshaft by means of
toothed spanner A.5.0195 till t h ereference stamped on the support’s
rear side panel is aligned with the one
stamped on the shaft’s rear journal.
(4) Key camshaft drive belts on the(4) Position and then tighten the six
cylinder heads retaining screws @in two or three successive steps,

crankshaft inner pulleys and on thepulleys of both camshafts. Belt
keying must take place with thebelt pulling section, opposite thejockey pulleys, fully stretched.
(5) Check that “5” clearance bet w e e n t h e camlhaft b e l t a n d t h eaccording to the specified torque andsequence (from A to F).
(5) Tighten screws @ securing thecamshaft support to the cylinder
heads.
1

0: Tightening torque
Head to cylinder block re-

4 Spring
5 Support

Nut

2 Washer
3 Washerprofile of the engine front support
is not below the specified min. value;
if it is, modify the profile of the
support till it meets the specified

taining screws:‘81 + 87 Narnvalue.

(8.3 + 8.9 kg-m
“S” min. clearance between camshaft
belt and engine from mounting
9 mm (0,3543 in)

60 + 64.4 ftdlb)

Y-

1 Head retaining screw
2 Camshaft support retaining screw

In case of in-car tightening, use
extension spanner A.5.0198 in accordance with the following tightening
torques:- for torque spanner with 300 mm(11.811 in) lever arm:

18. Fit camshaft driving belts.
(1) Fit camshaft drive pulleys andtighten the retaining screw to specified torque being careful, at the sametime, to stop pulley rotation bymeans of toothed spanner A.5.0195.

c

0: Tightening torquepulleyCamshaftscrew:(6) Completely loosen the belt
jockey pulley lock nuts and thentighten them again.
(7) Turn the crankshaft a few times
in its working direction so that thebelts may take up their final po-

retainingsition.
(8) Act on the camshaft till cams are

57t62 N - m(5.8 + 6.3 kg-m

6 3 + 70 Nam

disengaged; loosen the belt jockey(6.4 + 7.1 kg-m

pulley lock nut and then retighten it

41.9 + 45.6 Wb)

46.3 + 51.3 f&lb)

according to specified torque.

Alfawiki.nl
01-29

M a y 1983

ENGINE MAIN MECHANICAL UNIT

0: Tightening torqueBelt jockey pulley lock nut(with cold engine)

0: Tightening torque
Pump body to support retaining screws:
8-I-1037 f 46 N.m(3.8 4 4.7 kgm

5.8 + 7.2 ftblb)

27.5 + 34 ftalb)

19. Fit oil pump.
(1) Turn crankshaft till piston No. 1
is at Top Dead Center in the compression stroke, as mentioned forheads reassembly.
(2) Turn the pump drive shaft sothat the next rotation, which Will
follow mating of the pump drive gearwith that on the crankshaft, will
position the distributor couplingaccording to the specified p angle.
Apply a coating of engine oil to thedrive shaft.
Distributor coupling positioning

p = 22”N-m(0.8 f 1 kgmm

1
2

Pump to rear cover retaining screws
Pump body to support retaining screw(5) Reassemble oil sump with proper gasket @ and tighten all retaining screws. Before doing SO,
evenly apply the specified cement to
the gasket (Cement Std. No.
DOW
3522-00040
CORNING
Silastik 732 RTV).
Before applying the sealant, remove
all traces of old sealant and of oilfrom all surfaces.

1
2

Rotor arm
Distributor locknut

3 Distributor shaft-coupling

21. Adjust clearance of intake andexhaust valves while engine is cold.
The relevant procedure is describedin Group 00 - Engine Maintenance.
Valve clearance (cold engine):
Intake0.35 4 0.40 mm(0.0138 + 0.0157 in)
Exhaust0.45 + 0.50 mm(0.0177 + 0.0197 in)
22. Fill chambers of camshaft supports with engine oil.
Oil quantity required for fill-up

0.250 kg (0.5511 lb)
1 Oil sump

1 Distributor coupling(3) Fit the oil sump pump on rearcover and tighten screws 0 according to specified torque.
a: Tightening torqueOil sump to rear cover retaining screws
IQ+24 Nhrn
(1.9 + 2.4 kg-m
13.7 + 17.4 ft+lb)(4) Tighten retaining screws @b e t w e e n p u m p body and support
according to specified torque.

May 1983

2 Gasket

20. Fit distributor on rear cover.
(I) Turn the distributor’s shaft sothat the rotor arm @ is positionedon the reference mark stamped on
the distributor’s body.
The rotor arm 0 should point
toward the No. 1 cylinder. This
position corresponds to ignition in
No. 1 cylinder and to correct coupling of the oil pump and distributor
shafts.
(2) If necessary, correct misalignment of the rotor arm with thereference mark stamped on the
distributor’s body by rotating thelatter and then tightening the lock
nut @ securing the distributor tothe cylinder block rear cover.

01-30

Alfawiki.nl

in each chamber

23. Fit support covers @ with
relevant gaskets 0.

1 Cover

2 Gaskets

ENGINE MAIN MECHANICAL UNIT

34. Assemble carburetor with spacer
and the interposed gaskets on intake
manifold studs.

@I: Tightening torqueSpark plugs:
2 5 G34 N-m(2.5 + 3.5 kg-m

0: Tightening torqueCarburetor nuts
19+24 N.m
(1.9 + 2.4 kg-m
13.7 + 17.4 ft.lb)
35. Perform following connections.
Fuel supply pipe @ from fuelpump to carburettor.
- Vacuum advance pipe @ fromcarburettor and advance controller located on distributor.

18.1 + 25.3 ft.lb)
38. Secure cap to distributor bodywith relevant springs, then connect
ignition cables between spark plugs
and distributor cap, securing them torelevant clamps.

(3) Key alternator and water pumpdrive belt on relevant pulleys.
(4) Adjust belt tension according to
specified

value
and
then lockbolts 0. For adjusting procedurerefer to Group 00 - Engine Maintenance.
L o a d : 7 8 . 4 0 N (8 k g ) (Arrow: 15 mm (0.5905 in)Cables connection must take place
according to the ignition sequence of
cylinders.

1 Bolts
2 Alternator3 screws
4 Bracket

40. Fill the engine with specified
engine oil (AGIP Sint 2000 lOW50
o r IP S u p e r M o t o r O i l lOW50).
Oil quantity required for fill-up
3.6 kg (7.93 lb)

2 Fuel supply pipe

39. Fit alternator and control belt.
(1) Secure bracket @ to engine

36. Fit oil filter by manually tightening it and insert dipstick.
37. By means of adapter A.5.0115

front-. cover and tightening therelevant screws 3(2) Position alternator on engine
support and tighten b o l t s 0

1 Advance pipe

fit spark plugs tightening themaccording to specified torque.

May 19830

without fully locking them.

01-32

Alfawiki.nl

ENGINE MAIN MECHANICAL UNIT

ENGINE LUBRICATION SYSTEMDESCRIPT.ION

1 Bypass valve
2 Oil filter
cartridge
3 Camshaft bearing housing

4 Oil sump
5 Gear pump
6 Pressure relief
valve

The engine is pressure lubricated bymeans of a gear pump. The pump is? I. -4I

i F --,
Oil pump

I

I Oil strainer-1 Oil filter cartridgeI

mounted on the rear cover of theengine and is actuated by a shaft

M

I

.I&

Block oil galleries,
Iwhich is driven by a gear fitted to the
crankshaft.
The maximum oil pressure is adjusted by means of a proper valve
fitted on the pump.
Oil is completely filtered in thesuction head by a strainer then by afilter with cartridge placed on the oil
passage and provided with a bypass
safety valve, should the cartridge
become clogged.
The oil filter, on the engine rearcover, has unions for the recirculation of the oil vapours at minimum
and high running.
The insufficient oil pressure isindicated on the combination meterby means of a warning light con-

II I

Connecting rod
half-bearings

nected to a manual contact inserted
on the main oil gallery of the block.

OIL PUMPOIL PRESSURE CHECK
NOTE

1.

Start engine and heat oil to 90°C

(194°F).

Oil passagi

2.

Remove oil pressure checking

manual contact.
3. Fit gauge to manual. contact- Returnhole.
4. Start)- BYpass passage

engineandrecordoilpressure as shown on gauge.

Alfawiki.nl
01-33

May 1983

ENGINE MAIN MECHANICAL UNIT

Enginespeed
r.p.m.

Enginesembly Engine Unit.
3. Tighten screws @ securing
pump to engine rear cover thenscrews @ fastening pump bodyto pump support to the specified
torque value.

Oil pressmekPa (bar,kg/cm2 , psi)
117.7 f274.6

1200

800

(1.18 f2.75,
1.2+2.8,

0: Tightening torqueScrews securing pump to engine rear cover
19+24 N-m
(1.9 + 2.4 kg-m
13.7 + 17.4 ft.lb)

17.07 c-9.82)
1350
411 .E + 568.7(4.12+5.69,

1500

4.2 +5.8 ,I

1 59.74 G82.49)

Screws fastening pump body topump support
Se-10 N-m
(0.8 + 1 kg-m
5.8 + 7.2 ft.lb)

5. Remove gauge and refit manualcontact.
If the oil pressure value is not within
the limits shown in table, the oilpump is to be checked.

REMOVAL
Remove fuel pump from cover (see:Engine Disassembly - Engine Unit).
1. Drain engine oil and remove oilsump. If required, tap with a wooden
mallet on attachment side of sump to
block.
2. Unscrew screws @ and withdraw pump from its seat.

DISASSEMBLY ANDASSEMBLY
1. Unscrew screws @ securing
pump body to pump support.
2. Withdraw driven gear avalve @ , spring @I and w a s h er @I.
3. Reassemble pump carrying out
the above procedure but in thereverse sequence. Slightly tighten
screws @ without locking fully
home.
4. Manually rotate driving. shaft
checking for ,crawling and regular

@1
2
3
4
5
6

Upper support
Driving gear
Driven gear
WasherWasher
Screw

7
8
9
10
11
12

Screw
Strainer
Pump body
WasherSpringValve

CHECKS AND INSPECTIONS
1. Check gears for wear, ensure
that--teeth are free from cutting or
chipping or that wear is regular andnot excessive on all the face length.
2. Check driven gear pin forindications of seituring and cutting.
3. Carry out same check as above
for the pressure regulator valve,
additionally ensuring that it slides in
its seat on pump body without
crawling. If the spring of the pressure
regulator valve is supposed to haveyielded, also considering the trouble
shown, replace valve.
4. Check that driving gear iscorredtly positioned on driving shaftof oil pump and that crankshaft
driving gear has the pin regularly
fitted.
.
5. Finally check working surfacesof shaft and rear cover, of driving
cam of fuel push rod, and the attachment point to the distributor for
cutting and signs of seizure.

INSTALLATION
1. Lubricate driving shaft with engine oil as per step 4.
2. Refit oil pump carrying out
procedure detailed in: Engine As-

M a y 1 9 8 3

01-34
Alfawiki.nl

1 Screw fastening pump to pump support
2 Screw securing pump

4. Fill engine with th.e specified engine oil (AGIP Sint 2000 lOW50 or
IP Super Motor Oil lOW50).

OIL FILTERREPLACEMENT
1. Drain hot oil of engine fromsump.
2. Remove filter using proper tool.

3. Fit a new filter of the prescribed
type. Manually screw in the filter.
4. Fill engine with prescribed engine oil. After fitting new filter, letengine run for a few minutes andcheck for oil leakages.

-ENGINE MAIN MECHANICAL UNIT

INSPECTION AND ADJUSTMENTCAMSHAFT SYSTEM

U n i t : m m (in)RIGHT SUPPORTtLEFT SUPPORTCamshaft531.364I

Tappet306.00 1200

clearanceI

305.02 1350

I

531.364305.04 1500

531.364I
I make0 . 3 5 f 0.40 (0.0138 + 0.0157)

Exhaust0.45+0.50 ( 0 . 0 1 7 7 + 0 . 0 1 9 7 1

Value of the angle of timing

Right support

23”

marks on camshaft supports

Left support

23”

All values are with cold engine

CHECKING VALVE OPENING AND CLOSING ANGLES

Unit: mm (in)EngineValve clearance for checking
”
E

(I 1

1350

1500

305.00305.02305.04m m (in)

0.7 (0.0276)

Opening BTDCa1zL

Closing ABDCb

48Om m (in)

0 . 7 (0.0276)

Opening BTDCc456

C l o s i n g ABDCd

P

Valve clearance far checking
5
r”
lz

1200

Crankshaft rotation ACW seen from flywheel side.

May 1983

01-36
Alfawiki.nl

ENGINE MAIN MECHANICAL UNITCYLINDER BLOCK

Unit: mm (in)Engineinspection data

Standard

1200

1358

1500

Class A

8 0 . 0 0 t 8 0 . 0 1 ( 3 . 1 4 9 6 +3.1500)

84.00t84.01 (3.3071 -3.3075)

Class B

8 0 . 0 1 e80.02 (3.1500+3.1504)

8 4 . 0 1 + 84.02 (3.3075 f 3 . 3 0 7 9 1Class C80.02 -80.03 (3.1504 + 3.1508)

84.02 G-84.03 (3.3079 4 3.3083)

Class D

80.03+80.04 (3.1508-3.1512)

8 4 . 0 3 + 84.04 (3.3083 f 3.3087)

Class E

80.04+80.05 (3.1512+3.15163

8 4 . 0 4 + 84.05 (3.3087 f 3.3091)

Cylinder bore “a”
Oversize

1st

8 0 . 2 0 +-80.21 ( 3 . 1 5 7 5 +3.15791

8 4 . 2 0 + 84.21 ( 3 . 3 1 5 0 f 3 . 3 1 5 4 )2nd80.40+80.41 (3.1654+3.1658)

8 4 . 4 0 + 84.41 (3.3229 f 3.3233)

3rd

80.60+80.61 (3.1733+3.1737)

8 4 . 6 0 + 8 4 . 6 1 ( 3 . 3 3 0 7 f 3 . 3 3 1 I)

Out-of-square between cylinder bore centreline

0.05 (0.00197)

and centreline of main bearings

Taper and out-of-round limit

Standard

0.01 (0.00041

Max

0.02 (0.0008)

Cylinder bore surface roughness

I

Cylinder bore grinding angle( 0 . 0 1 9 7 ~ 1 o-3 + 0.0394~10”)
9 0 ” + 1200

Front
Main bearing diameter “b”

o.5.10-3+l~10-3

63.663 G 63.673 (2.5064 + 2.5068)

Rear

63.673 -63.683 (2.5068 + 2.5072)

CentralWidth of rear main bearing support “c”

2 3 . 6 8 + 2 3 . 7 3 ( 0 . 9 3 2 3 + 0.9343)

Alfawiki.nl
01-37

IWay 7 9 8 3

ENGINE MAIN MECHANICAL UNIT

PISTONS, COMPRESSION RINGS AND PINS
Pistons

u
-a
m

Ia

Unit: mm (in)Engir

Inspection data

1200
Class A (Blua)79.96 +79.97 (3.1480 + 3.1484)

83.96 f 83.97 (3.3055 + 3.3059)

Class B (Pink)

79.97 f79.98 (3.1484+3.1488)

83.97 f 83.98 (3.3059 + 3.3063)

Class C (Green)

79.98+79.99 (3.1488-3.1492)

83.98 -83.99 (3.3063 + 3.3067)

Class 0 (Yellow)

79.99 + 80.00 (3.1492 e-3.14961

83.99 + 84.00 (3.3067 + 3.3071)

Class E (White)

80.00 G-80.01 (3.1496 +3.1500)

84.00-84.01 (3.3071 f3.3075)
84.15F84.17 (3.3130 t3.3138)

Standard
Piston diameter

1500

1350

“ a ” (I)

Oversize

1st80.15+80.17-(3.1X5+3.1563)

2nd80.35-80.37 (3.1634+3.1642)

84.35f84.37

3rd

80.55-80.57 (3.1713-3.1720)

84.55G64.57 (3.3287 -3.3296)(3.3209f3.3217)

1.525 + 1.550
0.0600+0.0610)
First compression ring groove height “c”(2)

1.525+1.545

1.525 + 1.545 (0.0600 + 0.0608)

0.0600+0.0608)

1.525e1.545
0.0600+0.0608)(3)
1.775+1.800
0.0699 + 0.0709)(2)

1.775 + 1.795
Second compression ring groove height “d”

0.0699+0.0707~

1.775 + I.796 (0.0699 + 0.0707)

1.775 + 1.795
0.0699-0.0707)(3)
4.015+4.w0(0.1581 -0.1590)

Oil scraper ring groove height “c”(2)

4.015 G-4.035
0.1581 +0.1589)

4.015 e-4.035 (0.1581 +0.1589)

4.015 e4.035(0.1581+ 0.1589:(3)

Pin seat bore “b”(1)

21.002+21.006 (0.8269+0.8270)

To be measured to right angle to the piston pin at 17 mm (0.6693 in) from piston skirt(2)

Borg0 Piston(3)

Mondial Piston

May 1983

m-38
Alfawiki.nl

ENGINE MAIN MECHANICAL UNIT

CONNECTING ROD AND CONNECTING ROD BEARINGS
Connecting rod

Unit: m m (in)Enginelnspecrion data

1200

I

1350

1500

I

Small end bush bore diameter “a”

21.007 + 21.015 (0.8270 f 0.8274)

Big end bore diamater “b”

52.696 + 53.708 (2.0746 + 2.1145)

Connecting rod bearings

Unit: mm (in)EngineInspection data--ea12ctclBlueI

1.831 + 1.835

1350

Red

1.827 + 1.831(0.0719+0.0721)(0.0720 + 0.0722)
Red

1.8?6 + 1.832(0.0719 + 0.0721)

1.966 + 1.962 (0.0770 + 0.0772)
Connecting rod

2.083 + 2.089 (0.0820 + 0.0822)

bearing thickness

2.210+2.216 (0.0870+0.0872)“a”

I

M a y 1983

2.337 + 2.343 (0.0920 + 0.0922)

4th

0 i-40
Alfawiki.nl

SO01.830 + 1.836

Blue(0.0721 +0.0722) T

Standard

I

ENGINE MAIN MECHANICAL UNITFLYWHEEL

Unit: mm (in)EngineInspection data

1200aRegriding dimensions (I)

1350

1500

24.0 + 24.2 (0.9449 + 0.9528)b

G 0.2 (0.0079)c> 20.95 (0.8248)

Parallelism of the driven plate contact face compared0.08 (0.0031)

with flywheel-to-crankshaft support face (as read at
a 100 mm radius)
Maximum out-of-flat of driven plate contact face0.02 (0.0008,
2.1 o-3

Surface roughness of driven plate contact face(1)

(0.0787~10”)

The depot of regrinding, dimension “b”, must be the same both on clutch driven plate contact face and on the face of theregister for the clutch cover, so that dimension “a” kept constant. Dimension “c” must not be lower than the specified limit.

Alfawiki.nl
01-41

May 1983

ENGINE MAIN MECHANICAL UNIT

Unit: mm (in)EngineInspection data

1200

I

Max. misalignment between the centrelines of the two

1350

1500

I

0.25 (0.0098,

pairs of crankpins and the journals centreline

I

Max. out-of-square between thrust ring face and0.03 (0.00121

main journals

I

Rear crankshaft bush diameter “b”

16.065 + 16.080 (0.6325 + 0.6331)

I

Fitment of rear crankshaft gear “U”

22’ + 26O

(distributor/oil pump drive)(.I )Re-cutting equally spaced on both shoulders

Thrust rings

Unit: mm (in)~~EngineInspection data

Thickness “a”

1200

*

1350

I

Standard

2.310 + 2.362 (0.0909 + 0.0930)

Oversize

2.437 t 2.489 (0.0959 + 0.0980)

1500

Main -bearings

Unit: mm (in)EngineInspection data

1200
Standard

Thickness “a”

I

1500

1.832 t 1.841 (0.0721 + 0.0724)

1stOversize

1350

1.959 f 1.968 (0.0771 + 0.0775)

2nd

2.086 t2.095 (0.0821 + 0.0825)

3rd

2.213 f 2.222 (0.0871 + 0.0875)

4th

2.34OG2.349 (0.0921 + 0.0925)

Alfawiki.nl
0 l-43

May 7983

ENGINE MAIN MECHANICAL UNITCAMSHAFT SUPPORT, CAMSHAFT AND TAPPET BUCKET
Camshaft support

Unit: mm (in)EngineInspection data

1350

1200

1500

1

Front

35.015 + 35.040 (I 3786 + 1.3795)

Central46.500+46.525 (1.8307+1.8317)

Rear

47.000 G-47.025 (1.8504+ 1.8514)

Bore of camshaft journalbearing diameter “a”

36.000 e36.025 (1.4173+ 1.4183)

Seat tappet bucket diameter “b”

Camshaft

Front

CentralRear

Unit: mm (in)I

Inspection datat

Enaine1200

IntakeCam height

1350

1500

I

8 . 5 (0.3346)

ExhaustCamshaft journal diameter

I

Front “a”

34.940 + 34.956 (I .3756 + 1.3762)

Central “b”

46.440 e46.456 (1.8283- 1.8290)

Rear “c”

46.940t46.956 (1.8480+ 1.8487)

Tappet bucket

Unit: mm (in)Inspection data

Engine1200

35.973 + 35.989 (1.4163 + 1.4169)

Diameter “a”

May 1 9 8 3

1350

01-44
Alfawiki.nl

1500

ENGINE MAIN MECHANICAL UNITCYLINDER HEAD, VALVES AND SPRINGS
Cylinder head

Unit: mm (in)EngineInspection data

1200

1350

I

1500

I

13.OOOf13.018 (0.5118+00.5125)

Valve guide seat diameter “d”
Standard

13.050 f 13.068 (0.5138- 0.5145)

Spare

13.064f13.082

Valve guide 0.0. “a”(0.5143+0.5150)

8.013f8.031 (0.3155+0.3162)

Diameter of valve guide bore “b”

9.8 + 10 (0.3858 4 0.3937)

Valve guide protrusion “e”
Min. cylinder head thickness after resurfacing “c”

77.25 (3.04131 (1)Max. error of parallelism between head surfaces

0.05 (0.00201

Max. out of flat

0.03 (0.0012)
1.6.10-3

Surface roughness(1)(0.0630.10”3)..

Resurfacing of cylinder head with hemispherical combustion chamber must be done on both banks of the same engine

Valves

Unit: mm (in)Engine
1200

1350

1

Intake7.985t8.000 (0.3144-0.3150)

Exhaust7.968+77.983 (0.3137 +0.3143)

Intake38.00 + 38.20 (1.4961 + 1.5040)

1500

Valve stem diameter “a”

Valve head diameter “b”
IExhaust33.00+ 33.20 (1.2992 + 1.3071),

oi-45
Alfawiki.nl

May 1983

ENGINE MAIN MECHANICAL UNIT

S p r i n g s

Engine1200
Length of valve spring withI

15w

25.25 (0.9941)

Inner spring

23.25 (0.9154)

Outer spring

425.32 + 452.76 (43-4 + 46.2) (95.68 + 101.85)

Inner spring

194.53+208.25 (19.85 t21.25) (43.76f46.85)

N (kg) (lb)length “a”

1350

Outer spring
mm (in)valve open “a”

Spring rating at

I

VALVE SEAT RECUTTING

recutting
Unit: mm (in)Engine1350

IntakeReference diametere “6 R ”
Exhaust2.9 (0.1142)

Cut limit of valve seat top surface “a”

Cut limit of valve seat mating

Intake1.07 f 1.37 (0.9421 + 0.0539)

surface “b”

Exhaust1.26 f 1.56 (0.0496 + 0.6614)

Valve seat top surface limit angle “a’

I

-.

1200

9 0 ” + 9o” 30

Valve seat mating surface limit angle “p’Valve seat inner face limit

Intake500

angle “y’Exhaust300

May 1983

01-46
Alfawiki.nl

1500

ENGINE MAIN MECHANICAL UNIT

FITMENT PLAYS OR INTERFERENCE FITS
Unit: mm (in)EngineInspection data

Cylinder bore/piston play1200

1 3 5 0I

Standard

0.03 4 0.05 (0.0012 + 0.0020)

Oversize

0.03 + 0.06 (0.0012 + 0.0024)-First compression
ring

0.035 + 0.067(0.0014 + 0.0026)

1500

I

0.035 + 0.067
0.035 + 0.067

2,(0.0014 f 0.0026)(0.0014 + 0.0026 \SecondRing/groove end float

compression ring

Oil scraperring

0.035 + 0.067(0.0074 + 0.0026)(;;~4;;~;2,,l

10.036 + 0.067(0.0014 + 0.0026)(f;;4y(;;26)@’**

0.025 + 0.057(opdg;;*E4)(1)0.025 + 0.057(0.0010 + 0.00221

0.025 4 0.057(0.0010 + 0.0022)

p)( 0 . 0 0 1 0 + 0.0022J
Maximum for

0.1 (0.0039)

each ring
0.007 + 0.019 (0.0003 + 0.0007)

Pin/small end play

Pin/seat bore playStandard

0.002 f 0.010 (0.0001 + O.OOO4)

Maximum0 . 0 1 8 (O.OOO7)

Front and rear

0.024 + 0.065 (0.0009 + 0.00261

Main bearing to-Central0.034 + 0.075 (0.0013 + 0.0030)

journal play

Maximum (withbearing in seat)0.1 (0.0039)
Red/Blue

Red/Blue
Connecting rod bsaringto-crankpin playStandard

0.034+ 0.662

0.032 + 0.064(0.0013 + 0.0024)(0.0013 + 0.0025)

Maximum (with

0.090 (0.0035)

bearing in seat)

Crankshaft end float

End float of big end

StandardMax

camshaft and bearing(0.0022 + 0.0098)

0.35 (0.0138)

Max

bearing

Radial clearance between

0.056 + 0.25

Standard

0.2 40.392 (0.0079 + 0.0164)
0.45 (0.0177)

Front

0.059 + 0.100 (0.0023 + 0.0039)

Central0.044 + 0.085 (0.0017 + 0.0033)

Rear

0.w + 0.085 (0.0017 + 0.0033)

0.10 + 0.33 (0.0039 + 0.0130)

Camshaft end float

0.011 + 0.052 (0.0004 + 0.0020)
0.1 (0.0039)

01-47
Alfawiki.nl

May 1983

ENGINE MAIN MECHANICAL UNIT

EngineInspection data

1350

1200

0.013 + 0.046 (0.0005 + 0.0018)

Standard

0.07 (0.0027)

Max

Valve stem-to
guide play0 . 0 3 0 + 0.063 (0.0012 + 0.0025)

Standard

0 . 0 9 (0.0035)

Max

Valve guide-to-seatinterference fit

I

1500

I

0 . 0 3 2 + 0.068 (0.0013 + 0.0027)

Standard

0 . 0 4 6 + 0.082 (0.0018 + 0.0032)

Spare
I

(I)

Borg0 Piston(2)

Mondial Piston

TEMPERATURES
TemperaturePart

150°C (302°F)

Oil pump/distributor drive gear for shrinking onto the crankshaft

GENERAL SPECIFICATIONSFLUIDS AND LUBRICANTS
Q-KY

Application

Engine oil when full

TYPE

OIL

kg (lb)AGIP SIN-T 2000 lOW50

3.15 (6.94)

Std.rd 3631-69352
IP Super Motor Oil 1 OW50

Filter

0.45 (0.99)

Std.rd 3631-69353
3.6 (7.94)

Engine oil and filter routine maintenance0 . 2 5 0 (0.55) (2)into each chest

Camshaft supports chests (I)(1)

Applicable only in the case of supports dismantling(2)This quantity relates to chests supply, completely drain, up to drain holes level

SEALING COMPOUNDS

Application

Joint face, cylinder block-to41 sumpDatwminationType

CEMENT

DOW CORNING: Silastick 732 RTV

Q.w-

Std. no. 3522-00640

Plugs of water galleries in cylinder
block and head

(I 1

CEMENT

LOCTITE 601 (green)Std. no. 3524-00011

Before applying LOCTITE, remove all traces of old Loctite and degrease threads using trichlorethylene or chlorothene

May 1983

01-48
Alfawiki.nl--

ENGINE MAIN MECHAN1CA.L UNIT

(1)

After having heated engine until intervention of radiator cooling electric fan, on cold engine, loosen, oil and tighten the six screw
securing heat to base by following the order shown in figure(1)

In the event of in-car tightening of head nuts with the aid of the extension A.5.0198 to be applied as shown, the torquespecifications are:torque spanner having a 300 mm (I 1.84 in) lever arm

torque spanner having a 400 mm (15.75 in) lever arm

N+m

57 f 62kg.m

5.8 + 6.3

Ib.ft

41.9 + 45.6N*m

6 2 - 67kg.m

6.3+ 6.8

Ib.ft

45.6 + 49.2

TROUBLE DIAGNOSIS AND CORRECTIONSCorrective action

Probable cause

Condition

I. Noisy engine
Replace thrust bearing

Knocking of crankshaft andbearing

Excessive crankshaft end play

Piston and connecting rodl

Fit wrong

Adjustl

Pin float

Adjustl

Excessive valve play

AdjustlTappet buckets wrong fit

Replacel

Weakened valve spring

Replaceknocking

Camshaft knocking

Water pump knocking

Improper shaft end play

Replace water pump assembly

I I. Other mechanical trouble
Seized valve seat

May 1983lImproper valve clearance

Replace and adjustl

Weakened valve spring

Replace01-50
Alfawiki.nl

ENGINE MAIN MECHANICAL UNIT

Condition

Excessive!y worn cylinderand piston

Faulty connecting rod

Probable cause

Corrective actionlWorn fit surfaces

Adjust or replacelPoor oil quality

User proper oillDirty air cleaner

Replace filterl

Too rich misture

Adjust or replace carburettorlShortage of engine oil

Add or replace oil
Check oil level on daily basislPoor engine oil quality

Use proper oillWorn or out-of-round crankpin

Grind or replacelWrong connecting rod bearing-to-

Replacecrankpin coupling

Faulty crankshaft bearinglShortage of engine oil

Add or replace oil
Check oil level on daily basislPoor engine oil quality

Use proper oillWorn or out-of-round crankshaft

Grind or replace

journallWrong connecting rod bearing-to-

Replacecrankpin coupling

Belt tensioner knocking

Wrong belt stretching

Restore stretch

Faulty timed

Wear of oil pump control gear

ReplacelLoosen engine oil drain plug

Tightenl

Oil leakage from sump gasket

Replace gasketl

Oil leakage from camshaft

Replace gasket

I I I. Lubrication
oil leakage

supports gasket
Oil leakage from engine gaskets
and seal rings

Replace gasketl

Oil leakage from oil filter gasket

Screw in filterlDirty pression regulator valve

Clean

l

Poor-engine oil quality

ReplacelDecreased of pressure

Alfawiki.nl

ENGINE MAIN MECHANICAL UNIT

SPECIAL SE.RVICE TOOLS
Tool number

Tool nama

Refer topaw

A.2.0195

Base for cylinder head support

01-17
01-19
01-24

A.2.0226

Yoke for cylinder head support

01-17
01-19
01-24

A.2.0378

Tool for locking the flywheel

01-15

A-3.01 0316

Yoke to remove and refit valves

01-17
01-24

A.3.0311

Puller of valve guides

01-18

A.3.0312

Driver of intake valve guides

01-18

A.3.0314

Driver of timing gear cover Seal

01-24

Support for removing and fitting

01-17
01-24

A.3.0321

valves

A.3.0324

Lever for removing and refitting
the valves

May 1983

01-52

Alfawiki.nl

01-17
01-24

Alfawiki.nl

FUEL SYSTEM

AIR CLEANER

6 Flame trap
7 Max. blow-by hose
8 Air cleaner body
9 Spring clip
10 Nut1 Cover
2 Cartridge
3 Cool air intake sleeve
4 Hot air intake sleeve
5 Min. blow-by hose

REMOVAL

5. if necessary, remove flamefrom within; if necessary, replace it.

Remove air

trap
6
hose@.

2. Remove flame trap from blowby hose, wash both with specificproducts, then dry them with com-0

cleaner body withcarriage cartridge as follows:
five
I. U n f a s t e nthespringclips @ that secure cover @ to air
c l e a n e r b o d y @; r e m o v e cover.
Remove cartridge 0.
2.
air
intakecoo I
Disconnect
3.
sleeve 3 as well as hot air intake
sleeve t.4
9.
4. Disconnect blow-by hoses 0
ad 0.

May 1983

from

max.

blow-by6.
Loosen
the
four
nuts
@
securing air cleaner body to carburetor; remove air cleaner body.

CHECKS ANDIbJSPECTIONS

pressed air. Install flame trap into
blow-by hose near oil filler.

INSTALLATION
Fit air cleaner, blow-by hoses and air

1. Thoroughly clean cartridge byintake sleeves back together following removal procedure in reverse

blowing low pressure compressed air

sequence.

04-2
Alfawiki.nl

FUEL SYSTEM

IDLE COMPENSATOR
DEsCRlPTlON
The idle compensator actually con-CHECKS ANDI N S P E C T I O N S ‘-

3. When thermometer shows specified temperature, verify thermostat

HOT AIR INTAKE CLOSINGTEMPERATURE

intake.

sists of a thermostat 0 that checks
the temperature of the engine intake
air and as a consequence either
opens or closes the throttle valve @located in the air cleaner’s intake
duct. The throttle valve mixes thecool air coming from outside withthat coming from the hot air intake,located on the exhaust gas pipes

1.

Warm up engine bringing it up tocommands, i.e. closing of throttle
valve thus fully closing the cool air

Cool air intake closing temperature
28 + 32% (82.4 + 89B’F)

steady running.
2. Turn engine off.
3.
Remove air cleaner cover as wellas cartridge.
4 . Inset-t a thermometer next to the

THERMOSTATREPLACEMENT
1.

Remove air cleaner from engine

under the left side cylinder head, or

thermostat inside the air cleaner.

it works either fully closed or fully(Refer to: Air Cleaner) _5. When thermometer shows speci-

open.

2.

fied temperature, verify thermostat

to air cleaner body.

Remove rivets securing air intake

commands, i.e. opening of throttle

3. Replace air intake as well as

valve thus fully closing the hot air

thermostat.

intake.

4. Connect air intake back to air

Hot air intake closing temperaturecleaner body by riveting it.
5. Fit air cleaner back to engine

33+ 37°C (91.4+ 98.6”F)(refer to: Air Cleaner).

COOL AIR INTAKE CLOSINGTEMPERATURE
1. With cold engine, remove air

1 Thermostat
2 Hot air intake Sleevecleaner cover as well as cartridge.

3 Cool air intake SieW@
4 Throttle valve
5 Air cleaner

thermostat inside the air cleaner.

2.

Insert a thermometer next to the

FUEL PUMPCHECKS AND
INSPECTIONS

reading is within specified values atrelevant engine rpm.

,

FUEL PUMP PRESSUREFISPA P u m p
17.7 G29.4 KPa

CAUTION:(0.177 + 0.294 bar,

When disconnecting fuel system

0.18 f 0.30 kg/cm2,
2.56 + 4.27 psi)

hoses, use a container with safety lid
to collect the petrol that is left overin the hoses.

at 5000 rpm

SAVARA Pump
17.7 + 29.4 KPa(0.177 + 0.294 bar,at 6000 r-pm

FUEL PUMP DELIVERYPRESSURE

0.18 + 0.30 kg/cm2 ,2.56 + 4.27 psi)

Disconnect fuel delivery hose
1.
from pump and from carburetor.
2. Replace same with a T-shaped
hose equipped with cutoff cocks.

If delivery pressure is not within
5.
specified values, replace the pump.
6. Disconnect T-shaped hose andrestore normal operating conditions.

3. Connect a pressure gauge to thehose’s free end.
4. Start engine up and with zerodelivery (cock on carburetor side isclosed), while keeping gauge at sameheight as pump, verify that gauge

Alfawiki.nl
04-3

May 1983

FUEL SYSTEMCARBURETORSW E B E R TWIN CARBURETOR(Except Switzerland, Sweden, Australia.)*q- 32 DIR 51A/250

for 1200 model- 32 DIR 81A/250

for 1350 model- 32 DIR 71A/250

for 1500 model

For 32 DIR 8IA/250 and 32 DIR i’7pR50 only

May 1983

04-4
Alfawiki.nl

FUEL SYSTEM

1 Carburetor cover including:
2 -Stud
3 Starting throttle
4 Starting securing screw
5 Starting shaft
6 Lever for starting shaft
7 Corrugated washer
8 Starting shaft lever securing nut
9 Starting control tie rod
10 Tie rod split pin
11 Tie rod washer
12 Dust cover cap
13 Dust cover plate
14 Carburetor cover gasket
15 Primary auxiliary Venturi
15 Secondary auxiliary Venturi
16 Pump delivery valve
17 Pump jet
18 Pump jet gasket
19 Primary corrector jet
19 Secondary corrector jet
20 Primary emulsioning tube
20 Secondary emulsioning tube
21 Carburetor body
22 Secondary idling jet
23 Secondary idling jet carrier
24 Shim adjustment washer
25 Lever return spring
26 Fast idling regulation lever together.with:
2 7 - Nut
28 - Adjustment screw
29 Bush for fast idling regulation lever
30 Lever securing screw
31 Starting control lever together with:
32 Cable securing screw
33 Bush for starting control lever
34 Shaft securing nut

72 Bush for sealed idling cap
35 Safety washer
73 Adjustment screw cap
36 Spring for loosen lever
74 Idling mixture adjustment screw
37 Secondary shaft securing nut
75 Sealed idling cap
38 Spring washer
76 Pump cover
39 Shim adjustment washer
77 Pump cover securing screw
40 Secondary throttle control lever
78 Pump diaphragm
41 Sheath securing screw
79 Primary shaft return spring
42 Cap for secondar/ idling hole
80 Pump filling spring
43 Throttle control lever
81 Throttles securing screw
44 Shim82 Primary main shaft
45 Loosen lever
82 Oversize primary main shaft
46 Bush for loosen lever
83 * Idling cut-off together with:47 Secondary throttle adjustment screw
84 - Gasket
48 Stop lever together with:85 Conic seal needle
49 - Bush for sealed idling cap
86 Bush50 - Spring
87 - Primary idling jet
51 Adjustment screw
88 Secondary main shaft
52 Sealed cap for lever adjustment screw
88 Oversize secondary main shaft
53 Primary shaft return spring
89 Throttle valve
54 Shim adjustment washer
55 Spring for adjustment screw of corrector idling 90 Secondary shaft return spring
56 Adjustment screw for idling mixture corrector 91 Closing screw for pump discharge space
57 Gasket for de-flood device
92 Primary main jet
58 Securing screw for de-flood device
92 Secondary main jet
59 Economiser body including:
93 Float
60 Cap for adjustment screw
94 Float fulcrum pin
61 Spring washer
95 Needle valve
96 Needle valve gasket
62 - Diaphragm adjustment screw
63 - Device box
97 Filter inspection cap
64 r Spring for diaphragm
98 Filter
65 - Diaphragm
99 Tie rod spring
66 - Device cover
100 *Cut-off cbmp
67 - Cover securing screw
101 Economiser body control tie rod
102 Eonomiser control lever
68 Retaining ring
69 Retaining ring
103 Washer for cover securing screw
70 Washer for economiser body control lever
104 Carburetor cover securing screw
71 Economiser control lever* Only for 32 DIR 8 1 A/250 and 32 Dl R 7 I A/250

CHECKS AND INSPECTIONS
B e f o r e r e m o v i n g carburetor f r o mengine, perform following checking
and adjusting operations:distance from float chamber cover with gasket @ firmly in qlace - iswithin specified “Qw” value.

--

Float leveling
Check f l o a t p o s i t i o n a s f o l l o w s :1.

(I) Remove the whole air filter (seeA i r C l e a n e r ) a n d disconnet t h e“QW” Dimension
6.75 + 7.25 mm (0.266 + 0.285 in)(6) T o correct “QW” dimension,
suitably bend float stopper 0.

gasoline feeding hose from float

chamber cover.

2. Needle valve tightness
Needle valve tightness is checked bymeans of a vacuum gauge. Keep float
chamber cover turned over and inhorizontal position and then proceed
as follows:(1) Connect gauge’s plastic hose @to petrol delivery pipe 0 on float
chamber cover.
(2) Load vacuum gauge air pump byacting on cam @ ; as a consequence,(2) Remove float chamber cover 40,

mercury will go up the graduateddata, that no deformation is present

scale.
(3) Wait for about then. seconds,
during which mercury will have toand that it freely rotates on its pin.
(4) If checked parts are defective,

remain steady, contraywise, replaceneedle valve.

(3) Make sure float @ is of theweight prescribed in the technicalreplace them.

(5) Keep float chamber cover @ in
vertical position so as that float is
sli&tly in touch on needle valve,w h i c h i s o f the s p r i n g - b o d y t y p e .

Using a gauge pin, check if float

1 Float stopper
2 Float
3 Gasket

4 Float chamber
cuver

Alfawiki.nl
04-5

May 7983

FUEL SYSTEM(3) In case the verified dimension“GW,” is not within specified value,

1 Petrol delivery
Piperemove cap and operate on travel(3) If “GW2” dimension is notwithin specified value,.loosen the nut
and operate on control lever adjust-adjustment

screw of economiser
diaphragm (see following figure).
(4) At the end of adjustment

ment screw of throttle valve (seeoperation, refit cap 0.

erations, tighten the nut.

next figure).
(4) Having completed adjusting op-

2 Connecting hose
3 Cam

Remove carburetor from car in oderto. carry out the following checks(refer to: Group 01 Engine Disas-1

Nutsembly - Engine Unit).
2 Economiser body

1. Choke opening (air valve) by
economiser
choke 0 opening
To adjust

1 Capproceed as follows:(1) Fully engage choke by moving

2. Throttle valve opening (gasvalve) with choke inserted.

(1) Secure carburetor to support
C.4.0103 (fitted with gasket) of thestarting control lever @ as shown in
relevant figure and at the same time
act on the economiser control
lever pushing it all the way back.

To adjust throttle valve @ opening

p u m p t e s t i n s t r u m e n t C.4.0101.
(2) Supply the carburetor with(2) Insert gauged point between
choke edge and duct making suredimension “GWl ” is within specified
value.

“GW,” Dimension
5.5 + 6.5 mm (0216 + 0.256 in)

3. Accelerator pump adjustment
Adjust accelerator pump as follows:

proceed as follows:(1) Fully engage choke by moving

petrol by connecting it to the tool’s

starting control lever @ as shown inreservoir.

relevant figure.
(2)-- Insert a gauged wire between(3) Set the graduated measuring
tubes C.4.0105 under the foreseen

throttle valve edge and first bodyduct making sure dimension “G,,,,2”

exhaust pipe -on support itself.
(4) Carry out twenty strokes corre-is within specified value.

sponding to as many complete
openings and closings of throttle“GW2” Dimension
0.9 + 1 mm (0.035 + 0.039 in)valve, operating on control lever 0.
(5) Check if volume of petrol
collected in the measuring tube
corresponds to specified “VW” value.

When pumping, briefly stop both in
throttle valve fully open and fully
closed positions.
Volume of petrol “VW” corresponding to 20 strokes of pump control
lever:“VW ” = 17 + 20 -cm3
(1.03 f 1.22 cu.inJ( 6 ) If “VW” value is not within
specified limit, check diaphragm ofacceleration pump and the pumpjet.

1 Ckoke air valve
2 Ckoke control leverMay 1983

1 Throttle valve
2 Srarting confrol lever

04-6
Alfawiki.nl

FUEL SYSTEM

WEBER TWIN CARBURETOR
For Switzerland, Sweden, Australia.
Carry out checks and ajustments following the procedures performed for the WEBER twin carburetors, previously described and referring to the tables provided in “Technical Data and Specifications ” relevant to check dimensions.

WEBER TWIN CARBURETOR - EXPLODED VIEW
(it will be provided in the next issue)

F

May 1983

04-8
Alfawiki.nl

FUEL SYSTEM

KEY(it will be provided in the next issue)

Alfawiki.nl
04-9

May 1983

FUEL SYSTEM

58
59
60
61
62
63
64
65

Central Venturi securing screw
Sheath securing screw
Air valve control iniermediate lever
Air valve control return leverBush
Air valve automatic opening control lever

66 Sheath support
67 Washer
68 Support securing screw
69 Bush70 Central Venturi
71 Economisier gasket

78

Securing nut

72 Economisier assy

79 Stud

73 Air valve spring
74 Idling cut-off
75 Air valve
76 Air valve control tie rod
77 Air valve shaft assy
Air valve securing screw

WasherCHECKS AND ADJUSTMENTS(6) To correct “A” dimension, re-Before removing carburetor fromplace washer located under needle

engine, carryvalve of properly bend float stopper.
(7) Reassembly carburetor cover, let

o u t the following

checks.
1. Check of float chamber hydraulic level
For float chamber hydraulic level
check, operate as follows:

the engine executes a few rotations
then repeat check operations until
the prescribed dimension is obtained.
2.

Needle valve tightness
To check needle valve tightness, seeRemove the whole air filter (see:Weber twin carburetor: Checks andAir cleaner) and disconnect the fuelfeeding hose from float chamber
cover.

Inspections - Needle Valve Tightness.

(I)(2) Remove float chamber cover(3) Make sure that float is of theprescribed weight indicated in theTechnical Data, that no deformation
is present and that it freely rotates

1 Choke (air valve)
2 Starting control leveraround its pin.
(4) If checked parts are defective,
replace them.
(5) Verify that value of distance“A” between fuel surface and float(3) In case the verified dimension“GS. ” is not within specified valve

chamber cover surface with assembled gasket, is within specified value.

loosen lock-nut and operate on
diaphragm travel adjustment nut ofe c o n o m i s e r b o d y 0 (see nextA = 21 + 23 mm (0.83 + 0.91 in)figure).
(4) At end of adjustment, tighten
lock-nut.
Remove carburetor from car in orderto carry out the following checks(see: Group 01 - Engine Disassemble- Engine Unit).
1. Choke opening by economiser.
To adjust choke @ opening proceed
as follows:(1) Fully engage choke by moving
starting control lever @ as shown in
relevant figure and at the sametime act on the economiser controll e v e r pushing it all the way back.
(2) Insert gauged point between
choke edge and duct making sureti;;nsion “GS, ” is within specified“GS,” Dimension
4.5 + 4.75 mm (0.177 + 0.187 in)Alfawiki.nl

04-11

1 Economiser bodyMay 1983

FUEL SYSTEM

2. Throttle valve opening (gasvalve) with volet inserted.
To adjust throttle valve @ opening
proceed as folltiws:(1) Fully engage choke as shown infigure.
(2) Insert a gauged wire between
throttle valve edge and the first bodyduct making sure dimension “GS2”

3. Accelerator pump adjustment
To check and adjust accelerator
pump refer to: Weber Twin Carburetor: Checks and Inspections - Accelerator Pump).
Volume of petrol “VS” corresponding to 20 strokes of pump control
lever:

19 + 23.5 Narn
(1.9 f 2.4 k g - m
13.74 + 17.35 ft.lb)

OVERHAULING
Carburetor should be overhauled
only if encountered defects cannot
be corrected neither through opera-

is within specified value.
“GQ ” Dimension
0.9 + 1 mm (0.035 + 0.039 in)@ : Tightening TorqueCarburetor retaining nuts

Twin carburetor Solex C32 EIES 45
1 s t . b a r r e l cm38+ 10(0.49 + 0.61)(in)
2 n d b a r r e l cm3
Total

s+ 10

tions. described in Checks and Inspections above nor through cleaning offuel filter, float chamber or jets.
When overhauling, keep following

(in)
cm3

(0.49-e 0.61)
16+20

items in mind:(in)(0.97 + 1.22)

a. Remove carburetor from engine
and disassemble it on bench.

Twin carburetor Solex C32 EIES 44
1 s t b a r r e l cm3

8+ 10

(in)
2 n d b a r r e l cm3(0.49 + 0.61)

thoroughly cleaned.

9+11(0.55 + 0.67)

b.

Total

(in)
cm3

All disassembled parts must be

17,: 21

most delicate parts such as
needle valve, throttle valve(1.04 + 1.28)(in)shafts, diaphragms, accelerator
pump and fuel filter.

Twin carburetor Solex C32 EIES 43
1 s t b a r r e l cm3

8+10(0.49 + 0.61)(in)
2 n d b a r r e l cm3
Total
1 Throttle valve
2 Starting control lever( 3 ) I f “GS2” dimension is notwithin specified valve loose nut andoperate on control lever adjustment
screw of throttle valve (see next

10+12
(0.61 + 0.77)

(in)
cm’

18+22
(1.10+1.34)(in)

Fit carburetor back to engine (refer
to Group 01 - Engine Assembly Engine Unit) tightening relevant.

(4) Having completed adjusting op-

nuts according to specified torqueand performing idle adjustment (refer to: Group 00 - Engine Mainte-erations, tighten the nut.

nance).

figure) .

Thoroughly and carefully checkC.

d.

Replace defective parts onlywith original ones and always
replace a I I gaskets.
Use special care in cleaning jets
so as not to damage relevant
ratings; if possible blow themwith a jet of compressed air.

CAUTION:
Once carburetor has been overhauled, it is advisable to perform
adjustments described in preceding
paragraph “Checks and Inspections”.

ACCELERATOR CABLE ADJUSTMENT
1.

Verify that throttle valve control
cable can freely slide inside sheath.

3. If required, adjust as follows:

2. Verify that clearance between
clevis slot @ and pin @ on
carburetor throttle valve opening
shaft is within specified G1 limit.

lock nut 0.
(2) Turn screw

Clevis slot to pin clearance
G, = 1 mm (0.039 in)(1) Loosen adjusting screw’s @@ till specified

clearance is reached.
(3) Tighten,lock nut.

CAUTION:To easy adjustment buck action of
return spring by manually partially
opening the throttle valve.

1 Adjusting screw
2 Lock nut

May 1983

04-12
Alfawiki.nl

3 Pin
4 Clevis

FUEL SYSTEMREMOVAL

FUEL TANK FLOATWARNING:

Before replacing any fuel line part,
carefully follow below instructions:a. Make sure shop is equipped withsuitable safety equipment.
b. Disconnect battery ground cable.
c. Place petrol drained from tankinto a suitable container equipped with a safety lid.

Remove float of fuel tank operating

Remove check valve from supporting

as follows:

clip on fuel tank.

1. S u p p o r t t a n k b y m e a n s o fcolumn lift and loosen screws securing the two clamps supportingtank to body.
2. Slightly lower column lift SO a s
to gain access to float located ontank upper side.
3. Disconnect from pipe union, on
float, the fuel delivery pipe @ andremove electric connections @ of
warning lamp and fuel level indicator.
4. Loosen the six screws securing

CHECKS AND
INSPECTIONS

1. Remove filler cap from filler
hose and take out all petrol fromtank with the help of a suitableclamp

1 Tank pipe side union
2 Outer side union

float 0 to tank and remove float.

FUEL TANK UNIT

w-w.
2.
LoosenCHECK VALVE

T@ and @

connecting fuel filling sleeve to tankand connecting pipe to feeding hose.
3.
Loosen and remove screw secur-

A

N

K

Check thank for flaws or any evid e n c e o f warpage; i f n e c e s s a r y ,replace it.

i n g g r o u n d c a b l e @) t o b o d y .

HOSES
Check hoses and make sure they are
not porous and show no evidence ofabnormal wear; replace hoses that are
not flawless.

PIPES
Check and make sure pipes are notclogged, oxidized or dented.

CHECK VALVE
1. Blow in an air into the valve
1 Float securing screw
2 Electric connections
3 Fuel delivery pipe
I

Ground cable

3 Clamplocated of fuel pipe side.
In doing so, one should notice someresistance and some air should comeout of the outer union.

2 Clamp

FUEL LINE

2. Now blow in an air jet into thevalve from outer side union.
The air jet should go right through4. support tank by means ofcolumn lift and loosen screws secur-

CAUTION:
Disconnect feedings pipes only if
absolutely necessary.

and come out of the fuel pipe side
union, without encountering any

ing the clamps supporting tankto body.
5. Slowly lower column lift so as toresistance.
3. If check valve does not comply
with above, replace it.

gain access to tank upper side.
6. Remove from float the electric

1. Remove filler cap and take out
all petrol from tank with the help ofconnections of warning lamp andindicator of fuel level, then, operat-a suitable pump.

2. R e m o v e

ing from tank rear side, remove
breather pipe together with retaining

clamps from hose
unions; plug all hoses and pipes to

Carefully fit all fuel line parts backprevent dust or dirt from going

together following removal opera-

in during disassembly operations.
3.
Free pipes from relevant holding
clamps on underbody.

tions in reverse sequence and paying

valve.
7. Remove tank and, if required
disassemble it.

Alfawiki.nl
04-15

INSTALLATION

special attention to below instructions.

May 1983

FUEL SYSTEMCAUTION:a. Carefully fit clamps back to line
unions without tightening them
too much to avoid damaging thehoses.
b. Fit fuel delivery pipes securely
to relevant holding clamps onunderbody, making sure samec.

surfaces.
Do not bend

or

twist

pipes

2. Do not twist or crush breather
hoses after fitting; fasten them withduring installation.
d. Start engine up and make surethere are no leaks from connec-

relevant clamps.

FLOAT
-

tions.

*

Be sure to replace tne gasket eachtime float is fitted back into tank.

FUEL TANK UNIT
1.

Fit tank back into car following

CHECK VALVE

are properly fastened.
Failure to follow this caution

removal operations in reverse se-

Be sure to fit check valve according

will result in damage to pipe

quence.

to proper working direction.

EXHAUST SYSTEM

1 Gasket

62 Nut

7 Front clamp

3 Hot air intake
4 Front manifolds
5 Nuts8 Central muffler
9 Support ring
IO B o l t

CHECKS AND
INSPECTIONS

Bolt

11 Rear clamp
12 Rear muffler
13 Support ring
14 Buffer
15 Nut3. Check buffer on exhaust pipe

allow separate removal of theexhaust system’s single compo-

1. C h e c k m u f f l e r s a n d e x h a u s t

end.
4. Check surface of hot air intake
making sure there are no warps or

pipes making sure they are not in any

dents that could impair normal air

way damaged or cracked and show
no evidence of corrosion; contrary-flow.

wise, replace them.
2. Thoroughly check supports ring

REMOVALand do not hesitate to replace thema.

if they are cracked, porous or worn.

May 1983

Instructions hereafter describedhave been compiled so as t o

04-16
Alfawiki.nl

nents.
b. Consequently, removal procedure may be changed dependingon the operation’s purpose.
c. When removing the entire ex-haust system, it is advisable toget someone to help you withit.

FUEL SYSTEMMANIFOLDS AND
MUFFLERS

3. Remove central muffler as follows:

Referring to the figure on page
04-16, proceed with removal as(1) Remove rear muffler (refer tofollows:
1.
Raise car on lift.
2.
Remove rear muffler as follows:

item 2 above).

(1) Loosen clamp 0 connecting
central element with rear one andrelease this one from support retaining rings @ .
(2) With a suitable hammer, lightly
and repeatedly strike all around the
muffler pipes connection area andthen alternately turn muffler @clockwise and counterclockwise so
as to make separation easier.

(2) Loosen clamps connecting central element with front one anddisconnect central element fromsupport retaining rings @.
(3) With a suitable hammer, lightly
and repeatedly strike all around thepipes connection area and thenalternately turn muffler @ clockwise and counterclockwise so as tomake separation easier.
(4) If necessary, use a plastic hammer and lightly strike the muffler inthe direction of removal till central
muffler comes off front manifolds.

4. Remove front manifolds as follows:(1) Loosen clamp connecting front
element to central one and move itfrom its seat.
(2) Loosen the nut securing hot air
intake bracket to cylinder head andwithdraw the warm air intake sleeve.
(3) Loosen nut @ securing manif o l d .flanges t o c y l i n d e r h e a d s .
(4) Remove manifolds @.

1
2
3

sequence and paying close attention
to below instructions:
Always fit new gaskets between
manifbld flanges and cylinder
heads.
b.

HOT AIR INTAKE
1. Raise car on lift.
2 . W i t h d r a w s l e e v e @ from air
intake @ _3. Loosen bolt @ connecting air
intake to manifolds and then remove

Clamp
Bolt
Nut

Fit single parts back together following removal operations in reverse

SUPPORT RINGS
Verify integrity of support rings andreplace them if necessary.‘

4
5
6

INSTALLATIONa.

(3) If necessary, use a plastic hammer and lightly strike the muffler inthe direction of removal till rear
muffler comes off the central muffler.

SleeveHot air intake
Screw

C.

Having completed installation,
check and make sure that
support rings move freely andare free of undue stress; checkbrackets making sure they havebeen properly secured.
While engine is running check all
pipe connections for gas leaks
and the whole exhaust system
for unusual noises.

clamp @ thus separating the hot air
intake half shells.
4. Loosen nut @ securing support
lever to left head and remove hot air
intake.

Alfawiki.nl
04-17

Mav 1983

FUEL SYSTEMSERVICE DATA AND SPECIFICATIONSTECHNICAL DATA-.

FUEL PUMP-- I

ALFA ROMEOType

Mechanical

FUEL TANK
Overall capacity

Model
Brand

part No.

1200

1350

1500

305.00305.02305.04510.355

FISPA

531.354

SAVARA

960.084.00

542.140SAVARA

906.130.00

I

50

Imp. Gall 11
ReserveI

6.5

Imp. Gall

1.434041 .Ol 4059.01

GENERAL SPECIFICATIONSFLUIDS AND LUBRICANTS

Application

Spacer on accelerator pedal rotation pin

Denomination

TYPO

GREASEAGIP FI Grease 15
Standard 3671-69810

May 1983

04-18
Alfawiki.nl

Q.ty

FUEL SYSTEM$ .6s ‘5
T-r+
1
1

M a y 1983

Alfawiki.nl

FUEL SYSTEM

6
LL

-

MN

B
1.

-

-

z

2
L

-

-

R

8
L

-

5:

P

-

-

-

-

*

3

a

-

-

:
J

E
?
j

May 1983

*
3

04-20

Alfawiki.nl

FUEL SYSTEMINSPECTION AND ADJUSTMENTWARM - COLD AIR AUTOMATIC MIXERFUEL PUMP
Fuel pump pressure

Pump delivery
Warm air inlet complete closing

FISPA

engine temperature

17.7 i29.4 KPa(0.177 + 0.294 bar)-

thermostat temperature(2.56 +4.27 psi)

Cold air inlet complete closing

at 5000 rpm

engine temperaturethermostat temperature

17.7 + 29.4 KPa(0.177 GO.294 bar)warm
>33+37 9=

I (>91.4+98.6’F)(0.18 + 0.30 kg/cm2 )SAVAR AI

cold
<28-32 93(<82.4+89.6 “F)-(0.18 - 0.30 kg/cm21(2.56 f 4.27 psi)
ar 6000 rpm

ACCELARATOR CONTROL
Clearance between adjustment fork slot and throttle control shaft pin

Gl

mm (in)1 (0.039)

Clearance between throttle control lever and relevant
complete opening stop
G2

mm (in)1 + 2 (0.039 f 0.079)

Alfawiki.nl
04-2 1

May 1983

FUEL SYSTEMp
R
In

May 1983

04-22

Alfawiki.nl

FUEL SYSTEM

Alfawiki.nl

FUEL SYSTEM

TIGHTENING TORQUES
Unit
N-m

Item

kg.m

ft-lb

Carburerors retaining nuts

TROUBLE DIAGNOSIS AND CORRECTIONS
Probable cause

Corrective actionlNeedle valve is dirty or its seat isloose on thread

Thoroughly clean petrol filter andneedle valve; tighten seat firmly: if
necessary, replace it with a new one(original parts)lFloat sticks (hard on pin or sides) oris heavy

Free the float and adjust its movement: if necessary replace it (original
parts)lPipes improperly tightened or broken

Tighten pipes and unions or replace
defective onesl

Gaskets are hard, worn or improperly
tightened

Replace gaskets and tighten themproperlyl

Acceleration pump diaphragm is

Replace diaphragmlFuel pump or pipes are overheated

Let bubbles out and try to eliminate
overheating causeslFuel pump is mechanically defective

Overhaul pump replacing defective
components or replace the whole

Condition

Fuel leakage

pump

Cold starting is difficult or
impossiblelPipes, fuel filter or carburetor ducts
are clogged by foreign matter

Thoroughly clean pipes, filter andcarburetorlFuel tank breather hose is clogged or
there is a water deposit on tankbottomUnclog breather hose and eliminate
water also from pipes and from carburetor float chamberlHaving verified that fuel level in float
chamber is absolutely correct, proteed to check following possible
carburetor troubles.

Restore proper fuel level in float
chamberlStarting control cable does not slide
freely, is broken, unhooked, etc.

Repair or replace cablel

Choke sticks so that it tends to stayeither fully open or fully closed

Free choke movementlStarting jet, if any, is dirty or has
been tampered with

Clean or replace jet

I

May 1983

I

04-24

Alfawiki.nl

FUEL SYSTEM

Corrective action

Probable cause

Cold starting is difficult or
impossible (continue)

Excessive fuel consumption

stickyFree valve movement so that it canproperly follow control cableStarting control valve, if any, is

ignition

Ignition and starting systems are out

Overhaulof ordersystems

Carburation, ignition or compression

Checking operations to be performed

are defective, as also mentioned incase of insufficient max speed

same as previously mentioned

Air cleaner intake stopped in the warm

thermostat located into
Replacecleaner air intake

positionandstarting

CAUTION:Special attention should be paid
when checking fuel consumption
since speed load, road type as well as
driving habits play an important partin establishing actual running fuelconsumption
Twin carburetor goes into action too

Adjust relevant controls

early

Slow pickup especially whenin direct drive

Carburation, ignition or compression
are defective, as also mentioned incase of insufficient max speed (pres-

Checking operations to be performed
same as previously mentioned

ence of exhaust smoke is possible)
A c c e l e r a t i o n p u m p n o t .properly
adjusted or defective or pump circuit

Overhaul pump and relevant circuitsof jet and valves is defective
Diffuser well is clogged or otherwise

Carefully overhaul air jet, diffuser

defective

and relevant well making sure that
all components are properly rated

Engine easily knocks, overheats or self-ignites

Carburation or ignition are defective,as also mentioned in case of insuffi-

Checking operations to be performed
same as previously mentioned

cient max speed
Octane rating of petrol used is too
low

Replace petrol in tank with a kindhaving a higher octane rating

Engine cooling system is defective

Check radiator, relevant thermostat
or shutter, if any, since the latter
could be improperly adjusted

Excessive scaling of engine cylinders

Proceed to scale the engine

Having also excluded any ignition
defect, engine compression will haveto be tested since there could beleaks coming from piston rings,
valves or cylinder head gaskets

Check engine compression by means

Engine compression is poor

Check compression and, if necessary,of suitable gauge screwed onto spark
plug holes; overhaul or replace any
defective engine parts

overhaul the engine

Alfawiki.nl
04-25

May 1983

FUEL SYSTEM

Probable muse

Condition

Improper engine idling or
progression phases

Power shortage (insufficient
max speed)

Exhaust system is unusuallyor excessively noisy

May 1983

Corrective actionl

Inadequate fuel level in float chamber or defective starter, ignition or
overall engine operation as previously
mentioned in connection with difficult cold starting

Perform same checks and repairs aspreviously describedlAdjustment of idling adjusting screws
is incorrect

Carefully repeat all relevant adjustments as per maintenance instructions

D Idling jet is dirty, loose or has been
tampered with

Check or replace idling jet

1 Progression holes or channels of
idling circuit are clogged or havebeen tampered with

Check and thoroughly clean holes
and channels

b Air leaks from fitting flanges or otherconnections

Tighten as required and, if necessary,
replace relevant worn gaskets

b Throttle valve shaft has air leaks
from intakes

Replace shaft and, if necessary, fit anoversize shaft after having suitably
reamed relevant holes in the bodyb Throttle valve or relevant controllingparts are sticky

Free throttle valveb Twin carburetor’s second throttle
valve does not work properly

Overhaul and clean

I Inadequate fuel level in float chamber or defective starting, ignition orcompression as previously mentioned

Perform same checks and repairs aspreviously describedm Main jet, power jet, air adjustingscrew or diffuser are clogged, loose
or have been tampered with

Check, thoroughly clean or replace
defective parts

b Fuel filter in tank or in carburetor
is clogged

Clean the filterb Air cleaner clogged

Clean air cleaner and replace cartridge

0 Throttle valve does not fully open

Check throttle valve and relevant
controlling partslReplace damaged parts

Holes in manifolds<lHoles in pipesl

Gas leaks from loose connections

04-26
Alfawiki.nl

Replace damaged parts
Tighten properly as required

FUEL SYSTEM

SPECIAL SERVICE. TOOLS
Tool name

Tool number

Refer topage

c.4.0101

Carburetor pump EST046

c.4.0103

Twin carburetor support (to be used

04-6

with C.4.0101)

c.4.0105

Beaker for carburetor pump tests (tobe used with C.4.0101)

Alfawiki.nl

04-27

May 1983

Alfawiki.nl

IGNITION, STARTING, CHARGING SYSTEMCONTENTSBATTERY . . . . . . . . . . . . . . . . . . . . . . . .05-2

Test stand inspection . . . . . . . . . . . . . 05-24

STARTER . . . . . , . . . . . . . . . . . . . . . . . .05-4

Service data and specifications. . . . . . 05-24

Wiring diagram. . . . . . . . . . . . . . . . . .05-4

Trouble diagnosis and corrections . . . 05-25

Disassembly . . . . . . . . . . . . . . . . . . . . 05-7

TRANSISTORIZED

Checks and inspections . . . . . . . . . . . 05-l 0

WITHOUT CONTACTS. . . . . . . . . . . . . .05-26

IGNITION

Reassembly . . . . . . . . . . . . . . . . . . . .05-l 2

Wiring diagram. . . . . . . . . . . . . . . . . . 05-26

Test stand inspection . . . . . . . . . . . . . 05-I 2

Description . . . . . . . . . . . . . . . . . . . . 05-27

Service data and specifications. . . . . . 05-l 2

Checks and adjustments. . . . . . . . . . .05-28

Trouble diagnosis and corrections . . . 05-13

Disassembly . . . . . . . . . . . . . . . . . . . . 05-31

CHARGING . . . . . . . . . . . . . . . . . . . . . . .05-15

Checks and inspections . . . . . . . . . . . 05-32

Wiring diagram. . . . . . . . . . . . . . . . . . 05-15

Reassembly . . . . . . . . . . . . . . . . . . . .05-33

Disassembly . . . . . . . . . . . . . . . . . . . . 05-l 8

Test stand inspections . . . . . . . . . . . . 05-33

Checks and inspections . . . . . . . . . . .05-21

Service data and inspections. . . . . . . . 05-33

Reassembly . . . . . . . . . . . . . . . . . . . . . 05-24

Trouble diagnosis and corrections . . . 05-36

Alfawiki.nl

May 1983

IGNITION, STARTING, CHARGING SYSTEMBATTERYWARNING:a.

battery at the same time withBatteries left on the shelf or in cars
unused for long periods graduallylose their charge. Therefor they need
to be charged up again when they are

your bare hands.

to be used.

Do not touch both the positive
and negative terminals of theb.

In case of necessity use a I2-volt
booster battery with jumper
leads for starting the engine.

CHARGINGCHECKSWARNING:

1. The container has no cracks ina.

it.
2. Verify that electrolyte level
covers electrodes of about 4 + 5 mm

Remove the negative connection
before starting to charge thebattery.
b. Do not let the electrolyte heatup above 45°C (113°F) during(0.16 4 0.2 in).
3. The top of the battery is clean

3.

and the terminals are not oxidized orelectrolyte withdirty.
4. The lead terminals are well
fastened on to the battery terminals

4. Calculate the specific gravity at

charging.

Take the temperature “t” of thea thermometer.

25°C (77°F) f r o m t h e f o r m u l a

CAUTION:a. Do not use naked flames near
the battery while charging.

and make good contact.

sg,, = sgt + 0.0007 (t - 25) (kg/dm3)b.

CLEANING

where:= Specific gravity of electrolyte
$gt
at PC
t
= Electrolyte temperature

CELLS TEST

1. Clean the top of the battery, its
terminals and the lead terminals witha solution of sodium bicarbonate inwater.
2. Before reassembling terminals, itis necessary to grease them with the

ExamplesSElectrolyte s.g. at 15°C ( 5 9 ° F ) :1.290 kg/dm3

1.

s.g. at 25°C

(77°F)

willbe:First connect the battery to thecharger and then switch on the
charger.

This test should be performed withthe correct electrolyte s.g.
Measure the discharge voltage at theterminals of each cell.

prescribed grease: Grease REINACH
E 10 Tat.

sg*s = 1.290 + 0.0007 (15 -- 25)= 1.283 kg/dm3

WARNING:
Do not let the cleaning fluid get into
the battery: it will react with theelectrolyte.
The electrolyte is acid and therefore(35.51 Ib/cu in)
2 . E l e c t r o l y t e s.g. at 35°C (95°F):
1.275 kg/dm3s.g.

ar 25°C ( 7 7 ° F ) w i l l b e :1.

Remove the plugs from the filler

holes.
2. Putthetestprobesintwoadjacent holes (positive and negative)
as shown. The needle should flip overto the green zone (charged).
3. Repeat for the other two pairsof holes.

dangerous to eyes, hands and clothes.
sg,, = 1.275 + 0.0007 (35 -- 25)= 1.282 kg/dm3(35.48 Ib/cu in)

SPECIFIC GRAVITY
1. Verify that electrolyte is atcorrect level.
2.
By means of a bulb hydrometer,
extract electrolyte from each cell andcheck the specific gravity.

5. Compare then the clensitycalculated at 25% (77°F) with the value
prescribed for an efficient battery.
An efficient battery electrolyte specific gravity is
d = 1.28 * 0.01 kg/dm3

4. If the needle stops in the red

6. If necessary charge the battery.

for each cell, charge the battery.

zone (low charge) at the same point

May 1983

05-2
Alfawiki.nl

IGNITION, STARTING, CHARGING SYSTEM

5. If the needle stops in the redzone (low charge) but at quite

3. If b a t t e r y v o l t a g e s h o w s l e s sthan 12.4V, charge the battery and(see: Group 00

different points for the different

repeat the test. If the voltage again
shows less than 12.4V. a celle maynance).

be shortcircuited. Change the battery
for another one.

Starting test

cells, put in another battery.

USING THE ELECTRONIC
BATTERY TESTER(MOTOROLA)

Also check alternator belt tension

1. Set instrument selector switch to
VOLT.
2. Take the ignition HT lead off
the coil.

Battery state

Connect the positive instrument clip
to battery positive (+) and negative

1. Set the instrument selector
switch to “Cond. Batt.“.

to negative (-). Set battery voltage

2. The needle should flip over tos w i t c h @ to 12V. t e m p e r a t u r ecompensator @ to the estimatedt h e G R E E N z o n e o n t h e REDGREEN scale.

battery temperature, and current

3. If it does not, put in anothercalibrator @ to the battery amps

battery.

Engine Mainte-

3. Start the engine and check theneedle does not drop below 9 V on
the Volt scale.
4. If it does, examine the starting
system (see: Starting).

according to type.

Power test
Voltage test
1. Switch selector 0 t o V O L T .
2. The reading on the VOLT scalemust be greater than 12.4 V.

1. Set instrument selector switch to“kW”.
2. The needle should read between 2 and 4 kW on the kW scale.
3. If it does not, put in anotherbattery.

Charge test
1.

1 Selector switch
2 Temperature compensation
3 Battery voltage switch
4 Current calibration

Set instrument selector switch to

VOLT.
2. Start the engine and let it idle
until the needle settles to its reading.
3. The reading should be between 13.6 and 15V.
4. If the reading is outside (above
or below) these limits, check thealternator for defects, especially thevoltage regulator (see Charging Checks and Inspections).

SERVICE DATA AND SPECIFICATIONSTechnical Data
Car
1200

1350 - 1500

1500 Quadrifoglio

Battery
12

VoltageV

Capacity

Ah

Discharge current

A

Electrolyte s.g.

kg/dm3

1.28 + 0.01

(lb/in 3 )(35.43 5 0.27)

Alfawiki.nl
05-3

43

55

45

60

181

255

185

275

May 1983

IGNITION, STARTING, CHARGING SYSTEM

General Specifications
FLUID AND LUBRICANTS
Application

Battery terminals

Denorninatioh

Type

GREASE

Grease REINACH: E 10 Tat
Std. no. 3671 - 69812

STARTERWIRING DIAGRAM

0

All

BatteryAl.
Al I. Starter
Fuseholder box
Gl.
ci85. Front service junction
Ignition switch
El.

May

1983

05-4

Alfawiki.nl

Q-W-

IGNITION, STARTING, CHARGING SYSTEMBOSCH STARTER MOTOR

I
I
I

1
2
3
4
5
6
7
8
9
IO

Dust co”er
Retaining ringBushCommurator casing
Brush holder
Brush spring
Excitation winding lug
Brush
Yoke
Electromagnet

Alfawiki.nl
05-s

11
12
13

Fork
Rubber block
Lamination

14 Rotor
I 6 Starting clutch
16 Snap ring
17 Pinion stop ring
18 Drive housing
19

Bush

May 1983

IGNITION, STARTING, CHARGING SYSTEMDUCELLIER

STARTER MOTOR

11

Trunnion
Fork
Screw
Rotor
15 Starting clutch
16 Snap ring
17 Pinion stop ring
18 Drive housing
19 Bush

1 Washer
2 Bush3 Commutator casing
4 Brush holder
5 Brush spring
6 Brush7 Yoke8 Electromagnet
9 Plate10 Locator

May 1983

12
13
14

05-6

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IGNITION, STARTING, CHARGING SYSTEM

8. Unscrew the two screws 0
securing the electromagnet @ to
the drive housing @ and take out
the electromagnet.
9. Remove the rubber block @with the lamination.
10. Unscrew the bolt @ serving as
clutch fork pivot.

I- Brush spring

2

Brush holder

positive
6. Extract
the
two
J-h
brush
the
from
brushes tJJ
holder @ and take off the brushholder with the two negative
brushes 0
3 .

1 Electromagnet
screw
2 Electromagnet

3 Drive housing
4 Rubber block
5 Bolt8

11. Withdraw the rotor 2 together
with the starting clutch 3 and theforked lever 0.

1 Positive brushes 3 Negative brushes
2 Brush holder
1 Pinion stop ring

2 Snap ring

7. Unscrew the excitation winding
lug @ securing nut @ from theelectromagnet
w i t h d r a w t h e iiri”& ?mpy?
with excitation winding.

14. Withdraw the starting clutch 0.

1 Fork2 Rotor3 Clutch

Hold the rotor in a vice with caps.
12. Free the pinion stop ring @from the snap ring @ with a box
spanner.
13. With a pair of pliers remove thesnap ring @ from the rotor shaft
and slip off the pinion stop ring.
1 Electromagnet
2 Excitation
winding lug

May 1983

3 Nut
4 Yoke1 Starting clutch

05-8
Alfawiki.nl

IGNITION, STARTING, CHARGING SYSTEM

15. Unscrew the inductor windsecuring screw on theing
1
y o k e82

0

4. Punch on the trunnion 6 forthe fork on the pinion housing 0.

and 13).

and extract the winding.

1 Inductor winding 2 Y o k e

8. Strip the rotor as for the Bosch(see: Bosch Starter Motor, steps 12

1
2

Lug
Commutator3

casingBrush holder

4
5
6

Rotor
Pinion housing
Trunnion

85.
Unscrew
thenuts
2remove the electromagnet 1 .

and1

16. If necessary, extract the bushes
from the commutator casing and thec’rive h o u s i n g w i t h t h e u s e o f apunch.

Nut

2 ForkMARELLI STARTER MOTOR

DUCELLIER STARTER
MOTOR

Hold the starter motor in a capped
vice.

Hold the motor in a vice with caps.
1.
Hold the pinion firm with pliers

securing the dust cover and take it
off.

1. Unscrew the two screws @and unscrew the pinion adjusting2.

screw 0. Take out the screw andwashers securing the commutator

the washers under it.

casing 0 and remove it.

1 Electromagnet

Unscrew the two nuts @ with

2 Nuts6.
Hold the electromagnet in a vicewith caps. Use a screwdriver to keepl

1 Washer

2 Screw clamping

2. Unscrew the two nuts clamping
the commutator casing @ and thestator yoke on the pinion housing onto the stud bolts. Remove thecommutator casing with the brushh o l d e r 0.
3. Unscrew the excitation windingl u g @ fixing nut on the electro.mannet. Remove the stator and therotor 4 .

0

the electromagnet shaft from turningand u n s c r e w t h e p i n i o n c l u t c hfork @ clamping nut 0.
Remove the fork, spring and striker.
7. If necessary take the inductor
winding out of the yoke (see: Bosch
Starter Motor, step 15.) and thebushes from out of the commutatorcasing and the drive housing.

1 Commutatorcasing
2 Nut

3 Screws
4 Dust cover

CAUTION:
When unscrewing nut 0, count theexact number of threads to when it isfree so that it may be screwed up the

3. Unscrew the electromagnet excitation winding lug nut and take thes a m e a m o u n t i n re-assembly a n dtaining the stator windings.

correct fork adjustment had.

4.

yoke out of the starter motor conExtract the pivot cotter pin andtake the starter engaging fork pivot.

Alfawiki.nl
05-9

May 1983

IGNITION, STARTING, CHARGING SYSTEM

Rotor insulation test

5.
Remove the rotor electromagnet
assemblage and take the rotor to

1. Set the tester to c? x 1 scale.
2. Put one prod on the commutator and the other on the segment
pack or shaft.
3. There should be no sign ofcurrent flow by the tester.

pieces as for the Bosch starter
motor (see: Bosch Starter Motor,
steps IZ., 13. and 14.).

1 Commutator

If greater errors than these are4.
pound or if the commutator is badly
scored, put in a new rotor unless itwould seem enough to turn the rotor
1 Electromagnet
2 Rotor3 Forkand smooth it with a piece of cloth
for rotors.

4 Clutch

Bosch and Marelli Starter Motors
6. If necessary, take the field
winding out of the yoke (see: Boschstarter motor. step 15) and thebushes out of the commutator casing
and out of the drive housing.

Max turning depth on nominal
thickness
0.25 mm (0.0098 in)

4.
If the insulation is broken (shortcircuit) put in another rotor.

Commutator

CAUTION:

continuity test

1. Set the tester to the fi x 100
scale.
2. Put the prods on the commutator segments of the pack undertest:
3. The test should show current
flow.

Repeat steps 2. and 3. for all thecommutator segments.

Rotor shortcircuit test on teststand
1. Position the rotor between thepole pieces of the rotor testing
apparatus and switch on.
2. Slowly rotate the rotor and rest

CHECKSAND INSPECTIONS

the steel blade on the rotor pack.

Before making any electrical inspection thoroughly blow-clean the components and especially the endsof the winding with compressed air
and clean the commutator with acloth slightly wetted with petrol.

Commutator wear
1. Put the rotor on a lathe.
2. Place a magnetic-based centesimal dial gauge on the lathe carriage
with the gauge feeler in contact withthe commutator 0.
Bosch and Marelli Starter Motors
3.
Eccentricity should not be more than
the stated maximum.
Max permissible commutator
eccentricity

3. The blade will stick to the packin correspondence with the faulty
lead cables if there is a short circuit.
If there is no electrical continuity,
put in a new rotor.

Excitation winding insulation
test

CAUTION:
Repeat steps 2. and 3. for all thepairs of commutator segments.

2. Put one prod on the lug of theinduction windings and the otherb.06 mm (0.0024 in)

May 1 9 8 3

1.

Set the tester to the ax 1 scale.

prod on the yoke.

OS-IO
Alfawiki.nl

IGNITION, STARTING, CHARGING SYSTEM

3.

The tester should give no sign ofcurrent flow.

2.

Put

one

prod

on

the

brush

3. Eye check the pinion teeth.

holder plate and the other prod on a
positive brush holder.
3.

The tester should give no sign ofcurrent flow.

4.

Repeat the test on the otherpositive brush holder.

4. If the pinion does not work
properly or the teeth show excessive
signs of wear replace the starterclutch.

Brush spring check1. Check that the brush springs
have not lost their elasticity and still
4. If insulation is broken, remove

ensure good brush contact on thethe excitation winding from the yokecommutator.
2.
If necessary, put in new springs.

and put another winding in its place(see: Bosch Starter Motor, step 15).

Excitation winding continuity
test‘I. Set the tester to the fi x 100
scale.
2. Put one prod on the induction
winding cable and the other prod on
the positive brush. (Repeat with theother brush).
3. The tester should show currentflow.

5. If insulation is broken, put in
another brush holder plate.

Electromagnetic efficiency
check
1. Shortcircuit the electromagnet
with the starter pin @ and connect
its positive pole @ to the positive
terminal of a battery.

Brush wear inspection
C h e c k t h a t t h e stator a n d r o t o r
brushes are not chipped or dirty withcarbon deposits and check that theirlengths are within the prescribed
limits.
Brush lengths (mid

2. Connect the battery’s negativet e r m i n a l t o the electromagnet’s
yoke 0.

Bosch 11 mm (0.433 in)Ducellier 9 mm (0.354 in)Marelli - m m (- i n )Bush wear inspection
1 Yoke2 Pin

3 Electromagnet
positive pole

3. The starter drive fork actuator
should trip. If it does not, put in
4. If continuity is broken in thewindings, remove the windings fromthe yoke and put in others in theirp l a c e ( s e e : D i s a s s e m b l y Bosch
Starter Motor, step 15).

another electromagnet.

1. Check that the two bushes on
the front and rear rotor shaft bearings are not excessively or unevenly
worn. Side play between shaft andbush should lie within the limits.

Pinion efficiency check

Shaft-bush clearance

1. Rotate the pinion clockwise as(0 bush 0 shaft) =shown in the figure. It should rotate
freely.

0.02+ 0.05 mm(0.00079 + 0.00197 in)

Positive brush holder insulation
test

c l o c k w i s e , i.e. in the direction of2.

1.

meshing. It should lock.

bushes (see: Disassembly BoschSet the tester to the ax 1 scale.

2. Rotate the pinion counter-

Alfawiki.nl
05-I 1

If wear is excessive, put in new

May 1983

IGNITION, STARTING, CHARGING SYSTEM

Starter Motor, step 16).

stand to correspond with the crownadjust the absorber current to thewheel and connect up to the electri-

value in the under-load test.
The torque should be that shown incal system.

CAUTION:
Make sure the bushes are assembled
properly and the rotor shaft turns
easily and without play.

the technical particulars.

REASSEMBLY

CAUTION:

2. Across-line test

The battery used in the test shouldhave a high enough capacity to avoid
voltage variations.

starter motor.

(1) Apply the rated voltage to the

Follow the disassembly steps in the
opposite order and lubricate t h e(2) Lock the crown wheel brake.
(3) Start up the starter motor andtake a quick reading. Current, voltage

following parts with the prescribed

and torque should be those given ingrease.

the technical particulars.

Surfaces in motion relative to thestarter motor.
Commutator casing bush.
Drive housing bush.
.

Pinion gear
Starting system sliding spiral.

coupling
Electromagnet push rod

3 . T e s t w i t h e-m. s w i t c h o n t h estarter motor(1) Remove the starter motor awayfrom the crown wheel so that thepinion will not engage it.

starter motor. Switch on the starter(2) Apply the rated voltage to thestarter motor. Switch on the starter
motor. The absorbed current shouldso that the pinion turns the crownbe that given in the technical data.

wheel and check for good working.
(2) Brake the crown wheel and(3) PICK-UP/CUT-IN voltage shouldbe that given in the technical data.

1. Under-load test(I) Apply the rated voltage to the

TEST STAND
INSPECTION
Put the starter motor on the test

SERVICE DATA AND SPECIFICATIONSTECHNICAL DATA AND INSPECTION
Starter Motor
533.051533.052536.611MARELLIE95 0.9 kW
12 v

VoltageV

Min brush length

mm

(in)

Max commutator eccenrricity

mm

(in)

Shaft-bush side play

mm

(in)

Under-load test (pinion meshed with crownwheel with torque dynamometer)
9.8- Voltage

V

10

10

-- Absorbed current

A

<230

<200

215

- Speedi-pm

3 1,450

3 1,450

1,800- Torque

N.m

5

5

5

(kg-m)

(0.51

(0.5)

(0.5)

(ft.1 b)(3.62)(3.62)(3.62).Across-line test (pinion meshed withlocked crown wheel)- Voltage

V

8

8

8

- Absorbed currant

A

G400

G380

400

- Torque

N.m

>lO.S

211

12

(kg.m)

(21)

PI.11

(1.2)

(ft.1 b)(2 7.231

I> 7.95)(8.68)

May 1 9 8 3

05-12
Alfawiki.nl

IGNITION, STARTING, CHARGING SYSTEM
Starter Motor
533.052533.051
BOSCH
EF 12V 0.8 kW
0001211215

Over running torque

DUCELLIER
6246/C536.611MARELLI
E95 - 0.9 kW
12v

N*cm

13+22

11317

(kg.cm)(1.3+2.2)(I .l + 1.7)

(I .5 * 0.3)

(in-lb)11.13+ 1.91)(0.95 + 1.48)(1.30 ? 0.261

15*3

EM Switch on starter motor- Max absorption current at rated
G4Q

<40

55

8

Gs

7

2.116

2.116

A
v

voltage- Min pickup voltage
Pinion module

2.116

TROUBLE DIAGNOSIS AND CORRECTIONS
Condition

Starter motor does not turn

Probable cause

I Break in electric circuit between

and no current flows

battery and starter motor

m Break in electric circuit between

Corrective action

Locate and repair it Check battery
terminals and starter cable terminals.
Tighten up the securing screws

starter motor and starter switch

Locate and repair it. Check switch
contacts and replace if necessary

m Battery terminals dirty or loose
c.onnections

Clean the terminals and tighten up
the connectionsb Starter motor electromagnet or winding or is earthed

Clean the moving and fixed contactsof the switch when possible andreplace it if necessary

1 Excessively worn brushes not making
contact on the commutator

Replace the brushes with other original ones after checking state of commuTator

Current flows but starter motor
does not turn, or turns slowly,

1 Rotor is rubbing against the pole

Replace the bearings if the bushes

pieces or is being held between theare too worn. Check bearing align-

poles

ment. Examine rotor shaft. See thatthe poles are well located and securely clamped into the yokeor starting does not take place

1 Rotor shaft seized UP

Replace the rotor and the piece withthe seized-up bush

) Field winding short circuited or
earthedTake out rhe field coils and put innew onesl

Broken or earthed rotor

Replace the rotorlRotor short circuited

Clean the carbon and copper dust
off-the commutator and brush holders and if necessary replace therotorStarter motor turns but starting
does not take place

D Crown wheel teeth worn: pinion
does not engage

Alfawiki.nl
05-13

Replace starting ring gear

May 1983

IGNITION, STARTING, CHARGING SYSTEM

Probable cause

Condition

Starter motor turns but starting
does not take place(continued)

l

l

l

Corrective action

Wrong assembly: pinion engages only

Check concentricity and pinion-ringpartiallygear distance

Impurities in the coupling: Clutch
does not slide on rotor shaft

Clean and lubricate. If necessary
clean the coupling completely

Pinion engages ring gear properly
but the engine does not start

be replaced. Faulty clutch to over-Pinion free wheel defective and must
haul or replace. Electra-magnet notworking properly: repair or replace

Starter motor turns normallyl

Defective mechanical parts

Check bearings. Examine bushes andbut makes excessive or unusual noise

Starter motor does not develop
max power

if necessary replace bearings. Foreign bodies have got into itll

Brush contact on commutator

notClean them out

Replace brushes or snug them by

goodrunning the motor on no-load forsome time. Check brush springloading and replace them if they havelost their elasticity

Brushes do not slide freely in the

Clean the brush-holder guides orreplace the brush holders if neces-guidessary
Excessive brush wearlOvalized commutator

Turn within in prescribed limits, remove mica and clean commutatorlMica projecting out of commutator

Remove mica and clean commutatorcopper sectionsll

Brushes press excessively on com-

Check brush spring loadings formutatorprescribed values

Wrong brushes

Replace with others of prescribedweSparking at the commutatorlElectrical overload in general

Overhaul the enginelSlack brush springs

Replace brush springslMica projecting from copper

Remove mica and clean the commutator.

May 1983

05-14
Alfawiki.nl.

IGNITION, STARTING, CHARGING SYSTEMBOSCH ALTERNATOR

Distance piece
Semipulleys
Distance piece
Fan
Stay bolt
Drive housing
Control side bearing
Plate
Feather key

May 1983

10
11
12
13
14
15
16
17

Rotor
Regulator side bearing
Stator
Diode - holder plate
Regulator mounting
Brush holder-voltage regulator
Brush spring
Brush

05-16
Alfawiki.nl

IGNITION, STARTING, CHARGING SYSTEMMARELLI A L T E R N A T O R

'-1

.J

1

2
3
4
5
6

PulleyCooling fan
Stay bolt
Distance piece
Drive housing
Bearing retaining plate-control side

7

8
9
10
11
12

Feather key
Rotor
Bearing-regulator side
StatorVoltage regulator support
Diode rectifier bridge

DISASSEMBLY

13
14
15
16
17
18

;\

Brush holders
Rectifier bridge guard
Excitation Tang
Positive terminal
Insulating washer
Voltage regulator

2.

Unscrew the two screws securingt h e v o l t a g e r e g u l a t o r @ to its
mounting @ and take out the brushholder regulator unit.

CAUTION:
The following procedures are intended for part replacement. If used
for component checking and inspection purposes, do not unsolder.

BOSCH ALTERNATOR
1. Hold the alternator pulleys 2
in a vice with caps, Release fan 81
and pulley to rotor shaft @ securing nut 0. Take off the nut,
the lock washer, the two semipulleys
with distance pieces and the fan with
washers and feather key.

May 1983

1

2

Fan
Pulley

3

Nut

4

Shaft

OS-18
Alfawiki.nl

12

Voltage regulator
Regulator mounting

I G N I T I O N,

3.

ST A R T I N G , C H A R G I N GSYSTEM

9. Extract the bearing 0 on thedrive housing end of the rotor

Hold the drive housing @ in avice and unscrew the stay boltss h a f t @ with an extractor (seeclamping the regulator mounting @to the housing 0.

following figure) or a punch presswith half-plates.
CAUTION:At reassemble use a new bearing if
the old one is worn or damaged andput it on the press with the help of apipe which must rest only on the
inner ring of the bearing.

1 Drive housing

1 Stator
2 Diode holder plate

4. Remove the regulator mounting

7. Unscrew the screws 0 securing
the diode holder plate to the regulator mounting and extract the diodeholder plate,

2 Regulator mounting

by tapping it on its edge with aplastic hammer as shown in theillustration.

1 Bearing

2 Shaft

DUCELLIER A L T E R N A T O R +1. Hold the alternator in a vicewith caps. Unscrew the screws 0
a n d 2 securing the voltage regulato its mounting and extract
tor 3

8

the voltage regulator.

15.

Extract the rotor @ by tapping

the rotor shaft @ on its end.with aplastic hammer as shown in theI.. ,illustration.

Diode holder plate securing screws

8. Unscrew the two screws aretainingthebearingsecuring
plate @ to the drive housing andextract the bearing.
CAUTION :At reassembly, use a new bearing if
the old one is worn or damaged.

1 Top screws
2 Side screws

1 Rotor2. Unscrew the two screws 0
securing the brush holder @ and2 Rotor shaft

6 . U n s o l d e r t h e stator @ ( r o t o r )three-phase connections to the diodeholder plate 0.

3 Voltage regulator

the earthing plate @.
3. Unscrew the cable terminal
securing screw @ and take out the
1 Screws

2 PlateAlfawiki.nl

05-19

brush holder.

May 1983

IGNITION, STARTING, CHARGING SYSTEM

7. Remove the regulator mounting
complete with stator and rectifier
bridge (the diode plate) by tapping it
on its edge with a plastic hammer.

1 Brush holder
2 Screws

IO. Extract the rotor @ by tapping
the end of the shaft with a plastic
hammer as shown in the illustration.

3 screw
4 Plate

4. Unscrew the two diode covtake out the excitaand take off the cover.
1 Rotor8. Unsolder the stator three-phaseconnections to the rectifier bridgetabs.

11. Unscrew the three screws securing the bearing retaining plate to thedrive housing and extract the bearing(see: Bosch Alternator - step 6).
12. Take the bearing off the drive
housing side of the rotor shift (see:Bosch Alternator - step 7).

MARELLI ALTERNATOR

1 Pin
2 Cover

1. On a vice fitted with protective
jaws, secure pulley @ of alternator.
Loosen nut @ securing pulley andfan @ to rotor shaft @; remove
nut, washer, pulley and fan together
with spacers and feather.

3 Nuts

6. Unscrew the alternator charge
indicator pin 0 screw,
6. Unscrew the three alternatorpack assembly stud bolts nuts 0.

9. Hold the rotor in a vice with
caps. Unscrew the nut securing thepulley @ and the fan @ -to therotor shaft. In order take off the nut,
the washer, the distance piece, thepulley, the second distance piece andthe fan with washers and feather key.

1 Pulley
1 Pin

May 1983

2Fan

2 Nuts05-20
Alfawiki.nl

1 Pulley
2 Nut

3 Fan
4 Shaft

IGNITION, STARTING, CHARGING SYSTEM

2. Disconnect voltage regulator
c o n n e c t o r s @ and @ of rectifier

5. Withdraw rotor @ h a m m e r i n g
by means of a plastic hammer on

bridge. Unscrew screw securing brushto voltage regulator
holder 4

shaft @ of rotor itself, as shown infigure.

8

support 3 and withdraw it.

suitable press with plates and punch,
withdraw bearing on voltage regulator support side from rotor shaft.

CAUTION:
On reassembly, use a new bearing (incase bearing is damaged or worn) by
mounting it on press with the aid ofa tube which must face bearing
retaining ring.
10. On a vice fitted with protective

1 Rotor2 Shaft

jaws, tighten control support 0.
11. By means of a drilling machine,
securingr e m o v e t h e n rivets @plate @ retaining bearing to control

6. Unscrew
Voltage regulator
Rectifier bridge connector
Rest voltage regulator
Sliding brush holder

nut and screw ofrectifier bridge guard 0; withdraw

support.
12. Withdraw bearing.

power pin @ and remove guard.
CAUTION:
On reassembly, use a new bearing, incase the removed one is damaged or

3. Unscrew tie rods @ assembling
control support @ to voltage
regulator support 0.

worn.

1 Guard

1 Tie rod
2 Control support

3 Voltage regulator

2

Pin

7. Unsolder connections of statort h r e e p h a s e s ro f i n n e d rectifier
bridge,1 C o n t r o l support 3 Plate
2 Rivets

support

4. Remove voltage regulator support by hammering on its edge bymeans of a plastic hammer, as shownin figure.

CHECKS
AtiD IWPECTIONSCAUTION:
Before starting electrical checks
thecomponents
blow-clean all
thoroughly with compressed air.

8. Withdraw rectifier bridge andstator from voltage regulator support; then unscrew positive terminal
with relevant washer.
9. By means of an extractor (see:Regulator Alternator Bosch) or a

Alfawiki.nl
OS-2 1

1. Slip rings(1) Inspect for wear,(2) If the rings are scored, but not
badly, put the rotor. on a lathe andrectify the rings with rotor cloth. If
the rings are badly scored, put in a
new rotor.

May 1983

IGNITION, STARTING, CHARGING SYSTEM(4) If there is no continuity in thewindings, put in a new stator.
6. Brush wear inspection
6- 1. Bosch Alternator(1) The brushes in the voltage
regulator should not be chipped or
dirty with carbon deposits; theirlengths should be within the prescribed limits.
Brush projection min.
5 mm (0.197 in)(2) In2.

Rotor winding continuity test

(1) Ser the tester to the AL x 1 scale.
(2) Put the prods on the slip rings.
(3) Winding resistance should be:
Bosch alternator 4 f 0.1 a
Marelli alternator 3.1 * 0.2 CL
Ducellier alternator 6.5 k 0.2 a(4) If the insulation is broken, put
in a new rotor.
4. Stator windings insulation test

case

of

excessivewear,

unsolders the brush cable as shown in
the illustration and put in newbrushes.

(I) Set the tester to the a x 1 scale.
(2) Put one prod on the stator packand the other prod on the terminals 0 of the first phase, then of
the second phase, and finally of thethird phase.
(3) The tester should show no signof current flow.

6-2. Ducellier Alternator and Mare//i(I) The brushes in the brush holder
should not be chipped or dirty withcarbon deposits; their lengths should
be within the prescribed limits.
I Phaseterminals

Brush length min.

(4) If there is no electrical continuity, put in a new rotor.
3. Rotor insulation test
(1) Set the tester to the a x 1 scale.
(2) Put one prod on a slip ring andthe other prod on the rotor core.
(Repeat for the other slip ring).

(4) If there is insufficient insulation,

Ducellier Alternator 6 mm (0.236 in)put in a new sTator.
5. Stator windings continuity test
(1) Set the tester to the a x 100

Marelli Alternator 7 mm (0.275 in)scale.
(2) Test for electrical continuity
between: 1-2, 1-3, 2-3.
(3) In each case the tester should
show current flow.

(2) In case if excessive brush wear,
put in new brushes: the one bysimply withdrawing i t f r o m its
seaT on the brush holder and theother by withdrawing it after unscrewing its securing screw.

(3.) The tester should show no sign
df current flow.

DUCELLIER

May 7983

05-22
Alfawiki.nl

IGNITION, STARTING, CHARGING SYSTEM

7. Brush spring inspection
The brush springs should be stiff

Reverse the two prods The tester
should show the prescribed re-enough to assure good brush contact
on the slip rings. If they are not, put
in a new voltage regulator unit.
8. Brush
holder unit electricalsistance.

continuity

Diode resistance in direct conduction
R = 0 -lOa
Power diodes - bridge inverted test

Direct current resistanceR = O+lOa

inspection(I) Zero tester in the a x 100 range
scale.
(2) Carry out inverted-test of bridge
operating as per direct test, by
inverting (in sequence) probes be-(1) Set the tester to the 52 x 100(2b)The rester shows current flow

scale.

and therefore the prescribed resis-(2) Put one prod on one and thentance.

tween positive heat sink and t h eon the other brush 0.
(3) Put the other prod

Reverse the prods and the testershows no current flow (infinite

three phases of bridge when testing
positive bridge.
Inverts (in sequence) probes between
negative heat sink and the threephases when testing negative bridge.

on

the

terminal 0.
(4) The tester should show current

resistance).

flow.

CAUTION:( 5 ) I f t h e r e i s n o eletrical conrinuity, check the brush holder and if

All excitation diodes must be tested
in this way.

(3) Verify on tester that current is
not present.

necessary put in new brushes and/or
Diode resistance for inverted

brush holder.

conduction
R =mcL

1 Diode holder plate
1 Positive hear sink
1 Brushes

2 Negative test sink

2 Terminal

DUCELLIER A N D MARELLI(3) If the tester readings are notthose prescribed, put in a new diodeholder plate.

c9.

Diodes inspection

9-1 Bosch Alternator(I) Set the tester to zero on the fi x
1 scale.
(2) Put the prods on a diode terminals.
Then either:(2a) The tester shows no current flow
(infinite resistance).
Inverse current resistance
R =w

9-2. Ducellier Alternator and Marelli
Power diodes - Bridge direct rest
(1) Zero tester in the a x 1 range
scale.
(2) Carry out direct test of positive
bridge, by setting the tester negative
probe on positive heat sink of bridge
and the other probe, sequentially,on each end of the three phases ofbridge. Check, on tesrer, that resistance value for direct current is therequired one.
(3) Carry out direct test of negative
bridge, by setting the tester positive

Energiration Diode Direct test
(1) Zero tester in the a x 1 range
scale.
(2) Connect tester negative probewith output of energization diodes(terminal D+) and second probe(in sequence) with the three phases.
(3) Verify on tester, that resistancevalues for direct current are therequired ones.
Diode R for direct current
R = 0+1os2
Energization Diodes Inverted test
(1) Zero rester in the ax 100 range

probe on negative heat-sink of bridge

scale.
(2) Operate as per direct test by
inverting tester probes between out-

and the other -probe, sequentially,

put of energization diodes (terminalon each end of the three phases ofD+) and the three phases (in se-

bridge. Check on tester, that resis-

quence). Verify,. on tester, thatcurrent is not present.

tance values is the required one.

Alfawiki.nl
05-23

May 1983

IGNITION, STARTING, CHARGING SYSTEMTESTSTAND INSPECTION

CAUTION :If the required resistance values are
replacerectifiernotmeasured,

3. Let the alternator rotate at
3,000 rpm for an hour with rheostat
load to give a voltage of 13 + 14V.

1. Put the alternator on the test

4. Slow down the motor until thestand and connect it to the stand’s

current output is from 1 + 2 A andelectric motor.
2. Make the following electricalthen disconnect load rheostats to getconnections:current reading and the correspond-(I) Terminal B+ to test standpositive.
(2) Terminal B+- to the pilot lightand to terminal D+.

ing rpm.

(3) Connection for test stand feet.

a voltage again of 13 + 14V. Take the

5. Keeping the voltage constant,vary the speed and the load rheostats
and take current readings together
with the corresponding rpm at
different point up to max current

bridge.

output.
6. The output current readings at

REASSEMBLY

the various speeds should all be equal

Reassemble the alternator following

the Technical Data.

to or greater than those reported in

the disassembly steps in the opposite
order, and taking care that:CAUTION:W h e n s o l d e r i n g t h e t h r e e stator
cables on to the diode holder plateand,for the Bosch Alternator,changing the brushes, the solderingmust be done as quickly as possible
so the diodes are not overheated.

1 Terminal B +2 Terminal D +SERVICE DATA AND SPECIFICATIONSTECHNICAL DATA AND INSPECTIONS

Alternator
0.120.489.798

125 - 14V - 45A

Brush wear limit

Voltage regulator resistance
Diodes resistance

i2

58+72

-

o-10

o-10

(I) Minimum readings when hot after 1 hour’s working at 5000 rpm with loading of 25 A

May 1983

05-24
Alfawiki.nl

o-10

IGNITION, STARTING, CHARGING SYSTEM

T R O U B LE D I A G N O S I S,AND CORRECTIONSBefore starting alternator troubleshooting, the battery should be fully charged (see: Battery)

Condition

Alternator does not charge

Probable cause

Corrective actionlSlack belt

Tension the beltlBroken charging or earthing

Check the circuit

circuit
Faulty brushes

Put in new brushes

Excitation diodes short circuited

Put in new diode holder platelBroken excitation circuit

Check the circuitlBroken rotor winding

Put in new rotorlInefficient voltage regulator

Put in new voltage regulatorlStator winding earthedPut in new statorlSlack belt

Tension the belt

Intermittent break in the

Check the circuitll

Insufficient or irregular
outputlcharging circuitlWorn brushes

Put in new brusheslInefficient voltage regulator

Put in new voltage regulatorlAn excitation diode disconnected

Put in new diode - holder plateor earthedll

Rotor partly short circuited

Put in new rotor

Stator disconnected, earthed or
partly short circuited

Put in new stator

Put in new voltage regulator

Excessive output

Inefficient voltage regulator

Noisy alternatorlWorn belt

Put in new beltlLoose pulley

Tighten up the nutlPoor bearings

Put in new bearingslAn excitation diode short circuited

Put in new diode-holder platel

Loose alternator

Tighten up the screws on the bracket

Alfawiki.nl
OS-25

May 1983

IGNITION, STARTING, CHARGING SYSTEMDESCRIPTION
The electronic ignition is an inductive discharge transistorized system
without contacts, constituted by thefollowing components.
ignition distributor with maga.

0

netic pulse generator A5 withcentrifugal
sparkmechanic
advance and vacuum advancecalibrator.
b.
C.

0

Ignition coil A8 with electronic
module.
Electronic module Nl0

The ignition distributor with mag-arm and cap, The pulses are gener-i n g heat maximum elimination andated by a magnetic pulse generator
located into a variable air gap circuit.

stable performances.
Besides conducting or interdicting

During rotation of distributor shaft,each time a tooth of the timer passes

the output transistor, the electronic

in front of the fixed pole piece
expansion, a signal is generated (byprocessing the signal provided by the

induction) at the winding ends oftor, conducting one linked with thecoil (pulse generator), with consequent control of the electronicengine rotation revolution numbers.

module.
The electronic module, constituted
by
a
set
of
integrated
circuits

coil charge current and of time
duration of conduction with genera-

mounted onto a ceramic support

netic pulse generator differs from theenclosed into a proof container is, in
its turn, mounted together with coil,traditional type as, in the place ofcontacts and of capacitor, it has awhich also operates as heat dissi-

m a g n e t i c p u l s e g e n e r a t o r (stator)

pator. Between the electronic mod-and, in the place of the cam, atoothed timer (rotor).
High voltage distribution to spark
plugs is obtained by means of a rotor

ule and the support, it is interposed aonto an aluminium finned support

grease coat with thermal high condutivity, with the purpose of ensur-

module has also the purpose ofmagnetic pulse generator of distribu-

It is thus obtained a control of thetion of constant energy spark,
independently of engine speed andbattery voltage.
A coupling capacitor, secured tom o d u l e r a d i a t o r and electricallyconnected with coil terminal andto ground, allows optimization ofprimary voltage wave form on coiland,consequently,

higher perfor-

mances.

r

Fuseholder box
Gl.
To ignition switch
Bl.
Al 2. Spark plugs
To elecrronic tachometer
Cl.
Magnetic pulse generator
A6.

Timer (Rotor)
A7.
Electronic distributor
A5.
Nl. Electronic Module
Ignition coilAS.

Alfawiki.nl
OS-27

May 1983

IGNITION, STARTING, CHARGING SYSTEMCHECKS AND
ADJUSTMENTS
ON CARS1.

WARNING:
Stroboscopic gun must always bedirectly connected with battery
terminals.

Check general rules
2. System functioning verification

CAUTION:
Each check for presence of voltage or(I) With ignition key inserted (ignition switch closed) and engine still,sparking, that is, ground discharging

check, by means of voltmeter, thatthe voltage on terminal 15 of coilthe high-and low voltage points, must

is equal to the battery voltage (12V).

be avoided unless they are required(2) After carrying out the ignition
timing operation (for timing see:current in electric connections, via

special verifications expressely listedwith application of special devices.
Besides, the following operations
must be avoided:.
Connection.

Distributor

MarelliI

Rotor arm

resistance

i.2

Bosch
I
1,000

5,000

I

I

be-

disconnect the tachometer cable and,tween tap of coil high voltage

with non-inserted ignition key, checkand distributor, by disconnecting the relevant cable (coilvia ohmmeter, that resistance values

not inserted, disconnect from a sparkof both primary and secondaryside) when motor is running or
during starting phase.

windings are the prescribed ones.

plug the connection high voltage
cable to distributor by setting theinterruption

Ground connection of coil low
voltage terminal connected withtachometer.

lGroup 00 Ignition System andSupply) check possible interruptionsin the coil windings. To this purpose,(4) Verify that resistance internal torotor arm of ignition distributor
corresponds to the prescribed value.

Use of trouble diagnosis equipments which allow the shortcircuit the low voltage signal,
between coil primary winding

Coil

Mardi

Bosch

0.72k.i 0%

0.7 - 1

free end at 5 mm (0.2 in) fromengine body.

Primary

winding
resistance
Secondarywinding
resistance

!a

5-2

and tachometer or not allowed.
(3) With ignition key not inserted
WARNING:(ignition switch open) verify func-

Before powering the unit, make surethat connectors of the electrictioning of ignition distributor bydisconnecting the connector between

system are properly inserted and thatthe module coil units is secured

module coil unit and distributor
and checking via ohmmeter, thatto ground so as to ensure an effective
connection.

corresponds to the prescribed value.

May 7983(5) Proceed as follows for systemgeneral verification with ignition key

resistance of pulse generator coil

OS-28
Alfawiki.nl

Put on insulation gloves and start theengine verifying that spark occur
regularly between cable and ground.

IGNITION, STARTING, CHARGING SYSTEMBOSCH DISTRIBUTOR

/’

1
2
3
4
5
6
7
8
9
10

Cap
Rotor arm
Dust cover
Retaining ring
Timer
Retaining ring
Pulse generator (stator)
SpringRetaining ringCounterweight

11
12
13
14
15
16
17
18
19

Alfawiki.nl
05-29

Pulse generator securing screw
Connector securing screw
Connector
Spring securing screw
SpringDistributor body
Advance regulator
Advance regulator
Spring securing screw

May 1983

IGNITION, STARTING, CHilRGING SYSTEMMARELLI DISTRIBUTOR

May 1983

1
2
3
4

Cap
Cap securing screw
Rotor arm securing screw
Rotor arm

5
6

Pulse generator securing screw
Pulse generator (stator)

7
8
9
10
11
12

05-30

Insulating support
SpringCounterweight
Distributor body
Advance regulator securing screw
Advance regulator

Alfawiki.nl

IGNITION, STARTING, CHARGING SYSTEMDISASSEMBLY
In the following are prqvided thedisassembly operations relevant toignition distributors, limited to thepart on which maintenance is carried
out.

BOSCH DISTRIBUTOR
Clamp distributor on a vice fittedwith protective jaws.
1. Remove cap 0 and withdraw
f i r s t t h e r o t o r a r m @ with rev
limiter and then the lubrication
felt.

The rev limiter is a centrifugal
located on the head of rotor arm
which interrupts the ignition distribution when the engine exceeds
6800 rpm.
2.

Remove dust cover 0.

1 Screw
4.

2 Connector

Remove cap securing springs @after
unscrewing
relevant
thes c r e w s 2 T h e n u n s c r e w 1 secur-00
ing stator to distributor body andscrews 0
3
securing advance regu-

6. Lift inductive winding
remove the advance regulator

lator to distributor body.

1 Cap

2 Rotor arm

1 Inductive winding
2 Advance ragulator
3 Dust cover

3. Operating as per figure, remove
retaining ring of timer.

1 Stator securing screw
2 Spring securing screw
3 Regulator securing screw
4 Spring

5. Operating on screw 0, remove
connector @ of distributor body.

7. From distributor shaft, remove
in sequence the timer, retaining
ring 0 and inductive winding @complete of stator and supporting
plate.

Alfawiki.nl
OS-3 1

May 1983

IGNITION, STARTING, CHARGING S Y S T E M

1 Counterweights
2 Springs
3 Pulse generator

4 Screws
5 Insulating
support2 Securing screws

1 Cap

5. Unscrew the four screws secur1 Retaining ring

2 Inductive winding0

2. Unscrew screws 2 securing
8. By means of a clamp, releasesprings @ of counterweights 1 ,ing advance regulator to lower baseof d i s t r i b u t o r b o d y , t h e n w i t h d r a w

rotor arm to body; then withdraw

body from its seat by using as

rotor arm 1

fulchrum the regulator shaft.

0.

then remove stop retaining rings8 3
and then withdraw counterweights.

CHECKSAND INSPECtIONSMARELLI DISTRIBUTOR
1 Counterweights

3 Retaining ring
1 Rotor arm

2 Springs

2 Securing screws

MARELLI DISTRIBUTOR

tor @ and timer 0 corresponds
to the “S” prescribed value.
3 . W i t h d r a w s p r i n g s @ and re-

Clamp distributor on a vice fitted

move counterweights 0.

with protective jaws.
1. Unscrew screws 2 securing cap

4. Unscrew securing screws 4 ,then remove pulse generator8 3

to distributor body;cap (iJ.

support 5

May 1983

By m e a n s of a feeler gauge, v e r i f ythat air gap between pulse genera-

0

then withdraw(stator) a n d m a g n e t i c i n s u l a t i n g

0.

05-32
Alfawiki.nl

Air gap
S = 0.4 + 0.5 mm (0.016 + 0.02 id

IGNITION, STARTING, CHARGING SYSTEM

2. Counterweights advance

CAUTION:(I)

Marelli Distributor

Carry

out

steps

1

and

2

relevant to vacuum advance verification.
(2) On vacuum spark advance con-Every time it is carried out a disassembly or replacement operation ofmagnetic pulse generator, it isanyway required to reassemble thetrol disconnected from test bed
vacuometer,r e a d , o n increasing

magnetic spacer of pulse generator
support.

r.p.m., the automatic advance curve(see: Service Data and Specifications).
(3) If the particulars are not within

2 Pulse generator

1 Timer

TEST
STAND INSPECTIONS

the prescribed values, carefully exam-

1. Vacuum advance(1) Mount the ignition distributor

return springs, timer, and pulse
generator. Replace faulty the parts.

ine the distributor and, particularly
the counterweights and relevant

on a test bed and carry out electric
connections.
(2) C a r r y o u t s p a r k r e s e t t i n g o n

REASSEMBLY

goniometer disc of test bed byrotating distributor manually or

For reassembly reverse the order ofwith the test bed motor without

disassembly and comply with theexceeding 50 r.p.m. speed.

following:
L u b r i c a t e the following com1.

(3) Carry out connection of vacuum
pipe to vacuometer of test bed.
(4) On increasing vacuum, read theadvance curve (see Service Data andponents by means of distributor
special grease.
.
Counterweights springs.
Counterweights
2 . L u b r i c a t e f e l t of. d i s t r i b u t o r
shaft with few oil drops.

Specifications).
(5) If the read curve -is not within
the prescribed deviations, replace thevacuum advance device.

SERVICE DATA AND SPECIFICATIONSTECHNICAL DATA AND INSPECTldNS
Ignition Distributor
542.168

Alfa Romeo Class

Type

I

MARELLI
SM 802 AX

542.161

I

BOSCH
0.237.005.004

I-3-2-4

Firing order

Pulse Generaxor Coil Resistancei-2

730 f 5%

1 1 0 0 ’1 0 %Internal resistance of distributor 1 rotor arm

A-L

5000

1000

Air gapmm

0.4 + 0.5

(in)

(0.015 + 0.019)

ELECTRONIC MODULE
Suppl; voltage

V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum controllable current
Radiator limit temperature

A

4+16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alfawiki.nl
05-33

6

- 30 + + 185°C (- 22 + * 365°F)

M a y 1983

IGNITION, STARTING, CHARGING SYSTEMAUTOMATIC AND PNEUMATIC ADVANCE CURVES

800

5"45'

3O45'

1700

13"45'

11015'

1800

140

120

2500

13O

II0

3000

12"15'

lO"15'

7"30'

5"30'

338

I

May 1983

OS-34

Alfawiki.nl

IGNITION, STARTING, CHARGING SYSTEMIGNITION COIL
542.167

AHa Romeo ClassType

542.162

MARELLIBOSCH

BAE 207B

0.221.6C10.002

Primary winding resistances-2

o-72,* lO.Vo

0.75 1

Sawndary winding resistancen

7900f10%6700 + 9600

SPARK PLUGS
535.420

Alfa Romeo ClassLODGE 25 HL

TypeFLUID AND LUBRICANTS
Application
Spark plug thread

Type

DemminationOIL

ISECO Molykote A
Standard 4500 - 18304

Q.W

TIGHTENING TORQUES
Unit
N.m

kg.m

ft.1 b25+34

2.5 + 3.5

18.08 + 25.31

Item
Spark plugs in IS-EC0 oil: Molykote A

Alfawiki.nl
05-35

May 1983

ENGINE COOLING SYSTEM,CONTENTS
COOLING SYSTEM . . . . . . . . . . . . . . .

07-2

ELECTRIC FAN CONTROL

General description . . . . . . . . . . . . .

07-2

THERMAL CONTACT . . . . . . . . , . . . .

07-6

Removal . . . . . . . . . . . . . . . . . . . . .

07-3

Removal and installation q I , . . . . . .

07-6

Hydraulic system leak test. . . . . . . .

07-3

Checks and inspections . . . d _ . I . . .

07-6

WATER PUMP . . . . . . . . . . . . . . . . . . .

07-3

HEADER TANK PRESSURIZED

Checks and inspections . . . . . . . . . .

07-4

PLUG . . . . . . . . . . . . . . . . . . . . . . . . . .

07-6

Installation . . . . . . . . . . . . . . . . . . .

07-4

Leak test . . . . . . . . . . . . . . . . . . . . .

07-6

THERMOSTAT . . . . . . . . . . . . . . . . . . .

07-4

SERVICE DATA AND

Removal . . . . . . . . . . . . . . . . . . . . .

07-4

SPECIFICATIONS . . . . . . . . . . . . . . . .

Checks and inspections . . . . . . . . . .

07-4

Inspection and adjustment . . . . . . . 07-7

Installation . . . . . . . . . . . . . . . . . . .

07-5

Tightening torques . . . . . . . . . . . . .

RAD I AT0 R . . . . . . . . . . . . . . . . . . . . .

07-5

TROUBLE DIAGNOSIS AND

Removal and installation . . . . . . . . .

07-5

CORRECTIONS . . . . . . . . 1.. . . . . . . .

Leak test . . . . . . . . . . . . . . . . . . . . .

07-6

Alfawiki.nl

07-6
07-8
07-8

May 1983

ENGINE COOLING SYSTEMCOOLING SYSTEM
GENERAL DESCRIPTION

1
2
3
4
5
6
7
8
9
IO
11
12

Electric fan
Thermostat
Radiator
Electric fan thermal contact
Cooling drain plugs
Centrifugal pump
Header tank
Cooling temperature transmitter
Heater
Cooling temperature warning light thermal contact
Cooling temperature indicator
Cooling temperature warning light

13

Cooling water level sensor for check control(I 500 Quadrifoglio model)
Cooling water minimum level warning light(1500 Quadrifoglio model)

14

May 1983

07-2
Alfawiki.nl

ENGINE COOLING SYSTEMCHECKS AND
INSPECTIONSINSTALLATION

The water pump cannot be overhauled and in case of failure must: bereplaced.
1. Check pump body and impeller
for indications of wide oxidation andcorrosion; if any, replace pump.
2. Verify that there is no excessive
play in the rotation and axial movement of impeller.

1. Fit water pump with new
relevant gasket to block and tighten
securing screws to specified torquevalue.
: Tightening torqueScrews securing water pump
19+24 N-m
(1.9 + 2.4 kg-m
13.74 + 17.35 ft.lb)
2. Check correct timing of engine
and key camshaft belt on camshaft

pulley. For the timing and belt
keying procedure refer to: Group 00- Engine Maintenance.
3. Refit front cover of camshaft
belt, pulley, alternator, pump andalternator driving belt, in reverse
order of removal.
4. Stretch pump-alternator driving
belt.
For the stretching procedure of belt
refer to: -Group 00 - Engine Maintenance.
5. At end of pump installation,
pour the coolant and letting theengine run for a few minutes checkagainst coolant leakages.

THERMOSTATREMOVAL
1. Drain coolant up to the lower
level of thermostat housing.
2. Detach coupling @ connecting
thermostat cover to radiator.
3. Screw out screws @ andremove cover
3 with relevant
gasket @ _4. Withdraw thermostat @ from
Imousing @ .

0

CHECKS AND
INSPECTlOONS
Thermostat should be checked inaccordance with the following procedure:
1. Fit thermostat @ to suitable
test equipment.
2. Fill container with water andswitch on equipment to heat water.
3. Check that, when thermostat
opens, temperature value read on
thermometer @ dial indicator is
84 + 88°C (183.2 + 190.4”F).
4. Additionally check that thermostat is fully open at 98°C (208.4”F)and valve travel greater than 7 mm
(0.28 in).
If above values are not met, thermostat must be replaced.

1
2
3
4

Coupling
Clamp
Cover
Screw

May 1983

5
6
7
8Washer
Thermostat
GasketHousing

07-4
Alfawiki.nl

1 Thermometer

2 Thermostat

ENGINE COOLING SYSTEMLEAK TESTI.
Remove radiator from car (Refer
to: Radiator Removal and Installation).
2. Close radiator outlet and inlet
unions.

compressed
air through radiatorbreather pipe until a pressure of

6. Test again radiator for leakages
as described above and then refinish+ 107.9 kPa; (0.9 + 1.0 bar;
98.1
1 + 1 .I kg/cm2 ; 14.22 + 15.64 psi) is
reached.

radiator with black synthetic enamel.
In case of leakages from radiator
fitted with side tanks (with gaskets),
replace the radiator.

4.

If leakages are found, clean area

to be soldered by a wire brush and3. lmmerge radiator in a tankpreviously filled with water anddeoxidate by “baked” hydrochloric

check for possible leakages inflating

5.

acid (zinc chloride).
Solder the leaking area.,

7. Refit radiator to car (Refer to:
Radiator - Removal and Installation).
Fill with coolant and check forleakages.

ELECTRIC FAN CONTROL THERMAL CONTACT
REMO-VAL AND
INSTALLATION
1. Drain coolant.
2. Disconnect thermal contact cables.
3. Unscrew thermal contact fromradiator.
4. Installation is carried out inreverse order of removal.
5.

At

the

procedure,end of installation
fill the circuit with

coolant and let the engine rotates
until coolant reaches the temperatureof 88 + 92°C (190.4 + 197.6”F) a n dverify that electric fan inserts.

CHECKS AND
INSPECTIONSCheck thermal contact according to
the following procedure:
1. Fit thermal contact @ to thetest equipment used for thermostat
test.
2. Fill container with coolant andswitch on equipment to heat water.
3. When warning light 0 illuminates, verify that temperature shownon thermometer dial indicator corresponds to the thermal contact setting
value 88 + 92°C (190.4+ 197.6”F).
1 Warning light

2 Thermal contact

HEADER TANK PRESSURIZED P L U G
LEAK TEST
1. Screw fitting @ to test equipment and insert on header tankpressurited plug.
2. Act on tool to increase pressure
and check on dial indicator thatblowoff valve opens at the required
setting pressure.
Pressurited plug setting pressure
69.6 kPa; (0.69 bar;

0.7 kg/cm’ ; 9.95 psi)

May 1983

1 Pipe fitting

07-6
Alfawiki.nl

2 Pressurized plug

ENGINE COOLING SYSTEMSERVICE DATA AND SPECIFICATIONSELECTRIC FANINSPECTION AND
ADJUSTMENTCAUTION:
Produit harmful to the paint. Avoid
contact with painted parts.

Electric fan intervention
88 - 92°C
temperature(190.4+ 197.6”F)

BELT TENSIONING
Load to be applied:

78.4

N

(8
17.64

kg
lb)
mm

Resultant arrow
105.6

in)

GENERAL
SPECIFICATIONSNALCO: 1006
INTERPOIND:

Jal

Auto

Cat.

3681-69955

COOLANTTHERMOSTATTEMPERATURE

Summer84 + 88°C- Start of opening(183.2 + 190.4”F)- End of opening

Water

986
(2084°F)- Bulb travel>7(> 0.28 :;I

7.3

Imp. Gall

1.61

WinterMin. temperatu re

RADIATOR

T

-10

-20

-35

OF

(14)

i-4)

1-31 I

1.8

2.6

Antifreeze cat.

Radiator leak control
pressure

COOLING SYSTEM SCALESREMOVER

1 0 7 . 9 kPa
bar;
(1.0
1 .I kg/cm2;
15.64 psi)

3661-69956 I(Imp. gall)
I

Water

(Imp. gall)(0.391 (0.57:
5.5

4.7

(I .2) (I .03

3.65

10.80)
3.65
IO.801

Antifreeze ready

PRESSURIZED PLUG

for use cat.

Pressurized @lug setting
68.6
kPa
pressure(0.69 bar;3681-69958 I

-

7.3

(Imp.

-

(1.61

gall)

0 . 7 kg/cm’;
9.95

Psi)

SEALING AND FIXING COMPOUNDS

Application

Sealing compound for cooling &tern

TYW

Sealing powder

Denomination

AREXONS Cat. 3522-00101

Q.W

7.3 g
0.20 (az)

ALUMASEAL can be used as an alternative.

Of-7
Alfawiki.nl

May 1983

ENGINE -COOLING SYSTEM

TIGHTENING TORQUES
ft*lb

Cooling.temperature transmitter on feeding manifold

33441

3.4 f 4.2

24.58 + 30.37

Water pump securing Screws

19 +24

1.9 + 2.4

13.74 + 17.35

TROUBLE DIAGNOSIS AND CORRECTIONS

Water leakage

Corrective action

Probable cause

Conditionb Radiator damaged

Repair or replacem Leaks in system couplings

RepairI Loose or broken clamps

Tighten or replace

I Leakages from thermostat

Replace gasket or thermostat

0 Damaged cylinder head gasket

Replace. Check engine oil for contamination* Loose cylinder head tightening

Restore correct tightening

screwsPoor circulationlPipes obstructed

Check pipes and clean systemlInsufficient

Top uplinoperative water pump

ReplacelWater pump and alternator driving

Adjustcoolant

belt loosen

Periodically change coolant at intervals

Corrosion and scales

recommended.
Follow instructions for use shown on
packaging.

Overheatingl

Inoperative

thermostat’lDirty and scaled radiator

ReplaceClean pipes flushing with the specified
descaling compound. Follow instructions
for use shown on packaging.

l

Ignition out-of-phase

RetimelPoor lubrication

Restore oil levell

Faulty water pump

ReplacelInsufficient coolant

Restore coolant level and check system
for leaks

May 1983

07-8
Alfawiki.nl

CLUTCHDESCRIPTIONThis is a hydraulic controlled, dry,singledisc clutch provided with athrust bearing @ which is always
pressureplate
in contact with

al @, operated through a masterc y l i n d e r0
7 which transmits fluid

spring @ . Diaphragm spring @pressure engaged driven plate. Dis-The latter operates on the withdrawal lever @ by a push rod @,pressure increase to operating cylinder @ piston.

moves thrust bearing (self centering)
and wins diaphragm spring action.
By means of gaskets performing on
cylinder, piston takes up possible
slacks and therefore driven platewear recovery is automatic.

engagement is obtained by a ped-

(1.5 + 1.9
10.8
13.7)

4

(!$I15 + 23
(1.5 + 2.4
10.8 + 17.41

1
2
3
4
5
6
J
8
9
10
11
12
13
14
15
16

17

May i983

12-2
Alfawiki.nl

Clutch disc
Bleeder screw

Operating cylinder
Control push rod
Flexible hoseBrake and clutch hydraulic system reservoir
Clutch master cylinder
Pedal
Clutch withdrawal lever
Diaphragm spring
Direct drive shaft
Thrust bearing support
Self centering thrust bearing
Clutch cover
Pressure plate
FlywheelBushCLUTCHHYDRAULIC CONTROL UNIT
CLUTCH PEDALCHECKS AND INSPECTIONS
1. Inspect pedal and pedal pad for
deformation or damage.

REMOVAL1.
Operating from the interior
compartment,
removestopperring @, and remove pin @ discon-

DISASSEMBLY
1. Remove boot @, remove stop-

2. Inspect bushes of clutch pedal,

per ring 0, then remove push rod
with fork 0, gaskets @ and 0,

pin and spacer for excessive wear orp i s t o n @,necting pedal @ Tram master cyl-

seizing.
3. Inspect return spring for fatigue

inder control fork 0 and returnor damage.

washer@spring @ .
2. Reniove c o n n e c t i o n0gasket @ .

and
and

spring.

INSTALLATION
Install clutch pedal on car in reverse
order of removal and apply grease tobushes of clutch pedal and to mastercylinder fork connection pin (AGIP
Fl Grease 15).

CLUTCH MASTERCYLINDERREMOVAL
Remove filler plug 0 o n
1.
reservoir 0, relevant gasket andfilter then, with a syringe, drain

1 Fork

3 Pedal

2 Pin

4 Stopper ring

2. Operating from the engine room,
remove pedal pin stopper spring @andrelev’ant
washer.
Unscrew
screw @ securing the bracket @for sheath stopper of accelerator
control cable, in order to be able towithdraw pedal pin enough torecuperate the clutch pedal from theinterior

compartment.

enough fluid to make level fall below
connection to master cylinder @.
flexible
2. Disconnect
SUPPlYhose @ from master cylinder.
3. Loosen connection and disconnect rigid pipe @ from mastercylinder.
4. Operating from inside the car,remove stopper ring, remove pin anddisconnect cylinder control fork
from pedal (see: Clutch P e d a l Removal).
5. Unscrew screws

fixing0
master cylinder to pedal assy andthen remove master cylinder.

1
2

Master cylinder
Stopper ring3

Gasket4 Piston
5
6

GasketBoot

7 Fork
8 Washer
9 Spring
10 Gasket
11

Connection

CHECKS AND INSPECTIONSCAUTION:
To clean or wash all parts of mastercylinder, recommended clean brakefluid must be used. Never use mineraloils or gasoline and kerosene to avoid
damaging rubber parts.

1. Check cylinder bore and piston
for score or rust and if found replace.
2. Check cylinder bore and piston
for wear. If the clearance between
cylinder bore and piston exceeds
value, replace
pistonspecifiedassembly or master cylinder assembly.
3. Check condition of boot and1 Stopper spring
2 Bracket

replace it if damaged.
4. Check all recesses, openings and3 Screw

3. Remove the two plastic bushes
from pedal.

1
2

Plug
Flexible pipe

3

Screws5Connection

internal passages to ensure that they

6
7

Rigid pipe
Reservoir

are clean and free from foreign

4 Master cvlinder

Alfawiki.nl
12-3

matter.

May 1983

CLUTCHDISASSEMBLYASSEMBLY
1. Lubricate sliding part surfaces.

1.

2. Install piston assembly to cylin-

reservoir, together with gasket andder body.
3. Make sure that master cylinder

filter, and by means of a syringe
drain enough fluid to make level fall
below connection to master cylinder.
2.
Remove flexible hose connecting

operates normally.
4. Make sure that piston can movemaximum stroke smoothly.

INSTALLATION
1. Install clutch master cylinder inreserve order of disassembly.
2. Top up oil to correct level inreservoir.
3. Bleed air out of hydraulicPush rod
Boot
GasketSpringRing

6 Cylinder body
7 Bleeder screw
8 Gasket
9 Pistonsystem (Refer to: Hydraulic System
Bleeding).

CHECKS AND INSPECTIONS@ : Tightening torque
Clutch hydraulic piping connections
15+18 Narn

Visually inspect

all disassembled

parts and replace parts which areworn or damaged.

(1.5 + 1.9 kg-m

CAUTION:

10.8 + 13.7 ft-lb)

To clean or wash all parts of operating cylinder, recommended clean

CLUTCH OPERATINGCYLINDER

brake fluid must be used. Neveruse mineral oils or gasoline andkerosene. It will ruin the rubber partsof the hydraulic system.

REMOVAL
1. Remove operating cylinder control hose, then remove clutch operating cylinder lock ring @ from its
seat on engine back cover 0.
2. Remove operating cylinder.

1. Check cylinder bore and piston
for score or rust.
2. Check cylinder wear, spring
efficiency and integrity of seal rings.
3. Check whether bleeder hole isclean.

reservoir and clutch master cylinderand remove pipe.
3. Loosen the rigid and flexible
pipes connections, connecting mastercylinder and clutch operating cylinder and remove pipes.

INSTALLATION
1. Install clutch line in the reverse
order of disassembly.
2. Top up oil in reservoir to correct
level.
3. Bleed air out of hydraulicsystem. (Refer to: Hydraulic System
Bleeding).

HYDRAULIC SYSTEMBLEEDING
The clutch and brake hydraulicmust be bled wheneversystemhydraulic system has been disconnected or air has entered it.
Refer to figure on page 12-2 (see:Description) and observe the following procedure.

CAUTION:a.

ASSEMBLY

INSTALLATION
Assemble clutch operating cylinder
in its seat on engine back cover
together with retainer ring.

HYDRAULIC SYSTEMP IPIN G

DISASSEMBLY
1.

Remove

push

rod

@

with

b o o t 0, p i s t o n @) a n d p i s t o n@ from operating cylinspring
der 0.
2. Remove push rod from boot.
3 . R e m o v e b l e e d e r s c r e w 0.

CHECKS AND INSPECTIONSVisually inspect clutch lines forevidence of its integrity. Replacedamaged parts. If leakage occurs at
joints due to loosening, retighten
and if necessary replace damaged
parts.

May 1983

Do

notre-use

brake

fluid

drained during bleeding oper-

Assemble clutch operating cylinder
in reverse order of disassembly.

1 Lock ring
2 Clutch operating cylinder
3 Back cover

Remove filler plug on supply

12-4
Alfawiki.nl

ation.
b. Exercise care to prevent splashing of brake fluid on painted
areas as it will damage thepaint.
c. During bleeding operation fluid
level in reservoir must be kept
above min. mark.

1. Remove clutch and brake hydraulic system reservoir plug and top
up with recommended brake fluid(ATE“S”
or AGIP Fl B r a k e
Fluid Super HD corresponding to
Alfa Romeo Part No. 3681.69905).
2. Remove bleeder screw protection b o o t @ o n O p e r a t i n gcylinder 0; install a hose on same*

CLUTCH

2. Check with a sliding gauge @for even wear of both facings a n dwhether clutch disc thickness is notnear to specified limit. Replace
disc if necessary.
Wear limit for disc thickness

6.5 mm (0.26 in)’&
1
A.4.0144 A

LA.2.0378

3
1 Flywheel
2 Cover fixing screws

Clutch cover
1
2
3

Clutch cover
Pressure plate working surface
Diaphragm spring3.

6. R e m o v e c o v e r @ and c l u t c hdisc 0.

1 Sliding gauge
Check fit of clutch disc hub @Flywheelon direct drive shaft @ for smoothsliding or excessive backlash. If

Check flywheel friction surface @for overheating, uneven wear, scoring, or removal of material. If necessary, disassemble flywheel ‘and grind
both working surface and clutch

necessary replace clutch disc.

cover support plane.
Grinding limit value

on planes

0.2 mm (0.01 in)

1 Clutch disc2 Clutch cover

1 Clutch disc
3 Clutch disc hub
2 Direct drive shaft

CHECKS AND INSPECTIONSINSTALLATION

Wash all disassembled parts except
clutch with suitable cleaning solvent
to remove dirt and grease before
making inspection and adjustment.

1.
If the two oil seals on crankshaft
and on direct drive shaft have been
removed when c l u t c h u n i t w a s
disassembled, i n s t a l l two new oil

1
2
3

Engine flywheel
Pressure plare support plane
Working surface

seals (Refer to: Group 01 Engine
Assembly - Crankshaft and Group 13
5Speed M a n u a l G e a r b o x S h a f t s

Clutch cover
Check pressure plate working surfor overheating marks,
face @
uneven wear, scoring and material
removal.
Replace clutch cover if necessary.

May 1983

and Gears).
2. Install flywheel if removed in

Clutch discInspect clutch disc for burn or oilyfacings, loose rivets and broken

disassembling clutch unit (Refer to:- Engine Assembly).
Group 01

torsional springs.

Be sure to keep clutch disc, flywheel

1. In case of clutch abnormalities
due to oil leakage at crankshaft or
direct drive shaft oil seal, replace

and pressure plate facings clean anddry.
3. Set clutch disc and clutch coverboth clutch disc and seals.

on flywheel.

12-6
Alfawiki.nl

CLUTCHSERVICE DATA AND SPECIFICATIONSGENERAL SPECIFICATIONSFLUIDS AND LUBRICANTS

1 Thrust bearing

2 BushApplication

Thrust bearing working seat @Denomination

TVP~- AGIP Fl Grease 33 FD

GREASE

Std. N . 367 I-69833134- IP Autogrease FD
Std. N . 367 I-69833134- ISECO Molykote BR2
Std. N. 3671-69841

GREASEEnd crankshaft bush @ISECO Molykote Paste G-

Std. N. 3671-69840

Clutch pedal-cylinder control fork

GREASEAGIP Fl Grease 15-

Std. N. 3671-69810

connection pin
Clutch pedal hub
Clutch hydraulic system supply- ATE “S” - S t d . N . 3681-69905

FLUID- AGIP Fl Brake Fluid Super HD
Std. N. 3681-69905- IP Auto Fluid FR
Std. N. 3681-69905

INSPECTIONS AND ADJUSTMENTS
FLYWHEEL AND CLUTCH COVER
Grinding limit values on working surfaces . . . . . . . . . . . . . . . . . . . . . _ . . . . . _ . , . . . _ . . _ _ . .

0.2 mm (0.01 in)

CLUTCH DISC
Disc

thickness

May 1983

atwear limit . . . . _ _ _ . _ . . . . . . . . _ . . . . _ . . . . . . _ . . . _ . . . . . . . . . . . . _12-8
Alfawiki.nl

6.5 mm (0.26 in)COMPLETE CAR

Condition

Corrective action

Probable cause

Spark is good:a. Check spark plugb. Check ignition timing
C.

Check fuel system

d. Check cylinder compression

Spark is not good:
Ignition system is out of orderl

Low or no current in primary

Check primary circuit for loose or

circuitdisconnected terminals
Verify that the electronic ignition unit
is properly functioningl

Rotor arm current leakage

Clean or replacelFaulty spark plugs

Clean, adjust electrode gap or replacelImproper ignition timing

Adjustl

Faulty ignition coil

Replacel

Cut-off in high voltage cable

ReplacelLoose connection or cut-off

Repair or replacein primary circuit

Fuel system is out of order

Low compressionlLack of fuelRefuell

Dirty fuel filter

Clean

l

Dirty or clogged fuel pipes

Clean

l

Faulty fuel pump

ReplacelFaulty carburetor choke

Check and adjustlIncorrect float level adjustment

Adjustl

Improper idling

Adjustl

Dirty or clogged carburetor jets

Disassemble and cleanlClogged fuel tank breather pipe

Repair and cleanlIncorrect spark plug tightening

Tighten to normallIncorrect valve clearance

AdjustlCompression leaks from valve

Remove cylinder head and lap valves

seats
l

Seized valve stem

Alfawiki.nl

00-33

Replace valve and valve guideMay 1983

COMPLETE CAR

Condition

High engine idling

Probable cause

Stiff accelerator cable andlCorrective action

Checklinkagel

Incorrect idle adjustment

Adjustl

Malfunctioning throttle valve

Check

ENGINE POWER NOT UP TO NORMAL
Low compression

Ignition system out of order

Previously mentioned

Previously mentionedl

Incorrect ignition timing

Adjustl

Dirty or worn spark plugs

Clean or replacel

Incorrect advance

AdjustFuel system out of order

Previously mentioned

Otherb Faulty fuel pump

Replace

I Clogged fuel pipes

Clean

Air intake system out oflClogged air cleaner

Replace cartridgel

Air sucking around manifold

Replace gasket

order

gasket or carburetor gasket

OverheatinglInsufficient coolant

Replenishl

Broken water pump drive belt

ReplacelFaulty thermostat

ReplacelFaulty water pump

Replacel. Clogged or leaky radiator

Clean, repair or replacelFaulty electric fan

ReplacelFaulty thermal switch

Replacel

Air in cooling system

Restore proper cooling systemtightness

Overcoolingl

Clogged jets (lean mixture)

Overhaul carburetorlIncorrect ignition timing

Adjustl

Faulty thermostat

ReplacelFaulty thermal switch

Replace

Alfawiki.nl
00-35

May 1983

COMPLETE CAR

Condition

Probable cause
Petrol used has low octane rating

Other

Corrective action
Replace with petrol having specified
octane rating

Dragging brakes

Adjust1 Slipping clutch

Adjust or replaceb Overloaded engine

Use proper gear in driving

NOISY ENGINE (while driving)
Engine knocking

I

Knocking due to carbon deposit

Disassemble cylinder head and remove
carbon deposit

I

Knocking due to incorrect

Adjust ignition timin,gignition timingm

Knocking due to improper petrol

Use petrol having specified octane rating.

Preignition (due to wrong type

Replace with specified type spark plugs

spark plugs)

Mechanical knocking
Crankshaft bearings knockinglWorn crankshaft bearings

This strong dull noise increases as

Replace bearings and either grind or
replace crankshaft. Check lubrication
systemengine is accelerated

Connecting rod bearingslWorn connecting rod bearings

Same as for above crankshaft bearings

knocking
This is a slightly higher-pitchednoise than the one caused by knocking of crankshaft bearings and it
also increases as engine is accelerated

Noisy pistonslPistons and/or cylinder liners

Overhaul the engine

are w( 2-rThis is a diffused metallic noise
which increases as rpm increase
and decreases when engine is warm

Noisy water pumpllPlay in rotor

Replace water pump

Improper adjustment of valve

Adjustclearancel

May 1983

Excessive crankshaft end play00-36
Alfawiki.nl

Replace crankshaft axial bearings

COMPLETE CAR

Probable cause

Condition

Corrective action

ABNORMAL COMBUSTION(backfire, self-ignition,
detonations)
Incorrect ignitionl

Incorrect ignition timing

Adjust timinglWrong type spark plugs

Replace with recommended type plugs

Fuel system out of order

Previously mentioned

Previously mentioned

Faulty cylinder headslIncorrect valve clearance

Adjustl

Excessive carbon deposit in
combustion chambers

Desassemble cylinder heads and remove
carbon depositlDamaged valve springs (backfire
detonations)ReplacelLoose oil drain plug

Tighten itlLoose oil pan screws

Tighten or replacelWorn or damaged oil pan gasket

Replace gasketlWorn or damaged cylinder blockand cylinder head gaskets and oilseal rings

Replace gaskets and oil seal ringsl

Loose oil filter

Tighten or replace, if necessarylLoose oil pressure switch

Tightenl

Dipstick does not fit tightly

Replace dipsticklWorn cylinders and pistons

Grind cylinders and replace pistonslImproperly assembled piston
rings

Assemble properlylWorn piston rings

Replace piston rings or, if required,grind cylinders and replace pistonslWorn piston rings and piston
ring seats

Replace pistons and ringslWorn valve guides and grommets

Replace valve guides and grommetslWorn valve sEems

Replace valvesl

Improper oil grade

Replace with specified oil typelEngine overheats

Previously mentioned

EXCESSIVE OIL CONSUMPTION
Oil leaks

Excessive oil consumption

Other

-

Alfawiki.nl

00-37

May 1983

COMPLETE CAR

Condition

Probable cause

Corrective action

EXCESSIVE FUEL CONSUMPTIONEngine power not up toPreviously mentioned

Previously mentioned

normalOtherlIdling too high

Adjust idlingl

Improper accelerator recovery

Adjustl

Fuel leaks

Repair or tighten fuel line unionsl

Clogged air cleaner

Replace cartridgel

Improperly adjusted carburetor

AdjustlWorn or damaged carburetor

Replace gaskets

gaskets

OTHER PROBLEMS
Reduced oil pressurelImproper oil grade

Replace with specified oil typel

Oil is missing

Replenish with specified oil typel

Overheating

Previously mentioned

0 Worn oil pump control valve

Disassemble oil pump, repair or
replace it

Excessive wear of slidinglWorn oil pumpRepair or replacel

Excessive play o f sliding parts

Disassemble and replace worn partsl

Clogged oil filter

Replace cartridgelFaulty oil pressure switch

ReplacelInsufficient oil pressure

Previously mentionedparts

Improper oil grade or contami-

Replace with specified type oil andnated oilreplace cartridgelFaulty air cleaner

Replace cartridgelOverheating or overcooling

Previously mentionedlInsufficient oil pressure

Previously mentionedlInsufficient

Adjust to specified valueslOverheatingl

Seizing of sliding parts

clearances

Previously mentioned

Alfawiki.nl

COMPLETE CARCHASSIS AND BODY MAINTENANCECHECKING FUELAND EXHAUSTSYSTEM

CLUTCH

1. Check fuel and exhaust systems,
especially at connections, making

tighten unions according to specified
torques or either overhaul or replacesure there are no leaks.
2. Check condition of all fuel andfaulty parts (Refer to: Group 12 -CHECKING CLUTCH SYSTEM
Check clutch pump @ and clutch
control cylinder @ making surethere are not oil leaks. If required,exhaust pipes replacing same if

Tightening Torques).
Make sure that clutch pump a n drequired.
3. Tighten all loose connections.

way damaged.

control cylinder boots are not in any

1 Oil supply plug

2 Oil drain plug

ASSEMBLY
DRIVE SHAFTCHECKING DRIVE SHAFTASSEMBLY
Visually check drive shaft assembly
for wear or deformation of its
various components, making sure
protecting boots are not in any way

damaged or show grease leakage.
If necessary,

replace damaged orworn parts.

1 Clutch pump

FRONT AXLE AND
FRONT SUSPENSION

2 Clutch control cylinder

GEARBOXDIFFERENTIALCHECKINGGEARBOX-D1 FFERENTIAL
OIL LEVEL
Check oil level making sure it reaches
filler lower edge; clean relevant cap
and tighten it.

REPLACINGGEARBOX-DIFFERENTIAL
OIL
1.

While engine is warm, remove oil

CHECKING FRONT AXLE
AND SUSPENSION
2.
Let oil drain completely (wait atleast 15 minutes); clean drainplug @ and tighten it.
3 . R e f i l l o i l p a n t h r o u g h SUPPIY
hole 0 with specified oil type andquantity. Refer to “LUBRICANTS”
chart for recommended oil type.

Gearbox-Differential casing Oil
wpacity

2.3 + 2.4 kg (5.07 + 5.29 lb)

pan drain @ and supply 0 plugs.

Alfawiki.nl

00-39

1. Block rear wheels with chocks
and raise front of vehicle fitting jackto proper lifting points (Refer to:“Lifting Points and Towing”).
2. Check front suspension parts forwear or damage.
Also check all bolts for proper
tightening; refer to: Group 21 Tightening Torques - for relevant
tightening torques.
Replace worn parts according torelevant procedures described in
G r o u p 2 1 Front Suspension.

May 1983

COMPLETE CAR

ADJUSTING WHEELBEARING PRELOAD
After replacement or disassembly of
bearings, carry out adjustment operating as follows.

For wheel bearing replacement refer
to Group 25.
1. Tighten wheel bearing lock-nut
according to specified torque and at
the same time turn hub 4 + 5 times
in both directions to allow bearings

5. Caulk nut taking care to avoid

to settle.

rotation in order not to alter clearance play.

@ : Tightening torque
Wheel bearing lock-nut
25 + 29 N-m(2.5 + 3 k g - m
1 8 . 0 8 + 2 1 . 6 9 &lb)

Apply specified grease quantity tobearings in the suspension.

CHECKING
SUSPENSIONHEIGHTSBe sure to perform following preliminary operations:a. Set up vehicle with all refill
liquids at max. level and withspare wheel.
b. Check tire pressure; refer to“Wheels and Tires” for specified

3. Check shock absorbers for oilc.

leaks or damage.

4.

Remove wheels.
5. Check brake pads for wear

2. Partially unscrew lock-nut a n d
hit the hub with a mallet to ensure(Refer to: G r o u p 22 - Front Discouter bearing settling against washer
and.nut.

Brake).

CHECKING
REAR AXLE
AND SUSPENSION PARTS

suspensions a few times.

torque).
4. Check and make sure axial play
is within specified value.

Bearing axial play0 + 0.05 mm (0 + 0.002 in)Luggage C = 490 N (50 kg; 1 IO lb)

t h a n 1 N.m; 0 . 1 kg.m; 0 . 7 2 ftalb -1. Check rear axle and suspension
for loose, worn or damaged parts.
2. With vehicle in nominal driving
condition, i.e. with static load (Refer
to: Checking Suspension Heights),
tighten loose bolts according to
specified tightening torque. Refer to:Group 25 Service Data and Specifications
for relevant tightening
torques.
3.
Replace worn parts according to
the relevant procedures described inGroup 25.

May 1983

shown in below figure.
e. Move vehicle up and down on

Static load equivalent to threepassengers plus luggage
Passenger equivalent to
A i- 6 = 490 + 245 = 735 N(50 + 25 = 75 k g )(110 +55= 165 lb)

3. t-land tighten the nut (moderately, so as to obtain a less

REAR AXLE AND
REAR SUSPENSION

d.

values.
Place car on lift.
Load weights on vehicle as00-40
Alfawiki.nl

COMPLETE CARFRONT SUSPENSIONHEIGHTplane passing on the base of the nut
connecting hub support to control

Check front wheel alignment picking

arm, and the straight line tangent toup specified “K’ dimension which is

the hub support.
Point 2:

obtained by drawing two lines
parallel to floor plane respectively

axis of the bolt securing control arm

through below definedpassing
points 1 and 2.

to chassis.

Point 1:
it is the intersection between the

Front wheel alignment dimension
A=12+7mm(0.47 4 0.28 i n )1 Probe2 Height check tool
3 Rule2. Carry out measurement ofdimension relevant to step 2. making
u s e o f t h e f o l l o w i n g tools a n dmoving only graded stem of checktool.
(1) Rule @ A.4.0146.
for suspension height(2) T o o l
c h e c k @ A.4.0149.
(3) Magnetic adapter @ A.4.0153.

1 Magnetic adapter
2 Tool for suspension height check
3
Rule
’

3. Directly read on graded scale(located on movable stem of checktool) rhe”&‘height dimension value.
‘fi”dimension must be picked up for

setting the graded movable stem ofboth front right and front left

check tool to the complete backward

suspensions.

position (see following figure).
(I) Rule @ A-4.0146.

DIMENSION MEASUREMENT
1. Carrymeasurement ofoutdimension relevant to step 1. making
use of the following tools and(2) T o o lfor suspension heightcheck@ A.4.0149.
(3) Probe 0 A-4.0150.

REAR SUSPENSION HEIGHT(1) Check rear wheel alignment‘bymeasuring specified ” B” dimension
which is the distance between the
two lines parallel to floor plane andpassing throughbelow

definedpoints 1 and 2.

Alfawiki.nl
00-41

May 1983

COMPLETE CAR

steering wheel and centre racks.
(1) Use suitable equipment andmeasure toe-out making sure it iswithin specified value.

Point 1:

Axis of bolt @ securing front rod
to wheel support.
Point 2:

Axis of bolt @ securing front rod
to body.

Toe-out
H - M = +4flmm(+0.157 f 0.04 in)

Car rear suspension height dimension
B = 23 * 7 mm (0.90 f 0.27 in)

Front toe-out angle
a= IO’
Wheel rim diameter0 = 340 mm (13 in)

1 Magnetic adapter 3 Rule2 Check tool

Proceed as follows to carry out
dimension measurement relevant topoint 1; set graded movable stem ofcheck tool to the completely backMeasurement of “B”dimension must

ward position, then measure dimen-

be carried out both for right tie rod
and for left tie rod of rear suspen-sion relevant to point 2. by moving
only graded stem of tool.

sion.

DIMENSION MEASUREMENT
1. Carry out measurement ofdimension relevant to point 1 and 2
making use of the following tools.
(1) Rule @ A.4.0146.
(2) T o o l f o r suspension heights
check @ A.4.0149.
(3) Magnetic adapter @ A.4.0206.

2. Directly read on graded scale(located on movable stem of checktool) the value of”B”height dimension.
In case the read values differ fromthe prescribed ones, replace springs.

WHEEL ALIGNMENTCHECKING FRONT WHEELALIGNMENTBe sure to perform following preliminary operations prior to checking
and, if necessary, adjust front wheel
angles.
a. Check tire pressure; refer toGroup 28 - Checking Tire
Conditions.
b. Set up vehicle with static load.
c. Pick up front wheel alignment’&”
dimension as well as rear wheelalignment “B” dimension (Refer
to: Checking Suspension
Heights).

1. Toe-out
On aligned wheels, verify thatsteering wheel racks are properly
centred. If necessary, w i t h d r a w

May 1983

00-42
Alfawiki.nl(2) If necessary, adjust toe-out asfollows:- Loosen side rod lock-nut- BY means of tool A-3.0156
disconnect vertical steering leverball joint (Refer to: Group21 - Coil Springs and Shockabsorbers).
- Suitably turn ball joint still
specified toe-out is achieved.
Min. possible toe-out adjustment is
42 mm (0;08 in) on H - M difference
to 1 turn(variation
corresponds- 1 mm (0,039 in) thread lead - ofone ball joint) meaning that semi
toe-out value is equal to:

L = (l/2 M + 2 f 0,5) mm(l/2 M + 0.08 f 0,020 in)

Orientate joint body @ locatedon side rod @ so that, after
being connected to steeringthelever 4 ,joint’s upper
level 1 is parallel to the lever’s
upper level 0.
Tighten lock-nut @ and thentighten to specified torque thenuts securing ball joint tosteering lever.

8

COMPLETE CAR@ : Tightening torqueNut securing side rod ball joint

Camber angle
p=O”125’

onto vertical steering lever
39+448 N - m( 4 + 4.9 kgdm
2 8 . 9 2 + 3 5 . 4 3 ft.lb)

Camber and caster angles cannot be
adjusted.

4. Max steering angles = 33” 30’

BRAKE SYSTEMCHECKING BRAKE FLUID
LEVEL
1 Joint’s upper level2 Joint body
3 Steering lever’s upper level
4 Steering lever
5 Side rod
6 Lock nut(3) Recheck toe-out value.

2.

Camber angle
0 = 2015’+ 30’

CHECKING REAR- WHEELALIGNMENT

Check and make sure fluid level in

Rear angles cannot be adjusted.

reservoir is not more than l/4 below

Toe-in angle

max. level. If fluid level is extremely
low, check brake system for leaks.

a= O”1 2 5 ’

CHANGING BRAKE FLUID/+ I- _a 1 a

1. Connect a hose to wheel
bleeders and let brake fluid drain
into a suitable container (refer
to: Group 22).

-4&
’I I

CAUTION:
Be extremely careful not to drop anyof the brake fluid on painted s’urfaces
since it is highly corrosive.
2. Refill system with new oil andbleed all air from the system (refer

3. Caster angle

to: Group 22 - Brake System Bleed-y= 1”$30’

ing).

Alfawiki.nl
00-43

May 1983

COMPLETE CAR(4) Maneuverability of control lever

BODY

must result to be easy and smoothrunning and when control lever is

LOCKS AND HINGES

engaged hooking tooth must be into
its seat in the scroll gear without2.

difficulty.

3. If required,c a r r y out travel

1 . L u b r i c a t e h i n g e s a n d locks.
Adjust lock striker plates.

CHECKING SEAT BELTS

STEERING SYSTEM

adjustment by operating on nut andlock nut of adjustment fork located

1. Check steering for sticking or

under passenger compartment central

stiffness when turning wheels in bathconsole.

directions,
2. Rotate steering wheel clockwise

CAUTION:.
If seat belts have to be washed,
do not use chemical detergentso r solvents since t h e y could
damage the buckles.
.
After a serious accident involving belt stress, replace same even
if apparently it does not seem to
be damaged.

and anticlockwise checking steerings y s t e m f o r e x c e s s i v e play. F o rrelevant

4. Besides, verify the following:(1) With control lever in the test
position also jaws must be at t-est.
(2) When operating control lever,tables must slide freely.
(3) Indicator lamp must switch on
w i t h i n one click o f p a r k i n g b r a k econtrol lever and switch off as soon
as control lever is at rest position.

refer to:adjustment
Group 23 - Checks and Inspections Guide Tube.
Rack
Box
and
3 . T i g h t e n , w h e r e r e q u i r e d , allsteering system connecting points.
(Refer to: Group 23 - T i g h t e n i n g
torques).

1. Check anchors making sure they
are not loose on mountings.
2.
3.

Check belts for wear.
Check proper working conditionof buckles and tongues,

4.

Fasten seat belts and check if incase of sudden movement they are4.

locked.
promptly
Contrarywise,
check retractors’ locking system.

necessary.
5 . C h e c k s t e e r i n g r o d bal1 a n d
flexible joints; replace them if worn.

If condition of any seat belt component is questionable, replace theentire belt assembly involved.

Check condition of steering box
protecting boots and replace them if

SERVICE DATA AND SPECIFICATIONSENGINE MAINTENANCETECHNICAL DATA - INSPECTION AND ADJUSTMENT

EngineEngines
1200

I

1350

1500

Valve clearance (cold engine)
Intakem m (in)

0.35GO.40

Exhaustm m (in)

0 . 4 5 t 0 . 5 0 (0.018+0.020)(0.014+0.016)

N (kg, lb)
mm (in)7 9 (8 ;3.63)

Alternator-pump belt tension
Force applied to belt
Deflection

15 (0.59)

Cylinder compression
Min compression pressurekPa (bar , p.s.i. , kg/cm2)

1 0 3 0 (10.30,149.39;10.5)

kPa (bar, p.s.i., kg/cm2)

9 8 ( 0 . 9 8 ; 14.22 ; 1)

Max compression difference

between cylinders

Alfawiki.nl
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May 1 9 8 3

COMPLETE CARCHASSIS AND BODY MAINTENANCETECHNICAL DATA - INSPECTION AND ADJUSTMENT
Axles and suspensions

Vehicle static loading arrangement (1)N

kg, lb)A+6 =490 -1-245 =735 (50+25 =75)(110 +55 =165)c = 490 (SOT; (110)

Front wheel alignment

mm (in)

A =12 f7 (0.47 iO.28)

Rear wheel alignment

mm (in)8 =23+7 (0.90*0,27)

Front wheel toe-out (2) (3)mm (in)M - H =4*1 ( 0 . 1 5 7 f 0 . 0 4 )Fronr wheel semi toc-out (21 (3)mm (in)L = (1/2 M +2 * 0.5) (l/Z M +0.08 *O.OZ)

a=io’

Front toe-out angle
Wheel rim diameter

mm (in)0 =340 (13.38)

Rear wheel toe-in

a=oOk 25’

Front wheel camber (3)p=-2’15’&30’

Rear wheel camber

p=0°&25’

Front wheel caster (3)+y=1”430’

Max steering angle (3)8 = 33” 30’(1)

Load vehicle, move it UP and down on suspensions a few times. Checking operations must be performed with vehicle fully set up
for driving.

(2)

When turning a steering side rod joint by 360’. M - H dimension changes by 2 mm (0.079 in).

(3)

These values are referred to a vehicle in nominal driving condition, i. e. with static load

Brake system

Disc brake
Disc min. thickness

m m (in)

9 (0.354)

Pad min. thickness

m m (in)7(0.276)

Drum brake
Lining min. thickness

m m (in)Max drum inner diameterm m (in)

0.5 (0.019)
229.6 (9.04)

Parking brake
Lever stroke, when applying a pulling force of= 98 N Il0 k g ) (22 lb)

2 notches

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00-47

May 1983

CLUTCH

TIGHTENING TORQUES

N.m

kg*m

fz-lb

15 + 23

1.5 + 2.4

10.8 + 17.4

Gearbox unit to engine resr caver securingbons and nuts

39 + 47

4+ 4.9

28.9 + 35.4

Hvdraulic system pipe fitting securing nuts

15 + 18

1.5 + 1.9

10.8 + 13.7

Clutch caver to angine flywheel unit securing
screwsTROUBLE’ DIAGNOSIS AND CORRECTIONS

Clutch slip

Corrective action

Probable cause

Condition

Some trouble symptoms may also be attributable to engine problems. First
determine whether engine or clutch is causing the problem.

Symptoms:- Car Will not respond toengine speed during acceleration- lnsufficient car speed

T O test for slipping proceed as follows:- engage parking brake- disengage clutch and shift gears into 4th- increase engine speed and gradually release clutch pedal; if car does not
move and engine does not stop, clutch is slipping- Lack of power during uphill
drivingl

Clutch facing excessively wornlClutch facing wet with oil or grease- Increasing of fuel consumption

Replace clutch disc
Replace clutch disc (replace enginel
gearbox oil seals) if faultylDiaphragm spring weak or damagedlFlywheel or pressure plate warped

Replace pressure plate
Repair per replace flywheel or clutch
caver

l

Clutch does not disengage well

Impurities in master cylinder, piston
does not return to start position

Clean cylinder or replace faulty parts

T O test for dragging clutch proceed as follows:- disengage clutch and shift gears into Reverse- shift gears into Neutral, then gradually increase engine speed- after a short interval, shift gears into Reverse
If noise is heard while gears are being shifted, clutch is dragginglClutch disc hub splines or rusted

12-Q
Alfawiki.nl

Clean or replace clutch discMay 1983

CLUTCH

Condition

Corrective action

Probable causellFlywheel and/or pressure plate

Repair or replace flywheel and/or

faciw worn or warsed

clutch caver

Engine supports not efficient

Inspect and/or replace engine supports

SPECIAL SERVICE TOOLS
Tool number

Tool name

A.2.0378

Tool for locking the flywheel

A.4.0144

Clutch disc aligning bar

Alfawiki.nl

12-l 1

Refer topage

May 1983

GEARBOXCONTENTS
5 - SPEED MANUAL GEARBOX.. . . .

13-2

Checks and inspections . _ . _ . . . . . .

13-25

Description . . . . . . . . . . . . . . . . . . .

13-5

Assembly . . . . . . . . . . . . . . . . . . . . .

13-25

Rear support . _ , . . . . . , . . . . . . . . .

13-5

SERVICE DATA AND

Rods and forks . . . . . . . . . . . . . . . .

13-6

SPECIFICATIONS . . . . . . . . . . . . . . . .

13-26

Shafts and gears . . . . _ . . . . . I . . . . .

13-10Technical data . . . . . . . . . . . . . . . . .

13-26

Differential carriers . . . . . _ . , . . , . _13-19

General specifications . . . . . . . . . . .

13-26

Crown gear and pinion . . . . . . . . . .

13-22

Inspection and adjustment _ _ . _ _ _ _13-28

Differential casing . . . . . _ . e . . _ . _ .

13-22

Tightening torques . . . . . . . . . . . . .

13-30

Gearbox - differential casing . . . . . .

13-24

TROUBLE DIAGNOSIS AND .

GEARBOX OUTER LINKAGE.. . . . . .

13-25

CORRECTIONS . _ , . _ . . . . _ . . . . _ _ . _13-31

Disassembly . . . . . . . . . . . . . . . . . . . .

13-25

SPECIAL SERVICE TOOLS n. . . . . . . .

13-33

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May 1983

GEARBOXS-SPEED MANUAL GEARBOX
Gearbox-differentlsl

unit and r e a r s u p p o r t

13.74 + 17.36)

21b(4 + 4.9
28.92 + 35.43)-.,Y . ,.C‘~19 + 24(1.9 + 2.4
13.74 + 17.36)

@ N.m
(kg-m
ft4b)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

May 1 9 8 3

17
18
19
20
21
22
23
24
25
26
27
28
29
3 0
31

Pin
Gearbox casing
Bushing
Central support
Oil plug
Speedometer sensor
Spring ring
Dowel
Rear caver
Valve
PIUJ
Plate
Pin
Flexible support
Rear support

13-2

Alfawiki.nl

Flexible bush
Oit seal ring
BracketBushing
Flexible support
Reverse gear switch
GasketPlug
D r a i n plug
Oil sump
GasketBushing
Oil seal ring
SupportLock ringG EARBOX

S h a f t e , geara a n d differen~ial c a e i n g@ 220.5 + 245(22.5 + 25
162.70 + 180.771

QI 69 + 8 5(7 + a.7
50.61 + 62.91)/

67 + 74(6.8 f 7.5
49.17 + 54.23)

@ N+m
(kg-m

ft4b)
1
2
3
4
5
6
7
8
9
10
11
12
13

Direct drive shaft
SpringBushing
P i nBearing
Reverse gear shaft
Reverse gear
Primary shaft
longueBearing
Lock ring
5th speed driving gear
Oil deflector

14
15
16
17
18
19
20
21
22
23
24
25
26

R.G. driven gear
Bushing
1 st speed driven gear
Retainer
Guide sector
Locking sector
Synchronizing ring
Lock ring
Sleeve

27

28
29

HUb

30
31
32
33
34
35
36

Fietainer
2nd speed drive gear
Shouldered ring

37
38
39

Alfawiki.nl
13-3

3rd speed driven gear
4th speed driven gear
Shim
Bearing
5th speed driven gear
Nut
Bearing
Shim
PinionBearingDifferential casing
Bearing
Crown gear

May 1983

GEARBOX

Roda and forks@ 25 + 2 6(2.5 - 2.7
18.07 + 19.52)

1
2
3
4
5
6
7
8
9
10

May 1 9 8 3

Lever
Main selector rod
Guide pin
3rdAth speed rod
Interlock plunger
1 sr-2nd speed rod
Interlock plunger
Detent hall
5th speed control fork
Ist-2nd speed lever

11
12
13
14
15
16
17
18
19
20

13-4
Alfawiki.nl

Sth-speed R.G. rod
Plug
Ealls
R.G. fork
Bushing
5th.speed - R.G. rod
1st.2nd speed control fark3rd4th speed control fork
Selector lever
Spring pin

T N*m
0
(kg-m
ftdb)

GEARBOXDESCRIPTION

Installation of vehicle

The gearbox has five forward andIn case of assembly of groups andinstallation on vehicle proceed as

one r e v e r s e gear. All g e a r s h a v e
synchromesh except reverse gear.

follows
1. Assemble gearbox differential

be fed in slowly till the level reaches

AII gears are in constant mesh andunit and engine unit (refer to.

have helical teeth. Reverse gear teeth

Group OI Separation and Assemblyof the Units).

the lower rim of filler hole, check foroil level and fit in plug.

are straight tut. The gears are operated by means of a floor-type gear

3. After installing drive unit on
vehicle fil1 up with prescribed oil( A G I P F I R o t r a M P S A E 8OWQO
or IP Pontiax HD 8OWQO), oil should

lever connected to the selector shafts

2. Assemble drive unit on vehicle(refer to. Group 01 Drive Unit -b y means o f a remote l i n k a g e .
Connectionof rear support to

Removal and Installation).

gearbox casing is obtained through acouple of elastic s u p p o r t s w h i c hreduce to a minimum the trans-

REAR SUPPORT

mission of vibrations to the speed
control lever.

DISASSEMBLY

suitable stand provided with bracket

Set gearbox-differential unit on

and proceed as follows:

1 . R e m o v e remote I i n k a g e 1 retaining clip @ from lever 83 andremove i-cd.

2. Dissassemble gearbox outer linkage from rear support (see. Gearbox
Outer Linkage - Disassembly).
3. Disconnect drive unit rear support from flexible supports 0

Differential and gearbox form asingle assembly. Crown gear-pinion
couple is of the hypoid type andhas a ratio of QI35 or 11139.

TRANSMISSION RATIOSI
Gear

Crown gear andpinion ratio

Gearbox
ratio

9135

11139

Overall ratio
1”

1:3.750

1:14,580

2”

1: 2.050

1: 7.970

lA3.293
1: 7.267

3-

I~I.387

1: 5.392

1: 4.916

4-

1: 1.027

2: 3.992

1: 3.6405”

1: 0.825

1: 3.207

1: 2.924

RM

1:3.091

1:12.017

1:10.957

Remove washers @ and bush 0.

and @ which connect it to gearboxdifferential casing @ by unscrewing0

the two screws 3 .

REMOVAL AND
INSTALLATION
Removal from vehicle
Should the whole drive unit beremoved from the vehicle and thetwo units be thereafter separated,
proceed as follows;
1. Remove drive unit from vehicle(refer to: Group 01 - D r i v e U n i t
Removal and Installation).
2. Separate
gearboxdifferential
unit from engine unit (refer to:Group OI - Separation and Assemblyof the Units).

1 Remote linkage
2 Bush
3 Lever

4 Washers
5 Retaining clip

1 Upper flexible support
2 Gearbox-differential casing
3 Screws
4 Lower flexible support
5 Rear support

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13-S

May 1983

GEARBOX

4. Remove pin @ inserted into
flexible support @ and remove theflexible support itself from rear
support should its replacement berequired.

ASSEMBLY
1.

Reassemble end flexible support
on rear support, the pair of flexible
supports on rear caver, then the rear
support itself following the reverse
order for disassembly and using thesame tools previously used.
2.
Reassemble the outer Iinkage of

3. Unscrew screw @ and remove
plate @ securing oil bleeder valve
to gearbox casing caver and remove
valve plug @ and valve aitself.

.

gearbox on rear support (refer to:
Gearbox Outer Linkage - Assembly).

RODS AND FORKS
1 Pin

2 Flexible support

DISASSEMBLY
5. Unscrew screws connecting flexible supports @ and @ to rearcaver of gearbox casing 0.
Remove flexible supports.

1.

Remove spring pin securing lever

to main selector rod 0 and remove
lever.

1 Valve plug
2 Screw.

1 Rear caver
2 Upper flexible
support3 Lower flexible
support3 Plate4 Valve

4. Unscrew and remove screws @f i x i n g r e a r caver @ to g e a r b o x
casing @ . Use a plastic hammer foloosen caver and remove it together

1 Main selector rod 2 Lever

with seal gasket @.
CAUTION:2.

ûearbox casing is made of aluminium

switch 0 and remove it together
with relevant washer from rear cov-

alloy.
Handle with maximum tare to avoid
damaging it.

Unscrew

reverse

gear

light

0

er 2 .

CHECKS AND INSPECTIONS
1. Clean metal parts of rear support
with solvent a n d check f o r i t s integrity.
2. Check amount of leverage articulation wear.
3 . Check o n i n t e g r i t y o f r u b b e r
bushings, and replace worn or
damaged ones.

May 1983

1 Switch

2. Rear caver

13-6
Alfawiki.nl

1 Screws
2 Rear caver

3 Gearbox casing
4 Seal gasket

GEARBOX8

5. Remove main selector rod 2
seal r i n g @ f r o m r e a r caver 1

S h o u l d removal of seal r i n g t a k eplace while gearbox is fully assembled (on stand or vehicle), special
tool A.3.0429 must be used.

A.3.Q42g7

r-i-l

10. Remove main selector rod

4

and recover selector 0, spring 8 3
and lever 0.

3 Seal r i n g
1 R e a r caver
2 Main selector rod

5.

Remove guide pin @ for mains e l e c t o r r o d @ return spring 1
7. U n s c r e w a n d r e m o v e screws8 4
with relevant fixing washers from oil
sump; remove oil sump @ together

1
2
3
4
5
6
7

Screw
1st and 2nd speed rod
Screw
3rd and 4th speed control fork
1st and 2nd speed leverScrew
1st and 2nd speed control fork

with relevanr gasket.

1 Selector
2 Lever

3 Spring
4 Main selector rod

11. Engage 5th speed and remove
9. Use tool A.3.0322 to remove thefollowing spring pins:
Pin @ securing reverse gear and5th speed lever on rod @securing safety lever on

5th speed and reverse gear rod @lock r i n g @ place on central
support 0.
Unscrew and remove the two halls
securing plug @ then remove thehalls themselves.

securing selector leveron rod 0.

1 Return spring
2 Guide pin

45

Sci-ews
Oil sump

3 Main selector rod

8. Unscrew screw 0 securing 1st
a n d 2 n d sseed control fork 13) o n
r e l e v a n t r o d @ a n d serez 6
securing 1st and 2nd- speed lever 5 .

8Remove lever @ from gearbox

0

casing. Loose and remove screw 3

fixing 3rd and 4th speed control
fork @ on relevant rod.

1 Speed selector lever pin
2 Main selector rod
3 Reverse gear and 5th speed lever pin
4 Reverse gear and 5th speed rod
5 Safety lever pin

Alfawiki.nl
13-7

1 Central support
2 Lock r i n g
3 Securing plug

4 5th speed andreverse gear rod

May 1983

GEARBOXASSEMBLY

12. Remove 5th speed and reverse

14. Remove the following compo-

gear rod @ together with 5th speed

nents from the seats on the rear

1. Set the corresponding 1st.2nd

c o n t r o l f o r k @ and sleeve 0.

support of gearbox casing:
The three detent halls @ fromand 3rd-4th speed control forks onrelevant synchronirer sleeve.

the three rods

2 . Insert d u m m y r o d . A . 3 . 0 3 0 3-

8- The two interlock plungers 3
after unscrewing screw 4

which give access to a channel
w h i c h cari b e inspected b y ascrewdriver able to move theinterlock plungers considered.

into assembly seat of 3rd and 4th
speed rod. Assemble through hole on
dummy rod a new spring with
relevant detent hall, after greasing,t h e n b y means of the driver tool
A.3.0309 insert: and compress t h e m
SO as to be able to move backward
rool rod to keep them into position.
3. Insert relevant rod into gearbox

1 5rh speed andreverse gear rod
2casing seat pushing at the same time
tool rod. Complete assembly of rod

3 5th speed controlb y i n t r o d u c i n g i t i n t o t h e smallfork

hub of the fork and by aligning the

Sleevehole on the latter with the slot on
the rod.
13. Use a driftpin @ to remove 3rd
and 4th speed rod 2 and recover
its relevant fork 8 1 from synchronizer sleeve. Proceed as above
for removal of 1st and 2nd speedr o d @ t o g e t h e r w i t h f o r k @.

3 Interlock plungers
4 Screw

1 Spring
2 Detent halls

During removal o f s p e e d r o d s ,depending upon the operation to be
carried out, i t may b e useful t okeep in their seats detent halls andinterlock plungers: u s e f o r t h i s
purpose tool A.3.0303.
1 3rd and 4th speed control fork
2 3rd and 4th speed rod
3 Driftpin
4
5

1st and 2nd speed control fork
1st and 2nd speed rodseats on the gearbox casing using

CHECKS AND INSPECTIONS

The withdrawal 3rd and 4th speed
rods and 1st and 2nd speed rods
proceeds, as the millings appear,

forks are not excessively worn or

respectively circular and rectangularshaped, in correspondence with thewarped.
Inspect w h e t h e r rods a r e n o t
2.

rear support of the gearbox, it iswarped.
3. Inspect w h e t h e r s l o t s o n r o d s

preventing thus the withdrawal frombeing completed.

May 1983

guide tool A.3.0304 and driver tool
A-3.0309.

Wash parts carefully before operatingon them. Superficial faults, wear andefficiency of certain organs cari bebetter detected.

n e c e s s a r y t o rotate t h e r o d s t oprevent the halls from getting inserted into the millings themselves,

4. Grease and assemble the twointerlock plungers in the horizontal

1. Inspect whether speed control

bear any nickings.
4.
I nspect whether detent halls andinterlock plungers bear any nickingsor seizing marks.

13-8
Alfawiki.nl

A.3.0304 -,A.3.0309

GEARBOX

5. Grease and assemble spring and1st~2nd speed rod detent hall, using

together with relevant spring, thentools A.3.0304 and A.3.0309. Greasea n d insert relevant bal1 into radial

one quarter of a rotation.

lock securing plug and unscrew it byhole on rod. Insert then rod itself

M o u n t lock ring of 5th speed andreverse gear rod on the end of theinto its seat on the gearbox casing,rod itself, on the differential side.

paying attention to the reciprocal
position of milling and of detent hall,and make it pass through the small
hub of relevant fork.
6. Use relevant securing plug toclose interlock plunger hole.
7. Grease and use tools A.3.0303
and A-3.0309 to assemble spring andreverse gear rod
5th speed anddetent hall.
Insert then rod 0, together with
5 t h s p e e d c o n t r o l f o r k 0, i n t osmall hubs of 5th speed and reversegear lever @ and into reverse gear
@ together with
control fork
relevant sliding sleeve.

9. Assemble partially main selectorrod, by introducing it from the rearside of the gearbox casing, insert itthen into the selector lever, into thespring and into the lever. Complete
then introduction of rod.
Align axes of lever holes with thec o r r e s p o n d i n g ones on rod andpinsusing tool
mount
springA.3.0322.

The speed selector lever pin @must be shim fitted while the otherlever% p i n @ must be fitted as aScrew
Ist-2nd speed rod
6th speed and R.G. rod
R.G fork
3rdAth speed rod
Selector
Main selector rod
1 st-2nd speed lever

striker on the edges of the pinitself, with the excess portion of thepin protruding on the selector’s side.

“S” clearance between 1st”2nd speed
lever and 3rd-4th speed rod
1.4 + 1.9 mm (0.055 + 0.075 in)

12. Align rhe holes and then fit rhe
retaining screw 0. Tighten it
according to specified torque.
0: Tightening torqueScrew securing 1st2nd speed
selector lever to rod:25326 N-m
(2.5 + 2.7 kgm
18.07+ 19.52 ftalb)
13. For gear synchronizing cen’ter
Ist-2nd and 3rd-4th speed control
forks - in that order - on toothed
1 Pin

2

Pin

rings with the help of a gauge; now
fit retaining screws and tighten themaccording to specified torque.

10. Fit the guide pin for the main

1 5tb speed and reverse gear lever
2 5th speed and reversa gear rod
3 5th speed control fork
4 Reverse gear control fork

selector rod return spring.

11. Position the 1st2nd speed lev e r @ on the relevant rod 0.
Turn rod @ SO that specified “S”
clearance is established between le-

8 . A l i g n a x e s o f holes a n d insert
spring pin of 5th speed and reverse
gear

lever

by

means

of

ver @ and rod 0.

CAUTION:
Prior to tightening, thoroughly clean
the retaining screw thread withOMNIFIT surface-active agent andt h e n coat it with OMNIFIT 150 H
cernent
0: Tightening torqueScrew securing fork to 1st2nd
and 3rd - 4th speed rod.

tool

A.3.0322.

2 1 f 23 N-m

Insert the two halls into their seats(2.1+ 2.3 kgm

on central support of gearbox casing

15.10 f 16.63 Wb)

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13-9

May 1983

GEARBOX

0: Tightening torque
R.G. switch to gearbox casing
40+49 N-m
(4 + 4.9 kg-m
2 8 . 9 2 + 3 5 . 4 3 ft-lb)

TESTING
Check working condition of springplunger-rod assembly making surethat speed selection is smooth andthat speeds do not jump out of theirposition and become disengaged.
1 5th speed gear
2 Hub

Check working condition of springplunger-rod assembly making surethat speed selection is smooth andthat speeds do not jump out of theirposition and become disengaged.

3 Nur

/

SHAFTS AND GEARS
14. Fit oil sump, with a new gasket,
on the gearbox casing and tighten

DISASSEMBLY

relevant screws.
15. Position rear caver, with a newgasket, on both gearbox casing

Pinion shaf-t gears

centering seats; fit the oil bleeder
valve with relevant retaining plate,
and then tighten all screws.
16. Apply a coating of ISECO
Molykote BR2 grease to the main
selector rod ,seal ring as well as toits work seat on the rod.
U s i n g 1001 A . 3 . 0 2 9 4 , fit the seal
ring on the rod.

1.

.

Remove rods and forks (refer to:Rods and Forks - D i s a s s e m b l y ) .
2. Acting on relevant sleeves, en-

5. Remove differential casing (Refer to: Group 17 - Differential

gage two speeds in order to prevent
pinion from turning.
3 . W i t h a p u n c h , e l i m i n a t e all

Differential Casing).
6. Slowly push pinion shaft toward
the differential casing and remove all

caulking from the gear train topinion locking nut 0.
4. With spanner A-5.0196, loosen
the nu-t and remove the hub 0, theparts making u p the train on thepinion (I~L, 2nd,
3rd
and
4th
speeds), being careful to mark thesequence and the position of gear

5th speed gear 0 with relevant
synchroniting unit, and the bushing.

bushings to be later followed during

1 Main selector rod

17. Fit the relevant lever on themain selector rod and then, using apunch, fit the retaining pin.

18. Fit reverse gear switch on rearcaver.

May 1 9 8 3

1 Pinion
2 Primary shaft

3 Direct drive shaft

13-10
Alfawiki.nl

reassembly.

GEARBOXCAUTION:If friction between the pinion andthe inner race of the rear taper roller
bearing hinders withdrawal of thepinion shaft, use tool A.3,0296.

r A-3.0296
-

-

l

-

1

2

7 . R e m o v e t h e pinion 0, w i t hrelevant taper roller bearing @ andadjusting washer 0, from thegearbox-differential casing.

Synchronizing units
R e m o v e t h e lock r i n g @ a n dthen remove in sequence: the synUsing tools A.3.0296
and
A.3.0297, remove the pinion front

9.

bearing outer race from the gearboxdifferential casing.

1 Taper roller
bearing

3 Pinion shaft
Pinion shaft
4 Pinion
front bearing
Adjusting washer

chronizer ring 0, the guide secror 0, the locking sectoi-@, andthe retainers @.

1
2

2 Adjusting washer
3 Pinion

3

Lock rini
4
Synchronizer ring 5
Guide secfor
6

Locking sector
Gear
Retainer

The 1 st speed synchronizing unit has
only one retaiher.
8. With tool A.3.i)296 remove therear bearing outer race from thegearbox-differential casing.
10. With the help of a press and of

Direct drive shaft

plates A-3.0306, remove the frontb e a r i n g @ inner race and the

clutch drive thrust bearing support

adjusting washer @ from the pinion

1.

Remove the lock ring 0 of theand then remove the support 0.

shaft 0.

13-l 1
Alfawiki.nl

May 7983

GEARBOXd--- - cl-3

1 Lock ring
2 Thrust bearing support

2.

lo

1

R.G. shaft retaining screw

2

1 Pin retaining
3 Joint
spring ring
4 Spring ring
2 Direct drive shaft 5 Pin

Remove the direct drive shaft oil

seal ring located on the front of the
gearbox casing.

4.

Having removed the direct drive

shaft, if necessaryL remove the directdrive shaft bush with the help of tool

A.3.0291. This tool removes also
T O remove
oil seal ring, withmounted unit, operate as per figure
making use of tool A.3.0452.

the oil seal ring.

2 Reverse gear
3 R.G. shaft

4 R.G. control fork

Primary shaft
1 . F i t lock t o o l A . 2 . 0 3 0 0 a t t h e
end of the primary shaft @ in orderto prevent it from turning.

3; R e m o v e t h e s p r i n g ring 0
retaining the pin @ connecting thethedirectdrive
shaft @ to
joint 0.
Remove the pin in question and pullout t h e d i r e c t d r i v e s h a f t . N o w
remove the spring ring @ retaininq
the pin that connects the primary
shaft to the joint; remove this latter
pin and pull out the joint from theprimary shaft.

Reverse gear shaft
1. Loosen a n d r e m o v e t h e R-G.
1 andshaft @ r e t a i n i n q screw

0

then remove the shaft, with relevant“q q e a r @ ‘and R . G . fork @its l o c a t i o n

on gearbox-

differential casing.

May 1 9 8 3

13-12
Alfawiki.nl

1 Primary shaft

GEARBOX

Fit
tool
A.3.0296
onthe9.
gearbox-differential casing and then

2. Loosen the screw securing the
primat-y shaft to its rear bearing andfit the A-3.0492 end piece.
Carefully tighten the screws securing

remove the oil deflector.
3. Using tool A.3.0495 remove thetool A . 3 . 0 2 9 6 to t h e gearboxdifferential casing to avoid damaging
the casing’s threads.

5th speed driving gear 0.

10. With the above mentioned tool,push the primary shaft toward thedifferential casing.

2 Lock r i n g

1 Bal1 bearing

7 . F i t pinion 0 back i n t o t h e
gearbox-differential casing.
8. Fit rear bearing on pinion
shaft 0, together with the firsto f tool
section(fork
shaped)1

5th speed driving gear

4. Pull out the tongue securing the
5th speed driving gear to the primary
shaft.
5. Loosen8

screw 5andsecuring

removeA-3.0490, at the location of the 4th
speed driving gear. Now fit thes e c o n d s e c t i o n o f tool A.3.0490
locking it on the pinion, by means of
the relevant nut, a’t: the location of
the 5th speed driven gear.
A.3.0490

the7

the primaryP’

shaft 3 front: floating bearing @.

Now remove the front floating
bearing from the primary shaft.
11. Remove the 4th speed drivinggear and relevant tongue.

1 Bearing lock ring 4 Front bearing
5 Bearing retaining
2 Fiear bearing
3 Primai-y s h a f t
screw
1

6.

PinionRemove lock ring @ from rear1bearing 0.

Alfawiki.nl
13-13

4th speed driving gear

May 1983

GEARBOX

12. Keeping tool A.3.0296 in place,Gears and splines

remove pinion shaft with all the part?
that are fitted on it; now totally1.

remove tool A.3.0490.
the tool
13. Completely
screw
A.3.0296 and insert tools A.3.0491
and A.3.0500 on its nut thread.
Unscrew tool A.3.0296 and remove
primary shaft rear bearing from its
seat, then separate it from the tool.
A.3.0491
A.3.0500

ASSEMBLY

Check that teeth contact patternof primary shaft and bevel pinion
gears extends to the entire working
surface. Unevenly worn gears or gears

Primary shaft
1.

First fit on the primary shaft thegears have not been damaged.

longue for keying of the 4th speed
driving gear.
2. Fit the shaft in its seat on the
gearbox-differential casing and thenFollow the same checking procedure
for splines of primary shaft, directd r i v e s h a f t , a n d o f t h e pinion.

fit the 4th speed gear on the shaft.
3. Lock the primary shaft’s front
end with tool A.2.0300 (refer to:

2 . Also c h e c k t h a t a b o v e mentioned toothing as well as the grooveon the synchronizing ring do notPrimary Shaft - Disassembly).
4. Fit tool A.3.0300 on the primary shaft’s rear end using it to key
the 4th speed gear.

with broken teeth must be replaced
making sure that relevant matingshow any scores, evidence of pitting
or excessive wear. Replace all parts
that are not flawless.

Bushings
Check pinion bushings for excessive
wear making sure that working
surfaces in contact with gears do nots h o w any scratches or evidence ofpitting. Replace all parts that are notflawless.
14. Remove the primary shaft @from the gearboxdifferential casing
passing through the Seat of the rearbearing.

Synchronizing unit

A.3.0300 1

w

Check sliding surfaces for scores andmake sure that sleeves slide smoothly
on relevant hubs; check synchronizing rings for excess wear.

5.

Using

tools

1. Carefully inspect all bearings byslowly rotating them: no vibrations,noise or sticking should be noticed if
bearings are in good working con-primary shaft.

avoid damaging the casing’s threads.

A.3.0491-

dition.
2. Check surface of all rings androtating parts making sure there areno scores, marks or roughness due tofriction of foreign matter. Replace allparts that are not flawless.

2 3rd speed gear

Reverse gear shaft
If any of the parts making up ther e v e r s e g e a r s h a f t assembly a r e

CHECKS AND INSPECTIONS
T h o r o u g h l y w a s h all p a r t s a n dvisually check them with extreme

defective or damaged, replace themwith new ones available as spareparts.
1 Bal1 bearing

tare for any surface flaws.

May 1983

andCarefully t i g h t e n screws o f t o o l
A.3.0296 on the gearbox casing to

Bearings

1 Primary shaft

A.3.0491

A.3.0296, fit rear bal1 bearing on

13-14
Alfawiki.nl

GEARBOX

6. With the help of suitable plyers

outer races and then fit them on the

3 . I f p r e v i o u s l y disassembled f o r

fit the lock ring in its seat on tha

gearbox casing, using the same tools

overhaul purposes, reassemble syn-primary shaft’s rear bearing support.

u s e d during d i s a s s e m b l y ( T o o lchronizing units (refer to: Synchro-

A.3.0296 for the rear bearing race,

nizing units).
4. Apply the prescribed engine oil

Make sure the lock ring is properly
lodged in its seat.

and tool A.3.0296 - together withtool A.3.0297 - for the front bearingrace).

7. Keeping the primary shaft
locked by means o f t o o l A . 2 . 0 3 0 0 ,fit tool A.3.0300 on same s h a f t ’ s

CAUTION:
T a k e special tare during a s s e m b l yrear end; center the shaft in the rearmaking sure that bearing races areexactly flat against casing surface.

bal1 bearing.
Fit primat-y shaft on rear bearing.
8. Fit roller bearing on the primary
shaft’s front end being careful to2.
Fit the proper shim, selected inadvance, on the pinion shaft (referalign the hole of the bearing’s outer
race with the corresponding hale

to: Adjustments - How to determine

in the gearbox-differential casing. Fit
securing screw into the hole in the
gearbox-differential casing.
Fit securing screw into the hole andfully tighten it.

Using a press and tool A.3.0307, fit
the taper roller bearing inner race on

pinion height).

the pinion shaft.

to outer surface of bushings and thenfit them on gears according to theirrelevant position at time of disassembly thus restoring the original
working surface pattern.
5. Partially insert bevel pinion into
the gearbox casing and then fit allparts making up the train, whileslowly p u s h i n g t h e pinion in tillis reaches its final position. During
this operation be sure to follow thesequence and positioning show in therelevant figure, paying special attent i o n to the R.G. driven gear @and to the 4th speed shoulder
washer 0.
Fit standard shim A.4.0141 @(9.60 mm (0.378 in) thick) and theinner race of the rear taper roller

Having completed primary shaft

bearing @, making sure that it fitsassembly, check and make sure it
turns freely on the bearings, without
sticking.

flat against the shoulder washer.

9.
Fit on primary shaft the longue
for keying of the 5th speed drivinggear.
10. With tool A,3.0300 fit the 5th
speed gear in its seat on the primary
shaft by the gearbox casing’s outerrear side.
11. Fit oil deflector in its seat on the
5th speed gear and tighten the
primary shaft retaining screw, without fully locking it.

.

Reverse gear shaft
1. Fit reverse gear shaft, with
relevant sliding gear and driving fork
into its seat o n g e a r b o x c a s i n g .
2. Tighten to specified torque thescrew securing the R.G. shaft to thegearbox casing.
0: Tightening torque
R.C. shaft to gearbox casing
retaining screw
19-24 N-m
(1.9+ 2.4 kg-m
13.74 + 17.36 ft-lb)

Pinion shaft gears
1. Coat with grease (AGIP FI
Grease 33 FD) the outer surface oft h e pinion t a p e r r o l l e r b e a r i n g s

1 Reverse gear
2 4th speed
shoulder3 Standard shim

4

Rear taper roller
bearing

5 Lock nut

Alfawiki.nl
13-15

May 1983

GEARBOXIn case of friction between the
bearing’s inner race and the pinion,
use tools A.3.0300, A.3.0301 foreasier fitting.

It is advisable net to exchange theparts belonging to the different
synchronizing units.

6. Fit the bushing and the hub of
the 5th speed driven gear and thentighten by hand the pinion gear train
lock nut.
7. E n g a g e t w o g e a r s a n d t h e ntighten the nut according to specified
torque, without caulking.

0: Tightening torque
Pinion gear train to pinion
shaft lock nut
2 2 0 . 5 + 245 N - m(22.5 + 25 k g - m
162.70+ 1 8 0 . 7 7 ft-lb)” ’

k.4.0142’3.
Fit rear taper roller bearing innerrace 2 and relevant lock nut onto0

dummy pinion 0.

5
6

1 Gear
2 Retainer
3 Guide sector
4 Retainer

7

Locking sector
Synchronizing
ring
Lock ring

2. Now follow the same procedure
for the 1st speed gear reme.mbering,
however, that in this case rhere iso n l y one retainer (refer to: Disassembly - Synchronizing units):

ADJUSTMENTS
8 . N o w Select t h e s h i m f o r f i n a lfitting (refer to: How to determine
Pinion Shaft Taper Roller Bearing
Pre-load).

Synchronizing units
1.

How to determine pinion height
CAUTION:Use only metric system in order toavoid confusion in computations.

As far as 2nd, 3rd, 4th and 5ths p e e d g e a r s a r e concerned fit re@ @
and
on
gear
tainers
body 0 placing locking sector @and guide sector @ between them.
Fit synchronizing ring @ on re-

T O d e t e r m i n e pinion h e i g h t , à n dtherefore shim thickness, proceed as

4. Tighten the nut according to
specified rolling torque using coupling tool A.2.0274, 1 dm. dia. sheave
6.5.0124 and weight C.2.0037.

0: Dummy pinion rolling torquea. For original bearings being
used again:
3 + 6 N.dm
(0.3 + 0.6 kg-dm
0.217 + 0.434 ft-lb)

follows:1.
Fit inner race of the pinion shaft
front taper roller bearing on dummy

tainers and sectors and then lock into

pinion A.4.0142.

alace all aarts w i t h r e l e v a n t lock2.

ring 0. ’casing.

May 1 9 8 3

1 D u m m y pinion
2 Taper roller bearing inner race

Insert dummy pinion in gearbox

13-16

Alfawiki.nl

b. For replacement bearings(new)
12+ 14 Nqdm
(1.2 + 1.5 kg-dm
0 . 8 6 7 + 1.085 f t - l b )GEARBOX

0: Tightening torqueA.2.0274

Screws securing tool C.6.0162
to gearbox-differential casing:
40+49 N-m

A.4.0142
C.5.0124
1(4 + 4.9 kgmm
28.92 + 35.43 f-t-lb)

1
2

Front taper roller bearing inner race
Rear taper roller bearing inner race

5. Turn dummy pinion a few times
in both directions to allow bearings

11. Determine as follows the “S”
thickness of the shim that is to be
f i t t e d b e h i n d t h e pinion h e a d :to settle.
6 . F i t a centesimal dia1 g a u g e t obracket A . 4 . 0 1 3 6 a n d r e s e t i t b y

Llmeans of reference gauge C.6.0161.

s

+

L2
- (k C)=2
8. Place the differential carrier,w i t h dia1 g a u g e , o n t h e h e a d o fdummy pinion and then take readingof “Ll ” value.

~ A.4.0136

C.6.0162

7

12. Among the various shims available as spare parts, Select the one
with thickness nearest to the value
determined as per above instructions.
Example:Ll = 0 . 8 6
L2 = 0 . 8 8
c

=

0.13

L, + L2s z!z- - (IC) =2

0.86W.88- (0.13)
2
0.86

(1)

+ 0.881.74
1.74:2=

(2)

0.67

(3)

- 0.130.67

Computed shimthickness
Selected shimthicknesr

7. Fit crown a x i s r e f e r e n c e t o o l
C.6.0162 into the differential carrier
Seat; tighten, in bias sequence andaccording to specÏfied torque, thefour screws securing it to the gearboxdifferential casing.

9. Repeat above operation by fitt i n g tool C.6.0162 into the Seat o f
the opposite side differential carrier
and take reading of “L,” v a l u e .
10. Read dimension “C” (plus o r
minus) etched on pinion.

Alfawiki.nl
13-17

s

=

0.74

S = 0.75 m m

Shim thickness thus determined in
t h i s one e n s u r i n g c o r r e c t pinion
height since readings have been taken
w i t h pinion in its actual o p e r a t i n gposition.

May 1983

GEARBOX

How to determine pre-load of
pinion &aft taper roller
bearings

roller bearings pre-loading:

CAUTION:

whereas 0.10 is a play-correcting
factor for taper roller bearing pre-various parts do not rotate.
6. Fit the shim selected as per
above computation; now fit thebearing inner race, all the parts
making up the 5th speed driven gearset and lastly the nut.

loading.

7. Tighten the nut to specified

Use only metric system in order toavoid confusion in computations.

S = 9.60 - G - 0.10

torque.
After having fitted all various parts as
described in paragraph “Reassembly -0: Tightening torque
Pinion shaft gear train locking
nut

Pinion Shaft: Gears, item no. 5”,
measure pinion end play by carefully

220 + 245 N-m( 2 2 . 5 + 25 k g - m
162.70,+ 1 8 0 . 7 7 ft.lb)

following the procedure describedhereafter:
1. Fit bracket A.2.0242 to gearbox
casing with the interposed spacers
A-2.0234 and then a centesimal dial

8. Coat all gears of primary andpinion shafts with specified gearbox-

gauge to the bracket.

-

-

F

-

J

1 Pinion
2 Front bearing--

3 Rear bearing

Select the shim with thickness
nearest to the value determined as
per above instructions keeping in
mind, however, that max. allowed
tolerance is * 0.02 mm and thatthicknesses available as spare parts
have a 0.05 mm variation step.

differential type oil (AGIP FI Rotra
MP SAE 8OW90 or IP Pontiax HD
8OW90).
Turn pinion shaft a few times in bothrotating directions to allow bearings
to settle.
9. Fit coupling tool A.2.0274, the1 dm rad. sheave C.!%O124, and The
C.2.0037 weight to the pinion shaft
nut.

A.2.0274 Example:
Standard shimthickness= 9.60G= 0.37

Play -correcting factor

Properly tighten the screws securing
bracket A.2.0242 to the gearbox
casing in order to avoid damaging

9.60
(I)

- 0.37

casing threads.
2. Turn pinion @ a few times inboth directions to allow bearings @and @ to settle. Push pinion byhand in one direction and reset thedial gauge.
3. Move pinion in the opposite
direction and take reading of “G”
play on dial gauge.
In case of subsequent end-playreadings, it is necessan/ to rotate
again the pinion in both directions to= 0.m

S =9.60-G-0.10= 9.60 - 0.37 - 0.10

9.23
9.23

(2)

0
-. 1 09.13
Computed shimthicknessS= 9.13Tolerance= 0.02Dimensional variation
steps of available spareshims= 0.05

Selected shimthickness= 9.15 mm

S

C-2.0037

6

allow bearings to settle.

5. Loosen and remove the nut as

10. Check that weight descends
normally without stopping and with-

4. Determine as follows the rearwell as the hub, rhe bushing, thebearing inner race, and the standard

Check that in such condition rollingshim “S” thickness for pinion taper

shim making sure that the train’s

torque is as specified.

May 1983

13-18
Alfawiki.nl

out pulling the disc too fast.

GEARBOX

0: Rolling torque of pinion withgear train.
a. For original bearings being
used again
4 + 7 N-dm
(0.40 + 0.70 kg-dm
0.289 + 0.506 ft.lb)
b. For replacement bearingshew)
1 3 + 1 6 N-dm
(1.3+ 1.6 kg-dm

1 Bushing0.939 + 1.157 ft.lb)

2. Fit bushing on primary shaft
making sure that holes for sub-In case of rolling torque values
greater or lower than specified ones,

sequent pin fitting are aligned; fit

correct them by fitting a rear shim
either 0.05 mm thinner or thicker

ring.
3. Insert direct drive shaft into its

than the one previously fitted.
In this instance, rechecking of rollingseat and connect it to the bushing byfitting the pin and a new retaining

torque is required.

spring ring.

11. Caulk the nut with punch andhammer.
12. First prevent shafts from rotat-

Make sure that retaining spring rings

ing by engaging two speeds and thentighten the screw securing the oil
deflector to the primary shaft
according to specified torque.
0: Tightening torqueOil deflector retaining screw
69; 8 5 N-m(7 + 8.7 kg-m
50.61 + 62.91 ft.lb)

are properly lodged in their respective seats so as to prevent pins fromdropping out.
4. After having applied grease( I S E C O : M o l y k o t e BR2) t o i t ssealing lip and to its work seat on
the shaft, fit a new oil seal ring on
the direct drive shaft with the help of
tool A.3.0323. During this operation
be careful not to damage the sealing
lip of coupling splines.
Use tool A.3.0453 to assemble oilseal ring on direct .drive shaft, on
assembled unit.

DIFFERENTIAL

Direct driveshaft

1. If previously disassembled, fit
direct drive shaft bushing @ togearbox casing using tool A.3.0308.

4

the pin and a new retaining spring

1

Taper roller

2
3
4bearingPhonic wheel
King nut
Lock ring5

Ball bearing

Alfawiki.nl
13-19

CAUTION:
Cover direct drive shaft splines with
tape.
5.

Fit

the

clutchdrivethrustbearing support and secure it to its
seat on the differential casing bymeans of the relevant lock ring.
Make sure that lock ring is correctly
lodged; check that its tongues arefacing the sleeve seat and thuspressing it on the casing.

TESTING
Check that hubs and synchronizing
rings are in perfect working condition and that engagement of gears is
noiseless and easy.

CARRIERS

6 Shim
7 Seal ring
8 Carrier
9 Seal ring
10 Differential shaft

A.3.0453 1

GEARBOXDISASSEMBLY

6 . Using tool A.3.0299, remove thedifferential carrier taper roller bear-’ing outer race.
IMPORTANT:The following procedure refers to theright hand differential carrier.
Difference between left differential
support and right one is only constituted by absence of phonic wheel
in the left differential support
1. Loosen and remove oil sump
relevant
withscrewsretaining
washers, now remove the sump andthe seal gasket.
theremoveand
2. Loosen

8

securing the differential.
screws 1
to the gearbox casing
carrier 2
Partially pull back the carrier andremove the two shims 0, being
careful to mark the relevant position
to be later followed during reassembly. Now completely disassemble
differential carrier.

Taper roller bearing outer race
Phonic wheel
Ring nut
Spring ring
Bearing
Oil seal ring
Seal ring
Differential carrier
Differential shaft

Lock differential carrier in a vice4.
and remove the ring nut securing thedifferential carrier on the bearing andphonic wheel using tool A.3.0298.

5. With The help of a press and ofplates A.3.0295, remove differential
s h a f t @ f r o m t h e c a r r i e r 0.
Remove the oil seal ring.

3 Shim1 screw
2 Differential carrier

3. Remove seal ringdifferential carrier @.

0Remove the bearing lock ring7.
from its seat in the differential
carrier.

from
1 Differential shaft

Alfawiki.nl

8. Now with tool A.3.0302, remove the ball bearing from thedifferential carrier.

GEARBOX

Following the same procedure, disas-

ential carrier, proceed as follows:

semble the left hand differential

1.

ring outer surface and fit it into its

carrier.
9.

-.I -.
Ff

Apply gearbox oil to the oil seal

In case of malfunction of speed

indicator device, remove sensor @from gearbox after removing retaining spring @ and replace it.

seat on the differential carrier using

L-.-J

tool A.3.0430.
CAUTION:
Make sure the crowfoot on the oil

1X.3.0292

seal ring points in the direction of
the differential shaft rotation.

T

T
i.-

.-i

A.3.0430

R

1 Spring ring

5. Apply grease (ISECO MolykoteBR2) to the oil seal ring inner surface
and to its seat on the differential
shaft. With tool A-3.0293 and thehelp of a press and a rest plate, fit
now the differential shaft.

2 Sensor

CHECKS AND INSPECTIONSHaving thoroughly washed all parts,
perform following checking operations:
1. Carefully inspect all bearings
while slowly r o t a t i n g t h e m : n o

2. With tool A-3.0302 and the helpof a press, fit the differential shaft
bearing into the carrier.

vibrations, noise or sticking should

L.I

be noticed if bearings are in goodI.-.I

working condition.
2. Check the surface of all rings
and rotating parts making sure thatt??

there are no scores, marks or roughness due to friction of foreign

A-3.0302

matter.
If surfaces of rings and of rotatingparts show scores, evidence ofabnormal wear, pitting or over-retaining ring nut. Make sure to fit a
new ring nut.

heating, replace them without hesitation.
3. Check that contact surface ofdifferential shafts splines extends tothe entire working surface; if any of
the teeth is chipped or show evidenceof abnormal wear, replace shafts
making sure that relevant matingparts have not been damaged.

ASSEMBLY
Referring to the right hand differ-

6 . A p p l y g e a r b o x o i l (AGIP Fl
Rotra MP SAE 8OW90 or IP Pontiax
HO 8OW90) to the mating surfaces
on differential shaft of the bearing

7. On differential shaft install firstring, nut and then phonic wheel,using. tool A.3.0293 together with apress and a rest plate.
8. After having applied a coating of
gearbox oil, fit the small seal ring in
3.

Fit the differential shaft bearing

lock ring.
4. Using tool A-3.0292 fit the taperroller bearing outer race into thecarrier.

Alfawiki.nl
13-21

the carrier’s groove.
9. Fit the right hand differential
carrier in its seat on the gearbox
casingMay 1983

GEARBOX

Following fhe same procedure, reassemble the left hand differential
carrier.
IO. Fit oil sump with relevant
sealing gasket.

scribed in paragraph “Differential
Casing - Assembly”, fit crown gear

3. With tool A.3.0287 remove
inner races of taper roller bearings

to differential casing.
2. Fit differential casing back tofrom the differential casing.

gearbox casing.

PinionPosition the pinion into its seat in
the gearboxdifferential casing and fit
bearings and gears (refer to: Shafts
and Gears).

CROWN GEAR
AND PINION
DISASSEMBLYTESTING

Crown gear

Verify back-lash between crown gear
and pinion in four diametrically1.

Remove differential

carriers

from the gearbox-differential casing(refer to: Differential’ Carriers- Disassembly).
2. Remove differential casing fromthe gearboxdifferential casing (refer
to: Differential casing - Disassembly).
3. Loosen and remove the screws
securing the crown gear to thedifferential casing and then remove
the crown gear.

A.3.0287 1 1

opposite positions. Irregular backlash, with excessive differences between the measured points, is anindication of crown gear deformationconsequent flatness error
withbetween gearbox casing/crown gearplace and differential casing plane.
Make sure the differential works
properly and is completely noiseless.
Incorrect assembly of’crown gear andpinion or worn taper roller bearings
could be the cause of the trouble.

Pinion1.
Remove gears from pinion shaft
and then withdraw the shaft from its
seat in the gearbox-differential casing, with relevant bearings (refer to:
Shafts and Gears).

CHECKS AND INSPECTIONSHaving thoroughly washed all parts,
proceed as follows:
1. Slowly rotate bearings checking
them for vibrations, noise or sticking.

DIFFERENTIALCASING

4. Loosen and remove the screws
and washers securing the crown gearto the differential casing.
Now remove the crown gear.

DISASSEMBLY
1. Remove left and right handdifferential carriers (refer to: Differential Carriers - Disassembly).
2. Remove differential casing fromgearbox-casing,

CHECKS AND INSPECTIONSHaving thoroughly washed all parts,
checking

performthe following
operations:

2. Check surface of all rotatingparts and of roiling tracks for scoresor any evidence of abnormal wear,
pitting or overheating; in the affirmative, replace the parts involved.
3. Make sure that contact patternof bevel pinion teeth extends to their
entire working surface. If any of theteeth are nicked, replace the pinion
and make sure the crown gear has
not been damaged as a consequence.

1. Slowly rotate bearings checking
them for vibrations, noise or sticking.
2. Check the surface of all rotatingparts and of all rolling tracks forscores and any evidence of abnormal
wear, pitting or overheating; in theaffirmative,
volved.
3.

replace the parts in-

Visually check gears, both plane-tary and side gears, making sure that
there are no scores or evidence of

Check both toothings for scores
and any evidence of pitting or excess
wear.

pitting, that contact pattern extends
to their entire working surface andfurther that mating is noiseless and

ASSEMBLY
Crown gear
1. Following the procedure de-

May 1983

1 Differential
casing2 Retaining screw

3 Crown gear
4 Taper roller
bearing

13-22
Alfawiki.nlsmooth.
If necessary, replace the whole
differential casing; in this case also
replace taper roller bearings.

GEARBOXlash and if now within specified
values, repeat above adjusting operations.

CAUTION:.
Use only metric system in order toavoid confusion in computations.

refitting previously disasWhen
sembled parts (carriers, differential
casing, bearings and crown gear), it isessential that also same A and B

5. Compute, as shown below, theaverage value “Hm” of the fourmeasurements picked-up as per item
4 above and determine the thicknessof “B” shims that will have to be

shims are used - or at least new onesof same thickness - and that they areplaced back exactly where they werelocated at time of disassembly.

fitted behind the crown gear side
carrier for pre-loading of taper roller
bearings.
3. Rorate crown sear as far as
backlash will allow and read thevalue shown on dial gauge.

B = Hm - 0.20
whereas 0.20 is correcting factor forbearing pre-loading.
Example of computation of the four
picked-up measurements:
HI = 1 . 8 8
Hg=

1.90

H,= 1 . 9 4 ;e

Ha= 1 . 9 6

4. Repeat the above reading onfour different points of the crownwar, equally distant o n e f r o m
the other.
Each of the four measured values
must fall within the range of 0.05 to
0 . 1 0 m m (2*10-” + 4-10m3 i n ) .

B = Hm -0.20 ==1.88+1.94+1.90+1.96

If backlash does not fall within these- 0.20 =4= 1.92 - 0.20 = 1.72 mm

6. Considering that max. allowed
toleranceis -I- 0.02 mm and thatshims available as spare parts have athickness variation step of 0.05 mm
select the thickness nearest to thecomputed value (in the above instance one would select the 1.70 mm
thickness).
7. Fit selected shims behind thecrown gear side carrier and tighten
retaining screws to specified torque(refer to: Step 2).
Crown gear to pinion b a c k l a s h
Adjust crown gear to pinion backlash
following the procedure hereafter
described.

values, proceed as hereafter described, remembering that total shimthickness (A + B) between differential carriers and gearbox casing mustremain constant otherwise it would
cause bearings pre-load to change:
in case backlash is below specified value, move crown g e a raway from the pinion by de-

GEARBOXDIFFERENTIALCASINGDISASSEMBLY
1. Remove rear support (Refer to:Rear Support - Disassembly).
2. Remove the clutch control fork
and then withdraw the thrust bearing
from the direct drive shaft (Refer to:
G r o u p 12).
3. With the help of a punch,
remove the clutch control fork
retaining pin.

creasing thickness of A shims
and equally increasing that of B
shims.
- in case backlash is above specified value, move crown gear
closer to the pinion by increasing thickness of A shims anddecreasing that of B shims by
the same extent.

Rotate pinion and crown gear to

When correcting shim thickness itshould be remembered that in orderto change dial gauge reading (min.
distance between crown gear andallow relevant bearings to settle andthen use tool A.2.0243 to lock thepinion teeth) by 0.01 mm (0.4.10-3in), one must move a thickness of

carriers
4. Remove differential(Refer to: Differential Carriers -pinion.
Properly tighten screws of tool0 . 0 1 5 m m (0.59-10-3 i n ) f r d m
one side to the other.

A.2.0243 on gearbox casing.
2.
Fit a centesimal dial gauge to a

Disassembly).
Remove differential casing with5.
crown gear (Refer to: Differential

Having completed fitting of shims,

magnetic base and place the gauge’s
indicating finger on the outer edge ofa crown gear tooth at right angles

tighten retaining screws to specified

Casing - Disassembly).
6 . R e m o v e rods and forks (Refer

torque (Refer to: Adjustments - How
to Determine Pre-load of Differential

to: Rods and Forks - Disassembly).
7. Remove shafts and gears (Refer

with the tooth’s side.

Casing Bearings). Double check back-to: Shafts and Gears - Disassembly).

1.

May 1983

13-24
Alfawiki.nl

GEARBOXCHECKS AND INSPECTIONS
1. Thoroughly clean casing withsolvent and check it for scores, nicks
or evidence of pitting.
2. Check the casing’s mating surfaces making sure there are no nicks,
no evidence of roughness nor or old
sealants.
3. Check that the clutch forretaining pin is not in any way

Shafts and Gears Assembly).

then fit thrust bearing on direct drive2.

shaft (Refer to: Group 12).

3. Fit differential carriers (Refer

7. Fit rear support (Refer to: Rear
Support - Assembly).

Fit differential casing (Refer to:
Differential Casing -Assembly).

to: Differential Carriers - Assembly).
4. Fit rods and forks. Thoroughly
clean rear cover and oil sump mating
surfaces; fit new gaskets with specified sealants and then fit coverand sump (Refer to: Rods and Forks- Assembly).

damaged.

5.

ASSEMBLY
1. Fit shafts and gears (Refer to:

Fit clutch control fork retaining

pin.
6. Fit the clutch control fork and

GEARBOX OUTER LINKAGE
DISASSEMBLY
1.

Loosen and remove the nut with

washer @ as well as the screw 0
securing the main selector rod @ to
the gearbox lever 0; then remove
the spacer @ and the two bush-

3.

CHECKSAND INSPECTIONS

extensions; now remove side wash-

metal parts with solvent and makesure they are in good condition.

Loosen and remove the nut @and the screw @ securing the
gearbox lever support 0 to theflexible bush @I ocated on the rear0

ers 3 as well as the spacer 0.

ings 0.

1. Thoroughly clean outer linkage

2. Check linkage articulated joints
for excess wear.
3. Make sure boot is in perfectcondition; i f d a m a g e d o r w o r n ,replace it.

ASSEMB.LY
1. Fit rear support (Refer to:
5-Speed M a n u a l G e a r b o x - R e a r

1 Gearbox lever

2 Spacer
3 Bushing

5 Rear support
6 Main selector rod

7 Retaining screw

4 Nut with washer

1

Support2

Nut

3 Washer
4 Flexible bush

5
6
7

SpacerkasherScrew

2. Loosen and remove the gearbox
lever guide @ retaining screws with

4. Remove rear support (Refer to:
5-Speed M a n u a l G e a r b o x - R e a r

washers 0; now remove the guide,
the boot aand the bushing 0

Support).
6. Lastly remove the flexible bushwith the help of following tools: alocated at lever’s end.

press, a plate, a base and punch tool.

1 Boot2 Screws with
washers

3 Bushing
4 GuideSupport).
2. Apply grease (AGIP Fl G r e a s e
15 or SHELL Retinax G) to thespacer 0 on the speed selector
lever to main selector rod connecand to the spacertion 40
securing the fork to the flexible bushon the gearbox cover.

0

Apply 5 g (0.176 oz) of same grease
to the speed selector lever guide 0.
3. Go on to fit all gearbox outer
linkage following disassembly procedure in reverse sequence.

1 Spacer
2 GuideAlfawiki.nl
13-25

3

Spacer

4 Main selector rod

May 1983

GEARBOXSERVICE DATA AND SPECIFICATIONSTECHNICAL DATA
Differential ratio
GearboxGearboxSpeed selector

lll39

9135

Speed
differential

lever positions

ratio

Gearboxdifferential
overall ratio

Speed
at 1000 r.p.m.
Km/h (mi/h)

Speed
at 1000 r.p.m.
Km/h (mi/h)

1

1 : 3.750

1 : 14,580

7.08 (4.39)

1 : 13.293

7.77 (4.81)

2

1 : 2.050

1 :12.96 (8.05)

1 :

7.267

14.21 (8.81)

3i : I.387

1 :

5.392

19.15 (11.89)

1 :

4.916

21 .Ol (13.05)

4

1 : 1.027

1 :

3.992

25.87 (16.07)

1 :

3.640

28.37 (17.63)

5

1 : 0.825

1 :

3.207

32.20 (20.0)

1 :

2.924

35.23 (21.89)

R.G.

1 : 3.091

1 : 12.017

8.59 (5.34)

1 : 10.957

9.42 (5.86)

7.970

1200

1200

1350

1350

EngineGearboxdifferential
overall ratio

1500

1500

GENERAL SPECIFICATIONSFLUIDS AND LUBRICANTS

APP.

Application

Name

Type

Qw

“0.

Inner surface of:- Seal ring of main selector rod

GREASE- Seal ring of priman/ shaft
1

ISECO Molykote BR2
Std. No. 367159941- Seal ring of differential shaft- Seal lip and work seat on shaft
Outer surface of:- Seal rings

May 1983

OIL

13-26
Alfawiki.nl

See item 5-

GEARBOX

APP.
“0.

Application

Outer races of differential casing and pinion
2

Name

Type

GREASEQ.W- AGIP: Fl Grease33 FD

taper roller bearings

Std. No. 3671 69833

Mating surfaces of:3-

Ring nut securing bearing to differential

See item 5

OIL

shaft

Outer surface of:4Spacer on main selector rod to speed

GREASE

selector lever connection-

AGIP: Fl Grease 15- SHELL: Retinax G- Spacer for lever to fork fitting

Std. No. 3671-69811

Speed selector lever guideFill-up of gearbox-differential casing

5 g (0.176 otj

OIL

5- AGIP: Fl Rotra MP SAE 8OW90

2,300 kg

- IP: Pontiax H.D 8OW90+O,lOO kg

Std. No. 363169408

5.07 lb + 0.22 lb)

Outer surface of differential carriers and6

relevant seats on gearbox casing

OIL-

See item 5

Bushings for bevel pinion driven gears

Outer surface of:- Gearbox rear flexible support

GREASE- UNION CARBIDE CHEMICALCOMPANY:- Flexible support for speed selector
lever upper joint

Ucon lubricant 50 HE-5100- MI LLOIL: slipping agent for
rubber sections
Std. No. 4500-I 7502

Outer surface of:- Fin for gearbox rear flexible support

GREASE- SPCA: spagraph- ISECO: Ergon Rubber Grease no. 3-

Std. No. 367169816

SEALANTS AND SURFACE-FIXING AGENTS

Application

Lower screws securing differential carriers

Type

CEMENT

to gearbox casing

Name

Q.ty

DOW CORNING: Silastic RTV732
Std. No. 3522-00040

Alfawiki.nl
13-27

May 1983

GEARBOX-

Application

Type

Screws securing forks to speed selector

CEMENT

Name

Q.W

Omnifit 150 H

rods

Std. No. 352400023
SURFACE

N.B. For surface cleaning use:

Omnifit-- Std. No. 3514-90003

FIXINGAGENT-CEMENT

Inner surface of bore for oil plug on

DIRING: Heldite

gearbox casing

Std. No. 3522-00015

INSPECTION AND ADJUSTMENTREAR SUPPORTRODS AND FORI<S“fl’ positioning of gearbox rear flexible support

1.

‘5” clearance between 3rd-4th speed rod 0 andlst-2nd speed selector lever @P

degreeS

90 4 2mm

1.4 + 1.9

(in)

(5.5. 10.*+7.4 IO-*)

2. End play between fork and synchronising unit
sleeves
Clearancemm(in1

0 250 + 0.375(9.8

1 O-3 - 1 . 5 1 O-*1

ROLLING TORQUES
I ternN*dm

Dummy pinion- Original bearings being used again

3

2.6

0.3

+ 0.6

0.217

+

0.434

-

12

+ 15

1.2

f

1.5

0.867

+

1.085

- Original bearings being used again

4

2- 7

0.4

+

0.7

0.289

+

0.506

-

13

- 1 6

1.3

+

1.6

0.939

+

1.157

Replacement bearings (new)Pinion with gear train

Replacement bearings (new)May 1983

13-28
Alfawiki.nl

GEARBOX

DIFF-ERENTIAL CASINGPINION

Thickness ‘3” of shims B for pre-loading of differential
casing taper roller bearings

1. Thickness ‘3” of shims for setting of pinion heights= H (avg.) - 0 . 2 0

H= clearance between gearbbx casing
and flange of L.H. differential carrier

0.20 = corrective value for bearing preloading

1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00

Ll, L2= crown gear shaft deviation values

Part No.

m m (in)mm (in)1.00 (0.04)
1.05 (0.042)
1.10 (0.044)
1.15 (0.046)
1.20 (0.048)
1.25 (0.05)
1.30 (0.052)
1.35 (0.064)
1.40 (0.066)
1.45 (0.058,
1.50 (0.06)= value engroved ou pinion

Thickness

Part No.

Thickness

C(0.062)(0.064)(0.066)(0.068)(0.07)(0.072)(0.074)(0.076)(0.078)(0.08)

101452101453101454101455101456101457101458101459101460101461101462101463101464101465101466101467101468101469101470101471101472

Alfawiki.nl

0.75
0.80
0.85
0.90
0.95
1.00
1.05
1.10
1 .‘I5
1.20
1.25

(0.W)
(0.032)
fO.034)(0.036)(0.038)(0.04)(0042)(0.044)(0.046)(0.048)(0.051101430101431101432101433101434101435101436101437‘101438101439101440GEARBOX

2.

Thickness “S” of shims for pre-loading of pinion
taper roller bearings

S= 9.60 - G -3.

Pinion to crown gear backlash

0.10

9.60 = sample washer thickness
mmBacklashG(in)= clearance measured by gauge

0 . 0 5 + 0.10
(Zrlo-3+ 4q0-3)

0.10 = corrective value

Part No.

Thickness
mm (in)

4.10
4.15
4.26
4.35
4.45
4.55
4.65
4.75
4.80

(0.164)(0.166)(0.170)(0.174)(0.178)(0.182)(0.186)(0.190)(0.192)700165700166700167700168700169I

700170700171700172700173

TIGHTENING TORQUES
Unit

N*m

Item

ft-lb

kg-m

LEVER AND FORKS
Screw securing 1st - 2nd speed selector
to rod

25

+

26

2.5 +

2.7

18.07 +

19.52

Screws securing forks to speed control
rods

21

+

23

2.1

-

2.3

15.10 +

16.63

Screws securing pin for R.G. sliding gear

19

+

24

1.9 +

2.4

13.74 +

17.36

screw

69

f

85

7

+

8.7

50.61 +

62.91

Bevel pinion gear train retaining ring nut

220 f245

22.5

+ 25

SHAFTS AND GEARS
Primary shaft outer bearing retaining

May 1983

13-30
Alfawiki.nl

162.70 + 180.77

G-EARBOX

Probable cause

TroubleCorrective actionlDifferential gears are worn or
damagedReplace gearsl

Excess play of hypoid

Check and replace, if necessarylCrown gear securing screws areloose

Tightenl

Bevel pinion shim is worn or
damagedReplace shimlPinion shaft retaining nut is loose

Check gearbox components andthen tighten the nut

Excess play in gear train

Adjust gear trainlTeeth of planetary and side gears
are worn, damaged or show evidence of pitting

Replace differential casingl

Irregular variations of driving
torqueAdjust engine idlingl

Not enough oil

Fill up to correct level

Transmission is noisy when inreverse gearl

Reverse gears are worn or damaged

Replace defective parts

Engagement/disengagement ofspeed is not easyFirst of all it should be established if the trouble is caused by the gearbox or by
the control system. If the clutch still transmits torque when the pedal is pusheddown, it means that it is not disengaged. Verify if the clutch properly couples(pedal is released) and uncouples (pedal is pushed-down) the engine to the gearbox casing. If clutch is not faulty, the trouble originates either from the gearbox
or from the control system.

Noisy both during accelerationand deceleration (drive shaft
assy already checked)lTransmission is noisy when in
curve, both with speed engaged
or when in neutral (drive shaft
assy already checked)

Transmission is noisy when inneutral (vehicle is not moving)

Speeds become disengaged

May 1983

gearslBushing on outer speed selector
lever is worn

Replace bushinglGearbox outer linkage needs adjusting and/or lubrication of joints is
insufficient

Check linkage, joints and controlslStroke of outer linkage parts is not
sufficient due to excess play

Check the system and, if necessary,
repair or replace worn partsl

Not enough oil in gearbox-differential casing

Fill-up to correct levell

Synchronizing units are faulty

Refer to “Synchronizing unit is faulty”

lInner controls are deformed orworn

Repair or replace defective partsl

Sleeves and gears are worn ordefective

Replace worn partsl

Excess end-play of the gear that
becomes disengaged (Noisy bothduring acceleration and deceleration)

Verify adjustment of gear train

13-32
Alfawiki.nl

GEARBOX

TroubleProbable cause

Corrective actionlBushing on outer speed selector
lever is worn

Replace bushinglPlungers are worn or damaged

teplace plungerslSprings can no longer be used due
to fatigue or because they arebrokenIeplace springsl

Rod millings are ‘worn or deformed

Replace rodslSelector fork and/or levers areworn or damaged?eplace the selector and/or the leverslSleeve and gear front toothing areworn or damaged

3eplace defective partslDistance between gear and sleeve
front toothing is incorrect

3eplace defective partslSynchronizing ring is worn

Replacel

Sleeve splines are worn or damaged

Replace

Reverse gear light do not lightup when R.G. is engagedl

Switch of R.G. light is faulty

Replace the switch

Speed selector lever vibrates
and is noisylLever return spring is out of orderdue to fatiguelBushing on outer speed selector
lever is faultylRefer to other items concerning
noisy gearboxl

Oil level is below normal or oil is
not of the specified type

Replace faulty parts and use
specified oillIncorrect clearances (not enough)l

Bearing and gear ‘adjustments areincorrect

Adjust clearances and replace
faulty partsl

Excessive torque or improper useof clutch

Replace faulty partslRetaining screws are loose

Replace faulty parts and tighten
screws to specified torque

Speed selection is poor

Synchronizing unit is faulty
or grinds

Seizure, pitting or breakage

Replace faulty parts

SPECIAL SERVICE TOOLS
Tool number

0 A.2.0234

Refer toTool nameSpacer for lockingof1 intermediate
1

paw

~

13-18

flange (ta be used with A.2.0242)

Alfawiki.nl
13-33

May 1983

GEARBOX

Tool number

Refer toTool namepage

A.2.0242

Support of dial gauge to read pinion

13-18

spacer thickness (to be used with A.2.0234)

A.2.0243

A.2.0274

A.2.0300

Tool for locking pinion

13-24

Adapter of sheave for checking

13-16

pinion bearing pm-load

13-18

Tool for locking mainshaft (to be

13-12

used with A.3.0300)

13-14
13-15

A.3.0287

Adjustable span puller for differential

13-22

carnier bearing cones

A-3.0291

Puller of bush shim and oil seal from13-12

mainshaft and gearshift rod

A-3.0292

Driver of differential bearing cups

13-21

CL-

A.3.0293

Driver of bearing and phonic wheel

13-21

retainer onto differential spindle

A.3.0294

Driver of oil seal onto gear shift rod

13-10(with assembled unit)-.

May 1983

13-34

Alfawiki.nl

GEARBOX

Tool name

Tool number

A.3.0295

Plate for whith drawal of differential

Refer to
paw

13-20

spindleA.3.0296

Puller / driver of rear pinion bearing
cup and puller of pinion shaft andmainshaft

A.30297

A.3.0298

13-11
13-13
13-14
13-15

Puller I driver of front pinion bearing

13-11

cup (use with A.3.0296)

13-15

Puller of speedometer pinion and

13-20

ring nut from shaft

A.3.0299

Puller of differential bearing outer races

13-20

Driver of mainshaft and 5th speed

13-15

driver gear

13-16

A.3.0301

Driver of pinion

13-16

A.3.0302

Puller I driver of drive flange bearing

A.3.0300

13-20
13-21

A.3.0303

Guide for fitting striking rod balls of

13-8

3rd. 4th and rev. striking rods (use13-9with A.3.0309)

Alfawiki.nl
13-35

May 1983

GEARBOX

Tool name

Tool number-

A.3.0430

A.3.0452

Refer topage

Driver of output shaft seal

13-21

Puller of drive spindle seal (with unit

13-12

assembled)

A.3.0453

13-19

Driver of drive spindle seal($-$D

A.3.0490

Puller of 4th - speed gear from13-73

mainshaft (to be used with

13-14

A.3.0296 and A.3.0492)

A.3.0491

Puller / driver of rear mainshaft

13-14

bearing (to be used with A.3.0296)

A.39492

Auxiliary shaft for removing 4th-speed

13-13

gear from mainshaft [to be used with
A.3.0296 and A.3.0490)

A.3.0495

Puller of 5th _ speed drive gear

13-13

A.3.0500

Tool for removing rear mainshaft

13-14

bearing (to be used with A.3.0296
and A.3.0491)

A.4.0136

Support of dial gauge for pinion

13-17

setting (to be used with C-6.01 61)

Alfawiki.nl
13-37

May 1983

GEARBOX

Tool name

Tool number

c.5.0124

C.6.0161

Refer topaw

Sheave for checking differential bearing

13-16

pm-load (to be used with A.2.0274 and

13-17

C.2.00371 . . . . . ..I

13-18

Reference gauge for pinion setting (to13-17

be used with A.4.0136)

C.6.0162

Tool for checking pinion setting (to be

13-17

used with A.4.0136)

Alfawiki.nl
13-39

May 1983

Alfawiki.nl

DIFFERENTIAL AND DRIVE SHAFT ASSEMBLYCONTENTS
17-5

Installation . . . . . . . . . . . . . . . . . . .

DIFFERENTIAL . . . . . . . . . . . . . . . . .

17-2

Crown gear and pinion . . . . . . . . . .

17-2

SERVICE DATA AND

Differential casing . . . . . . . . . . . . . .

17-2

SPECIFICATIONS . . . . . . . . . . . . . . . .

17-6

DRIVE SHAFT ASSEMBLY . . . . . . . . .

17-2

General specifications . . . . . . . . . . .

17-6

Removal . . . . . . . . . . . . . . . . . . . . .

17-3

Tightening torques . . . . . . . . . . . . .

17-6

Disassembly . . . . . . . . . . . . . . . . . . . . 17-3

TROUBLE DIAGNOSIS AND

Checks and inspections . . . . . . . . . .

17-4

CORRECTIONS . . . . . . . . . . . . . . . . . .

17-6

Assembly . . . . . . . . . . . . . . . . . . . . .

17-4

SPECIAL SERVICE TOOLS . . . . . . . . .

17-6

a

c

Alfawiki.nl

May 1983

DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY

DIFFERENTIAL
CROWN GEAR
AND PINION

DIFFERENTIALCASINGFor crown gear and pinion overhauling procedure refer to: Group 13

Fey differential casing overhaulingprocedure refer to: Group 13
5Speed M a n u a l G e a r b o x Differential Casing.

- 5-Speed Manual Gearbox
Gear and Pinion.

- Crown

DRIVE SHAFT ASSEMBLY‘fl/ %A\

1

2

Shaft
Wheel nut

3 Washer4
Drive shaft
5 Washers
6 Stopper ring
7 inner race
8 Cage9 Ball10 Clamp
11Boot
12 Clamp
13 Clamp
14 Boot
15 Clamp
16 Inner cover
17 Seal ring
18 Outer ring
19 Inner race
20 Cage21Ball
2 2 Stopper ring
23 Outer cover24

24.58 + 26.75)

@ N*m
Ikgmm
ftdb)

A Outer joint
B Inner joint

Plate

May 1983

17-2
Alfawiki.nl

DIFFERENTIAL AND DRIVE SHAFT ASSEMBLYASSEMBLY
Reassemble joints being careful to fit
parts back into their original position, as marked at time of disassembly, and following the procedure
hereafter described.

OUTER JOINT (A)
1. Thoroughly coat with grease(Molykote VN 2461 C or Optimol
Olistamoly 2 L N 584) the cage, theinner race and the steel balls; pack

4 Inner cover
5 Plate6 BootOuter coverOuter ring

Plates retaining
screwsMark outer ring, cage and joint’s

3 Outer ring

1 Inner race
2 Cagethe joint’s recess with 40 g (1.41 oz)of the same type grease.
2.
Fit boot on shaft being extremely careful not to damage it in any
way along the splines; to this effectsplines should be covered with tape.
3.
Fit lock ring to groove on joint’s

inner race with a reference line toensure proper positioning when assembling.
j” 6. Use pliers to remove lock ring.

inner race. Make sure lock ring i s
properly and securely lodged in its
Seat on the shaft.
4. Following disassembly procedure in reverse sequence, now fit the
inner race and the cage.
Inner race should be fitted SO that its
face, on which lock ring was previously fitted, faces to outside of thejoint.
5. Fit steel balls as shown in the

7. Now remove the. constant-speed
joint from the shaft with the help ofa press, two half-plates, a punch and

CHECKSAND INSPECTIONS

figure.

a base.
suitable‘equipment,
1. Using
thoroughly clean all joint parts.
2. Check working surfaces and bails
for scores or any evidence of wear
due to friction of foreign matter;
replace the joint,

if necessary.
Remember that broken boots willcause loss of lubricant and will also
allow foreign matter to enter which,in turn, will cause faulty operation of
the constant-speed joints; usually thisproblem is easily detected during
testing.
3. Make sure that play in bothandjoints is not too much since excessive
play is the cause of noise during

remove inner cover from the joint.

sudden torque reversal; this is evi-

9.

denced by a knocking sound which is

8.

Slip

boot

off

the

shaft

Remove both seal rings from thejoint’s outer ring.

easily detected during testing.

10. Remove steel balls from theShould disassembly by required, it is

joint and then disassemble the joint

advisable to replace the joint protect-

into its different components: outering boots as well as the seal rings on

ring

the constant-speed joint on gearbox-

0,

0.

race 1

May 1983

cage 0,

and

inner

differential side.

1
7-4
Alfawiki.nl

CAUTION:
Do not exchange this joint’s steel
balls with those of the inner joint as
theirdiameter is different.

DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY

Fit washers on shaft, wheel side,

way along the splines; to this effectaccording to numbering marked atsplines should be covered with tape.

7. Fit lock ring following disassembly procedure in reverse se-time of disassembly. Now fit the

2. Following disassembly proce-quence.

constant-speed joint with the help ofa press, of two half-plates and of tool

dure in reverse sequence, now fit the
inner race and the cage.

A.3.0605.

3. Fit steel balls as shown in the
figure and verify that the joint works

6.

properly.

8.

Fit the boot; fit new clamps andtighten them using suitable pliers
being careful not to damage the bootin doing so.
9.
Fit the three plates to the innercover, insert relevant screws andwashers, and lastly fit the outer cover
onto the six screws.

INSTALLATION
1. Insert shaft into wheel hub.
2. Connect shaft to differential
drive shaft and lock securing screws
to specified torque.

7. Finish up lubricating by packing
joint with 40 g (1.41 02) more of theabove mentioned grease and makesure that balls are completely surrounded by grease.
8.
Fit boot on joint; fit new clamps
and tighten them using suitable pliers
being careful not to damage the bootin doing so.

@ : Tightening torque33 -F 36 N-m(3.4 + 3.7 kg-m
24.56 f 26.75 ft-lb)
CAUTION:
Do not exchange this joint’s steel
balls with those of the outer joint as
their diameter is different.

4. Fit inner cover to the joint andthen fit the latter on the shaft withthe help of a press, of two halfplates, of a base and a punch.

3. By means of a new nut, secure
wheel hub to shaft. Tighten nut tospecified torque, then caulk it.

0: Tightening torque226 + 275 Ndrn
(23+ 28 kg-m
166.30 + 202.46 ft.lb)

INNER JOINT (B)Thoroughly coat with grease (Molykote 2461 C or Optimal Olistamoly 2
I- N 584) the cage, the inner race andthe steel balls; pack the joint’s recess

5. Pack joint with 40 g (1.41 02)
more of the above mentioned grease
and make sure that balls arewith 40 g (1.41 02) of the same typegrease.

completely surrounded by grease.

1.

6.

Fit boot on shaft being extreme-ly careful not to damage it in any

Fit both seal rings on the joint’s

outer ring.

Alfawiki.nl
17-S

May 1983

DIFFERENTIAL AND DRIVE SHAFT ASSEMBLYSERVICE DATA AND SPECIFICATIONSGENERAL SPECIF~ICATIONSFLUIDS AND LUBRICANTS
Application

Denomination

TVP~

GREASE

Drive shaft assembly constant-speed

Q.ty

Molykote VN 2461 C

8Q 9(2.82 oz)or Optimal Olistamoly 2 LN 584

joints (for each joint)

Std. No. 3671-69843
Split grease quantity between the twosides of each joint;s crown of steel balls

TIGHTENING TORQUES
N.m

Screws securing (in oil), with outer spacer, drive

33

+

36

226

+ 275

3.4

+

3.7

23

f 28

24.58 + 26.75

shaft assembly to differential shaft
Nuts securing drive shaft assembly to wheel hub

166.30 + 202.46

TROUBLE DIAGNOSIS AND CORRECTIONSCorrective action

Probable cause

Condition

Necking during sudden torquel

Too much play between seats andReplace the joint

steel balls

reversall

No renough lubricating grease andSmear with grease and replace bootsleakage from the boots

SPECIAL SERVICE TOOLS
Refer toTool number

A.3.0605

Tool nameBase for withdrawal and fitmend of drive
shaft from constant speed joint.

May 1983

17-6
Alfawiki.nl

weFRONT SUSPENSIONCONTENTSDESCRIPTION . . . . . . . . . . . . . . . . . . .

21-2

SERVICE DATA ANDFRONT WHEELS HUB . . . . . . . . . . . . .

21-3

SPECIFICATIONS . . . . . . . . . . n . . . . .

21-9

Removal . . . . . . . . . . . . . . . . . . . . .

21-4

Technical data . . . . . . . . . . . . . . . . .

21-9

Disassembly. . . . . . . . . . . . . . . . . . .

21-4

General specifications _ . . . . . . . . . .

21-10

Checks and inspections . . . . . . . . . .

21-5

Checks and inspections _ . . . . . . . . .

21-10

Assembly . . . . . . . . . . . . . . . . . . . . .

21-5

Tightening torques . . . . . . . . . . . . .

21-11...................

21-6

TROUBLE DIAGNOSIS ANDFRONT SUSPENSION . . . . . . . . . . . . .

21-6

CORRECTIONS . . . . . . . . . . . . . . _ _ . .

21-l 1

Coil spring and shock absorber . . . .

21-6

SPECIAL. SERVICE TOOLS . . . . . . . . .

21-13

Transverse and semi-trailing link . . .

21-8

Installation

Refer to Group 00 - Chassis and Body Maintenance
for:
l
l

Checking Suspension Height
Wheel Alignment

Alfawiki.nl
May 1983

FRONT SUSPENSIONDESCRIPTION

1
2
3
4
5
6
7
8
9

Coil spring
Steering lever
Strut
JOIre bootShaft
Semi-trailing link
Transverse link
Ball joint
Hub support

May 1983

IO Wheel cover
11
Bearing
12 Hub nut
13 Wheel hub
14 Wheel screw
15 Brake disc
16 Dust cover
17 Rim21-2
Alfawiki.nl

FRONT SUSPENSIONREMOVAL
1. Place the car on lift, block rear
wheels and lift the front by means ofa jack, then support it on stands sitedin adjacent position to the bearing
points (refer to: Group 00 - Lifting
Points and Towing).
2. Remove wheel from the operative side.
3. Remove the. nut caulking 4
and unscrew it out of drive shaft 3
end.
4. Remove drive shaft from differential shaft by unscrewing the six
securing, screws. Remove shaft withthe two constant-speed joints.
5 . D e t a c h caliper @ from hub
support, without disconnecting itfrom hose 0.

8

1 Screws

2 Bracket

7. Unscrew and remove nut securing ball joint pin 0, on semi-trailing link 0, to hub support. Holdhub support properly, and by using
the A.3.0157 withdraw pin.

1 Dust cover
2 Dust cover securing screws

2. Using a screwdriver withdraw
seal ring from hub support (shaftside).
3 . W i t h d r a w h u b @ from its
support @ by means of a press, a
suitable punch and two plates.

1
2

3 LinkBall joint
Semi-trailing link

1Hub

2 Hub support

DISASSEMBLY
1

Hose

4

Hub nut

2 Caliper

5 Brake disc3

6

Drive shaft

Dowel

6. Loosen and remove the fourscrews @securing vertical guide

1. Clamp hub support in viceprovided with protective jaws, unscrew dowel and remove brake

Alfawiki.nl

4. Reclamp hub support in viceprovided with jaws and using a punch
remove two calkings on ring nut
securing bearing to support. Usingand octagonal spanner with proper
extension unscrew ring nut andFRONT SUSPENSION

5. Withdraw bearing from hub
support by means of press puller

I

A.3.0302 and two plates.

- A.3.0330

6.

Reclamp hub in vice and using asuitable tool withdraw bearing innerrace.
1 Hub support
1 Hub support

2 Hub

2 Bearing5.

Lubricate seal ring outer surface

with prescribed oil (AGIP Fl Rotra
HP SAE 8OW90 or IP Pontiax HD
2. Clamp hub support in vice pro-

8OW90) and fit ring it its seat on hub

vided with jaws, fit a new ring andsupport by means of tool A.3.0330.

using octagonal spanner A.5.0239
screw ring nut into its seat on support, tightening it to the specified
torque.
3.

Caulk ring nut edge.

@ : Tightening torque
Bearing ring nut

226 + 225 N-m(23 + 27 kg-m
116.3 + 195.2 ft-lb)

CHECKSAND INSPECTIONS
l . Carefully clean hub and hub
support and visually check surfaces
for damage. Replace damaged parts,
if required.
2. Replace, at any rate, bearing
assembly, ring nut and seal ring.

ASSEMBLY
1. Fit new bearing @ to hub
support @ by means of press, tool
A-3.0330 and stand A.3.0415.

4. Insert support 0 into relevant
hub @ using press, tool A.3.0330
and plate.

Alfawiki.nl
21-5

6.

Clamp

hub

supportinvice

provided with jaws and fit dust coverand brake disc.

May 1983

FRONT SUSPENSIONINSTALLATION

Nut securing semi-trailing linkball joint to hub support
39-48 N - m

1. Reinstall hub-hub support assembly in the reverse order ofremoval and tighten following parts
to the specified torque values:(4s4.9 kg-m
29.9 + 35.43 ft.lb)(2) Connect shaft to differential
drive shaft by locking the six securing screws to the designed torque.
(3) By means of a NW nut, secure
shaft to wheel hub. Tighten nut todesigned torque and caulk it.

2. Refit caliper to hub support.
@ : Tightening torques
Nuts securing vertical guide to
bdy
12+ 1 5 N-m@ : Tightening torques@t Tightening torqueScrew fixing caliper on hub

Screws securing drive shaft todifferential shaft

support59 G-74 N - m(I,2 f I,5 kgpm
El,84 + 11 ft.lb)

33+36 N - m(3.4 + 3.7 kg-m

(6 + 7.5 kg-m

24.58 + 26.75 ft.lb)

43.4 + 54.2 ft.lb)
Screws securing hub support to

Nut securing wheel hub toshaft
2 2 6 + 275 N-m(23 + 28 kg-m
116.3 + 202.5 ft.lb)

3. Refit shaft, by doeing as follows:(1) Insert splined end into wheel
hub.

strut braket
39-48 N - m(4 + 4.9 kg-m
28.9 f 35.43 ft.lb)

FRONT SUSPENSIONCOIL SPRING AND SHOCK ABSORBER

39.05 + 62.91)

28.9 f 35.43)

39.05 + 62.91k
I
‘
.lj

@ N-m
(kg-m
ftlb)

39.05 + 62.91)
1
2

WasherUpper washer

3
4
5
6
7

Rubber support
Complementary retainer
Retainer
Rubber seat
Upper cap

10 Lower washer
11 Rubber bound bumper
12 Lower cap
13 Lower retainer
14 Thrust bearing
15 Bearing washer
16 Seal ring

8
9

Boot
Spring18 Steering leverMay 1983

17 Strut

2Alfawiki.nl
1-6

19
20
21
22
23
24
25

Strut bracket
Flexible bushSemi-trailing link
Ball joint
Flexible bushTransverse link
Flexible bush

FRONT SUSPENSIONREMOVALrear

6. Hold strut properly, then loosen
and unscrew the four screws 0

wheels, jack up front of vehicle, thensecuring strut bracket to hub sup-support it by stands placed in adja-

port.

1.

Place

car

on

lift,

block

A.2.0251

7

cent position to jacking points (refer
to: Group 00 - Lifting Points andTowing).
2. Remove four screws and wheel.
Unscrew nut securing ball pin of3.
steering track rod @ to lever @ of
strut 0.
4 . U s i n g A . 3 . 0 1 5 6 puller withdraw upwards pin of steering trackr o d @ to lever @ of strut 0.
1 Securing nut

2 Tool nut

3. Withdraw following parts (referto figure of page 21-6 1: washer 0,
upper -washer 01 rubber supp o r t 0, c o m p l e m e n t a r y r e t a i n 0, w i t he r @, lower washerb o o t @, s p r i n g r u b b e r seat @relevant
retainer
5
and

0

with

cap 0, rubber bound bumper 0 ,@ with relevant lower
spring1 Screw

1 Strut
2 Strut lever@ secured to compression
cap
tool.
If required, gradually release springfrom tool, then separate spring fromlower cap.
Then remove lever retainer 13
from spring lower cap.

3 Ball joint
4 Steering track rod

0

4. Referring to the following fig5. Operating withing engine com-ure, dismantle cap retainer 0 topartment, loosen and remove four

DISASSEMBLY

following parts, taking care innuts @ securing strut to body 0.

Clamp strut in vice and carry out
disassembly as follows:

numbering them and mark direction
to be kept during assembly: roller

Hook spring by’tool A.2.0251

thrust bearing @ , bearing wash-

1.

and screw two nuts @ of tool so as
to progressively compress spring until-upper cap is released.

er @

and

lower

seal

ring @ .

Mark lower capas SO as to identify
them during assembly.

WARNING:
Compress spring as minimum as
possible so as to allow upper cap
rotation with relevant gasket andretainer.
When compressing spring, ensure thattool is always hooked firmly tospring and lower cap.

2.
1 Body2

Nut

Unscrew shock absorber securing

nut @ as shown on following
figure.

Alfawiki.nl
21-7

1 Lower retainer
2 Thrust bearing

3 Bearing washer
4 Seal ringMay 1983

FRONT SUSPENSIONCHECKS AND INSPECTIONS
Clean all the components.

Refit remaining parts of strut .assembly complying with sequence
shown on figure.

j’..
.;-’ Self-lubricating bush
Check self-lubricating bushes embod;..;,,,ied in strut lower cap retainers for’ : signs of excessive wear which are
showed by metallic dust appearing,,on’bush working surface.

Shock absorber

A.3.0157.

If required verified setting data relevant to shock absorber built-in
strut. (Refer to Service Data andSpecifications-Checks and Inspections).

6. Loosen bolt @ securing transverse link @ to engine cross member @ and bolt @ securing tosemi-trailing link @ , then withdraw the removing transverse link.
7. Loosen bolt @ securing semitrailing link to body and remove thelink.

Replace shock absorber in case they
are removed because of inefficiency
or oil leakages are detected.

Springs
Visually check springs for anomalous,
signs.

2. Remove wheel from the operative side.
3. Loosen and remove shaft securing nut (wheel side).
4. Detach constant-speed
jointfrom differential drive shaft byloosening the six securing screws
and remove shaft.
5. Remove nut securing semi-trailing link ball joint pin @ to hub
support and withdraw pin using toolSpring lower and upper caps shouldbe those corresponding with the-side.(righthand .or l&hand) to which
strut is installed.

Rubber parts
Replace rubber parts if deformed,
damaged or aged.

INSTALLATION
1, Install strut in the reverse orderof removal and tighten following
parts to the specified torque:

ASSEMBLY
1. Lubricate seal ring and thrustbearing of spring lower cap 0
retainer with grease (AGIP Fl Grease
33 FD, IP Atitogrease FD).
Refit all parts of retainer to strut
complying with direction and ordermarked during disassembly.
2. If previously removed, refit tool
A.2.0251 to spring @ and lower
cap @ with tool clamped in vice;
compress spring so that subsequentassembly procedure can be carriedout.

@ : Tightening torqueScrew securing hub support to
strut bracket

39t48 N - m(4 + 4.9 kg-m
28.9: 35.43 ft-lb)
Nut securing strut to body12+ 15 N-m(I,2 + I,5 kg-m
8,84 + 11 ft.lb)
Nut, steering tie rod ball joint
on bracket lever

39 + 48 N-m(4 + 4.9 kg-m

A.2.0251

1ro

2 8 . 9 + 3 5 . 4 3 ft.lb)

TRANSVERSE AND
SEMI-TRAILING LINKREMOVAL

1 Lower cap

May 1983

2 Spring

1. Place car on lift. Support frontof vehicle on stands sited in adjacent-position to jacking points and block
rear wheels by hand brake.

2Alfawiki.nl
1-8

1Cross member

2
3
4

Bolt
Transverse linkFin

5 BoltSemi-trailing link

6
7

Bolt

8. If required, after checking flexible joints: remove flexible joints
from semi-trailing links and transverse jinks by means of proper tool.

FRONT SUSPENSIONCHECKS AND INSPECTIONS
Clean all the components
1. Visually check semi-trailing links
and front transverse links for blows,
deformations, oxidation, cracks.
2. Examine condition of flexible
bushes in semi-trailing and transverse
link knuckles.
3. Check that semi-trailing link balljoint pivots free from crawlings orwith notable slack in its seat.
Avoid flexible joints coming into
contact with oil or grease.

INSTALLATION
1. If previously removed, it flexible
joints, inserting them from thechamfered side, to semi-trailing link
and front transverse link.

CAUTION:To ease joints installation, lubricate
outer surface with the fluid prescribed for rubber parts fitting tometallic seats (MILLOIL Slider for
rubber sections; UNION CARBIDECHEMICALS COMPANY Ucon Lubricant 50 HB - 5100).
2. Install transverse links and semitrailing links to body in reverse orderof removal and torque-tighten screw
securing semi-trailing link ball joint
pin to wheel support to the specified
values.

@ : Tightening torqueScrew securing semi-trailinglink ball joint pin to wheel
support
39+448 N-m(4 + 4.9 kg-m
28.9 4 35.43 ftdlb)
Screw securing transverse andsemi-trailing links
53+ 8 5 N-m( 5 . 4 + 8 . 7 kgm
39.05 + 62.91 ftlb)
3. Refit drive shaft (see: Front
Wheels Hub - Assembly).

Tighten fixing points of semitrailingand transverse link flexible joints tospecified torque with car having its
nominal height (see: Car Height).

SERVICE DATA AND SPECIFICATIONSTECHNICAL DATASHOCK ABSORBER

COIL SPRING
Wire diameter

mm (in)13.6 (0.535)

Shock absorber type

Coil diameter

mm (in)160 (6.299)

Piston rod diameter

mm (in)20 (0.787)

Free length

mm (in)293 (I 1.535)

Strokemm (in)148.5 (5.846)

Stiffness

N/mm
Wmml
(lb/in)

24.5

(2.51
(140)

Alfawiki.nl

hydraulicFRONT SUSPENSIONGENERAL SPECIFICATIONSFLUIDS AND LUBRICANTS

Application

TYPe

GREASE

Seal ring and spring lower cap retainer

Denomination
I

I

Q.W
-

AGIP Fl Grease 33 FD
IP Autogrease FD

thrust bearing

Norm. 3671-69833134

FLUID

Hub support seal ring outer surface

AGIP Fl ROTRA HP SAE 8OW90
IP Pontiax HD 8OW90
Norm. 3631-69408

FLUID

Outer surface of the semitrailing link-

MILL01 L: Slider for rubber sections
UNION CARBIDE CHEMICALS COMPANY

and front link silent block

Ucon Lubricant 50 HB-5100
Norm. 1500-l 7502

CHECKS AND INSPECTIONSDATA OF SHOCK ABSORBERS SETTINGSHOCK ABSORBER

I

LEFT

I

542.353

Alfa Romeo Part Number

I

I

RIGHT
542.352

Compression

N (kg) (lb)

1 0 7 . 9 + 1 8 6 . 4 (11 + 19) (24.25+ 4 1 . 8 9 )Expansion

N (kg) (lb)215.X + 3 1 3 . 9 ( 2 2 + 3 2 ) ( 4 8 . 5 + 70.55)

Compression

N (kg) (lb)421.83559.2 (43 + 5 7 1 ( 9 4 . 8 + 1 2 5 . 7 )Expansion

N {kg) (lb)1128.15G1324.3 (115 + 135) ( 2 5 3 . 5 + 2 9 7 . 6 )Low speed

High speed

NOTE:

May 1983

The shock absorbers are integrated in the strut tubes

21-10
Alfawiki.nl

FRONT SUSPENSION

TroubleSteering wheel shocks,
vibrations or shimmying(cont.)

Vehicle drifts or wanders

Steering wheel excessive play

Noise

Tires squeal when taking
a curve

Abnormal tires wear
(or uneven)

May 1983

Probable cause

Corrective actionl

Excessive play in steering linkage

Check and replace if requiredlLoose screws
box

Tightenl

Unserviceable shock absorber orloose securing points

securing steering

Tighten or replace

Drifting becomes evident when vehicle is running on a flat surface with hands
off steering wheel. Reference should also be made to: Group 25 - Trouble
Diagnosis and CorrectionslWorn or faulty tire

ReplacelImproper tire air pressure and/or
loose wheel nuts

Adjust and/or tightenlDifference in height between rightand left tire tread

Replace tire with thinnest treadlAsymmetric suspension height

Restorel

Incorrect steering geometry

RestorelBrake dragging

Check and restore working conditionslWorn suspension linkage flexible
bush

Replace worn componentslConnection steering-suspension
faultyReplace faulty componentslPinion-rack mating incorrectly
adjusted

AdjustlWorn steering components

Replace worn components

l

Loose
screwsTightensteering box securing

Improper tire air pressure

AdjustlDamaged and worn ball pin or
steering parts; or lack in lubrication

Replace or lubricatel

Loose steering or suspension
linkageTightenl

Faulty shock absorber

ReplacelFaulty wheel bearing

ReplacelFaulty suspension linkage bush

ReplacelDamaged coil springs

ReplacelLoose shock absorber securing nut

Tightenl

Improper tire air pressure

Adjustl

Incorrect steering geometry

Restorel

Incorrect driving

Avoid incorrect drivinglRefer to: Group 28-Wheels andTires

Wheels and tires

l

21
-12
Alfawiki.nl

FRONT SUSPENSION

Corrective action

Probable cause

TroubleStiff steering wheel

Improper tire air pressure

Adjustl

Excessively worn tire

ReplacelPinion-rack mating incorrectly
adjusted

Adjustl

After these preliminary operations, if trouble persists, check and operate as
follows.
Jack up front of vehicle and support on safety stands. Separate strut knuckled
arm from track rod and move steering wheel.
a) If steering wheel is light to move, check and locate cause of trouble in steering linkage, suspension or front axleb) If steering wheel is hard to move, check and locate cause of trouble in steering box or steering column.

1

Improper steering box’lubrication
or/and oil contamination (b)Lubricate

Improper steering linkage lubrication, grease contamination orabnormal steering wheel wear (a)Correctly lubricate, replace greaseor worn parts

Worn or seized ball pin (a)Replace

Deformed steering linkage (a)Replace

Incorrect steering geometry (a)RestoreSPECIAL SERVICE TOOLS
Tool name

Tool number

A.2.0251

Tool for compressing and retaining spring

A.3.0156

Puller of upper pin from stub axle

A.3.0157

Refer toI

page

Puller of wheel hub support lower joint

pin

Alfawiki.nl
21-13

May 1983

FRONT SUSPENSION

Refer toTool name

Tool number

Page

A30302

Puller/driver of cup of front hub

21-5

bearings

A.3.0330

\

21-5

I

(to be used with A.3.0415)

A.3.0415

0

Driver of seal and bearing of front hubs\

Base of withdrawal fitment (to be usedwith driver A.3.0330)

IO

21-5

cl

A.5.0239

May 1983

Wrench for bearing front hub nuts

21-14
Alfawiki.nl

21-5

FRONT AND REAR BRAKESCONTENTSDESCRIPTION . . . . . . . . . . . . . . . . . . .

22-2

Control lever . . . . . . . . . . . . . . . . . .

22-17

Brake system bleeding . . . . . . . . . . .

22-3

Control cables . . . . . . . . . . . . . . . . .

22-18

Pedal assembly . . . . . . . . . . . . . . . .

22-4

SERVICE DATA AND

Brake master cylinder . . . . . . . . . . .

22-6

SPECIFICATIONS . . . . . . . . . . . . . . . .

22-l 9Hydraulic system piping . . . . . . . . .

22-8

General specifications . . . . . . . . . . .

22-19

Brake pressure regulator valve . . . . .

22-8

Inspection and adjustment . . . . . . .

22-20

Servobrake . . . . . . . . . . . . . . . . . . .

22-9

Tightening torques . . . . . . . . . . . . .

22-21

Vacuum system . . . . . . . . . . . . . . . .

22-l 0

TROUBLE DIAGNOSIS AND

Front disc brake . . . . . . . . . . . . . . .

22-10

CORRECTIONS . . . . . . . . . . . . . . . . . .

22-22

Rear drum brake . . . . . . . . . . . . . . .

22-15

SPECIAL SERVICE TOOLS . . . . . . . . .

22-26

PARKING BRAKE . . . . . . . . . . . . . . . .

22-17

Refer to Group 00 - Chassis and Body Maintenancefor:lBrake System

Alfawiki.nl

Mav 1 9 8 3

FRONT AND REAR BRAKESSERVICE BRAKE
BRAKE
SYSTEM BLEEDING

the pedal all the way down; now
tighten the bleeders.

Bleed brakes following the proceduredescribed hereafter and being careful
to perform the following:

carry out the operation by operating

It is up to the operator whether toat the same time or separately on thefire bleeder screws.

a. Check that during bleeding thefluid level in the reservoir does
not go below the “MIN” level.

CAUTION:
During bleeding operation always
keep the level of fluid in reservoir
above the “Ml N” level.

(3) Remove hoses from bleeders andfit relevant caps.
5. Press brake pedal all the way
down and check whether; immediately after the pedal’s initial free travel,
you feel a direct action on the fluid
without elasticity, if not so, repeat
bleeding operation.
6. Restore fluid level in the reservoir and close it with relevant cap.

b. Do not reuse the oil drained
during bleeding operation.
c. Work with extreme care in order
to avoid damaging painted surfaces through contact with thefluid.
1. Place car on a lift.
2. If required, refill reservoir withspecified fluid (ATE “S” or AGIP Fl
Brake Fluid Super DE or IP Auto
Fluid FR).
3. Remove dust covers from bleeders located on calipers or on wheel
cylinders.
4. Carry out bleeding operations
closely following the instructions
described hereafter.
(1) Fit a small hose to the bleeder of
each front brake caliper, of each rear
wheel cylinder, and of bleed screw ofbrake pressure regulator. Place thehose other end into a transparent
container previously partially filledwith specified brake fluid.
(2) Loosen the above mentioned
bleeders and press a few times thebrake pedal all the way down,

releasing it very slowly and waiting a
few moments in between pressings.
Repeat this operation till the fluid
coming out of the hoses is free of air
bubbles and then press once more

Alfawiki.nl
22-3

May 1983

FRONT AND REAR BRAKESPEDAL ASSEMBLY

@ N-m
(kg-m
ft-lb)
1 Retainer
2 Washer
3 Gasket
4 Pedal assy bracket
5 Stop light switch
6 Pin

7
8
9
10
11
12

Bull ringSpacer
Accelerator pedal
Bolt
Plastic bush
Pin

13 Brake pedal
14 Bull ring
15 Spring
16 Spacer
17 Clutch pedal

DISASSEMBLY

b. Passenger compartment
1. Separate from accelerator pedal
the control cable @ and release

Carry out removal of pedal assembly
operating as follows:electric connection @ of the stopa. Engine seatlight switch.

1. Disconnect electrical wiring @of brake fluid level warning light and2. By removing retaining rings,
return springs and connecting pins
disconnect the brake and clutch
pedals from control forks @a n d @ o f t h e r e l e v a n t mastercylinders.

with a syringe take out all brake andclutch fluid from reservoir @2. Unscrew unions @ connecting
the four pipes that start out from thebrake master cylinder 0. F r o mclutch master cylinder @ remove

3. By unscrewing the four securingnuts
0, separate from pedal
assembly the servobrake - braker
master cylinder unit.
4.
By unscrewing the two securing
b o l t s @ remove clutch masterthe pipe @ and the hose @ connecting it to the reservoir.
3. From servobrake remove theconnected to the vacuum
sleeve 90cylinder from pedal assembly.
5. Unscrew the six nuts (set inevidence by figure) securing pedal
assembly to body and remove

intake pipe.

4. R e m o v e s c r e w@ securing
sheath clamp plate of the accelerator
control cab le.
1 Hose2 Clutch mastercylinder3 Pipe4 Pipe unions

May 1983

Brake mastercylinder6 Brake liquid tank
7 Electric cables
8 Screw

pedal assembly from engine seat.

9bolt @.

5

Sleeve22-4
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6. Remove, if necessary, the accelerator pedal from hinge to pedal
assembly support by unscrewing

FRONT AND REAR BRAKESCHECKS AND INSPECTION
1. Verify condition of pedals, of
pedal assembly and gasket.
2. Check against presence of ex
cessive wear and mesh in bushes, pin
and spacer.
3. Check against presence of yield
in return springs.
4.

If necessary, remove and replace

the stop light switch.

4. Lubricate end of accelerator
cable before connecting it to pedal.
Then, after securing the sheath clamp
plate to pedal assembly, adjust its
travel (see: Group 04 - Accelerator
Control Adjustment).
5. Tighten to the prescribed torquethe unions of brake master cylinder
pipes and the union of clutch mastercylinder pipe.
0: Tightening torques
Unions of brake master cylin-

REASSEMBLY

der pipes

reverse the order of disassembly and8+10 N - m(0.8+ 1 kgam

apply a coat of the prescribed

5.78 + 7.23 ft.lb)

For pedal assembly, reassembly,

grease (AGIP Fl Grease 15) to the1

Electric
connection
2 Cable3 Nut
4 Bolt5

Clutch mastercylinder fork
6 Brake mastercylinder fork

parts subject to sliding and to return

Union of clutch master cylin-springs.

der pipe
15 + 1 9 N - m(1.5+ 1.9 kg-m
10.85 + 13.74 ft-lb)

INSTALLATION
1.
Reinstall pedal assembly to bodyby reversing order of removal and

6.

DISASSEMBLY

complying with the following.
(1) Replace, if required, the gasket

7. Carry out bleeding of brake

Disassemble pedal assembly operat-

between pedal assembly and body.

Bleeding) and of clutch (see: Grouping as follows:
Remove retainer @ of pedals
1.

(2) Tighten, to the prescribed

12 Hydraulic Control Sub-assembly

torque,Hydraulic System Bleeding).

pin @ and washer @ .
2. Withdraw Pin and recover peda l s @ a n d 0, a n d s p a c e r ‘@.
3.
Remove plastic bushes @ from
pedals.

t h e n u t s secuging p e d a lFill the brake and clutch oil tankup to maximum level.
hydraulic system (see: Brake Systemassembly to body.
0: Tightening torque of pedal
assembly nuts
9+15 N-m( 0 . 9 5 1.5 k g - m
6.51 + 10.85 ft.lb)(3) Lubricate forks connecting bothbrake and clutch pedals to therelevant master cylinders, with AGIP
Fl G R E A S E 1 5 ; t h e n riconnectthem.
2.
Reconnect to pedal assembly the
servobrake together with brake master cylinder and then clutch mastercylinder.
3.
If previously removed, reconnect
accelerator pedal after lubricating
spacer. Make sure that accelerator
pedal can freely rotate after tightening securing nut to the prescribed
torque.
1 Retainer
2 Washer
3 Pin
4 Bush5 Pedal
6 Spacer
7 Pedal0: Tightening torqueSt10 N - m(0.8 f 1 kg-m
5 . 7 8 + 7.23 f t - l b )Alfawiki.nl
22-5

May 1983

FRONT AND REAR BRAKESBRAKE MASTER CYLINDER

N-m
(h-m
*lb)
1
2
3
4
5
6
7
8
9
10
11

Level indicator
Reservoir
Union
Seal ring
SpringSupport disc
SpringWasherGasketSpace sleeve
Intermediate piston

May 1983

12 Gasket
13 Tab washer
14 Lock ring
15 End washer
16 Gasket
17 Washer
18 H shaped gasket
19 Bush20 Push rod piston
21
Space sleeve
22 Gasket

22-6
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23
24
25
26
27
28

29
30
31
32

WasherSpringSupport disc
Return spring
Setscrew
WasherMaster cylinder body
FilterGasketCap

FRONT AND REAR BRAKESb.

Tighten to the prescribed torquetwo new nuts securing brakesyringe in order to suck theliquid of brake clutch tank.

master cylinder to servobrake.

b. A S piping is removed, remember.

to plug up the ends in order toavoid foreign matter from entering.
To remove pipes, loosen unions.

To remove(T): Tightening torque

Brake master cylinder nuts toservobrake
BENDITALIA

on both ends.

(1.2+ 1 . 5 kgmm

hoses, unscrew
unions collecting pipes-to hoses

8.68 + 10.85 ft4b)

and remove them. Then, discon-12+ 1 5 N-m

3. Loosen and remove bolt @connecting the Panhard rod @ tobody and loosen the equalizer
securing bolt @.

nect hose on the other side.
ATE
21 + 28 N-m(2.1 + 2.9 kg.m
15.2 + 21 ft4b)c. Pipes must be connected tomaster cylinder and tightened tothe indicative prescribed torque.

c.

At the end of installation on car,both front and rear flexible
cables must not result to be
kink. For their check, take as
reference the writing with therelevant

manufacturer
marklocated on end of pipes, or thelight coloured band (for front
cables) located along pipe itself.

@ : Tightening torque
Unions securing pipes to brakemaster cylinder
8-10 N - m(0.8 + 1 kgmm
5.78 + 7.23 ft.lb)

d. Having completed installation of
piping, fill up brake fluid reservoir to proper level and bleed
the brakes (Refer to: Brake

1
2
3
4

UnionsFork
SpringPanhard rod

5
6
7

Bolt
Bolt
screwsSystem Bleeding).
4 . L o w e r Panhard bar in order toTightening torquesd: Fill reservoir up to proper level
using only specified fluid (ATE
“ S ” o r AGIP Fl B r a k e F l u i dSuper ED, or IP Auto Fluid FR).

Hose unions of brake hydraulicsystem
IO+ 1 5 N - mlocated on rod itself. Remove springby withdrawing i t f r o m equaliz-(1 + 1.5 kgmm

er

7.23 + 10.85 ft-lb)

required, also clutch system (Refer
to: Group 12 Subgroup HydraulicControlHydraulic
SystemBleeding).

HYDRAULICSYSTEM PIPINGCHECKS AND INSPECTIONS
Thoroughly check all brake systempiping (pipes and hoses) making surethey are not out of shape or cracked
and that outer surfaces of pipes do
not show any evidence of oxidation.
Replace parts that are not flawless.

REMOVAL AND
INSTALLATION

Pipe unions of brake hydraulicsystem8+10 N - m(O-S+ 1 kg-m
5.78 + 7.23 ft.lb)

1 Spring

2 Ring

BRAKE PRESSURE
REGULATOR VALVE

34 Equalizer
5 BoltPin

REMOVAL0

1. Unscrew the three unions 1 ofthe brake pressure regulator pipes,

CAUTION:taking care to close, by means of

the brake pressure regulator.

caps, the two feeding pipes of brakein o r d e r t opressure regulator,
prevent tank emptying.
2. Remove from body, the brakepressure regulator valve by unscrew-

CAUTION:ing the two securing screws @ anda. In case of removal or reinstallation of brake pipings, use aremoving f o r k @ f r o m c o n t r o lspring 0.

May 1983

04

5. If necessary, remove bolt @and equaliter.

2. Bleed brake system (Refer to:
Brake System Bleeding) and, ifeasy spring @ withdrawing frompin 0, and from rubber ring @2Alfawiki.nl
2-8

Do not disassemble components of

INSTALLATION
1. Reinstall to body the brakepressure regulator valve by tightening
bolts to the prescribed torque:( 1 . 5 + 2 . 4 kg.m)
15 + 24 N.m( 1 0 . 8 5 + 1 7 . 3 5 ft.lb) a n d ( i f pre-

FRONT AND REAR BRAKESINSTALLATION
1. On bank, reconnect master cylinder to servobrake tightening securing nuts to the prescribed torque(see: Brake Master Cylinder - Installation).
2. For reinstallation on car of thewhole unit, reverse order of removal
and comply with the following.
(1) Tighten unions of pipes to theprescribed torque: IO + 14 N.m(1 + 1,4 kg-m) (7.23 + 10.84 ft.lb).
(2) Lubricate connecting pin withprescribed grease (AGIP Fl GREASE15); then reconnect fork to brake
pedal.
(3) Restore level of brake fluid; thencarry out bleeding (see: Brake
System Bleeding).

VACUUM SYSTEM
1. Visually check hoses making
sure they are in no way damaged or
clogged; also make sure clips are allproperly tightened.

so that the crawfoot in the above
figure points towards the intake
manifold _2. Remove non-return valve (iJafter
havingremovtirelevant
clips 0,A Intake manifold side (black)
B Servobrake side (white)

Valve

2 Clips

3. Check valve thoroughly making
sure it works properly, meaning thatit allows air flow only in the direction shown by crawfoot.
4. When fitting non-return valve
back to hose, be careful to position it

FRONTDISC BRAKEDBA CALIPER@ 59 + 73(6 + 7.5
43.38 + 54.23)(0.2 f 0.35
1.45 + 2.53)
1
2
3
4

Caliper setting
clip
Caliper support
Pad
Pad retainingclip

5 Retainers
6

Plate

May 1983

7
8
9
10
11
12

Dust cover
PistonSeal ring
Floating caliper
BleederBracket13
14

Washer
Screw

b
@ N.m
(kg+m
ftilb)

2 Alfawiki.nl
2-10

FRONT AND REAR BRAKES

5. Remove both pads, each with

Pad replacement
I.

Lift car’s front end positioning it

on safety stands (Refer to: Group 00- Lifting Points and Towing).

relevant dowel pin 0, and thenremove pins from pads,-1

11. Restore proper brake fluid levelin reservoir (ATE “S” or AGIP Fl
Brake Fluid Super ED or IP Auto
Fluid FR).

2. Using suitable pliers remove
CAUTION:retainers @ from setting plates 0
as shown in the figure below.

To restore correct braking, pushbrake pedal all the way down a few
times.

Caliper unit
REMOVAL
Remove caliper unit as follows:
1 Fad dowel pin

1. By means of a syringe, suckbrake fluid from feed tank.
2.

Disconnect brake fluid hose 0.

3. Loosen and remove the two
CAUTION:
When pads are off, do not push brake
pedal in order to avoid piston from1

Plares

2 Retainers

being ejected from its seat on floating caliper. When replacing pads use
only original spare parts and replace

3. With the help of a punch, push
p l a t e s 0 and @ a n d t a k e them

them on both calipers.
Pad assembly must be carried out byout.

p o s i t i o n i n g t h e crawfoot i n t h eforward rotation direction of the

Plates are not interchangeable.

brake disc.

screws @ securing caliper unit to
hub support and then remove thewhole caliper unit.
CAUTION:
In case of caliper unit replacement,
make sure that on front axle aremounted calipers of the same type
only.

6. Clean pads seats on caliper withalcohol.
CAUTION:
Do not lubricate in any way either
the pad’s resting seats on calipers nor
pad dowel pins.

1 Upper plate
2 Lower plate

3 Floating caliper

4. Press floating caliper so as topush it toward the lower groove andthen remove it from the support.

7.

Fit dowel pins on pads and thenfit same into relevant seat.
8. Push piston towards its position
into floating caliper.
CAUTION:
To avoid overflow of brake fluidwhen the piston is pushed back, it isadvisable to suck some of the fluid
from the reservoir by means asyringe.

9.

Now fit the floating caliper andboth setting plates.

1 Securing screws

2 HoseINSTALLATION
Fit back caliper unit as follows:
1. Fit caliper unit and bracket for
brake fluid hose and then tighten
relevant retaining screws to specified
torque.
0: Tightening torque

CAUTION:
Do not lubricate setting plates.

Caliper retaining screws
59+73 N-m

1 Caliper support

2 Floating caliper

10. Fit relevant retainer on each

(6 + 7.5 kg-m

plate,

43.8 f 54.23 ft-lb)

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22-11

May 1983

FRONT AND REAR BRAKESCHECKS AND INSPECTIONS
Thoroughly wash all parts in alcoholand dry them with a jet of compressed air.

2. Lubricate boot inner surface
with the above mentioned grease,and fit it into its seat.
3. Fit floating caliper on relevant
support (Refer to: Pad Replace-

CAUTION:
Do not use metal tools and detergents containing mineral oil.
Floating caliper body
1. Check cylinder surface forment).
4. Connect oil pipe back to floating
caliper and tighten relevant union to
specified torque; fill reservoir up
with specified brake fluid (ATE “S”
or AGIP Fl Brake Fluid Super ED or
IP Auto Fluid FR).

cracks, evidence of excessive wear
and presence of rust or foreign
matter.
2. T o r e m o v e rust or foreign
matter, clean the surface with a very

0: Tightening torque
Brake pipe to caliper union
IO+14 N-m
(1 + 1.5 kg-m
7.23 f 10.84 ft.lb)

fine emery cloth.
3. In case of more severe damage
replace floating caliper body.
4. Check bleeder and make sure it
2. Connect brake fluid hose (Refer
to: Hydraulic System Piping).
3. Fill brake fluid reservoir up to

5. Bleed brakes (Refer to: Brake
System Bleeding).

is in good working condition.
CAUTION:At the end of installation on car,Pistonmax. level (ATE “S” or AGIP F 1
Check piston outer surface forcracks, evidence of excessive wear,

make sure that hose are not kink.

deterioration and presence of rustBrake disc

Brake System Bleeding).

or foreign matter. In case just one ofabove flaws is present, replace the

REMOVAL AND INSTALLATION

Floating caliper

piston or the whole floating caliper.

Brake Fluid Super ED or IP Auto
Fluid FR).
4. Bleed brake system (Refer to:

DISASSEMBLY
If required, carry out disassembly of
brake caliper operating as follows:
1. Empty brake fluid reservoir witha syringe.
2. Disconnect brake fluid hose.
3. Remove floating caliper (Refer

CAUTION:
Do not clean piston surface withemery cloth but go on and replace it.

dowel pin.

Replace seal ring and booteach time3.

they are disassembled.

removal procedure in reverse se-

Caliper support

4.
Remove dust cover @ and thenuse a jet of compressed air to remove

Check element good condition andreplace it if necessary.
Clips
Make sure they are not damaged orabnormally worn; replace them ifnecessary.
INSTALLATION
If previously disassembled, carry out
reassembly of floating caliper operat-

1 Floating caliper

May 1983

3 Piston
4 Seal ring

Install disc and caliper following

quence.

a vice equipped with protecting jaws.

2 Dust cover

2. Remove brake disc from hub
support after having removed theSeal ring and bootto: Pad Replacement) and close it inbrake piston @ from cylinder.
5. Remove seal ring @ from its
seat on cylinder.

1. Remove from hub support, thewhole brake caliper without disconnecting it from hose (see: Group 21 Front Wheel Hub).

CHECKS AND INSPECTIONS
1. Thoroughly clean brake discs
and check that working surfaces are
not deeply scored or porous. Replaceor machine them if necessary.
2. Should machining of disc working surfaces be required, keep inmind the following:ing as follows:(1) Always machine both surfaces ofeach disc, removing the same amount

1. G r e a s e c y l i n d e r , p i s t o n a n dofsealing ring applying a coat of rhe
prescribed brake grease (Grease ATE(2) Machining must be performedmaterial from each surface.

Bremsrylinder Paste or DBA Grease);according to tolerances indicated in
the Service Data and Specifications

fit seal ring on cylinder and thenSection - “Checks and Adjustments”.

insert control piston.

2
2-12
Alfawiki.nl

FRONT AND REAR BRAKES

Pad replacement
1. Lift car’s front end positioning it
on safety stands (Refer to: Group 00- Lifting Points and Towing).
2. Using a suitable punch, push pad
d o w e l p i n s @ as shown, in the
figure that follows:

1.

CAUTION:
When pads are off, do not push brake
pedal in order to avoid piston frombeing ejected from its seat on floating caliper. When replacing pads use
only original spare parts and replacethem on both calipers.
Pad assembly shall be carried out by
positioning crawfoot towards theforward rotation direction of brake
disc.

Empty brake fluid reservoir witha syringe.
2. Disconnect brake fluid hose.
3. Remove pads (Refer to: Pad
Replacement).
4. With a plastic hammer, strike
floating caliper @ till it comes offfrom its support @ _6. Clean pads’ seats on caliper withalcohol.
1 Pins3. Remove, in sequence: the lower
pin, the cross spring plate 0, andthe upper pin.

CAUTION:
Do not lubricate in any way thepads’ retaining seats on calipers.
7. Push piston back into floating
caliper.

CAUTION:
To avoid overflow of brake fluidwhen the piston is pushed back, it isadvisable to withdraw some of thefluid from the reservoir with asyringe.
8.

Fit pads into their relevant seatand then complete assembly byfitting, in sequence: the first dowel
pin, the cross spring plate, and the
1 Cross spring plate

4. With suitable pliers, remove thepad on cylinder’s side.

second dowel pin.
9. Restore proper brake fluid inreservoir (ATE “ S ” o r -AGIP Fl

1 Floating caliper

2 Caliper support

5. Fit caliper on a vice equippedwith protecting jaws and remove thedust cover’s @ lock ring 0 as wellas the boot.
6. Use a jet of compressed air toremove brake piston @ fromcylinder on floating caliper bodyaRemove seal ring @ from its
seat on cylinder.

7.

Brake Fluid Super ED or IP Auto
Fluid FR).

5. With a plastic hammer, strike
floating caliper on cylinder’s side
thus removing the other pad.

CAUTION:To restore correct braking, pushbrake pedal all the way down a few
times.

Caliper unit
REMOVAL AND INSTALLATION
Removal and installation proceduresof ATE calipers are like those of
DBA calipers (Refer to: DBA Caliper
Removal and Installation).

1 Lock ring

2 Oust cowr

4 Seal ring
5 Floating caliper

3 Piston

CHECKS AND INSPECTIONS
For checks and inspections of ATE

Floating caliper

calipers,

refer to: DBA caliper -Checks and Inspections.
1 Pad on cylinder’s side
2 Brake disc

DISASSEMBLY
If required, carry out disassembly offloating caliper, operating as follows.

May 1983

2 2 - 1 4

Alfawiki.nl

INSTALLATION
If previously disassembled, carry out

FRONT AND REAR BRAKES

assembly of floating caliper, operat-

7. Proceed and complete the assembly fitting the pads and securing

ing as follows.
1.

Apply

a

coating

of

the

pre-

them by means of relevant dowel

scribed brake grease to cylinder,

pins (Refer to: Pad Replacement).

piston and seal ring; fit seal ring on
cylinder and then insert control

6. Fill reservoir up with specified
b r a k e f l u i d ( A T E ‘5” or AGIP Fl

piston.

Brake Fluid Super ED or IP Auto

2. Lubricate boot inner surface
with the mentioned brake grease;

Fluid FRI.
9. Bleed brakes (Refer to: Brakethen secure it with relevant lock ring.

System Bleeding).

Make sure boot and relevant lockring are properly fitted.

6. If the step on the piston does

CAUTION:At the end of installation on car,3. Fit floating caliper on relevant

n o t m a t c h t h e square caliper’s
diagonal, r o t a t e t h e p i s t o n w i t hsuitable pliers till the position

support.
4. Connect oil pipe back to floating

make sure that hose are not kink.

Brake discrequired by the square caliper is

For all operations concerning brakereached.

discs refer to: DBA Caliper Brake

caliper.

Disc.

0: Tightening torque
Brake pipe to caliper union
IO+ 14 N-m(1 + 1.5 kg-m
7.23 + 10.84 ftelb)
5. Using a square caliper with a 2@
angle, v e r i f y t h a t b r a k e c o n t r o lpiston is properly positioned.

REAR DRUM BRAKE

@ N-m
(kg-m
ft.lb)
1
Bleeder cap
2 Bleeder
3 Dust cover
4 Piston
5 Seal ring
6 Spring
7 Cylinder body
8 Knuckle pin securing plate
9 Jaw driving plate
10 Jaw return spring
11 Spring

14 Vibration -damping spring
Vibration - damping spring stop

19 Adjustment lever
20 Jaw
21 Shoe holder disc

Alfawiki.nl
22-15

May 7983

FRONT AND REAR BRAKESJAW REPLACEMENT
RemovalI. Remove wheel and brake drum
together with hub (see: Group 25
Rear Hub).
2. Operating from passenger compartment, loosen cormol cables ofparking brake, b y o p e r a t i n g o n
adjustment nut and lock-nut.
3. Operating from wheel side, release control cable end @ f r o mlever @ and release it from fair-

6. Disassemble, (if required) the
adjustement device, operating asfollows:(1) Remove retain spring 0, Thenfrom jaw, withdraw pin @ together(2) Remove
seal
ring @ andseparate from jaw the swinging lever 0
1 of the adjustment device.
The removed seal rings must anyway
be replaced during reassembly.

1

Swinging lever

4

Pin

2

Spring

3

Lever

5
6

Retain spring
Seal ring

lubricating the following contact
surfaces:.
Swinging lever nut and adjustment device lever nut.
surfaces
Contact

betweenadjustment device and swinging
5. Remove the two jaws fromlever.

brake holder disc and if required,releasing
after
them,
separate

Installation

jaw jointing

Removal1.

Remove

jaws

(see:

Jaw

1 Screws

2 UnionDisassembly
1. Remove dust covers @ f r o mcylinder body @, then, pitk up thejaw opening control pistons 0,
t o g e t h e r w i t h g a s k e t 0, w h i c h

To correctly position the new jaws
on brake holder disc, operate byreversing o r d e r o f r e m o v a l a n dcoupling with the following:a r e e j e c t e d b y s p r i n g 0; t h e n
withdraw spring itself.
protection
bleeder
2. Removecap @ and remove bleeder.

a. L u b r i c a t e w i t h b r a k e g r e a s econtact surfaces between theunder mentioned components.
jaws and opening control cylinder.
toothed surfaces of the jaw
adjustment device.
gears of the jaw return springs.
b. On installed jaws, before assemblying drum, set the adjustment
device lever so as to maximum
1 Spring

May 1983

2 SquareRe-

3. Unscrew and remove the twoscrews @ securing cylinder to brakeholder disc; then remove cylinder.

.

from

CYLINDER FOR JAW
OPENING CONTROL

ing to j a w o p e n i n g c y l i n d e r , b y

damping spring

spring0square 0.

Chassis and Body Maimenance).

operating on union 0, as shown infigure.

7. If previously disassembled, reassemble the adjustment device after

6 Lower spring

control lever (see: Group 00

2. Disconnect The oil delivery pip-

jaw vibration _ damping springs 0.

4 Control cable end
5 Fairlead

repeatedly operating on brake
pedal.
d. Adjust travel of parking brakeplacement - Removal).

upper return spring 0, shoe lower
return spring @. Remove then theUpper spring
Lever
Vibration

tance between jaw-drum b ywith spring @ and lever @ of theadjustment device.

lead 0,4. By means of a suitable clamp
release, in the following order: shoe

12
,3c. On installed drum, adjust dis-

reduce opening of jaws.

2Alfawiki.nl
2-16

1
2
3
4

Dust cover
PistonGasketCylinder body5
6
7

SpringBleederCap

FRONT AND REAR BRAKES@ c o n n e c t i n g l e v e r @topin
adjusting fork @ , withdraw pin

placed between support and body.

with washers from fork and separate
this one from the lever.
lever to its relevant support @ andseparate the two components.
3 . W i t h d r a w b u s h @ and h a n dle @ from lever, remove pin
4 Lock nut

2 Screws
3 Nut

5 Bracket

To reinstall control lever withsupport, reverse the order of removal
and complying with the following:

2. Unscrew bolt @ securing the

1 Lever

REINSTALLATION

1.

Apply a coat of specified grease

Fl Grease 15 or S H E L L(AGIP
R e t i n a x Gll) t o s u r f a c e s w h e r ecables slide in the incovered section

gear paw1 @ rotates and withdraw

and to fork adjusting screw.
2. Carry out parking brake adjusTment (see: Group 00 Chassis andthe pin from its seat.

Body Maintenance).

stopper cotter @ on which ratchet

4. Separate from lever the whole
block of ratchet gear control with

DISASSEMBLY

p u s h b u t t o n 0, spring @, stopp e r 0, r o d @ a n d pawl 0.
5. If necessary, remove switch of
the parking brake indicator from

With reference to the following
exploded view remove the control
lever operating as follows.
pin fromcotter
1. Withdraw

brake support.

CONTROL CABLESREMOVAL
1. Operating from the driver s
compartment remove rear console
and, by operating lock nut andnut of adjustment fork loosen
control cables and withdraw themfrom equalizer.
2. Remove rear wheel and drum
together with hub (see: Group 25 Rear Hub - Removal).
3. Operating on wheel side release
control cable end @ from lever @and free it from f a i r - l e a d @.
Release control ,cable from brakeshoe holder 0, withdraw it fromthis last and remove it after releasing
it from the underbody clamps.

6 . 5 1 + 10.84)

1

Handle

2

Lever

9
10
11
12
13
14
15

3 Pushbutton
4 Spring
5 Stopper
6
7
8

Rod
Paw1
Pin

CHECKS AND INSPECTIONS
1. Check

components

visually

against excessive wear and otherdamages.
Check, in particular, surface con-BushSector gear
Light switch
Bolt
supportPin
Adiustment fork

REASSEMBLY
For reassembly of the support andlever unit, reverse the order ofassembly and, in particular comply

support, and wear conditions of pawl

with the following:
1. Lubricate brake lever bush andratchet gear components with speci-

teeth and scroll gear.

fied grease (AGIP Fl Grease @or

2. Check against presence of elec-

SHELL Retinax Gll).
2. Tighten to specified torque of2 Levertric cable discontinuity and thatparking brake indicator switch is

9 t

CHECKS AND INSPECTIONS

properly(6.51 f 10.84 ft.lb) bolt hinging leverditions of the lever coupling bush tofunctioning.

3. Replace worn or faulty components.

May 1983

15 N.m

(0.9

+

1.5

to brake support.

22-18
Alfawiki.nlkg.m),

1 Brake shoe
holder

3 Control cable

4 Fair lead

Make sure that control cables are
sound; replace them if necessary.

FRONT AND REAR BRAKES

Application

Q.W

Denomination

Brake pedal hub (inner GI)

GREASE

Clutch pedal (inner 0 )AGIP Fl Grease 15
Std. 3671-69810.Dowel pin connecting brake pedal
to master cylinder control clevis
Spring adjustment square bush forbrake pressure regulator
Spring seat fork on brake pressure regulator

Parking brake cable sliding surfaces

GREASE

Knuckle of parking brake cables on rear

AGIP Fl Grease 15
Std. 3671-69810

brake shoes

SHELL RETINAX - G - 11

Terminals of parking brake cables

Std. 3671769811

Adjustment fork screw
Screw (or spacer) fixing parking brakelever to support plate
Parking brake trip
Knuckle bush for parking brake lever

INSPECTION AND ADJUSTMENTFRONT BRAKES

Brake pad thickness

Brake pad - rotor clearance- when installing

0.1

mm

(3.94 . lop3 in)-on operation (clearance
determined by pad auto-

0.05 + 0.2 mm

matic feed)( 1 . 9 7 low3 + 7.87. 1O-.3 in)Min. S (wear limit or min.
serviceability thickness)

Dimension for brake disc burning

mm (0.276 in)

REAR BRAKES
Brake shoe lining min. thickness

0.5 mm (0.02 in)Drum wear limit dimensions- max. inner diameter

229.6 mm (9.04 in)Dimension for brake drum burning

May 1983

7

22-20
Alfawiki.nl

FRONT AND REAR BRAKESHANDBRAKE LEVER
ADJUSTMENTBRAKE PRESSURE
REGULATOR VALVE

Number of free notches

Adjustment.
- Unloaded caron the sector gear before
wheels locking- Valve piston at end of travel

1 G-3- Load: 60 N (6 kg) (13.22 lb) applied to hook of fixture A.4.0148

TIGHTENING TORQUES
Unit

I

N*m

Item

Unions of brake hydraulic system pipes

8

+

kg*m

ft.lb

10

0.8

+ 1

5.78 f 7.23

15

1

+

1.5

7.23 + 10.84

Unions of brake hydraulic system (on calipers andunion of shoe holder plate)

IO +Union of clutch system pipe

15

+

19

1.5

+

1.9

10.84 + 13.74

Screws retaining caliper to wheel hub

59

f

73

6

f

7.5

43.8

Screw securing front brake disc to wheel hub

6

A

8

0.6

+

0.8

4.34 +

9 f44

4

+

4.5

28.9

9

f15

0.9

+

1.5

6.51 + IO.84

5

f.

8

0.5

+

0.8

3.61 + 5.78

BENDITALIA

12

f

15

1.2

+

1.5

8.67 + 10.84

ATE

21

f

28

2.1

+

2.8

15

Securing bolt of brake pressure regulator valve

15

f

24

1.5

f

2.4

10.84 t 17.3

Equalizer securing nut

39

f

48

4

+ 4.9

28.9 - 35.4

Panhard bar securing bolt

69

f

85

7

+ 8.7

50.6

Screws securing wheel cylinder to back plate

6

-5 .9

0.6 + 0.9

4.34 + 6.51

Bolt fixing parking brake lever to support

9

f

0.9

6.51 + 10.84

Bolts securing knuckle pin to axle3

Nut securing pedal assembly unit to body

f 54.23
5.78+ 32.53

Intermediate piston setscrew for ATE
brake master cylinder

Nut jointing brake master cylinder to servobrake

15

Alfawiki.nl
22-2 1

+

1.5

+ 21

+ 62.9May 1983

FRONT AND REAR BRAKES

TROUBLE DIAGNOSIS AND C.ORRECTIONS
The following are the indispensable presuppositions for any trouble diagnosis of braking system verification of:- Tyre wear
- Tyre pressure- Brake fluid or any way, verification of compliance with programmed maintenance specifications.

Condition

Excessive pedal travel

Probable cause

Corrective actionlLeakage in brake master cylinder

Overhaul brake master cylinderl

Leakage in clutch master cylinder

Overhaul clutch master cylinderl

Faulty no-return valve of vacuum
systemReplace check valvelFluid leakage from brake pressure

Adjust or replace

regulator

Spongy pedall

Fluid leakage from braking system
unionsTighten unionsl

Air in system

Bleed systemlFaulty brake adjustment

Adjust shoe-to-drum clearancel

Air in system

Correct as necessarylFaulty brake adjustment

Adjust shoe-to-drum clearancelReservoir filler cap vent hole

Clean and bleed system

cloggedl

Swollen hose due to deteriorationor use of poor quality hose

Replace hose and bleed systemlDistorted brake shoes, or exces-

Replace faulty parts

sively worn
drum
0

Soft

or

or cracked brakeswollencaliperseals

Drain hydraulic system, flush withalcohol and replace all sealsl

Use of a brake fluid with too low
boiling point

Poor braking effectl

Fluid leakage

in brake lines

Replace with specified brake fluidand bleed system

Check master cylinder, piping andwheel cylinder for leaks, and repairl

Air in brake lines

Bleed systeml

Excessive shoe-to-drum clearance

AdjustlGrease oil mud or water on lin-

Clean brake mechanism and check forings or pads

cause of problem. Replace lrnrngs or
pads

22-22
Alfawiki.nl

FRONT AND REAR BRAKES

Probable cause

Corrective actionl

Deterioration of linings or pads

Replace linings and/or pads. If necessary grind discs a n d t u r n d r u m slLocal fit of linings or pads

Condition

Poor braking effect(continued)

Replace linings and/or pads. If necessary grind discs and turn drumslMaster cylinder or wheel cylinders

Repair or replacein poor conditionllFrozen or seized caliper pistonson disc brakes

Disassemble caliper and free up as
required

Binding mechanical linkage at

Free up as required

brake pedal and shoes

Unbalanced brakeslImproper tire inflation

Inflate to correct pressurelImproper adjustment of shoes-to-

Readjust

drum clearancelGrease oil mud or water on linings

Clean brake mechanism and check foror padscause of problem. Replace linings orpadsl

Mud in brake drum

Clean

l

Excessive wear or deterioration of

Replacelinings or padslWheel cylinder in poor condition

Repair or replacelPoor sliding condition of brake

AdjustshoelLooseness of cylinder body orback plate securing bolts/nuts

Fasten or replacel

Scored or out-of-round drums

Recondition or replace brake drum asrequired. Check for improper lining
contact with drum and grind lining if
necessaryllBrake pressure regulator incor-

Adjust or overhaul (if required) or

rectly adjusted or not efficientreplace brake pressure regulator

Deteriorated wheel cylinder seal

Recondition or replace cylinder

rings
l

Incorrect adjustment of wheel

Adjustbearingsl

Incorrect adjustment of wheel

Adjustalignment

Brakes fade

Use of improper linings or brakelinings are contaminated

Alfawiki.nl

Replace linings

FRONT AND REAR BRAKES

Probable cause

Corrective actionlOut-of-rround or off-center drum

Fur-n drum or replace as necessaryl

On disc brakes, lateral runout of

Check with dial indicator, turning discbrake rotor is excessive

my hand. If runout exceeds specifica-

Condition

Pedal pulsates

ions, repair or replace discl

Rear lock (Under light brake

Excessive variation in thickness of

illeasure around disc face with micro-

brake rotor surfaces

neter. Replace disc as required

Faulty brake pressure regulator?eplacepedal force)

Rear lock (Under heavylPoor front braking effect

Disassemble and adjust front brakeslGrease oil mud or water on linings

Jean or replacebrake pedal force)or pads
3eplacelExcessrve wear of linings or pads

l

Local

linings or pads

shave or [replacel

Master cylinder or wheel cyllndet

3epair or replace

fit

of

In poor condition

Servobrake out of orderll

Air leakage at check valve

nspect check valve

Ait- leakaye at seal ring between
vacuum box and control body

Replace set-vobrake assemblyl

Air leakage at disc valvel

A i r l e a k a g e a t p i s t o n s e a l rinyl

Air leakage at seal ring between

Replace seal ring

master cylinder and servobrakel

Not adjustable engine idle

D a m a g e d prplng o r c o n n e c t o r sEngine sucks air through servobrakespeed (no leakage at con-

Repair or replace

Replace check valve or servobrake assemblv

nectors)
Parking brake does not brakel

Impt-opet- adjustment

Adjustl

Front and rear cables damaged or

Replace cables

brokenl

Faulty connection of rear cables

Check cable connection

to brakes

When parking brake controll

Shoes are jammed on drums

Unlock or replace faulty partslReturnRemove obstacle and replace cables

lever is released, the car remains braked

travelofcablesisob-structed

Alfawiki.nl
22-25

May 1983

FRONT AND REAR BRAKES

Probable cause

Condition

Corrective action

When parking brake control

Control lever release pushbutton

Disassemble lever, and release or re-does nor spring backplace ifl

Wires

Restore connectionlFaulty switch

ReplacelFaulty lamp

Replacellever is released, the car remains braked(continued)
The brake ON indicator does

disconnected

not illuminate

SPECIAL SERVICE TOOLS
Refer toTool

numberTool nameI

A.4.0148

Tool for calibratingbrake p r e s s u r eregulator

May 1983

22-26
Alfawiki.nl

pageSTEERING SYSTEM-CONTENTSSTEERING SYSTEM . . . . . . . . . . . . . .

23-2

Removal . . . . . . . . . . . . . . . . . . . . .

23-7

GENERAL DESCRIPTION . . . . . . . . . .

23-2

Disassembly _ . . _ . . . . . . . . . . . . . . .

23-8

STEERING WHEEL AND COLUMN . . 23-2

Checks and inspections. . . I . . . . . . .

23-9

Assembly _ . _ . . . . . . . . . . . . . . I . . .

23-9

Steering wheel . . . . . . . . . . . . . . . . .

23-2

Steering column . . . . . . . . . . . . . . .

23-3

SERVICE DATA AND

Steering lock-ignition switch . . . . . .

23-4

SPECIFICATIONSSTEERING LINK RODS . . . . . . . . . . .

_.... _._.___._..

23-l 1

23-5

General specifications _ . . . _ . _ . . . .

23-11

Removal . . . . . . . . . . . . . . . . . . . . .

23-5

Inspections and adjustments . . _ . _ . 23-12

Checks and inspections . . . . . . . . . .

23-6

Tightening torques . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . .

23-6

TROUBLE DIAGNOSIS AND

Assembly. . . . . . . . . . . . . . . . . . . . .

23-6

C O R R E C T I O N S . _. . _ _. _. . . _. . . _. , 23-13

Installation...................

23-6

SPECIAL SERVICE TOOLS . . . . . . .

STEERING BOX . . . . . . . . . . . . . . . . . .

23-7

Alfawiki.nl

23-l 2

23-13

May 1983

STEERING SYSTEMSTEERING SYSTE.M

39 4 48
28.92 + 35.43)

1
2
3

Track rods
Steering rack
Universal joints

4
5

Lower column
Upper column

@ N.m
kg-m
ft.lb)(4 + 4.9
28.32 + 35.43)

GENERAL DESCRIPTION
Steering i s b y r a c k a n d p i n i o n .
The track rods are connected to thecentre of the rack by means offlexible joints. Owing to their length,

they reduce the variation of wheel
movement resulting from suspension
movements. The steering column isin two sections The lower partis positioned so as to collapse underaxial loads. The upper part is pivoted
to allow adjustment of the steeringcolumn height.

STEERING WHEEL AND COLUMNSTEERING WHEEL

4. By means of tool A.3.0451,
withdraw steering wheel from COIumn operating as per figure.

REMOVAL
1. Remove hub 0, to gain accessfo screws @ securing warning horn
pushbutton @ on steering wheel
and remove them.
2. Disconnect

eletricconnecof warning horn pushbutton and remove it.
3. Unscrew and remove nut 0with washer @ securing steeringtion @

wheel to column.

1
2
3

Hub
Screw
Horn push-buttonMay 1983

4
5
6

ft-lb)
Electric connection
Nut
Washer

23-2
Alfawiki.nl

STEERING SYSTEM

9. Removethe whole column.

if necessary.
2. Check against presence of damages or absence of lubrication in
universal joints. Replace lower col-DISASSEMBLY

umn if necessary.

1. Unscrew bolt securing universal
joint to upper column section.
Remove lower column.
2. Remove steering lock operating
as follows.
Secure column support @ together
with upper column @ on vice fittedwith protective jaws and, operating
as shown in figure, unscrew thebroken head screw securing steering
lock to column support; withdraw
steering lock.

3.

Verify integrity of upper column

and, in particular, that: working
surfaces of bearings are safe fromscratches; tooth of splined parts are
not damaged or worn; hole where pin

4. Verify integrity of column sup-ASSEMBLYC.

disassembly and comply with. thefollowing:
Apply a coat of grease (AGIP F 1
a.
Grease 33 FD or IP Autogreaseb.

FD) to bearings where uppercolumn rotates.
Lower bearing must be completely introduced on column
support and upper bearing mustC.
1 Column support 2 Upper columnd.

ignition switch to column sup-hammer, on upper column, by meansof a plastic hammer (as shown insupplied as spare part, whichmust be tightened into its seat

unit

on

a

figure) as long as column can bewithdrawn from support with relevant upper bearing.

e.

Distance between cover and steering
wheel structure
B=O+6mm(O+00.236in)s.jve clearance is present.
For securing of steering lock port, make use of proper screw

theobtain correct stop of steering
wheel in the required position.
On steering wheel and coverassembled, make sure that, on all
lowered position of steering
wheel, B dimension (between
cover of steering column andsteering wheel structure) corresponds to the prescribed value.

be assembled so as it faces upper
plane of support.
Verify that upper column canfreely rotate and that no exces-

vice,

Keeping

2 cutoutb. Adjust tightening of steering
wheel inclination lever so as toport -and replace it if necessary.

For reassembly reverse order of3.

1 Boltof steering lock works, is sound.

b r e a k i n g o f Tts h e a d .
until
During junction of lower column
to upper one make sure that
securing bolt positions correctlywith respect to cutout portion.

INSTALLATION
Assemble column by proceeding inreverse o r d e r a n d f o l l o w t h e s e
instructions.

4. Withdraw lower bearing fromcolumn support.

WARNING:
Make sure that undue stress is notapplied to steering column duringassemblv.
a.

CHECKS AND INSPECTIONS
1. Check against presence of damages or malfunctions in column
bearings. Lubricate them with theprescribed grease and replace them

May 1983

Loosen the wheels and couple
the column lower universal joint
to pinion of steering box,
then insert securing bolt 3

d. After tightening of components,
verify that on maximum travel
condition of steering wheel,(straight ahead and straightdown) functioning is correct.
a. At the end of assembly, verify
proper functioning of combination switch unit and efficiencyof warning horn.

STEERING LOCK- IGNITION SWITCHREMOVAL AND
INSTALLATION

making sure that it positions

1. Remove lower cover of column

correctly with respect to pinion

support (see: Column - Removal).
2. Disconnect harness of the steer-

cutout portion 0.

23-4
Alfawiki.nl

STEERING SYSTEMCHECKS AND INSPECTIONS

ing lock - ignition switch.
3. Remove the broken head screw
securing steering lock to column

1.

Verify good conditions of cables

and connectors.
2. Check proper operation of the

support.
R e m o v e s t e e r i n g - lock unit
4.

whole assembly by verifying all
positions are reached smoothly;

withdrawing it from its seat incolumn support.
For installation, reverse order of
5.

check also the locking device operations properly, after rotating steering
wheel and extracting key.

removal and secure steering lock @to column support by means ofspecial screw @ provided as sparepart, and tighten it as long as its head

1 Steering lockbreakes.

2 Screw

STEERING LINK RODS

@ N.m
(kg-m

fMl)

1
2
3
4

Spacer
Plate

7

Nut

8

Elastic jointRod
NutBall joint

9
10
11

Nut
WasherPlate

5
6 Washer@39 f 4 8
(4 + 4.9
28.92 + 35.43)

5. Turn steering wheel to the rightto make easier the disassembly ofr o d s 0 f r o m s t e e r i n g b o x 0,
remove nuts 0,3washers @, and

REMOVAL
1. Place car on lift, block rear
wheels, jack up front of vehicle, thensupport it by stands placed in adja-

plate 0, then remove rods.

cent position to jacking points (Refer
to: Group 00 - Lifting Points and@-I

Towing).
2.
Remove four screws and wheel.
3. Unscrew nut securing ball pin ofsteering track rod @ to lever @ of
strut 0.
4. Using puller.A.3.0156 withdraw
ball joint pin @ of steering trackrod upwards, taking it out from strut
levers.

1 Strut
2 Strut lever3

Ball joint

4 Steering track tocl

Alfawiki.nl
23-5

1

Rod

2 Steering box
3 Nut

4 Washer
5 PlateMay 1983

STEERING SYSTEMCHECKS AND
INSPECTIONS
1.

Loosen fixing nut 0, unscrew
3.
ball joint @ and remove it fromrod 0.

During tightening of bolts, make surethat on the static load position,
upper plane of ball pin is parallel togasket face.

Check against damage or wear in

the steering rods ball joints, .andverify that pivot free from crawlingor with notable sla.ck in their seats. If
necessary, replace them.
2. Check elastic joints against
damage, wear or excessive slack. If
necessary, replace them.
3. Check steering rods against
damage or deformations. If necessary, replace them.

DISASSEMBLY
1. Extract elastic joints from rodsby means of a press and of suitable
tools (a punch and a base).

1
2

Rod
Nut

3 Ball joint

3.

ASSEMBLY
Proceed in reverse order to disassembly and use the same tools
previously used.
On reassembly of ball joints, makesure that the two tie rods have thesame length they had before disas-

INSTALLATION

order of removal.
Assemble rods on steering box
1studs and fix them with plate,washers and nuts without locking
them.

2.

Measure articulation jut in orderto maintain it on reassembly.

May 1983

rods

toleversonsteering tubes by tightening the nuts
securing the ball joint pin to thespecified torques.

23-6
Alfawiki.nl

Nut fixing ball joint to lever onsteering tube and elastic joint

28.92 + 35.43 ft.lb)

Assemble steering link rods onvehicle by proceeding in reverse

Connect@ : Tightening torqueto rack.
39-48 N - m(4 f 4.9 kg-m

sembly.

2.

Lock the elastic joint fixing nuts

to the rack studs, with the front
suspension in nominal height, corresponding to static load.

4. Verify(Refer to:toe-out
Group 00 - Chassis and Body Maintenance).

STEERING SYSTEMSTEERING BOX

1

upper cap

9

2
3
4
5
6
7
8

Adjusting screw
SpringPlunger
Seal ringBushRack box
Left cap

IO Bearing
11
Lock ring
12 Lock ring
13 Lower cap
14 Boat15
16

Pinion

17
18
19

20
21
22

Bush
supportRight cap
Pad
Studs
Rack

SleeveClampsteering box by estracting it from thesteering rod slit on the left side andremove rubber supports @.

REMOVAL
1. Place vehicle on ramp a n d
support it by stands placed in thejack seats (refer to: Group 0 0
Lifting Points and Towing).
2. Remove left wheel after screwing up fixing screws.
3. Turn steering wheel to the rightand disconnect rods from steeringbox (refer to: Steering Link Rods Removal).
4. Disassemble b o l t 0 f i x i n glower universal joint @ to pinion @5. Remove plastic cap @ p r o tecting rack.

1 Universal joint
2 Bolt3 Pinion

4 Protection cap

fixingscrews@steering box @ to body, then

6. Remove(4 4 4.9-J
28.92 + 35.43)

remove brackets 0.

1

Steering box

7. After disengaging pinion @2

Pinion45SupportBracketfrom universal joint 0, remove

3

Universal joint

6

Screw

Alfawiki.nl
23-7

(kg-m
ft-lb)

May 7983

STEERING SYSTEMDISASSEMBLY

6.

Remove the cover @ from rack

9. Remove pinion from rack box

1. Remove clamp @ fixing rightb o o t @ t o s l i d i n g s l e e v e 0.
2 . E x t r a c t e n d c a p 0, r e m o v eb o x 0, s c r e w U P a n d e x t r a c t
adjustment screw 0, spring @together with the bearings, by meansof a plastic hammer and a supportingand plunger @ for backlash. Thenlever with a screwdriver and remove

base.

plastic support @ and extract rightboot 0.

lower protection cap @ of rack
control pinion.

CAUTI0.N:
Plastic bellows be replaced wheneverdisassembled from steering tube forany reason.

1 End cap
2 Support
3 Right boot4 Clamp5 Sleeve

1 Covei-2 Adjustment
screw
3 Spring

7.

3. By means of nut and lockunscrew and extract studs 0, then4 Plunger
5 Rack box
6 Lower cap

Extract rack @ from guideremove plate @ and spacer @ forrod support.
4 . R e m o v e c l a m p @ fixing leftand extract it fromboat
4
sleeve 1 , then extract sleeve fromrack tube.

8

1 Rack10.

Remove

lock

ring

1

fixingbearing@ on pinion 83 , after
placing it in a vice provided withprotective jaws.

tube 0.

2 Guide tube

8. Remove lock ring @ fixing
pinion bearing to rack box.

1 Sleeve
2 Spacer
3 Clamp4 Left boot5 Plate6 Nut and lock nut
7 Studs

Remove the sliding member @5.
from rack guide tube 0.

1 Lock ring
2 Bearing

3 Pinion

11. Disassemble bearing @ from
pinion 0 by means of a punch anda suitable base.
1 TubeMay 1983

2 Sliding member

1 Lock ring

23-8
Alfawiki.nl

STEERING SYSTEM

to point 3) and introduce it into theguide tube after rotating pinion, inorder to realite, when assembly isready, reciprocate positioning between rack and pinion verified bydimension “A” with pinion oriented(obtainwith cutout downwards
angle u = 90”f 26”).

Thickness gauge 3 Steering tube
Sliding member(2) In case of defect, selectanother sliding member from therange of available thicknesses,
forthe above recommended-0-0conditions to be met. (Thicknesses may be distinguished by
Reference dimension for pinion-rackpositioning
A = 125mm (4.921 in)

1 Pinion3.

different-color paint spots on
the pads, as follows in increasingorder: white - yellow - r e dgreen blackish blue).
(3) If tolerance “G” cannot be
met with any of the available
sliding member, replace steering

2 Bearing

Provide internal room of steering

tube.

box with 40 g (1.41 oz) grease (AGIP
Fl grease 33 FD or IP Autogrease

Employment of a new steering
tube.

FD), l u b r i c a t e p i n i o n b u s h a n dassemble pinion by means of a

Replace also the sliding member

punch, a base and a plastic hammer.

and use a new one with paintspot of the same color as the

6. Select rack sliding member
depending on the available guidesteering tube. Maximum backlash in this way is 0.044 mm(1.73 - 10m3 in).

tube, as follows:
Apply 15 g (0.53 oz) of grease,a.

00

Employment of already existing
steering tube.

as per item 3, inside the sliding sleeve(1) Check that the sliding mem-surface.

ber @ slides the whole steering

8. Assemble left boot, sliding

tube @ if pushed by handwith a slight stress; by means ofmember, sliding sleeve, then insert
studs, spacer and plate. Assemble

a thickness gauge 0 verify
backlash ’ G” between pad andslot does not exceed the recommended value in any position.

right boot, a new guide support,
checking that the internal tooth fits

Maximum allowed backlash “G”

1 Bearing2

the tube seat; then place end cap.
9. Lubricate plunger and backlash
adjustment screw with grease recommended at point 3. With rack

between pad and slot

rod in central position assemble

G = 0.1 mm (3.94 - 10m3 in)plunger, spring and screw and adjust
pinion-rack backlash, as follows.

Rackbox(I) By means of spanner A.5.0204,
tighten plunger adjustment screw to4.
During assembly use plunger andadjusting screw of the same materialtheindicative
torque:(0.3 kg.m; 2.17 ft.lb).

(plastic or metal).
5.
Lubricate rack with grease (refer

May 1983

a n d lubricate rack tube external

23-10

Alfawiki.nl

3

N.m

STEERING SYSTEM

rotated with respect to each other,with reference to the boot bodyjunction line.
12. Center steering stroke by obtaining dimension “A” as per figure
indicated at step 5.

INSTALLATION
1.

I

4
CJ

at the prescribed torque 39 + 48 N.m(4 t 4.9 kg.m, 28.92 + 35.43 ft.lb).
Refit end cap on the rack box.
2. With the wheels in the straightahead position, mount steering rods
and Tighten them at the prescribedt o r q u e 3 9 + 48 N-m (4 + 4.9 kg.m,
28.92 + 35.43 ft.lb) with vehicle atnominal height.
(Refer to:toe-out
3. Check

1 Steering box
2 Adjusting screw
2 Aligned space and notch
4 Screw rotation(2) Check with space in the screw ismost centered with respect to anotch in the box; loosen screw until

Mount steering box assembly on

vehicle by tightening securing screws

10. Verify that steering pinion rotates up to the rack rod end-of-stroke

the diametrically opposite space tothe one centered with the firstin both directions smoothly.

notch on the box is aligned.

both ends of each boot not to be

11. Tighten boots fixing clamps, forGroup 00 - Chassis and Body Maintenance).

SERVICE DATA AND SPECIFICATIONSGENERAL SPECIFICATIONSFLUIDS AND LUBRICANTS

Denomination

Application

Column supporf spacer for hinging to

GREASE-

Std. No. 3671-69810

body (external surface)

Steering column bearings

AGIP Fl grease 15

Q.ty

GREASEAGIP Fl grease 33 FD

Steering rack rod (ext. surface)

IP Autogrease FD

Pinion bush

Std. No. 3671-69833

Rack-pinion backlash take-up plunger
Backlash adjustment screw (on thread)

15 9

Rack sliding sleeve (internal surface)(0.53 02)

Rack box tint. room)

Side rod silentblock (ext. surface)

FLUlD

UNION CARBIDE CHEMICALSCOMPANY: Ucon lubricant 50HB - 5100
Ml LLOI L: lubricant for elastomer seal
Std. No. 4500-17502

Alfawiki.nl
23-11

May 1983

STEERING SYSTEMINSPECTIONS AND ADJUSTMENTS
3. Light

1.
Dimension “A’ for rack rod centering in the steering
tube

mm (in)125 (4.921)

B

2. u cutout positioning angle on rack pinion (rackcentered as per point 1)

4.

mm (in)A“5” between steering column covers andsteering wheel structure

O f 6 (0+0.23)

Thickness of rack guide pad. The available thickness,in increasing order are provided in the below list (theycan be distinguished by the paint mark on pads):
whiteyellowred
green
blackish blue

5. Maximum clearancea

mm (in)G

90426

degrees“G” between pad and slot

0.1 (0.3.10-2)

TIGHTENING TORQUES
Unit

kg*m

N.m
Item

39

+ 4 8

4

Nut securing steering wheel to steering column

17

+

21

1.7 +

Nuts securing track rod to steering box

39

+

48

4

Bolts securing upper steering column to lower

27

+

31

14

f

16

Nut for toe-out adjustment on track rod
Screw securing steering box to bodyNut securing track rod ball joint to lever

frlb

+ 4.9

28.92 +

35.43

2.1

12.29 +

15.18

+

4.9

28.92 +

35.43

2.7

f

3.1

19.52 +

22.41

18

1.4

+

1.8

10.29 +

13.01

+

20

1.6

+

2.0

11.56 +

14.46

55

f

69

5.6

+ 7

40.49 +

50.61

39

+ 4 8

4

+ 4.9

28.92 +

35.43

on strutsteering column and to steering box pmron
Bolt securing steering column lower support

to body
Nut securing steering column upper support
to body (“1(‘)

With steering wheel release lever to the locked position

May 1983

23-12
Alfawiki.nl

STEERING SYSTEMTROUBLE DIAGNOSIS AND CORRECTIONS
Probable cause

Condition

Excessive steering wheel backlashllCorrective action

Loose steering box screws

Tighten screws

Damaged steering rods or universal

Replace defective components

jointsReplace bearings

Column noise in drive

Worn column bearings

Drive noiselLoose steering box screws

Tighten screwslWorn steering levers

Replace defective partsl

Excessive pinion-rack backlash

Calibrate backlashl

Inadequate suspension angles

Restore proper angleslWorn or deflated tyres

Check and restorel

Scarce pinion-rack backlash

Calibrate backlashlScarce lubrication

Lubricatel

Damaged universal joints

Replace jointslInterference of column with

Calibrate backlash

Drive hardening

switch unit

SPECIAL SERVICE> TOOLS
Tool name

Tool number

A.3.0156

Track rod ball joint puller

Alfawiki.nl
23-13

Refer topaw

23-5

M a v 1983

Alfawiki.nl

CONTENTS
DESCRIPTION . . . . . . . . . . . . . . . . . . .

25-2

SERVICE DATA AND

REAR HUB . . . . . . . . . . . . . . . . . . . . . .

25-3

SPECIFICATIONS . . . . . . . . . . , .

25-8

Removal . . . . . . . . . . . . . . . . . . . . .

25-3

Technical data . . . . . . . . . . . . . . . .

25-8

Checks and inspections . . . . . . . . . .

25-4

General specifications . . . . . . . . . .

25-9Installation . . . . . . . . . . . . . . . . . . .

25-4

Controls and regulations . . . . . . . .

25-9

REAR SUSPENSION . . . . . . . . . . . . . .

25-5

Tightening torques . , . . . . _ . , . .

25-9

Shocks absorbers . . . . . . . . . . . . . . .
Coil springs . . . . . . . . . . . . . . . . . . .

25-5

TROUBLE DIAGNOSIS AND

25-7

CORRECTIONS . . . . , . . . . . . . . . . .

2510

Rear rigid axle . . . . . . . . . . . . . . . . .

25-7

SPECIAL SERVICE TOOLS . . , . .

25-l 1

Refer to Group 00 - Chassis and Body Maintenance

fClr:
Rear Axle and Rear Suspension
Wheel Alignmentl Checking Suspension Heightll

Alfawiki.nl

May 1983

REAR SUSPENSIONDESCRIPTION

1 Shock absorber

5 Front tension rod

2 Spring
3 Rear tension rod
4 Wheel hub

6 Rigid axle
7 Panhard b a r

The rear suspension is a rigid axle

The transversal connection is carried

Between axle and body near theone. The axle longitudinal anchorageis carried out by means of two

wheel hubs are interposed thesuspension springs with coaxial shocktension rods, on each side, connectedout by means of a tension rod(Panhard b a r ) anchored on one
side to the axle and on the other toto the body and placed according to

the body, in order to prevent bodyabsorberry. The wheel rebounds arelimited by rubber pads assembled on

a Watt parallelogram, so as to limit

side movements with respect to thethe shock absorbery.

car raising when braking.

wheels.

May 1983

25-2
Alfawiki.nl

REAR SUSPENSION-.

REAR HUB

1

Grease seal ring

2 Inner bearing
3

Drum

4

Outer bearing

5
6
7

WasherNut

Hub cover

REMOVAL
1. Block front wheels with asuitable system, then lift rear part ofcar and position it on support stands(see: Group 00 - Lifting Points andTowing).
2. Remove wheel from the operative side.
3. Withdraw dust cover from its
seat.

CAUTION:
Do not drop bearing.

6. Operating in bench and using ascrewdriver withdraw grease seal ringfrom hub.
The seal ring must not be reutilited.

4. Operating as per figure, remove
wheel hub stop nut caulking andremove it.
5. Move hub with drum, withdraw
washer and outer bearing.
9. Using tool A-3.0355 withdraw
from its seat outer ring of innerbearing.

7. Withdraw inner bearing from its
seat.
8. Using tool A.3.0349, w i t h d r a w
from its seat outer ring of outer
bearing.

Alfawiki.nl
25-3

May 1983

REAR SUSPENSIONCHECKS AND
INSPECTIO’NS

2. By using taker-in A.3.0329,
assemble outer ring of inner bearing
on hub, inserting at wholly in its
seat.

Clean bearings and other details
carefully, then dry them with compressed air.

4. Lubricate hub inner bearing
with 9 specified grease and insert
into its seat. Lubricate seal ring withspecified grease and insert it into its
seat on hub by using tool A-3.0459.
Lay off a coat of the same grease on
the knuckle pin, on its relevant
threaded end, on washer and on
securing nut.

WHEEL BEARING
If the surfaces of tracks and conicalrollers present pittings, roughnesses
and ovalizations, replace bearing
unit.

CAUTION:
Should a bearing be no more utilizable, replace both the inner and theouter one at the same time.

3.
Lubricate outer rings of bearings
with bearing specified grease (AGIP
Fl Grease 33 FD, or IP AutogreaseFD), and insert 40 + 55 g. into
the hub inner chamber.

KNUCKLE PIN
5. Assemble hub on stem pin andthen insert outer bearing lubricatedwith specific greade, washer and new
check nut.
9. Carry out wheel bearings preloading adjustment (see: Group 00
Maintenance of Mechanical Components and Body), then peen nut.
7. Apply specific bearings grease
onto the dust cover lid then assemble
it on the stem pin; re-assemble wheel.

Make sure knuckle pin is not damaged and thread is sound; replace pin
if necessary (for replacement see:
Rigid Axle).

INSTALLATION
1. By using taker-in A-3.0328 assemble outer ring of outer bearing onhub, inserting it wholly in its seat.
1 Dust cover
2 Bearings outerrings

A.3.0328/

May 1983

3 Hub
4 Grease

CAUTION:
The grease must not get in touchwith drum braking surface.

25-4
Alfawiki.nl

REAR SUSPENSIONREAR SUSPENSION@ 33.35 + 36.26(3.4 + 3.9
24.58 + 28.2)

@ N-m
(kg-m
h-lb)

(7 + 8.7
50.63 + 62.93)
24.58 + 28.2)
Upper cup
Rubber bumpers
Lower cup
Upper gasket
Upper cap
Shock absorber

7 Coil spring
6 Shook absorber anchor fork
9 Rear tie rod
10 Stud plate
11 Stem pin
12 Gaskets

13 Front tie rod
14 Brake adjuster
15 Panhard bar
16 Pin17 Rear axle

SHOCKS
ABSORBERSREMOVAL
3. Release bolts 0 and bolt @After duly blocking front wheels,
lifting car front and placing it on

securing rear tie rods and Panhard
bar to body respectively.

supports stands (see: Group 00 Lifting Points and Towing) remove
shock absorbers as follows:
1. Remove wheels.
2. Release bolts 20securing front
tie rods @ to body.
1 Front tie rod

2 BoltAlfawiki.nl
25-5

May 1983

REAR SUSPENSION

6. From luggage compartment release and remove lock nut and nut ofb. Insert springs coaxially to theshock absorbers and make sure

upper shock absorber fastener, thecaps and upper spring support
gaskets are properly assembled
and positioned.

remove cap and anti-shock rubber
bumper.

1 Bolt2 Bolt3 Tie rod

4. Screw out rigid tube connectiono f b r a k e hydraulic system andextract flexible hose from support
square. Apply a cap to rigid tube.

7. Release and remove nuts andwashers of lower shock absorber
fastener, then lower hydraulic hoist,
remove springs from axle and shock
absorbers.
8. Separate from schock absorberrubber bumper, cap, and attaching
fork, after removing the relevant
fastening screw.

c. Set up car in nominal position,corresponding to static load
(see: Group 00 Maintenanceof Mechanical Components andBody) and set the bolts securing
tie rods and Panhard bar to bodyto the prescribed torque.

CHECKS AND INSPECTIONS
1. Check shock absorber efficiency
and replace it, if oil leaks are found.
1 Rigid tube
2 Square

3 Flexible tube

5. Place column hoist provided
with A.2.0070 support under theaxle and lift it to release shock
absorbers from end-of-stroke.

2. If necessary, verify shock absorber calibration data (see: Service
Data and Specifications - inspection@ : Tightening torques
Bolts securing tie rods to body33.35 + 38.26 N-m(3.4 + 3.9 kg-m
2 5 . 2 8 + 28.2 ft.lb)

and Adjustment); replaceshock
absorbers, if required.
3. Check wear status, damages anddeformations of rubber components.
Replace them, if required.

Bolts securing Pahnard bar tobody
68.67 + 86.35 N - m(7 + 8.7 kg-m
50.63 + 62.93 f-t-lb)

INSTALLATION
Assemble shock absorbers on car ind. Restore rear brake oil delivery

the inversed order with respect totube connection and perform

removal and remember the following

brake system air bleeding (see:indications:Group 22 - Front and Rear

a. Assemble shock absorber com-

Brakes - Brake Air Bleeding).

ponents and secure their upper
part to the b o d y .

May 1983

25-6
Alfawiki.nl

REAR SUSPENSION

Flexible hose connections

COIL SPRINGS

9.8 t 14.7 N - m(I + 1 . 5 kg-m
7.23 + 10.85 ft.lb)

REMOVAL
Remove co.il springs with the same.

procedure followed for removal of

Adjust parking brake leverstroke (see: Group 00 - Mainte-

shock absorbers; only remember notnance of Mechanical Compo-

to disjoin shock absorber from upperMbody coupling.

nents and Body).

L A.2.0070

REMOVAL
If necessary, disassemble axle asfollows:
1.
Release and remove bolts secur-

1. V e r i f y
the springs has no
stretches or deformations.
2.
Verify spring efficiency by comparing its stiffness values with theprescribed ones (see: Service Data

4. Slightly lift column hoist andremove the previously loosened tie
rod and Panhard bar bolts.
5. Slowly lower hoist driving thethe brake
axle
extracting
andadjustment spring from stud on the
Panhard bar.

2. If necessary, disassemble silent-and Specifications).
3. Check wear status, verify pres-

Assemble again the whole suspension

CHECKS AND INSPECTIONS

ence of damages or deformations ofcomponents. Replace ifrubbering tie rods to axle; remove tie rods.
blocks from tie rods and Panhard bar
by using adequate bases and extractors.

on the car by the inversed procedurethan for removal.

necessary.

INSTALLATION
Assemble coil springs onto car again
in the inversed order of removal andbear in mind all indications and notes
reported in paragraph Shock Ab-

IMPORTANT.
With static load car (see: Group00 - Maintenance of Mechanical
Components and Body) set thebolts securing tie rods andPanhard bar to the prescribed
torque.
3. Extract dust cover from brakesorbers Installation.
@) : Tightening Torque
Tie

REAR RIGID AXLEREMOVAL AND
INSTALLATION
Place car on hoist bridge, support its
rear part by placing some stands inthe jack seats and remove the wholerear suspension as follows.
1. Remove wheels.
2. Working from passenger compartment, remove rear console forparking brake equalizer to be accessible. Then act on adjustment fork
nut and lock nut and loosen parking
brake control cables as much as toallow their releasing from equalizer;
extract them from sheath locking
bracket.
3.

After providing the column hoist

with support A.2.0070, remove coilsprings with caps and gaskets (see:Coil Springs - Removal).

rod

and

Panhardbar

securing bolts

3 3 . 3 5 + 3 8 . 2 6 N-m(3.4 + 3.9 kg-m
24.58 f 28.2 ft-lb)
Lubricate with prescribed grease(AGIP Fl Grease 15) the hole inthe brake adjustment spring
support stud on the Panhard bar

drum and caulk wheel hub nut.
Remove nut and drum complete withhub and bearings.
4 . S c r e w o u t c o n n e c t i o n02 o fbrake hydraulic system rigid tube on
jaw control cylinders and remove
rear tubes @.
5. Screw out and remove nuts @fastening stem pin and brake shoe
7
plate @J to rear axle.

and the fork.
Carry out brake adjustment
spring calibration (see: Group 22- Brake Adjustment).
Set the brake hydraulic system
connections to the prescribed
torque and perform air bleeding(see: Group 22 - Brake System
Air Bleeding).
@ : Tightening Torque
Rigid tube connections

7.85 + 9.8 N-m(0.8 + 1 kg-m
5.78 - 7.23 ft-lb)

Alfawiki.nl
25-f

1 Block shoe plate 3 Nuts
4 Rear tubes
2 Connection

May 1983

REAR SUSPENSIONNOTE FOR CAR OVERLOADED ON REAR AXLE
Should high overloads be applied to the rear axle, like in the case of gas installation. the series rear springs can be replacedon sedan versions with springs having part number 705.507, in case of overload of about 980 N (100 kg)(220.46 lb)
with respect to static load, they allow a “rear position” level increased by about 15 mm (0.59 in) with respect to the one
indicated in Group 00 - Checking Wheel Alignment.

GENERAL SPECIFICATIONSFLUIDS AND LUBRICANTS

Denomination

Type

Wheel hub inner cavity and dust cover

GREASE

Q.ty

AGIP Fl Grease 33 FD

40+55 gIP Autogrease FD

1.41+1.94 oz.

Std. No. 367 l-69833/34
Seal ring rim

Bearing inner rings and relevant outer races

Bearing housings on pin
Internal diameter of hole in brake adjustment

GREASE

spring support stud on Parrhard bar.

AGIP Fl Grease 15
Std. No. 3671-69810

Brake adjustment fork
Tie rod end (front and rear) silentblock

FLUID

outer surface and Panhard bar (atUNION CARBIDE CHEMICALS CO.
Ucon Lubricant 50 HB-5100

assembly)
Outer surface of rubber bound bumper

MILLOIL Lubricant for elastomer seal(at shock absorber assembly)

Std. No. 4500-17502

Outer surface of wheel hub seal ring

OIL

AGIP Fl ROTRA MP SAE S O W 9 0
IP Pontiax HD SOW90
Std. No. 3631-69408

CONTROLS AND REGULATIONSSTEERING GEOMETRY(See: Group 00 - Rear Axle and Suspension)

WHEELS BEARINGS PRELOADING ADJUSTMENT(See: Group 00 - Rear Axle and Suspension)

Alfawiki.nl
25-9

May 1983

REAR SUSPENSIONDATA FOR SHOCK ABSORBER CALIBRATION

Alfa Romeo Part Number

542.147

Compression

N (kg) (lb)

5 9 f 1 4 7 (6+ 1 5 ) (13.23G33.07)

Extension

N (kg) (ib)78+ 1 7 7 (8e-18) (17X4+39.68)

Compression

N kg) (lb)

2 7 5 f 4 1 2 (28+42) (61.73G92.59)

Extension

N (kg) (lb)

638 f 834

Low speed

High speed(65 + 85) (14XW87.39)

NOTE: Values to be measured with shock absorbers at 20 L PC (68 f 3.BF) temperature

TIGHTENING TORQUES

N-m

Item

kg-m

Ib+t

Bolts securing Panhard bar to body

68.67 + 86.35

7

+

8.7

50.63 + 62.93

Bolts securing front and rear tie rods to body33.35 + 38.26

3.4

+

3.9

24.58 + 28.2

Bolts securing stem pin to axle

39.24 + 48.1

4

+

4.9

29.92 + 35.43

Brake hydraulic system rigid tube connections

7.85 + 9.8

0.8 +

1

5.78 +

Brake hydraulic system flexible hose connections _.

9.8 + 14.7

1

1.5

7.23 + 10.85

+

7.23

TROUBLE DIAGNOSIS AND CORRECTIONSWhen rear suspensions are suspected of being noisy, carry out a careful check to determine if the noise actually originates in
the rear suspensions or if it is due to the tires, road surface, exhaust system, engine, transaxle or wheel bearings.

Probable cause

Condition

Noise

Corrective action

Loose wheel screws

Tighten to specified torque

One or more attaching bolts loosen

Tighten to specified torqueLack of lubricating grease on

Lubricate as required

bearings

May 1983

Faulty shock absorber

Replace

Damaged or worn wheel bearing

Replace

Wheel and tire out-of-balance

Balance

Damage to rubber parts such as
lower arm bushing

Replace damaged parts

2 5Alfawiki.nl-10REAR SUSPENSION

Condition

Probable cause

Corrective action

Instability in driving.
This trouble is also related tolLoose wheel screws

Tighten to specified torquefront suspensions. For troublelShock absorber malfunction

Repair or replacel

Incorrect steering geometry

Yielded coil springsl

Yielded coil spring

ReplacelDamaged tie rod silent-blocks

ReplacelLoosen tie rod connections

Tighten or replace

diagnoses also refer toGroup 21SPECIAL SERVICE TOOLS
Tool number

Tool name

Refer topage

A.2.0070

Rear axle support

25-6
25-7

A.3.0328

Driver of rear hub outer conicalbearing outer race

A.3.0329

Driver of rear hub inner conicalbearing outer race

A.3.0349

Hub outer bearing outer race
extractor

A.3.0355

Hub inner bearing outer race

extractor

A.3.0459

Driver of front hub seal

25-4

Alfawiki.nl
25-11

May 1983

WHEELS AND TIRESCONTENTSCHECKING TIRE CONDITIONS . . . . .

28-2

CHECKING WHEEL CONDITIONS . . .

28-4.................

28-2

Wheel balance . . . . . . . . . . . . . . . . .

28-4

Checking tire

Tire inflation . . . . . . . . . . . . . . . . . .

28-2

SERVICE DATA AND

Tire rotation . . . . . . . . . . . . . . . . . .

28-3

SPECIFICATIONS . . . . . . . . . . . . . . . .

28-5

TIRE REPLACEMENT . . . . . . . . . . . . .

28-3

General specifications . . . . . . . . . . .

28-5

Replacement . . . . . . . . . . . . . . . . . .

28-3

Inspections and adjustments . . . . . .

28-5

Wheel screw . . . . . . . . . . . . . . . . . . .

28-4

Technical data . . . . . . . . . . . . . . . . .

28-6

Alfawiki.nl

May 1983

WHEELS AND TIRESCHECKING TIRE CONDITIONSCHECKING TIRE
Abnormal tire wear
1. Check tread thickness. If below

Correct abnormal tire wear according to below chart.

min. allowed limit (1 mm; 0,04 in.)
replace tires.
If tires are provided with “tread wear
indicator”, when marks appear, re-TroubleProbable cause

Corrective action

place tires.
2. Remove pebbles, glass or any
other foreign material embedded in
the threads.
3. Check tread and side walls forcracks, holes, separation or damage.
4.

1 Underinflation(both sides wear)

Check and adjust

1 Hard cornering

Reduce speed

1 Lack of rotation

Rotate tires

Iverinflation

Check and adjustpressure

Incorrect toe-in or

Adjust as requiredpressure

Check tire valves for air leakage.
Shoulder wear

TIRE INFLATION

1.

Check tire pressure. If necessary,adjust it to specified value.
Tire pressure should be measured
when tire is cold.

Center wear
Feathered edge

2. After inflating tires, check valves
for leakage. Whenever tire pressure ischecked, be sure to tighten valve caps

toe-out

firmly by hand to keep dust andwater out.
Toe-in or roe-out wear

b Unbalanced wheel

Balance or replace

Malfunctioning

Replace dampersldampers. Lack of rotation

Uneven wear

May 1983

28-2
Alfawiki.nl

Rotate tires

WHEELS AND TIRESTIRE ROTATION
Operation to be carried out every

5,000 km (3,107 miles).

0

1. Tires tend to wear unevenly andbecome unbalanced after a certain
running distance. Uneven tire wear
often results i n p r o b l e m s t h a t ,however, one tends to tink as beingcaused by other car components.
Front tires also tend to wear unevenly because of improper alignment of front wheels.
2. Therefore, to equalize tire wear,--:,

it is necessary to rotate tires periodically. Following are some different
allowed arrangements for tire rotation.

-t

TIRE REPLACEMENT
adversely affect riding, braking,_

CAUTION:
Different types of tires, such as bias,
bias belted and radial tires, must not
be under any circumstances. Different
types of tires can adversely affectC.

vehicle handling and may cause
driver to lose control.
a.

When

replacingaworn

tires in pairs on the same axle.
When replacing only one tire, it

position
4. Tighten wheel screws with prop-

should be paired with the one

er wheel wrench in crisscross andprogressive fashion.

having the most tread in order toordamaged tire, use a replacement
tire of the same size and load

speedometer calibration.
It is recommended to fit new

2. After having positioned thewheel, fit the four screws properly
into place.
3. Tighten screws by hand as far as
possible keeping the wheel in correct

handling,
groundclearance,
body-to-tireclearance,andd.

equalize braking action.
When replacing tires refer to thecarrying capacity as that withwhich the car was originallyprocedure described in the relevant
paragraph: “Replace-equipped with by the Manufacturer. The use of tires having
different size and/or load c a pacity than those approved by
the manufacturer is not allowed
since it changes the car’s tech-ment”.

nical characteristics.
b. For the same above mentioned
reasons, do not use tires andwheels other than those recommended, and do not mix
tires of different brand or tread
pattern.
The use of tires and wheels otherthan those recommended or themixed use of tires of different

REPLACEMENT
1. To replace a tire using a jack in asafe manner, refer to: Lifting Points
for jacking up.
WARNING:
Never get under the vehicle while it is
supported only by jack.
Always use safety stands to support
side member of body construction
when you must get beneath the

Alfawiki.nl@e sure to check wheel screws fortightness, after the wheel has been
run for the first 1,000 km (621
miles); do the same thing in case offlat tire repair, tire rotation, etc.

WHEELS AND TIRESWHEEL SCREW

Be careful not to smear threaded
portion of screw not relevant seat@-Fc with oil or grease.

CAUTION:
Two types of wheel screws are used:
one is designed for use with steel
wheels and the other for use withlight alloy wheels. Do not mix
different type wheel screws.
1
2

Screw for light alloy type wheels
Screw for steel type wheels

CHECKING WHEEL CONDITIONS

points, in order to ensure satisfactoryit taking the following points into
consideration:
1. Correct unbalance as soon a s

steering condition as well as maximum tire life. If any defect is pres-relevant symptoms appear such as
wheel tramp and shimmy.

ent, repair or replace as required.

2. Balance wheel with tire both
statically and dynamically.

Inspect wheels thoroughly paying
special attention to the following

1. Check wheel rim, especially rim
flange and bead set, for rust, distortion, cracks or other faults whichmight cause air leaks. Proper functioning of tubeless tires depends on
effective sealing between tire bead
and wheel rim.
2. Thoroughly remove rust, dust,
oxidixed rubber or sand from wheel
rim.
Rim’s bead seats should be suitably
cleaned (for ex. using neutral typedetergent, cloth, etc...) being careful
not to damage the wheel surface’s
protecting film.
3.
Replace wheel when any of thefollowing occurs:.
Bent, dented or heavily rusted
.
.

wheel
Bolt holes are out-of-round
Excessive side or radial runout.

Air leaks through welds

WHEEL BALANCE
Inspect wheel and tire for proper
wheel balance; if unbalanced, correct

May 1983

4. Lock rear wheels by means of
two wedges, one for each wheel.
5. Set up balancing machine andauxiliary equipment; make sure indicating finger is placed under suspension’s cross arm and in line with thearm-wheel support joint.
6. Start up the engine, engage 4th
speed and then rev engine up to max.

WHEEL BALANCINGPROCEDURE

speed as per speedometer reading.
7. Perform wheel balancing according to usual “Equitron” type balancing machine procedure.

CAUTION:
Considering the special construction
features of the differential assembly,
it is imperative that balancing ofwheels - especially of front ones be performed according to theprocedure hereafter described inorder to avoid serious damage.

Front wheels
1.
Lift car front with a dolly-type
hydraulic jack placing same underrelevant lifting point (Refer to:
Lifting Points for jacking up).
2. Place two stands in line withfront jacking points located undercar body.
Lower car till it rests on stands
3.
but locking the jack as well (thusachieving a three-point support).

28-4
Alfawiki.nl

Rear wheels
1. Lock front wheels by means of
two wedges, one for each wheel.
2.
Lift car rear, inserting jack underaxle. Position two stands in correspondance with stand rear seats andthen lower the car.
3. Set up balancing machine andequipment; make sureauxiliary
probe is placed under the suspension
spring. Let the wheel rotate bymeans of a wheel accelerator device,
then carry out balancing operations
with the modalities for balancing
machine of the .“Equitron” type.

WHEELS AND TIRESBALANCE WEIGHTS
POSITIONINGa.

Be sure to place correct balance
weights on inner edge of rim.

b.

Do not pure more than two
weights on each side.

c.

Two types of balance weights
are used: one is designed for use
with steel wheels and the otherQ
Li

for use with light allowy wheels.
Do not mix different typebalance weights.
d.
1.

L,
D
s
Ls

= location of balance weights= tramp direction= shimmy direction= location of unbalance causing
heavy area

Balance weights

Properly rebalance wheel andtire whenever puncture is repaired.

Maximum allowable at rim flange:
8 g (0.28 O L )Balance weights:
10 4 40 (0.35 + 1.40 02)
at 10 g (0.35 02) interval

SERVICE DATA AND SPECIFICATIONSGENERAL

SPECIFICATIONSFLUIDS AND LUBRICANTS

Application

Tire beads

Denomination

TYW

FLUID

Q-v

UNION CARBIDE CHEMICALSCOMPANY: Ucon lubricant 50 HE-5100
MILL01 L: lubricant for elastomer seals
Stel. No. 4500-17502

INSPECTIONS AND ADJUSTMENTS
DYNAMIC BALANCE
8 g (0.280 04
Max. allowed residual unbalance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 mm (0.04 in)Thread thickness limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1,000 km (621 miles)
Wheel screws tightening after the first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balance weights (at 10 g (0.35 oz) interval). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28-S
Alfawiki.nl

10 + 40 g (0.35 + 1.40 OZ)

May 7983

WHEELS AND TIRESTECHNICAL DATA..

May 1983

28-6
Alfawiki.nl

Alfawiki.nl

Alfawiki.nl

ELECTRICAL SYSTEMCONTENTS
HOW TO READ THE WIRINGDIAGRAM

Windscreen wash/wiper . . . . . . . . . .

40-28......................

40-2

Windscreen wiper . . . . . . . . . . . . . .

40-29

Wiring diagram . . . . . . . . . . . . . . . .

40-2

Headlight wash/wiper . . . . . . . . . . .

40-32

Power supply routing . . . . . . . . . . .

40-3

Headlight wiper . . . . . . . . . . . . . . . .

40-33

POWER SUPPLY ROUTING . . . . . . . .

40-4

Windscreen washer and headlight

Schematic/Power supply routing . , . l 40-4

washer . . . . . . . . . . . . . . . . . . . . . . .

40-34

Fuses . . . . . . . . . . . . . . . . . . . . . . . .

40-5

ELECTRIC ACCESSORIES . . . . . . . . .

40-36

Ignition switch . . . . . . . . . . . . . . . .

40-6

Horns, heated rear window, cigar

ELECTROMECHANIC AND

lighter, clock . . . . . . . . . . . . . . . . . .

40-36

ELECTRONIC DEVICES . . . . . . . . . . .

40-7

Horns . . . . . . . . . . . . . . . . . . . . . . .

40-37

Relays and timer . . . . . . . . . . . . . . .

40-7

Heated rear window . . . . . . . . . . . .

40-38

Electronic devices and intermittence; 40-7

Power window. . . . . . . . . . . . . . . . .

40-39

LIGHTING SYSTEM..............

40-10

Power windows and door locks . e . ,40-4 1

Lamps . . . . . . . . . . . . . . . . . . . . . . .

40-10

Door lock control unit . . . . . . . . . .

40-42

Combination switch assembly . . . . .

40-l 1

Check Control and Trip Computer. .

40-43

Outside lighting . . . . . . . . . . . . . . . .

40-13

ELECTRIC COMPONENT LOCATION.

40-45

Front combination lamps . . . . . . . .

40-17

Engine compartment . . . . . . . . . . . .

40-45

Rear combination lamps . . . . . . . . .

40-l 9Passenger compartment . . . . . . . . . .

40-45

Inside lighting . . . . . . . . . . . . . . . . .

40-20

HARNESS LAYOUT . . . . . . . . . . . . . .

40-46

General harness . . . . . . . . . . . . . . . .

40-46
40-46

BOARD INSTRUMENTS AND
TRANSMITTERS . . . . . . . . . . . . . . . . .

40-22

Engine compartment . . . . . . . . . . . .

Cluster. . . . . . . . . . . . . . . . . . . . . . .

40-22

Passenger compartment and luggage

Engine cooling and lubrication , , . . 40-24

room (LH) . . . . , . . . . . . . _ . . . . . . 40-47

Fuel supply, brake and clutch oil

Dashboard ( LH) . . . . . . . . . . . . . . .

minimum level transmitter, tachymetric pulse generator . . . . . . . . . . .

SWITZERLAND-AUSTRALIA
40-26

HEADLIGHT WASH/WIPER . . . . . . . .

MODEL

VARIATION . . . . . . . . . . . . . . . . . . . . .

WINDSCREEN WASH/WIPER AND

40-48
40-49

Tachymetric control unit - fast idle.
40-28

electromagnet - hand brake switch. . 4049
Cl RCUIT DIAGRAM . . . . , . , . . . . . , ,40-50

May 1983

Alfawiki.nl

1‘uELECTRICAL SYSTEM

r-----7i

The example shows continuity be-COrangetween terminals 2 and 3 with thecontrol set to position 1.

CN

Orange - black
Orange -white
Grey

pI----- @iiP%?
1’
The chain line, on wiring diagram,delimits those areas containing thespecific variations for the models
indicated by “U .,.I’.

The detail shows a reference to knot
relevant to electronic device N ._.

CB
H
HG
HN
HP?
HV
G
GB
GN
GR
GV
N
NZ
M
MB

l+++(m)FT(‘)
The connection identifies two wiring
variations, present in alternative andconnected in the same way. The
wiring variations are referred to themodels indicated by “U . . . “,

MG
R
RN
S
SB
SN
V

The figure shows the type of diagramused to identify the two connectors
relevant to each joint: for the maleconnector it is applicable diagram(m); for the female one it is applicable diagram (f).

VB
VN
z
ZN

Grey - yellow
Grey - black
Grey - redGrey - green
Yellow
Yellow-white
Yellow - black
Yellow - red
Yellow - green
Black
Black - violet
Brown
Brown -white
Brown - yellow
Red
Red - black
Pink
Pink -white
Pink - black
Green
Green -white
Green -black
VioletViolet - black

In case of mixed color, the base color
is indicated first, followed by thepresent stripe col.or.
BN = White with Black stripes
i.e.

Cable colors
A
AB
AN
AR
In the horizontal line, table shows
position of control or of switch to be
operated. In the vertical line it shows
the terminals between which continuity generates.

Light blue
Light blue - whiteLight blue - black

Cable section
sectionnot indicatedCable
0 . 5 mm2 (0.39 . 10m3 in2).

isLight blue _ red
White

6
RN W h i t e - b l a c k
BR White red
BLN Blue - black
BLR Blue - red

POWER SUPPLY ROUTINGThis type of diagram is helpful in
identification of specific troubles
relevant to the part of electric
diagrams concerning supply i.e.: thewindscreen wiper is not functioning.
A first check’ shows efficiency of
instrumentation supply. From distribution diagram it can be notedthat supply of both instrumentation
and windscreen wiper are realized via
ignition switch and fusebox. T h eresult is then that ignition switch
operates correctly and no failure ispresent along wiring between battery
and switch itself.

Failure must then be due either tofusebox (see.: Fuses- Services protected by fuses) or to the following partsof the electric system, that is in
the wiring windscreen wiper or in the
ground connection.
For fault identification, refer then to
the windscreen wiper wiring diagram.

Alfawiki.nl
40-3

May 1983

ELECTRICAL SYSTEM

POWER SUPPLY ROUTINGSCHEMATIC/POWER SUPPLY ROUTING

4r- - - -1

fO(I\
E
0:

-

I
I
-,
” m+
;
z
LL
I

\I
-

-

I

May 1983

I-/ I\c -\IY
rN“! 0P

- - -

- -

-

I

I
\
-

Y
n
II

-

- -

- - -

-

Alfawiki.nl

ELECTRICAL SYSiEM

FUSES

CHECK

LOCATIONCAUTION:?he fusebox is integral part of thea.

In case a fuse blows, before

support board and is lo&d on left

replacing it, make sure that theside of the intermediate bulkhead, in

cause of failure has been removed.

the engine compartment.

b.

Use fuse having the prescribedamperage, only. Do never use

C.

fuses having amperage greaterthan the prescribed one.
Correctly insert fuse into fusebox, aligning it carefully withrespect to its seat.

cl.
1 FuseShould car remain stationary
for a long time, remove fuseprotecting supply circuit ofclock.

SERVICES PROTECTED BY FUSESIn the following table, for each model, it is specified which are the services protected by each fuse.

Model

---I-

Protected Service

1350

1500 Q.*1500

905.02905.04905.06905.03905.05905.07I
X

X

Power windows
Door lock control unit

16

Heated rear window

76

1

I

x

X
X

Clock
16
Horns-cigar lighter

X

Passenger compartment roof lamp- Intermittence of direction and.
hazard lights- Stop switch

X
8

Roof lamp timer
Trip Computer- .-Windscreen wiper-Windscreen Wiper electronic intermittence generator. Windscreen wiper controlWindscreen washer pump controlCluster
Heated rear window switch- Hazard lights switch Heater switch%--l--8X

Power window switch Power window
Clock

Alfawiki.nl
40-S

May 1983

ELECTRICAL SYSTEM

Modal

81
:

Protected Service

Cut-off solenoid valve - Reverse switch

Ampere1200905.001360
905.02305.031500 a.*905.04905.05

8

X

X

X

1500
905.06905.07

8
Trip Computer - Check Control

X

Side lights left front and right rear-R. H.number plate light

X

Clock

X

9
Check Control
Cigar lighter

X

Side lights right front and left rear-i. H.number plate lightX

Check Control -Trip Computer-Headlights wiper
10

Heater control lighting lamp - Cluster lighting lamp Side light warning lamp

X

11

Risht low bean

X

X

12

Left low beam - Rear fog light switch

X

X

X

13

Rioht full beam

X

X

X

14

Left full beam - Headlights warning lamp

X

X

X

a* = Quadrifoglio

IGNITION SWITCHREMOVAL AND
INSTALLATION
For removal and installation of theignition switch - antitheft steering

lock group, refer to: Groupe 23 Steering Wheel and Column.

May 1983

40-6

Alfawiki.nl

ELECTRICAL SYSTEM.-ELECTROMECHANIC AND ELECTRONIC DEVICESRELAYS AND TIMERLOCATION
The relays and the roof lamp timer
are inserted into the special socket
which is integral part of the fusebox

support board, located on left side ofintermediate bulkhead. For location,refer to “Electric Component Location”.

CHECK
The relays and the timer, must be of
the type indicated in the specifictable on page 40-8.

ELECTRONIC DEVICES AND INTERMITTENCESLOCATION
The electronic device for headlights
and flashing changeover, and thewindscreen wiper electronic intermittence generator, are mounted on a
support board, located in the intermediate bulkhead, in proximity to
the fuse holder box.

The device which controls intermittences of both side lights and hazard
lights, is located in the dashboard
inside.
For identification of the various
devices, see: “Electric Component.Location”.

Alfawiki.nl
40-7

CHECK
The electronic devices and intermittences must be of the type indicatedin the specific table on page 40-g.

May 1983

ELECTRICAL SYSTEM“Relays and Timer” Table

External view+
4%

Passenger compartment
roof lamp timer

NlO

Horns relay

13

12

Headlight wiper relay

14

May 1983

1

2

3

4

Front power windows
relay

Position

L

Heated rear window
relay

Symbols

5

112

40-8
Alfawiki.nl

ELECTRICAL SYSTEM“Intermittences and electronic devices

External view

Component

Symbols

Windscreen wiper electronicihtermittence

N14

Electronic device for2

headlights and flashingchangeover

N18

L

Hazard and direction
lights intermittence

N13

P

-

+

++

Alfawiki.nl
40-9

M a y 1983

ELECTRICAL SYSTEM

LIGHTING SYSTEMLAMPSCAUTION:
Before starting operations on lighting
system, make sure that the ignition
switch is to the “ST” position andthe battery ground cable is disconnetted.

Lamp characteristic data, type ande l e c t r i c p o w e r a r e l i s t e d i n thefollowing table.

Electric power
Lamps

IWI

TYPe

Front combination lamps :
56/60

-

low beam and full beam (H4 halogen lamp)-

front side light4-

front direction indicator

21Side direction indicator lamp

3

Rear combination lamps :-rear direction indicator

21-

rear side light5-

number plate light5-

reversing light21-

rear fog light21-

rear side and stop light

S/21

Warning lamp

1.2

Roof lamp

IO

TYPES OF LAMPSThe lamps used for the car are offour types. For removal the following procedure is recommended.

Bayonet lamp - type B
2.
To remove it from lampholder, press
the bulb, rotate it counterclockwise,
then withdraw it.

Halogen lamp - type A
1.
To remove it from lampholder,

Whole glass - type D
4.
It is pressed into lamp holder and to
remove it, it is necessary to withdraw

disconnect connector, then rotate
retaining spring being careful not tolamp out of lampholder.

touch it with naked hands.

Cylindrical lamp - type C
3.
To remove it from lampholder,release it from contacts pulling
towards outside of lampholder.

May 1983

40-l 0
Alfawiki.nl

For installation of lamps, reverse
order of removal.

ELECTRICAL SYSTEMCOMBINATION SWITCH ASSEMBLY

VIEW FROM M

d
5

1
2
3
4

Left lever
Turning stalk
COnnector
Connector

5678Connector
Connector
Connector
Right lever

Alfawiki.nl
40-l 1

May 1983

ELECTRICAL SYSTEM

T h e fOiiOWiIIQ table shows thecorrespondances between positionsof combination switch controls andthe concerned services.

Stalk rotation

Left lever

Service enabled

PositionControl0- zero position1- side ligho

2- low beams

A- zero position

B

Movement parallel
to steering wheel axis

- full beam flashing (paired to rotation inI

D
Movement parallelOFF

the 0 and 1 positions)- Headlight change over (paired to rota-.

tion in position 2 )- Right - hand direction indicator- Neutral position

to steering wheel planeS

T

Control

Position- Left ” hand direction indicator

Service enabled- zero position
Movement parallel- windscreen wiper intermittence

to steering wheel plane- windscreen wiper Ist speed- windscreen wiper 2nd speed

Right leverON

Movement parallel to steering
wheel axis

- windscreen washer and/or headlight
wash-wiper with wiping stroke driven
from control unitOFF

- zero position

REMOVAL AND
INSTALLATION
1.

Removing steering wheel.

Unscrew the five securing
2.
screws and remove upper and lower
shell covers of steering column(see Group 23 - Steering Wheel andColumn).
Disconnect connectors @ of3.
the combination switch unit.
Remove combination switch
4.
the two
unscrewing
unit by1 securing it to steeringscrews 0
column.
If necessary, disassemble combination switch unit separating the ‘CWO
levers.
For installation reverse order of5.
removal.

1 Screw
2 Connectors

CHECKS AND INSPECTIONSCheck harness integrity and, by

May 1983

40-I 2

Alfawiki.nl

means of a tester, check electric
continuity.

ELECTRICAL SYSTEMOUTSIDE LIGHTINGOUTSIDE LIGHTING - FRONT SIDE

Alfawiki.nl

May 1983

ELECTRICAL SYSTEMOUTSIDE LIGHTING - REAR SIDE
(for the 1200 - 1350 - 1500 models)

1d

i
,
I’
-

May 1983

40-l 4
Alfawiki.nl

ELECTRICAL SYSTEMHEADLIGHT SWITCH

LocationLow beam/full beam light changeo v e r is executed via left lever of
combination switch (see: Combina-

The switch is mounted on gearbox

When in the O F F position = ma
When in the ON position = 0 fi

(see: Group 13).

tion Switch Assembly).

DIRECTION LIGHT SWITCH
Operation of direction indicators is
executed via left lever of combinaCombination
switch (see:
tion

Check
Connect a tester to terminals ofreverse switch and verify the following resistance values.

Switch Assembly).

HAZARD LIGHTS SWITCH

W h e n in the O F F position = -aWhen in the ON position = 0 a

REAR FOG LIGHT SWITCH

Location

STOP LIGHT SWITCH

The switch is mounted on upper
ornament of central console (see:Groupe 66 - Consoles).

Check
Verify switch functioning by checking whether continuity between

Location

terminals occurs in accordance with

The switch is mounted on upper
ornament of central console (see:Group 66 - Consoles).

the indications provided in table.

Location
The switch is mounted on the

REVERSE LIGHT SWITCH

relevant bracket of pedal assembly.

Check.
Verify switch functioning by checking whether continuity between

Check
Connect a tester to terminals of stop
light switch and verify the following
resistance values.

May 1983

40-16
Alfawiki.nl

terminal occurs in accordance with
the indications provided in table.

ELECTRICAL SYSTEMFRONT COMBINATION LAMPS

7 Lamp1 Front combination lamp
2 Halogen lamp
3 Securing spring

8 Lampholder
9 Lamp4 Supply connector
5 CoverIO Plastic cover
11
Headlight wiper clamp

6 Lamp holder

REMOVAL AND
INSTALLATIONWith reference to the exploded viewproceed as follows.
Operating from engine com1.
partment inside, disconnect harness
from cover 0.
2.

Remove grille (see: Group 75 -Grille).
3.

Unscrew the two nuts securing

combination lamps to body.

5.
For combination lamp installation, reverse order of removal.
Adjust luminous beam by fol6.
lowing the procedures described in“Setting of headlights low beam”.

(2)
Unscrew the two screws securing transparent cover @J to combination lamps 0, then remove it.

Replacementof transparent cover @ can be carried out on mounted
combination lamps 0, by operatingf r o m e n g i n e comparment inside.
4.

Operating from fender inside,(1)

Rotate lampholder @ counter-

unscrew nut securing combination

clockwise and withdraw it fromlamps

transparent cover IO

tofenderitself

and

re-

0.

move it.

Alfawiki.nl
40-l 7

May 1983

ELECTRICAL SYSTEM(3) For installation of transparent
cover, reverse order of removal.

6.
For installation, reverse order ofremova I.

LAMP REPLACEMENT
Headlights and front side lights
1. Operating from engine compartment inside, rotate cover 0
clockwise, then remove it.

CAUTION:
Do not touch with the hands glass ofheadlight halogen lamp 2 . If thisoccurs, wash the glass.

Front direction indicators
1.

1.

Operating from fender inside,compress the two springs securingtransparent cover of side direction
i n d i c a t o r @ to fender @, t h e nremove it.
Withdraw lampholder @ from2.
direction indicator 1 _0

3.
Replace lamp @ by pulling
the relevant bulb.
4.

Install direction indicator byreversing order of removal.

Operating from engine com-

rotatelampinside,
h o l d e r @ counterclockwise, thenpartment

remove it.
Press lamp bulb @ and rotate
2.
it in order to withdraw lamp.
Replace the lamp and install3.
lampholder 0.

SETTING OF HEADLIGHTSLOW BEAM
Carry out the following procedure toadjust headlight low beam.
Check that tires are inflated at1.
the right pressure and that car is freefrom any load excepted those ofservice supplies and of one passenger
equivalent.
2.

1 Cover

Disconnect
conSuPPlY
nector 0.
3.
Rotate securing spring @counterclockwise,
and remove it.
4.
Withdraw halogen lamp @ andPosition the car and the possible

test equipment on an horizontal
plane. If no test equipment is available, place the car in front of a clear
screen.

2.

replace it. On reassembly, replace thelamp, make sure the cover is properly

1 Lamp2 Lampholder

Side direction indicators

positioned by correct alignmentof the notches.
5.
To remove headlight lamp @,withdraw lampholder 0, press bulb
and rotate it counterclockwise.

1
2
3
4

Side direction indicator

Lamp
Lampholder
Fender

1 Supply connector
2 Halogen lamp

3 Securing spring
4 Lamp5 Lampholder

May 1983

Move car back of about IO m
(32,8 ft) and switch on low beams.
The luminous beam must be in
3.

40-18
Alfawiki.nl

compliance with geometric dimensions provided in figure.

ELECTRICAL SYSTEM

A
B

C= distance of headlight centre
from ground= height of luminous beam
= IO m (32,8 ft)

Orientation is correct when thefollowing condition occurs:

6 = 470 m m (‘l8,5 in)Distance D between luminous beams

centre must be equal to distance E
between headlight center.

The dimensions indicated in the
diagram comply with provisions inforce in Italy. For other countries,
comply with national provisions.
For correction of possible orientation errors, from engine compartment inside, operate on adjustingscrews of headlights set in evidence
in the following figure.

1 Horizontal direction adjustment screw
2 Verrical direction adjustment screw

REAR COMBINATION LAMPS

1 Combination lamps
2 Lamp3 Lampholder

REMOVAL AND
INSTALLATION4.

For installation of combination
lamps, reverse order of removal.

With reference to the exploded view,

LAMP REPLACEMENT

operate as follows.
I.
Open back door and lift rear
trim.
2.

The following procedure is applicable
to all lamps and lampholders.

Disconnect connector.

3.

Unsaew the six nuts securing
combination lamps to body, thenremove combination lamps.

40-19
Alfawiki.nl

May 1983

ELECTRICAL SYSTEM

1.

Open back door and lift rear

trim.

3.
Press bulb of lamp and rotate itin order to remove.

Press on lampholder side 0,2.
pull; then remove it.

4.
Replace lamp and refit lampholder.
5.
For identification of lamp location, refer to diagram of the following figure.

40-J

Diagram refers to the left rear
combination lamp.

1 Rear fag light
2 Side light
3 Stop and side lights
4 Direction indicator
5 Reverse light
6 Number plate light

The right-hand one is specular withrespect to the left-hand.
The rear fog light is present in theleft rear c o m b i n a t i o n l a m p o n l y .
1 Lamp2 Lampholder

INSIDE LIGHTING
1200 and 1350 model

0

H4

OGl

--I
P
z

0

A l -%
‘
=-

it*

Nl

May 1983

40-20
Alfawiki.nl

h nz

ELECTRICAL SYSTEM

1500 a n d 1 6 0 0 Quadrlfogllo m o d e l

Al Battery
61 Ignition switch
F3 Passenger compartment roof lamp
F16 Ignition switch lighting lamp
Gl Fusebox

G30 Power window and door lock connector
G86 Passenger compartment roof lamp connector
H4 Roof lamp switch on passenger compartment pillar
NlO Passenger compartment roof lamp timer

ROOF LAMP
Lamp replacement
1.
By means of proper tool,
remove transparent cover, pressure
inserted into lampholder.

2.

Withdraw and replace the lamp..

Alfawiki.nl
40-2 1For lamp installation, reverse
3.
order of removal.

May 1983

ELECTRICAL SYSTEMCAUTION:
Before starting operations, make surethat the ignition key is to the “ST”
position and ground cable is disconnected.

REMOVAL AND
INSTALLATION
1.

securing c l u s t e r @ to support
bracket @.
2.
Remove the pressure inserted
cover 0, disconnect harness 0,
then remove cluster.
3.
For installation, reverse orderof removal.

Unscrew the four screws @LIGHTING AND WARNINGLAMPSREPLACEMENT,.

Remove cluster (see: Removal
and Installation).
2.
Rotate lampholder and withdraw it; then remove lamp fromlampholder itself.
3.
Replace lamp with an identical
one then carry out installation by
reversing order of removal.

1 Cluster

2 Connector5
3 Cover
4 Bracket
5 Screw

Alfawiki.nl
40-23

May 1983

ELECTRICAL SYSTEMENGINE COOLANT LEVELSENSOR

Connect the two ends of tester1.
to sensor connector just as per figure.

Check

2.

Location

Check sensor proper function-

ing by verifying the following:

The sensor is inset-ted into header
Float lifted: &Float lowered: 0 atank of cooling system.

Alfawiki.nl

ELECTRICAL SYSTEMFUEL LEVEL TRANSMITTER
Removal and installation.

For removal and installation see:Groupe 04 - Supply System.

Connect a lamp indicator topins of float plug, as per figure.
3.
Check device proper functioning by verifying the following.

2.

Float lifted:

CLUTCH AND BRAKE OILMINIMUM LEVEL
TRANSMITTER

lamp indicator off
Float lowered:lamp indicator on

Check
Set the ignition key to the MAR1.
position.

Alfawiki.nl

40-27

May 1983

ELECTRICAL SYSTEMWINDSCREEN WASH/WIPER AND HEADLIGHT
WASH /WIPER
WINDSCREEN WASH/WIPERrr
I

I m---J

r-

-

PI9
0’
I n I
L-+3
r--l

Al Battery
Bl Ignition switch
82 Windscreen wiper control switch
83 Windscreen washer and/or headlightwash/wiper pump control switch
Gl Fusebox
G85 Front service ConnectOr
L13 Windscreen washer liquid level sensor
N7 Trip Computer
N8 Check Control
N14 Windscreen wiper electronic intermittence
PI Windscreen wiper motor
PI9 Windscreen washer electric pump
CL4 R.H.D. L.H.D. Quadrifoglio model

Alfawiki.nl

ELECTRICAL SYSTEMWINDSCREEN WIPER

1
2
3

Motor
Motor cover
Linkage

4Nut
5 SpacerBush
Cowl top cover
Nut
Wiser arm

4.

REMOVAL AND
INSTALLATION
1.

6
7
8
0

Disconnect motor 0 harness.
0 fromWithdraw brushes 0

2.
wiper arms 9 .
Lift covers of nut @ securing
3.

0

wiper arms @, unscrew nuts, then

IO
11
12
13

Brush
Bush
SpacerNut

Remove cowl top cover 0(see: Group 75 - Cowl top cover).
Withdraw bush @) , unscrew
5.

Unscrew the three screws secur7.
ing motor 0 to linkage @ andnut securing motor shaft to linkage.

nut 8, then remove it together
with spacer @ .
Unscrew the three screws secur6.
ing linkage @ to body, then remove it.

remove wiper arms.

Remove motor 0 and with8.
draw cover @.
For windscreen wiper installa9.
tion, reverse order of removal.

May 1983

40-29
Alfawiki.nl

ELECTRICAL SYSTEMTROUBLE DIAGNOSIS AND CORRECTIONS

Probable cause

Condition

Windshield wiper does notlBurnt fuse

Replace fuse

Loose connection or open circuit

Restore connection

Improper switch contact

Verify combination switch; (right light);

operatellCorrective action

replace, if necessarylForeign material interrupts link

Take off foreigti’material

mechanism

Windshield wiper operatingl

Disconnected rod.

Connect rod.

l

Seized or rusted arm shaft

Replace shaftlShort circuit of motor armature

Replace motorlWorn brushes or seized shaft

Replace brushes

speed is too slow

Windshield wiper does not

0 Low source voltage

Verify voltage supply. Humming of motor

Replace motorlFaulty auto-stop device

Replace auto-stop devicelFaulty wiper motor

Replace motor

stop correctly

Washer fluid does not eject

Clogged washer nozzle or hoseFree nozzle or hose(washer motor operates)

Wiper does not operate inter-l

Faulty wiper switch

Replace combination switch (right lever)mittently but operates at low
and high speedslFaulty wiring

Verify wiringl

Faulty intermittence

Replace intermittencelFaulty auto-stop device

Replace auto-stop devicelFaulty intermittence

Replace intermittencelLine voltage below 10 volts

Restore voltagelFaulty intermittence

Replace intermittenceIntermittent speed is too
short for proper wiping

Intermittent speed is too long,for proper wiping

May 1983

40-30
Alfawiki.nl

ELECTRICAL SYSTEM

Probable cause

Condition

Intermittent speed is erratic

Corrective actionlFaulty wiper switch

Replace switchl

Faulty wiring

Verify wiring. Faulty wiper motorlFaultyintermittence

Alfawiki.nl
40-31

Replace motor
Replace intermittence

M a y 1983

ELECTRICAL SYSTEMHEADLIGHT WASH/WIPER
1500 Quadrlfogllo

model

Bs

I;
I!jI1
1

I 1 1 ’1 r

!

i
I
I
i
1w--B 1I

May 7983

40-32
Alfawiki.nl

ELECTRICAL SYSTEMHEADLIGHT WIPER
1500 Quadrlfogllo m o d a l

1
Motor
2 Bracket
3 Headlight wpsher hose
4 . Grille
5 Wiper arm
6 Nut

7
Nut
B Wiper arm
9 .Headlight washer hose
10 Bracket
11 Motor

Unscrew the six screws secur5.
@toing motors @ andbracket @ and @ ! then remove
motors.

REMOVAL AND
INSTALLATIONWith reference to the exploded view
above proceed as follows.
1.
Disconnect harness of motor (iJ .
6 and7
2. Lift cover of nuts
securing wiper arms @ and 8 ,unscrew nut and disconnect headlight washer hoses @ and @.
3.
By means of tool A.3.0602,
remove wiper arms @ and @.

0

8

4.
Remove grille (see: Group 75 ”
Grille).

Alfawiki.nl
40-33

6.
tion,

For windscreen wiper installareverse order of removal.
May 1 9 8 3

ELECTRICAL SYSTEM

SPECIAL SERVICE TOOLS

Refer toTool number

A.3.0602

Tool name

Page

Wiper arm puller

Alfawiki.nl
40-35

May 1983

ELECTRICAL SYSTEMHORNSHORN CONTROLPUSHBUTTON

Location
The horns are mounted inside engine
compartment on support brackets

Is=3

Location

located under front combination

The pushbutton is located at centreof steering wheel (see: Group 23 -lamps.

Removal and installation

Steering Wheel and Column).

Operating from engine com1.
oartment inside, disconnect hornCheck

h a r n e s s 0.

1.

2. Unscrew the nut @ securing
horn 2 to support bracket 0; thenremove the bracket.
3.
For installation, reverse order ofremoval.

Connect ends of tester topushbutton terminal, operating as
per figure.
Check pushbutton proper func2.
tioning by verifying the following:

Pushbutton lifted: -&Pushbutton depressed: 0 a

1 Harness
2 Nut

3 Bracket

TROUBLE DIAGNOSIS AND CORRECttONS

Corrective action

Probable cause

Condition

I
Only one side operates

Poor tone quality on one sidelFaulty hose

Replace hornl

Loose connector contact

Restore connection

Adjust tone by operating on the relevant

Tone adjustment not good

adjusting screw 0

Both horn volume reducedl

Low battery charge

Charge battery or replacelFaulty charging system

Verify charging systemlFaulty connector contact

Rest&e connection-

Both horns do not operatelWiring cut-out

Restore connectionlFaulty control push button

Replace push buttonlDischarged battery

Charge batterylBoth horns faulty

Replace both horns

40-37
Alfawiki.nl&fay 7983

ELECTRICAL SYSTEM

4.

Dry end of ruling pen to remove

6.

By means of a hot air jet, heatsilver compounds.
Once the repair has been carried5.

the repaired area for about 20
minutes, k e e p i n g t h e o r i f i c e o fout, wait for about 10 minutes, thenverify electric continuity of the wirein object.

heat-gun at about 3 cm (I,2 in) fromsurface. If a heat-gun is not available,
let dry for 24 hours.

During test, do not touch’ with thefingers the repaired resistor,

1 Filament
2 Interruption

3 Rule4 Ruling pen

POWER WINDOW
1 3 5 0 m o d e l ( I t a l y , o n l y ) and 1 5 0 0 m o d e l

Al Battery
Bl Ignition switch
B9 Heated rear window control switch
812 Hazard lights control switch

821 Right front power window control switch
822 Left front power window control switch
Gl
Fusebox
G36 Power window switch cable connector

Alfawiki.nl
40-39

I1 2 Front power windows relay
PI4 Right front power window motor
PI 5 Left front power window motor

May 1983

ELECTRICAL SYSTEM

POWER WINDOWS AND DOOR LOCKS
1500 Quadrlfogllo model

I
I

I

I

I

1

I

I

r e-- 1

Alfawiki.nl
40-4 1

May 1983

ELECTRICAL SYSTEMDOOR LOCK CONTROL UNIT

LOCATION
The door lock control unit is locatedinside passenger compartment, in thegear lever console, behind Check
Control and Trip Computer.

REMOVAL AND
INSTALLATION
1; @wi;ydisc;;;ey;e “,“,:“,Ivant harness.
Remove control unit @ by2.
unscrewing the screw securing it to
Trip Computer 0.
For control unit installation, reverse
order of removal.

May 1983

1 Door lock control unit
2 Trip Computer
3 Instrument holder
4 Check Control

40-42
Alfawiki.nl

ELECTRICAL SYSTEMLOCATION
Check Control and Trip Computer

For instrument installation, re3.
verse order of removal.
When reading a red led diode isused to set in evidence the enabledfunction in order to allow user aneasy identification.

are inserted into a special instrument
holder integrated into gear leverconsole, in centre position, under
dashboard.

REMOVAL AND
INSTALLATION
1.
Withdraw instrument holder 3from console and disconnect therelevant harness.
2.
Remove Check Control 2 andTrip Computer 1 by unscrewing,for each one, the two securing screws
to instrument holder.

For an easier comprehension of the

Indications and the Check Control

symbology used for the two instruments, in the following table reference i s m a d e t o T r i p C o m p u t e r

signallings, pairing them to relevant
symbols.

1 T r i p C o m p u t e r 3 instrument h o l d e r
2 Check Control

Check Control

Trip Computer12

lstantaneous consumption in L/100 km

7

Windscreen washer fluid level warning lamp

Medium consumption for the covered distance in L/100 km

8Engine oil level warning lamp

9Engine coolant level warning lamp

10

Cluster warning lamp

11

Stop lights warning lamp

12Side lights warning lamp

13

Main red warning lamp

14

Main green warning lamp

starting from zeroing by red Key (Start Key)
3

Fuel consumption in litres since trip start, starting fromzeroing by red Key

4

Medium speed in km/h since trip start, starting fromzeroing by red Key

5

Drive time in h/min since trip start, starting from zeroingby red Key

6

May 1983

Time in hoursjmin

40-44
Alfawiki.nl

ELECTRICAL SYSTEMELECTRIC COMPONENT LOCATIONENGINE COMPARTMENT

1
2
3
4

Passenger compartment roof lamp timer
Horns relay
Heated rear window relay
Headlight wiper relay

5
6
7
8

Front power windows relay
FuseboxElectronic device for headlights and flashing changeover
Windscreen wiper electronic intermittence

PASSENGER COMPARTMENT

1

Hazard and direction lights intermittence

40-45
Alfawiki.nl

May 1983

ELECTRICAL SYSTEMHARNESS LAYOUT
GENERAL HARNESS

1 Engine comparment harness
2 Front part and dashboard harness
3 Roof lamp harness
4 Luggage room harness
5 Passenger compartment harness

ENGINE COMPARTMENT

A3 Alternator with built-in electronic regulator
A8 Ignition coil
Al 1 Starter
01 Alternator charge warning lamp
E9 Side direction light lamp
Gl Fusebox
G46 Headlight connector
G53 Engine compartment ground
G73 Rear service connector
G85 Front service connector
H2 Reverse right switch
HI7 Brake fluid min. level control switch
L2 Pressure switch for engine oil min. pressure

May 1983

L5 Thermostatic switch for engine coolant max. temperature warning lamp
L6 Thermostatic switch for engine cooling electric fan
L7 Transmitter for coolant temperature gauge
L17 Odometer pulse generator
Ml Cut-off solenoid valve
N14 Windscreen wiper electronic intermittence
N18 Electronic device for headlights and flashing changeover
02 Horn
P2 Engine coaling electric fan
P4 Headlight wiper motor
PI9 Windscreen washer electric pump
01 Air ventilation heater fan

40-46
Alfawiki.nl

ELECTRICAL SYSTEMPASSENGER COMPARTMENT AND LUGGAGE ROOM (L.H. DRIVE)

Alfawiki.nl

May 1983

ELECTRICAL SYSTEMDASHBOARD (L.H. DRIVE)

Bl Ignition switch
82 Windscreen wiper control switch
84 Control switch for headlight, flashing, low beam and full beam
B5 Horns control switch
B6 Direction lights indicator switch
B9 Heated rear window control switch
Bll Rear fcg light control switch
B12 Hazard lights control switch.
821 Right front power window control switch
822 Left front power window control switch
C7 Clock

May 1983

F8 Air ventilation controls lighting lamp
G5 Connector
G6 Cluster B connector
G7 Cluster R connector
G86 Passenger compartment roof lamp connector
H3 Stop light switch
H13 Choke switch
N13 Hazard and direction lights intermittence
06 Cigar lighter
Q4 Air ventilation heater fan control

40-48
Alfawiki.nl

ELECTRICAL SYSTEMSWITZERLAND-AUSTRALIA MODEL VARIATIONTACHYMEiRlC C O N T R O L U N I T - F A S T I D L E E L E C T R O M A G N E T-HAND BRAKE SWITCHTACHYMETRlC CONTROL UNIT - FAST IDLE/ ELECTROMAGNET(For vehicles 1350 - 1500 and 1500 Quadrifoglio models for SWITZERLAND and AUSTRALIA)and HAND BRAKE SWITCH(For 1500 Quadrifoglio vehicles, A USTRA LIA models)0
r - 1

Al Battery
A8 Ignition coil
Bl Ignition switch
B2 Windscreen wiper control switch
Cl Electronic rev. counter
07 Hand brake warning lamp
Gl Fusebox
G6 Cluster B connector

HANDBRAKESWITCH

INDICATOR(1500 Quadrifoglio)

Check
1.
Set the ignition key to the MAR
position.
Connect a tester to terminal of2.

G7 Cluster R connector
G30 Power window and door lock connector

G85 Front service connector
HI Hand brake switch
Ml Cut-off solenoid valve
M4 Idle speed electromagnet
N16 Tachymetric control unit

handbrake indimtor as shown infigure.
3.
The following resistance values.
shall be read.
Brake engaged: 0 a
Brake disengaged: &Alfawiki.nl
40-49

May 1983

ELECTRICAL SYSTEMCIRCUIT DIAGRAMKEY
A l Batter/A 3 Alternator with built-in electronic regulator
A5 Ignition distributor
A8 Ignition coil
All Starter
Al2 Spark plugs
Bl Ignition switch
82 Windscreen wipercontrol switch
B3 Windscreen washer and/or headlight wash/wiper pumpcontrol switch
84 Control switch for headlight, flashing, low beam and full beam
B5 Horns control switch
B6 Direction lights indicator switch
B9 Heated rear window control switch
Bll Rear fw light control switch
812 Hazard lights control switch
821 Right front power window control switch
822 Left front power window control switch
Cl Electronic rev. counter
C2 Electronic tachometerC4 Fuel level gauge
C6 Coolant temperature gauge
C7 Clock
Dl Alternator charge warning lamp
D2 Direction light warning lamp
D3 Side light warning lamp
04 Full beam warning lamp
D5 Brake fluid level warning lamp
07 Hand brake warning lamp
D8 Fuel reserve warning lamp
D9 Choke warning lamp
Dll Engine oil min. pressure warning lamp
D13 Engine coolant max. temperature warning lamp
El
Front direction indicator light lamp
E2 Front side light lamp
E8 Low beam and full beam lamp
E9 Side direction light lamp
El 1 Rear direction light lamp
El3 Tail light lamp
El4 Raversa light lamp
El5 Stop light lamp
El6 Rear fog light lamp
El7 Number plate light lamp
F3 Passenger compartment roof lamp
F8 Air ventilation controls lighting lamp
F12 Cluster lighting lamp
F16 Ignition switch lighting lamp
F17 Switches lighting lamp
Gl Fusebox
Hl Handbrake switch

May 1983

HZ Reverse light switch
H3 Stop light switch
H4 Roof lamp switch on passenger compartment pillar
HI 3 Choke switch
H17 Brake fluid min. level control switch
H27 Contact switch, on rear door, for heated rear window
I2
Heated rear window relay
I3 Horns relay
I4
Headlight wiper relay
112 Front power windows relay
L2
L5
L6

Pressure switch for engine oil min. pressure
Thermostatic switch for engine coolant max.temperature
warning lamp
Thermostatic switch for engine cooling electric fan

L7 Transmitter for coolant temperature gauge
L9 Transmitter for fuel level gauge
L12 Engine oil level indicator
L13 Windscreen washer liquid level sensor
L14 Engine coolant level sensor
L17 Odometer pulse generator
Ml Cut-off solenoid valve
M4 Idle speed electromagnet
Nl Module for electronic ignition
N7 Trip Computer
N8 Check Control
NlO Passenger compartment roof lamp timer
Nil Door lock control unit
N13 Hazard and direction lights intermittence
N14 Windscreen wiper electronic intermiuence
N16 Tachymetric control unit
N17 Trip control unitfor fuel flow
N18 Electronic device for headlights and flashing changeover
01 Heated rear window
02 Horn
06 Cigar lighter
PI Windscreen wiper motor
P2 Engine cooling electric fan
P4 Headlight wiper motor
PI0 Right front dwr lock motor
PI 1 Left front door lock motor
P12 Right rear door lock motor
PI3 Left rear door lock motor
P14 Right front power window motor
PI5 Left front power window motor
P19 Windscreen washer electric pump
P20 Headlight washer electric pump
Ql Airventilation heater fan
Q4 Air ventilation heater fan control
al L.H.D. 1200 model
UZ L.H.D. - R.H.D. 1350 model
U3 L.H.D. - R.H.D. 1500 model
U4 L.H.D. - R.H.D. 1500 Quadrifoglio model

40-50
Alfawiki.nl

p&-3-

Alfawiki.nl

------------------I
I

Alfawiki.nl

ELECTRICAL SYSTEM

KEY
Al Battery
A3 Alternator with built-in electronic regulator
A5 ignition distributor
A8 Ignition coil
All Starter
Al 2 Spark plugs
Bl Ignition switch
82 Windscreen wiper control switch
83 Windscreen washer and/or headlight wash/wiper pumpcontrol switch
84 Control switch for headlight, flashing, low beam and full beam
85 Horns control switch
B6 Direction lights indicator switch
B9 Heated rear window control switch
I311 Rear fog light control switch
812 Hazard lights control switch
B21 Right front power window control switch
822 Left front power window control switch
Electronic rev. counterClc 2 Electronic tachometerc 4 Fuel lwel gauge
C6 Coolant temperature gauge
c7 Clock
Dl Alternator charge warning lamp
02 Direction light warning lamp
03 Side light warning lamp
04 Full beam warning lamp
05 Brake fluid level warning lamp
D7 Hand brake warning lamp
08 Fuel reserve warning lamp
09 Choke warning lamp
Dll Engine oil min. pressure warning lamp
013 Engine coolant mBy. temperature warning lamp
El
Front direction indicator light lamp
E2 Front side light lamp
ES Low beam and full beam lamp
E9 Side direction light lamp
El 1 Rear direction light lamp
El3 Tail light lamp
El4 Reverse light lamp
El5 Stop light lamp
El6 Rear fog light lamp
El7 Number plate light lamp
F3 Passenger compartment roof lamp
F8 Air ventilation controls lighting lamp
F12 Cluster lighting lamp
F16 Ignition switch lighting lamp
F17 Switches lighting lamp
Gl Fusebox
HI Handbrake switch

May 1983

H2 Reverse light switch
H3 Stop light switch
H4 Roof lamp switch on passenger compartment pillar
HI 3 Choke switch
HI7 Brake fluid min. level control switch
H27 Contact switch, on rear door, for heated rear window
I2
Heated rear window relay,I3 Horns relay
14
Headlight wiper relay
I12 Front power windows relay
L2
L5
L6

Pressure switch for engine oil min. pressure
Thermostatic switch for engine coolant max.temperature
warning lamp
Thermostatic switch for engine cooling electric fan

L7 Transmirter for coolant temperature gauge
L9 Transmitter for fuel level gauge
L12 Engine oil level indicator
L13 Windscreen washer liquid level sensor
L14 Engine coolant level sensor
L17 Odometer pulse generator
Ml Cut-off solenoid valve
M4 Idle speed electromagnet
Nl Module for electronic ignition
N7 Trip Computer
N8 Check Control
NlO Passenger compartment roof lamp timer
Nil Door lock control unit
N13 Hazard and direction lights intermittence
N14 Windscreen wiper electronic intermittence
N16 Tachymetric control unit
N17 Trip control unit for fuel flow
N18 Electronic device for headlights and flashing changeover
01 Heated rear window
0 2 Horn
0 6 Cigar lighter
Windscreen wiper motor
PI
P2 Engine cooling electric fan
P4 Headlight wiper motor
P I 0 Right front door lock motor
PI1 Left front door lock motor
PI2 Right rear door lock motor
PI3 Left rear door lock motor
PI4 Right front power window motor
PI5 Left front power window motor
PI9 Windscreen washer electric pump
P20 Headlight washer electric pump
Cl1 Air ventilation heater fan
Q4 Air ventilation heater fan control
ai L.H.D. 1200 modela2 L.H.D. - R.H.D. 1350 modela 3 L.H.D. - R.H.D. 1500 modela4 L.H.D. - R.H.D. 1500 Quadrifoglio model

Alfawiki.nl
40-53

Alfawiki.nl

BODY-SHEET METAL PANELSCONTENTS
GENERAL INFORMATION., . . . . . . . .49-2

Symbology . . . . . . . . . . . . . . . . . . . . .49-21

Identification codes . . . . . . . . . . . . . .49-2

Removal and installation

Lifting points. . . . . . . . . . . . . . . . . . .49-3

procedures . . . . . . . . . . . . . . . . . . . . .49-22

Wheel alignment. . . . . . . . . . . . . . . . .49-3

Radiator core support . . . . . . . . . . . .49-29

BODY COMPONENT PARTS . . . . . . . . .49-5

Hoodledge panel with core

Body components . . . . . . . . . . . . . . . 49-5

support removed . . . . . . . . . . . . . . . .4g-31

Under body components . . . . . . . . . ,49-6

Hoodledge panel with radiator core

BODY CONSTRUCTION . . . . . . . . . . . .49-7

support removed (Partial

Body construction . . . . . . . . . . . . . . .49-7

replacement) . . . . . . . . . . . . . . . . . . .49-33

BODY SEALING . . . . . . . . . . . . . . . . . . .49-9

Front side member. . . . . . . . . . . . . . .49-35

Description. . . . . . . . . . . . . . . . . . . . .49-9

Central pillar . . . . . . . . . . . . . . . . . . . .49-37

BODY ALIGNMENT . . . . . . . . . . . . . . . .49-11

Outer side member. . . . . . . . . . . . . . .49-39

Measurement operations . . . . . . . . . .49-l 1

Outer side member (Partial

Measurement points. . . . . . . . . . . . . .49-l 2

replacement) . . . . . . . . . . . . . . . . . . .49-41

CAUTIONS FOR THE OPERATORS . . .49-14

Rear fender . . . . . . . . . . . . . . . . . . . .49-43

Safety rules . . . . . . . . . . . . . . . . . . . .49-14

Drip with rear fender removed. . . . . .49-45

Body and outer components

Lower rear panel . . . . . . . . . . . . . . . .49-46

protections. . . . . . . . . . . . . . . . . . . . .49-l 4Upper rear panel . . . . . . . . . . . . . . . . 49-47

Cautions during replacement

Rear part of rear floor with rear fender

operations . . . . . . . . . . . . . . . . . . . . .49-l 5

and rear panel removed . . . . . . . . . . .49-49

Cautions during welding operations . .49-l 5

Rear side member with rear panel

REPLACEMENT OPERATIONS . . . . . . .49-20

and rear floor removed. . . . . . . . . . . .49-51

How to read this chapter . . . . . . . . . .49-20

Roof panel. . . . . . . . . . . . . . . . . . . . . 49-52

Alfawiki.nl

May 1983

BODY -SHEET METAL PANELSGENERAL INFORMAi-ION

IDENTIFICATION DATA

Identification andcertification label

Chanis No.

Identification andcertification label

Identification and-certification label

Chassis no.

See Group 00 - Identification Data(according to CEE/ISO standard specifications)
See Group 00 - Identification Data

May 1983

49-2
Alfawiki.nl

BODY -SHEET METAL PANELSLIFTING POINTS

Front towing eye
and jack seat
Rear towing eye

1.

Jack and safety stands

Front axle and suspensionr
WARNING:a. After lifting the car by means of hydraulic jack,provide to support car weight by means of safety
stands.
b. Before lifting car rear (front) side place wheel chocks
by positioning them at front (rear) wheels.

Toe-out

Haif toe-zlut

M - H =4+1

(in)

M-.H =0.16*0.04mm

L = ‘12 lv-- 2 f 0.5(in)

L=1/2M -0.08f0.02
a=lof

Toe-out angle
Rim diameter

Securely position hydraulic jack and safety stands in the
points identified in figure.

WHEEL ALIGNMENTCAUTION:
The technicians assigned to the repair and replacement
operations of sheet panels, shall always take into account,content of the remaining part of the “Workshop Manual”
in order always to maintain original quality and functioning conditions of car as a whole. As restoration ofcar correct alignment is of particular importance, in thefollowing part are provided the data relevant to geometryof both front and rear suspensions. For any further
information, refer to the specific Groups.

mm

2.

mm

0=340

(in)

0= 13.39

Camber angle

fl=-295’f30’

Caster angle

y= l”f30’

Max steering angle

6 = 3350’

Rear axle and suspension

Toe-in angle

U=O”+25’

Camber angle

p=O”+25’

Wheel alignment is measured with cBr under nominal
height (see: Group 00 - Wheel alignment).

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49-3

May 1983

0
z

0
m

Alfawiki.nl

Alfawiki.nl

BODY -SHEET METAL PANELSBODY CONSTRUCTION
BODY CONSTRIJCTION

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49-7

May 1983

BODY -SHEET METAL PANELSBODY SEALINGDESCRIPTION

The following figures, show the body areas which aresealed by Manufacturer.
The scalings applied to these areas, must be smooth andfree from scratches or gaps.

possible sealing faults.
ICIR: Paraflex Alpha 3M
8531 IE
8536/ETake care not to apply too much sealing and not toallow other unaffected parts to come in contact with thesealing.

Alternative: part. no. 3522-00014

Sealant for bolted joints
Body components sealing

Sealant for joints between panels assembled by bolting.

Paint seal, after priming or painting, and then sleek bymeans of a brush along all sheet joints in order to remove

Alfawiki.nl
49-9

3M - Autosealer 8573E - part. no. 3522-00045

May 1983

BODY -SHEET METAL PANELS

View from L

View from I

Detail M

BODY ALIGNMENTMEASUREMENT OPERATIONS
Method of measurement operation.
When a tram tracking gauge is used, adjust pointers(A) and (B) to equal lenghts as shown in the following figure.
Check pointers and gauge itself in order to make surethat no clearance is present.

.

When a measuring tape is used, verify there is noelongation, twisting or bending.

If, during measurement qperations, tape interfere with
one or more parts of car body, accurate measurement of
distance and length will not be possible.

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49-11

May 1983

BODY - SHEET METAL PANELSMEASUREMENT POINTS

May 1983

49-12
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BODY -SHEET METAL PANELS

Alfawiki.nl
May 1983

BODY-SHEET METAL PANELS

2.
.

Outer parts protection
When removing external parts (hood, back door,
moldings, finishings) it is necessary to protect bodysurfaces with clothes, protection tape or otherI
Arm different
lengthmaterials, in order not to damage or scratch vehicle
body.

.

The scratched painted surfaces must be repaired: even
Maladjusted
electrodelengtha slight scratch may cause corrosion.
Align both electrod-

CAUTIONS DURING

CORRECTREPLACEME-NT OPERATIONSINCORRECTUse genuine spare parts.
.

It is recommended always to use genuine spare parts.
This allows perfect repair and restoration of vehicle
original functioning.

(3) Electrode end diameter
It is necessary to carefully verify diameter af electrodeends in order to obtain the required welding strength.
Before starting working, make sure that end diameter (D)has a value proportional to sheet thickness.
Remove burnt and foreign matters from electrode ends.

CAUTIONS DURING WELDINGOPERATIONS
Spot welding150°

1. Spot welder
Before starting welding operations, carry out the following checks in order to obtain welding sufficient strenght:

D=Zt i-3 (mm)(1) Welder arm adjustmenta)
Keep the arm as short as possible in order to obtainwelding maximum pressure.
b)

D= Electrode end diameter,t =Sh;thickny

Tighten arm and tips securely so as they do not getloose during soldering operations.

Spot welder a/m

2.

;

~

Condition and preparation of panels to be soldered

If the surface of the parts to be welded presents gap, paintfilm, rust or dust, this prevents welding current flow, thus
reducing soldering area and, as consequence, strengthof welding spot.
Before starting welding, verify conditions of the parts tobe welded, carrying out proper corrections.
(1) Clearance between the parts to be welded.
Presence of any clearance between surfaces to be welded,
causes reduction of current flow, The welding thus

Arm minimum
lenghtobtained, results to be insufficient and poor in strength,
Before carrying out soldering, match the surfaces and,
when necessary, tighten them by means of a clamp.

(2) Electrode alignment
Align ends of upper and lower electrodes. A misalignmentof electrodes generates insufficient pressure of soldering
points and, as consequence, an insufficient strength ofpoints themselves.

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49-15

May 1983

BODY -SHEET METAL PANELS(2) Electrode installment.
Operate such as sheet forms a tight angle with electrodes.
if not so, current flow will be low and the obtained
welding streng.ht insufficient.
(3) Welding of three or more overlapped sheets. In
the areas where three or more sheets are overlapped,
spot welding must be repeated.

INCORRECTINCORRECTCORRECT(2) Welding of metal surfaces.
Prepare the surfaces to be welded, removing all impurities
and foreign matters (paint, dust, rust) in order to obtain
perfect welding.

In casa three or more overlapped
sheets ara welded, repeat welding
twice.

(4) Number of spot welding points.
Generally, efficiency of spot welders available in the
Repair Shop is lower than efficiency of spot welders usedat the Factory. As consequence, the number of spot
welding points performed at the Service Shop should be
increased by 20 ” 30% with respect to weldings performedat the Factory.
(5) Minimum welding pitch.
The minimum welding pitch is function of thicknessof sheet to be welded. Generally, the values provided
in the following table, should be observed.
(3) Anti-corrosion procedure applicable to all metal
surfaces.
Coat the surface to be+ welded high conductivity
anti-corrosion agent. It must be applyed to end of
surface to be welded, also.

Preliminary operation

ThicknB (t)mm (in)Minimum pitch (I)
mm (in)0.6 IO.0241

10 (0.39) or more

0.8 (0.031)

12 (0.47) or mare

1.0 (0.039)

18 (0.71) or more

1.2 (0.047)

20 (0.79) or more

1.6 (0.063J

27 (1.06) or more

1.8 (0.071)

31 (1.22) or mom

Apply anti-corrosion agent
to the whole surface, end
included.

1
3. Cautions during spot welding(I) Spot welding selection
Use the direct welding method (for the parts this method
can not be applied to, use the MIG welding method).

May 1983

Alfawiki.nl

I

IBODY - SHEET METAL PANELSMIG welding
01
1f

1. Conditions of panel to be welded.
By means of belt sander or wire brush, remove any
foreign matter from surface.
Paint films, rust or oils present on sheet surface, causes

CORRECTIt must form an opening ofabout 3 mm dia., when stressing

decrease of welding strength, thus generating blow holes.
i2.

INCORRECTt(2) Test to be carried out after welding, by means ofchisel and hammer.
.
Insert tip of a chisel between the welded sheets andslightly tap on chisel until, between sheets, it isobtained a 3 to 4 mm clearance (0.12 to 0.16 in); if,on the welded part, no strain is present, test result is.

Cautions during welding operations.
establishedholes)
welding(ofpre(II Pluga) Make a hole, having 6 to 6 mm diameter (0.20
to 0.24 in) on one of the two sheets to be welded,
then match the two sheets and clamp them.
b) Position the torch at right angle with respect tosheet, then fill metal into the hole.
Each time welding is stopped, on the surface anoxide film generates which causes blow holes. If thisoccurs, remove oxide by means of a wire brush.
c) Make sure that welding between upper and lower
sheet is perfect.

then positive.
If sheets thickness is not equal, clearance between
sheets must be limited to 1.5 to 2 (0.059 to 0.079.

in).
Take into account that the above value is only areference one.
The mentioned clearance changes according ta
position of welding spots, flange length, welding
inclination and other factors.

Part around the hole

D O never exceed this limits in order not to cause
detachment of welding points.
.

After test,

make sure that the strained part is

Plug welding

I

Reference value: 3 to 4 mm
(0.12 to 0.16 in)Panel edge
Butt weldiirg

Slightly tap by meansof a hammerr Point to be weldad

Reference value: 1.5 to 2.0 mm(0.059 to 0.079 in)

SEC. A-A(2) Butt welding.
a)

By means of intermittent weld, tack the two surfaces
to be welded in order to prevent strains and align thetwo surfaces, then, fill in the spaces by placing small

Slightly tap by meansof a hammer

Mav 1983

welding beads.

49-18

Alfawiki.nl-.

BODY - SHEET METAL PANELSREPLACEMENT OPERATIONSHOW TO READ THIS CHAPTER
The formulation of the present part of the manual isuniform for all the replacement operations. For its structure, refer to the following example.

:I) HOODLEDQE PANEL WITH RADIATOR CORE SUPPORT REMOVED
carry c4lyII rwl~mml rmr R.dl.LM Em. swplrt km, bm ,,nm”,d,(Iv) REMINDER WHEN REM<
II) $u#lsl bl”~
- BY rm.“l 01 .iT SW, cut.nd. b” m*anl 0‘ .nr dir.-

In detail:(1) “HOODLEDGE. PANEL WITH RADIATOR CORESUPPORT REMOVED”
In the title it is indicated the element to be removed(hoodledge) specifying, if required, the operative
condition (in this case, radiator on core support
removed). If the element is not in the requiredconditions, it is necessary, to execute preliminary
removal of the other components; in the present case,
it is necessary to remove the radiator core support,
referring to the specific replacement procedures.
(II) “SERVICE JOINT”
Any information concerning the welding operations
to be carried out is shown in the figure indicating thewelding method and the spot numbers, together withaccurate location of spots on the elements to bejoined.
Example: a l

The parts Tepresented by chain line, set in evidence thecomponents which must result to be removed or forwhich it is required the preliminary removal, accordingly
to step (I 1.

(III)PARTS TO BE WELDED
A list is provided relevant to the components which
are to be welded using the methods indicated in step
(II).
(IV)REM~NDER WHEN REM~V~NG/INSTALLING
Indication is provided, relevant to the main operations to be carried out, with special care in identification of the areas concerned in the cut operations,selection of the equipments to be used and definitionof welding methods to be adopted.

3 -Welding spot number
Welding type (spot welding:see simbology on page 2 1)

LL Parts to be welded

May 1983

49-20
Alfawiki.nl

SYMBOLOGYBODY -. SHEET METAL PANELS

Spot welder

CUTTING AND WELDING/BRAZINGOPERATIONSThe symbology used for the cutting and welding/brazing
operations is shown in the following figures.

ed by means of air

CO2 arc weldingn n n nMIG plug weld

Cutting performed by means
myhTr air chisel..

m

MIG seam weld/point weld

Spot welding

l l l lSpot welding of two overlapped sheets@I @I@@

Spot welding of three overlapped sheets.the value in parenthesis 1..

Brazing1

indicates the number of weld spots

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May 1983

BODY -SHEET METAL PANELS

Welding - brazing(3) Cut-off damaged parts.
Tools required:.
Air saw.
Air chisel

Sealing

REMOVAL AND INSTALLATIONPROCEDURES(4) If welding spots are not visible, remove paint bymeans of rotary wire brush.
Tools required:

COMPONENT REMOVAL.

Rotary wire brush(1) Make sure that all the damaged parts have been
detected, by measuring the installation main dimensions.
Refer to ‘“Body Alignment” drawing.
Tools required:.
Centering gauge.
Tracking gauge.
lConvex rule
Rack-and-lever jack or car lift(2) With a body-frame repair system, carry out draw
operations, depending on deformation condition. Reuseof the reclaimable parts must be performed in accordancewith the figures contained in “Body Alignment”.
Caution during operation:.
Carefully secure drawing chains to body and equipment, so as to prevent accidental release during
operation execution.
.
Apply draw stress in the direction opposite tocollision.

May 1983(5) Punch all the welding spots in order to make centering of a drill.
Tools required:.
HammerlCenter punch

4 9 - 2 2 - -.
Alfawiki.nl

BODY -SHEET METAL PANELS

Caution during operation.
Punch deeply in the center of each, welding spot. A

III I -

Ill ‘inon-centered punch does not allow complete cut ofnugget. Besides, a shallow marked hole location does-I

flJ!lJ

not allow a reliable drive of drill.
As a rule, punching must be executed from sides of
the components that are to be removed.

.

Hole must have a diameter
below 8 mr nn 0.31
in1
I’

1

?

:i

E.g.: replace outer side member
leaving central pillar in its original position.

(7) By means of a chisel remove the remaining spot
welding parts.
Tools required:.
Chisel.

Hammer

PREPARATION FOR MATING PARTSINSTALLATION(6) Remove welding spots by means of a spot cutter oran air drill.

Tools required:.
Air sander

Tools required:.
Spot cutter.

(1) By means of a sander, grind sheet in correspondencewith welding spots.

.

Disc sander

Air drill

Caution during operation:.
Use a drill speed of about 1000 r.p.m. in order toobtain the best results.

Cautions when grinding
Take care not to cut much on base metal: this may
generate decrease of sheet thickness and, then,welding strength.

.

Cautions during operation:.
Take care not to drill mating parts. In case holes havebeen made, plug them making use of gas or MIG plug
welding.
Presence of holes, decreases strength of the concerned.

component, besides, it may generate water leakage.
When, for new components, are used holes alreadydrilled in welded parts (just as per those of the spot
welding) make use of a drilling machine having small
diameter drill (below 8 mm (0.31.in)) and complete
welding as soon as possible.

I

CORRECT’ INCORRECT

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49-23

May 1983

BODY -SHEET METAL PANELS

Carefully remove iron powder from the surfaceslwhich have been grinded and from surrounding areas.
Presence of iron powder, causes decrease of welding
efficacy and can also generate corrosion,(4) Apply primer to edges of new components andof body panels which are to be welded.

(2) By means of a hammer and dolly correct deformed
areas. ’Tools required:.
Hammerl

DOllY

Cautions during operation:.
Check against presence of even the smallest deformations, in particular, in the inner panels where
they are hard to be found. Infact, if they are notremoved, they can cause a strength decrease due tostress concentration.

Before welding apply conductive antirust paint on edgesof all sheet parts which are to be assembled.
Recommended paint:
Part. No. 3540-44401
SAVIU: Zincovid No. 7949
SCHRAM LACK: Extrinom Punktschweifarbe
GLASURIT: Glassomax 7 F 4625 (red color) **Carefully check meting parts of each pillar(3)

Remove paint from welding edges.

Tools required:.
Belt sander.
Disc sander

May 1983

To be used with catalyst
Glassomax Harter 965-7/l in the proportion 1 :I0(part. No. 3541-20003).

Panels must be welded within 15 minutes of the paintapplication (air drying time of paint film).
The film thickness after drying must be 0.005 to
0.025 mm. (2 to 9.8) 10s4 in.

49-24
Alfawiki.nl

BODY - SHEET METAL PANELSPREPARATION FOR NEW COMPONENTINSTALLATION(1) If a partial replacement is to be carried out, it isnecessary to maintain an overlapping tolerance of about
50 mm (1.97 in) during cut of non-usable sheets, in orderto have a sufficient mating surface.

Cautions during operation:
Remove paint from both sides of components thatare to be welded, such as the surfaces to be spot
welded, spot welding rims and edges of surfaces to be
butt welded.
The remaining paint, prevents current flow into spot
weldings, with consequent poor strength of spot. It.

Tools required:.
Air saw.
.
.

can also generate depressions in the plug MIG welding.

Hack saw
Tracking gauge
Convex rule (or equivalent)

It is recommanded always to use genuine spare parts. This
ensures a perfect repair and restoration of vehicle functioning.

(4) Apply primer to component and body surfaces
which are to be spot welded.
Tools required:.
Wire brush.

Conductive anti-rust paint(2) MIG plug weld.
This method must be used for those areas which can
not be reached by spot welder. To carry out this operation, drill, in the welding spots, making holes having 5 to
6 mm. (0.20 to 0.24 in) dia.
Tools required:.
Puncher.

Air drill

INSTALLATION(1) New service parts temporary installation.
Holes must have 5 to 6 mm
(0.20 to 0.24 in) dia(3) Remove paint from components to be welded.
Tools required:.
Belt sander.

Disc sander

Tools required:.
Vise pliers.
Convex rule.
Tracking gauge (sight).
Centering gauge.
Port power.
Jack.
Spot welder.
Mig welder

49-25
Alfawiki.nl

May 1983

BODY - SHEET METAL PANELS(3) Grind MIG welding by means of a sander machine.

Cautions during operation:.
Position components as per figures provided in “Body
Alignment”. Into body compartments, install the.

Tools required:.
Air sander .
.

movable parts (i.e. windscreen, doors, hood, backdoor) in order to carry out check of clearances,
grades and parallelism. If necessary, adjust sheets
until correct alignment is obtained.
Clamp parts to be welded by means of pliers andCl isc sandersome welding spot.

CORRECTINCORRECT

Cautions during operation:.
Take care .not to grind excessively on spot weldings:
it may generate decrease of sheet thickness and,.
(2) ExecuTion of the required weldings.

consequently, welding strength.
Remove iron powder from grinded surfaces andsurrounding areas.

Carry out welding complying with specifications provided
in “Cautions during Welding”.

Presence of iron powder, causes decrease of welding
efficacy and can also generate corrosion.

Tools required:l
Spot welder.
M IG welder.
Autogenous welder(4) After welding execution, remove clamps used for
securing edges and remove possible dinging.

May 1983

49-26

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BODY -SHEET METAL PANELS(7) For under body protection, apply a coat having 4 mm
(0.16 in) thickness:

Antidrum: part. No. 3523 + 00001
Alternatives: 3M
Body Plast 8874 E
Body Schutz 8864 E
WI Grey protective acrylic 854751(5) Apply anti-corrosion agent to the welded components.
(6) Apply sealer to joints.
This operation must be carried out carefully in order toprevent corrosion in the welded joints.
Refer to figures provided in “Body Sealing”.

m Area to he protected

49-27
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May 1983

BODY -SHEET METAL PANELS

May 1983

49-28
Alfawiki.nl

BODY - SHEET METAL PANELSRADIATOR CORE SUPPORT

Parts to be weldeda.

c. Radiator core support and hoodledge panel upper

Radiator core support and engine support lower crossmemberd.

Par-tRadiator core support and engine support lower crossmembere.

Radiator core support and hoodledge panelb. Radiator core support and hoodledge panel upper
pati

REMINDER WHEN REMOVING.
By means of air saw, cut along line A.

REMINDER WHEN INSTALLING.
By means of clamps, temporarily secure new radiatorcore support, then adjust it.

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49-29

May 1983

BODY - SHEET METAL PANELS.
lInstall parts temporarily
Check and adjust clearances, grades and parallelisms.

May 1983

49-30
Alfawiki.nl

BODY - SHEET METAL PANELSHOODLEDGE PANEL WITH RADIATOR CORE SUPPORT REMOVED
Carry out replacement after Radiator Core Support has been removed.

) Front

Parts to be weldedh. Upper hoodledge assembly and engine upper crossa. Upper hoodledge assembly and lower hoodledge
b. Lower hoodledge assembly and dashboard loweri.

Hoodledge assembly and engine upper cross member

1.

Hoodledge assembly and hoodledge side reinforce-

sheet
c. Upper hoodledge assembly and dashboard lower
sheet
Lower hoodledge assembly and side memberd.
Lower hoodledge assembly and side member
e.
f. Lower hoodledge assembly and front side member
g. Upper hoodledge assembly and engine upper crossmembermember(spring seat cap reinforcement)
ment
m. Hoodledge assembly, hoodledge side reinforcement
and engine upper cross membern. Hoodledge assembly, hoodledge side reinforcement
and engine upper cross member

REMINDER WHEN REMOVING. By means of air saw, cut according to lines A, B, D
and, by means of air chisel, cut according to line C.

Alfawiki.nl
49- 31

May 1983

BODY -SHEET METAL PANELSR EM I N D E R W HE N I N S TA L L I N G.

When are removed welding spots of the three over-g

Install together radiator core support and hoodledge
panel; then verify alignment dimensions concerning
hoodledge panel. Refer to drawings provided in“Body Alignment”.

lapped sheets drill the whole (welding spots are
identified by dimension line shown in the figure).
.

Carry out, from both sides, MIG plug welding ofdrilled sheets.

MIG welding

May 1983

49-32
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BODY -SHEET METAL PANELSHOODLEDGE PANEL WITH RADIATOR CORE SUPPORT REMOVED(Partial Replacement)
Carry out partial replacement after Radiator Core Support has been

removed.

Service joints

Parts to be weldeda. Upper part hoodledge and lower part hoodlege

REMINDER WHEN REMOVING. By means of air saw, cut according to lines A and B.

REMINDER WHEN INSTALLING
Precaution when cutting the spare half hoodledge panell

Cut spare half hoodledge
non-replaced panel part.

panel aligned with

Overlapping
tolerance

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49-33

May 1983

BODY -SHEET METAL PANELS

Dimension check and fender temporaneuous installation
L
Install together radiator core support, half hoodledge0panel and body.
Check alignment dimensions referring to drawings
provided in “Body Alignment”.

May 1983

49-34
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BODY -SHEET METAL PANELSFRONT SIDE MEMBER WITH HOODLEDGE PANEL REMOVED
Carry out replacement after Hoodledge Panel has been removed.
Service ioints

Parts to be weldeda.
b.

Plate and replaced side member
Plate and present side member

REMINDER WHEN REMOVING.
By means of air saw, cut according to line A in figure,in correspondence with the hole located on side
member.

REMINDER WHEN INSTALLING
Precaution when cutting spare side member.
l49-35
Alfawiki.nl

Cut spare side member aligned with n&-replaced side
member part.

May 1983

BODY -SHEET METAL PANELSCENTRAL PILLAR
Service joints

SECTION A-A

Parts to be weldeda.

Pillar and pillar inner reinforcement

C.

Outer pillar and inner pillarb.

Outer pillar and inner pillard.

Inner pillar and roof panel side memberl-Remove paint in correspondence with the four

REMLNDER WHEN REMOVING. Unscrew the two screws securing rib to roof panel

welding spots of pillar reinforcement lower part at
about 115 mm (4.52 in) from lower edge of outerside member (see sect. A-A).
Punch the four welding spots and remove the rein-

inner side member.
.

BY means of air saw, cut according to lines A and B,
shown in figure.

forcement pat-t.
By means of disc sander carry out grinding of contin-.

.

uous welding joining central floor side member @to inner central pillar @ _1 Reinforcement
2 Body side ring

3 Central floor side member
4 Inner central pillar
1

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49-37

May 1983

BODY - SHEET METAL PANELS.

REMINDER WHEN INSTALLING
Precaution when cutting spare pillar.
Cut spare pillar aligned with the upper and lower partof non-replaced pillar part.

By means of clamps, temporarily secure central pillar.
Check component alignment.
After continuous welding of central pillar, carry out.

tinning.
.

Temporarily secure both front and rear doors.
Check and adjust clearance, grades and parallelism.

.

I===T===
Overlapping 7
tolerance

I=F

Overlapping
tolerance

May 1983

49-38
Alfawiki.nl

BODY -SHEET METAL PANELSOUTER SIDE MEMBER
Service joints

Parts to be weldeda. Outer side member, front side member and inner
front pillarb.

Outer side member, diaphragm and central floor side
member

REMINDER WHEN REMOVING.
By means of air chisel, cut according to line A shown

c. Outer side member and closing inner central pillar
d. Outer side member and inner wheelarche. Outer side member and outer wheelarch
Outer side member and central pillar reinforcementf.

.

Remove paint in correspondence with the four
welding spots of pillar reinforcement lower part at
about 115 mm (4.52 in) from lower edge of outerside member (see section A-A).

in figure.

l

Alfawiki.nl
49-39

Punch the four welding spots.
By means of a drilling machine, remove welding spotsof the 3-layered sheet joints.

May 1983

BODY-SHEET METAL PANELSREMINDER WHEN INSTALLING
Precaution during cutting of outer side member.
Cut outer side member aligned with non-replaced
panel partl

The continuous welding areas of outer side member
to central, front and rear pillar, must be tinned.

I

Overlappine
tolerance

Welding indications.
Use the MIG welding method to weld the threeoverlapped sheets along the whole perimeter fromboth sides.

May 1983.

Apply anti-corrosion agent to boxed part inside.

49-40
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BODY -SHEET METAL PANELSREMINDER WHEN INSTALLINGn MIG welding

Precaution when cutting outer side memberl

Cut outer side member aligned with non-replaced
panels.

The continuous welding areas of outer side member
to central, front and rear pillar, must be tinned.

.

Apply anti-corrosion agent to boxed part inside.

Welding indicationl

Use MIG welding method to weld the three overlapped sheets along the whole perimeter from bothsides.

May 1983

49-42
Alfawiki.nl

BODY --SHEET METAL PANELS.dREAR FENDER
Service jointsbParts to be welded
a.
b.
C.

d.

e. Fender and floor
Fender and drip
Fender and upper rear panel
Fender and upper rear panel

Fender and outer wheelarch
Fender and inner wheelarch
Fender and inner fender reinforcement
Fender and outer wheelarch

f.
g.
h.

REMINDER WHEN REMOVING. By means of air chisel, cut the area shown in figure.

Take care not to cut frame of rear fender.

REMINDER WHEN INSTALLING
Precaution when cutting spare fenderl

Cut spare fender aligned with non-replaced panel
part.

Alfawiki.nl

49-43

May 1983

BODY --SHEET METAL PANELS

Fender temporaneous installation.
By means of clamps, temporarily secure rear fender.

.

The fender area of continuous welding to roof
panel side member, must be tinned.

Sealer application.
Apply sealer to wheelarch outer side.

.

Temporarily secure the adjacent components: doorand backdoor. Check clearances, grades and parallelism.

May 1983

49-44
Alfawiki.nl

BODY -SHEET METAL PANELSDRIP WITH REAR FENDER REMOVED
Carry out replacement after Rear Fender has been removed.
Service joints

Parts to be weldeda. Drip and rear fender inner frameb. Drip and rear panel,

REMINDER WHEN REMOVING. By means of air saw cut according to lines A and B
shown in figure.

REMINDER WHEN INSTALLING
Caution when cutting spare dripl

Cut spare drip aligned with the non-replaced drip
part.

Take care not to cut fender frame.

Alfawiki.nl
49-45

May 1983

BODY-SHEET METAL PANELSLOWER REAR PANEL
Service joints

Parts to be welded

a.
b.
c.

Cross member and rear panel
Cross member and floor
Cross member and side member

REMINDER WHEN REMOVINGl

By means of a saw, cut areas A and B taking care notto cut central area, mentioned in the figure, in order
not to cut floor in correspondence with spare wheel
compartment.

lPunch junction points of lower rear panel to rear
floor of spare wheel area.

Precaution during welding.
For the spot welding, make use of a brass wire.

I+1
Centml area

May 1983

49-46
Alfawiki.nl

BODY - SHEET METAL PANELSUPPER REAR PANEL
Service joints

Parts to be welded
a.
b.
C.

d.

Rear panel and drip
Rear panel and outer fender
Rear panel and outer fender
Rear panel and floor

REMINDER WHEN REMOVING.
BY means of air saw, cut according to line A.

REMINDER WHEN INSTALLING
l49-47
Alfawiki.nl

By means of clamps, temporarily secure the upper
rear panel.

May 1983

BODY - SHEET METAL PANELS.

Temporarily secure backdoor and check clearances,
grades and parallellisms.
Check correct positioning and alignment of bumper
to rear panel.

May 1983

Precaution during welding.
For the spot welding, make use of a brass wire.

49-48
Alfawiki.nl

BODY -SHEET METAL PANELSREAR PART OF REAR FLOOR WITH REAR FENDER AND REAR PANELREMOVED
Carry out replacement after .Rear Fender and both Lower and Upper Rear Panel have been removed.
Service joints
:

-4~ e

-6mb

1
s
F

Parts to be welded
a.
b.
C.

Rear floor and rear side memberd.

Rear floor, rear side member and inner rear wheelarch

Rear floor and rear side member
Rear floor and central cross membere.

Rear floor and rear seat cross member-Rear floor and outer fender

REMINDER WHEN REMOVING. By means of air saw, cut according to line A.

f.

.

By means of a drilling machine, remove welding spots
from the S-layered sheets joints.

Alfawiki.nl
49-49

May 1983

BODY - SHEET METAL PANELSREMINDER WHEN INSTALLING
Secure rear floor temporarily and carry out marking
along side member and cross member from floor
underside.
This easy drilling operation of the MIG welded spots.
In order to obtain the best welding result, make useof spot welder as far as possible.
Carry out holes for the MIG welding in the rear floor
where spot welder can not be used.
In rear floor installation, temporarily secure fenderand rear panel.
Check installation dimensions in accordance withdrawings provided in “Body Alignment”.
With the components temporarily secured, carry out
temporaneous MIG weldings in some points of rear
floor.

.
.

May 1983

Apply sealant to non-replaced surfaces of rear wheelarch and of floor, in accordance with “Body Sealing”.
Apply anti-corrosion agent to weldings under floor,then apply primer.

49-50
Alfawiki.nl

BODY - SHEET METAL PANELSREMINDER WHEN 4NSTALLINGl

After temporaneous securing of side member torear floor, carefully check dimensions provided in“Body Alignment”.

May 1983

49-52
Alfawiki.nl

BODY -SHEET METAL PANELSREMINDER WHEN INSTALLING. Before carrying out welding, apply the adhesive toljoints between roof and central rib.
.

May 1983

Apply sealant to the areas indicated in “Body
Sealing”.
Carry out tinning in the areas between roof and rearfender, which are continuous welded.

49-54

Alfawiki.nl

DOORSCONTENTSFRONT DOOR . . . . , . . . . . , _ . . . . . , M

Internal finishing panels . . . . . . . . . 55-7

55-2

Door assembly . . . . . , _ . . . . . , . . . .

Fixed glasses . . . e . . . . . . . . . . . . 1 _55-3Internal finishing panels . . . . . . , . . 55-3

Window regulator devices andWindow regulator devices andglasses . . . . . . . . . . . . _ . . . . . . _ _ . .

55-7

glasses . ” _ . . . . n . . . , . . . . . , , . . . .

55-7

55-3

Door locks and handles . . . . . . . . . .

55-8

Door locks and handles . . , . . . . . . .

55-4

Moldings and seals . . . . . . . . . . . . . .

55-8

Door mirror 1 . . . . . . . . . . : . . . . . . .

55-4

SERVICE DATA AND

Moldings and seals . . ..,.....,,..

55-4

SPECIFICATIONS. m . . ~ ~. . . m ~. . _ _ . .

REAR DOOR . . . . . . . . . , . . . . . . . . . .

55-6

Door assembly. . . _ d . . . . , . . . . . . ,55-7

Alfawiki.nl

55-9
Tightening torques . . . . . . . . _ . . . . 55-9

May 1983

DOORSFRONT DOOR

@II* 1

1

2
3
4
5
6
7
8
9
10
11
12
13
14

May 1983

Door
Door lock device
Lock block clamp plate
Lock block
HandleMolding and weatherstrip
Molding
Molding
Glass velvet seal with trim
Glass
Door mirror
Ring nut
RubberHinge

3 5 21(1.36+2.2
9.83 + 15.9)

15 Tie rod
16 Hinge
17 Window regulator device
18 Panel lower clamps
19 Seal
2 0 Sealing screen
21
Upper trim and weatherstrip
22 Door lock control
2 3 Panel
24 Window regulator handle
2 5 Arm rest
26 Power window switch (1500 and 1500 Quadrifoglio models)
27 Power door locks device (1500 Cluadrifoglio model)

55-2

Alfawiki.nl

DOORS

DOOR ASSEMBLYREMOVAL AND
INSTALLATIONWith reference to exploded viewproceed as follows:

screws, then remove it.
2. Remove ornament covering thedoor securing screws, then remove

panel @ to door. Remove panel
by bending it.
4. Remove plastic rivets securing

unscrewing the six screws, thenupper trim @ to door.
5. Remove hook of door lockcontrol rod. then remove uppert r i m @) ,la. Only for the 1500 and 1500
Quadrifoglio models.
Disconnect harness and then proceed

remove it.

window regulator handle @ .
3. Remove plastic rivets securing

1. Disconnect door from tie rod
a n d f r o m h i n g e s @ and @ b yremove it.

3. Unscrew the five nuts securingwindow regulator @ to door, thenas per step 1.

6. For upper trim and panel
installation, reverse order of removal.

WINDOW REGULATORDEVICES ANDGLASSES
2. For door installation reverse
order of removal and tighten screws
securing .hinges t o d o o r t o r h eprescribed torque.
@ : Tightening torqueScrews securing hinges to door

3a. Only for 1500 and 1500 Quadrifoglio models
Disconnect harness of window
regulator motor, unscrew the fivenuts securing power window @to door, then remove it.

REMOVAL AND
INSTALLATION
1. R e m o v e p a n e l@I uppertrim @I and sealing screen @ .

1 3 G-21 Ndm

2 . L o w e r g l a s s @j) c o m p l e t e l y ,unscrew
the two nuts securing(I .36 + 2.2 kg-m
9.83 + 15.9 ft4b)

w i n d o w r e g u l a t o r d e v i c e @ to
glass, then remove by rotating it.

INTERNAL FINISHINGPANELS
Cover end of the tool used forremoving plastic rivets in order not
to damage or scratch the body.

REMOVAL AND
INSTALLATION
4. Install window regulator andglass by reversing order of removal.

Lift ornament of arm rest @1.
and unscrew the three securing

Alfawiki.nl
55-3

May 1983

DOORS

DOOR LOCKSAND HANDLESREMOVAL AND
INSTALLATION@I upper

1. Remove panel
movesealing
trim @Iandscreen @ .
2. Lift glass @J completely inorder to avoid damage.
3. Remove plastic fasteners securing levers to door.

DOOR MIRROR
6. Withdraw clamp plate of lock
block @ by means of proper tooland remove lock block @.

REMOVAL AND
INSTALLATION
1. Remove panel @ and upper
trim @J _2. Withdraw rubber @I and unscrew the two screws securing mirror @I to door.
3. Unscrew ring nut 1
andremove door mirror 11 .
4. Install door mirror by reversing
order of removal.

O@

4. 1500 Quadrifoglio model-Release connecting rod between
lock @ and door lock electric
device 0 . To remove it, if necessary, disconnect harness, and unscrew the two nuts securing it todoor.

7. Unscrew the three screws securing lock @ to door then removelock.
8. Unscrew the two nuts securing
handle @to door, then remove
hand le.

UOLDINGS ANDSEALSCover end of the tool used tor
removing moldings in order not todamage or scratch the body.

REMOVAL AND
INSTALLATION
1. Operating as per figure, remove
molding with weatherstrip @.

5. Release connecting rod between
lock block @ and lock 0.

May 1983

9. Install handle and lock byreversing order of removal.
10. Verify proper functioning ofdoor opening control and, if necessary, loosen the three screws securing
door lock clamp and move it until
perfect closing is obtained.

55-4
Alfawiki.nl

DOORS

2. Remove molding 8 .
3. Remove panel 8 and upper
trim with weatherstrip @ .
4. Remove door mirror 0 .
5. Remove molding 7 .
6. Remove glass 8 0 and glass
velvet with trim 8.
7. Reposition moldings and seals
by reversing order 05 removal.
8. With reference to the following
figure take care to secure glass velvet
seal on clamp @ of glass guide 0
located inside the door.

CAUTION:
Apply proper grease to hinges, tie
rod and door lock device.

1 Glass guide2 Glass velvet seal clamp

Alfawiki.nl
55-5

May 1983

DOORSREAR DOOR

3 N-m
(kg+n
ftw

1
2
3
4
5
6
7
8
9
IO
11
12
13

May 1983

Door
SpacerOoor lock device
Rubbers
HandleFixed glass
Melding
Fixed glass guide
Molding
Glass velvet seal with trim
Glass
Molding and weatherstrip
Door lock control

14
16
16
17
18
19
20
21
22
23
24
25

Hinge
Window regulator device
Hinge
Panel lower clamp
Seal
Sealing screen
Upper trim and weatherstrip
Door lock control
Window regulator handle
Arm rest
Panel
Door lock electric device (1500 Duadrifoglio model)

55-6
Alfawiki.nl

DOORS

DOOR ASSEMBLY

2. Remove ornament covering thedoor securing screw, then remove

REMOVAL AND
INSTALLATIONWith reference to exploded viewproceed as follows:

window regulator handle @I _3. Remove plastic rivets securing
panel @ to door. Remove panel
by bending it.

1. Unscrew the four screws securi n g h i n g e s @ a n d I@ t o d o o r

4. Remove plastic rivets securing
upper trim @ todoor.

and remove it.
la. Only for the 1500 and 1500
Quadrifoglio models.

5. Remove hook of door lockcontrol rod,then remove upper

trim @ .

WINDOW REGULATORDEVICES ANDGLASSESREMOVAL AND
INSTALLATION
1.

Remove

panel

I@ ,

upper
19 .
2 . L o w e r c o m p l e t e l y g l a s s 81 1
trim @ and sealing screen

and windscreen the two nuts securing

Disconnect harness and then proceed

window regulator device to glass.

as per step 1.

3. Unscrew the three nuts securingwindow regulator @ to door andremove it from lower side by lifting
glass 0 .
2. For door installation reverse
order of removal, tighten screws
securing hinges to door to the

6. For upper trim and panel
installation, reverse order of removal.

prescribed torque:
0: Tightening torqueScrews securing hinges to door
13+21 N - m(1.36 + 2.2 kgam
9.83 f 15.9 ft.lb)

INTERNAL FINISHINGPANELS
Cover end of the tool used forremoving plastic rivets in order not
to damage or scratch the body.

FIXED GLASSESREMOVAL AND
INSTALLATION
1.
Removepanel @ , upperand lower completely
trim
glass 811 .
2. Unscrew the screw securing
fixed glass guide 8 to door, movesealing screen 19
and recover8

spacer 0.
3. Unscrew the screw securing
fixed glass guide @ to door frame.
4. Slightly detach the glass velvet
seal @I in correspondence with
fixed glass guide @ and remove

1. Lift ornament of armrest @6. Install fixed glass by reversing

Remove fixed glass guide @4.
and fixed glass @.
5. Remove glass 0 .
6. Install glass and window re-and unscrew the three securing

order of removal.

gulator by reversing order of re-

REMOVAL AND
INSTALLATION

guide.
5. Remove fixed glass.

screws, then remove it.

moval.

Alfawiki.nl
55-7

May 1983

DOORS

DOOR LOCKSAND HANDLESREMOVAL AND
INSTALLATION
1. Remove panel@f uppersealing
move
trim
@
and
screen @ .
2. Lift glass @) completely inorder not to damage it.
door lock control
3. Releaserod @) from door lock 0.

6. Only for 1500 Quadrifoglio
model
Release connecting rod between
lock @ and door lock electric
device @ _ To remove it, if necessary, disconnect harness and unscrew
the two nuts securing it to door.

MOLDINGS A N D
SEALSCover end of the tool used forremoving moldings in order not todamage or scratch body.

4. Unscrew from door the door
lock control rod @ securing screw
and remove it.

REMOVAL AND
INSTALLATION

7. Unscrew the three screws securing lock @ to door, then removelock.
8. Unscrew the two nuts securing
handle @ to door, then remove
handle.

1. Operating as per figure, remove
molding with weatherstrip @ .

9. I n s t a l l h a n d l e a n d l o c k b yreversing order of removal.
IO. Verify proper functioning ofdoor opening control and, if necessary, loosen the three securing screwsof lock clamp and move it .until
perfect closing is obtained.

2. Remove molding @ and @.
3. Remove panel @ and upper
trim with weatherstrip @ .
4. Remove fixed glass-guide 8 ,fixed glass @ and glass 11
8 .
6. Remove glass velvet seal withtrim @ .

5. Release from door the door
opening control rod.

May 1983

55-8
Alfawiki.nl

DOORS

6. Reposition molclings and seal by
reversing order of removal.
7. With reference to the following
figure, take care to secure glass velvet
seal on clamp @ of glass guide @located inside the door.

CAUTION:
Apply proper grease to hinges anddoor lock device.

1 Glass guide2 Glass velvet seal clamp

SERVICE DATA AND SPECIFICATIONSTIGHTENING TORQUES

N-m

kg.m

ft-lb

13421

1.36 + 2.2

9.83 f 15.9

Item

Screws securing hinges to front door
Screws securing hinges to rear door

I

13+21

Alfawiki.nl
55-9

I

1.36 + 2.2

I

9.83 f 15.9

May 1983

Alfawiki.nl

HOODS

HOOD POSITION
ADJUSTMENT

rod is positioned in the center ofhood lock slit by operating on
the two screws 0. Then,
temporarily tighten the lock.

Loosen the four screws securing
hinges to hood and move hoodforward, backward and side to side
until correct position is obtained.

1 Screws

2 Hood lock device
1 Hood2 Hood bumper.

With the hood lock temporarily
tightened to body, verify thathood bumper 0, located onhood 1 come in contact withbody 3 ; if not so, properlychange hood bumper heightby screwing or-unscrewing them.

8

CAUTION:.
During installation of hoodlock @ make sure that strikerl.
.

3 BodyFix hood lock by tightening
securing screws.
Verify proper functioning ofhood lock opening control.
Lubricate hood lock mechanismwith proper grease.

REPLACEMENT OF HOOD OPENING CONTROL CABLE
CAUTION:
In case of breakage of hood opening
control cable, it is possible to open
the hood by pulling the nylon-madeemergency cable @, lowted in the,passenger compartment inside.
1. Cut the cable in proximity tohood lock device @ and loosenscrew of sheath supporting bracke t @.
2. Operating from vehicle inside,
withdraw cable and sheath of hoodopening control lever 0.
3. Insert the new cable with sheathand secure it to hood opening
control lever.
1

Cable

2 Hood lock device
3 Cable retaining ring

Alfawiki.nl
56-3

4 Bracket
5 Hood opening control
6 Nylon-made emergency cableMay 1983

HOODS

6. If necessary, adjust sheath
position by operating on special
bracket @.

4. O p e r a t i n g f r o m e n g i n e compartment inside, insert cable 0 intoeyelet of hood lock @ and securecable end to cable retaining ring 0.
5. Verify functioning of hood

CAUTION:
Lubricate the cable with suitable

oil letting it slide into sheath.
.

Do not bend excessively cablesheath in engine compartment inorder to prevent opening stressincrease.

.

opening control.

BACKDOOR

1
2
3
4
6
6

Vibration-damper striker
Seal
Backdoor lock device
Shock absorber
Hinge
SupportBackdoor
Backdoor trim
Hinge
Shook absorber
Seal
Movable shelf

REMOVAL AND
INSTALLATION
Beforeremoval or

installation,

proceed as fol lows:.
Place a cloth or other padding

on backdoor corners in order toavoid damaging or scratchingvehicle body.

May 1983.

Provide a support for backdoor
to be used on removal fromshock absorbers.
lRelease the two cables supporting shelf under rear window.

For removal and installation of
backdoor, two operators are required.

56-4
Alfawiki.nl

13 Vibration damper striker
1 4 Badge
16 Label
16 Electric contactS
17 Backdoor striker

W ith reference to exploded view
above proceed as follows:

1. By means of a screwdriver drill,
remove the two rings securing rods ofshock absorbers @ and @I andwithdraw rods from their seat.

HOODSREPLACEMENT OF BACKDOOR OPENINGCONTROL CABLE
1. Cut cable @) in proximity to
backdoor lock device @ and loosenscrew of bracket @ sheath securing.

2. Operating from vehicle inside,
withdraw cable and sheath frombackdoor opening control lever 0.
3.

Insert new cable with sheath andsecure i t t o backdoor o p e n i n gcontrol lever.
4. Operating from luggage room,
insert cable 1 into eyelet of backdoor lock device @ and securecable end on cable retaining ring @ _0

5. Verify proper functioning of
backdoor opening control.
6. If necessary, adjust sheath
position operating on special bracket @.
CAUTION:.
Lubricate the cable with proper
oil letting it slide into sheath.
.
Do not bend excessively cable

1 Cable2 Backdoor lock device
3 Cable retaining ringMay 1983

4 Bracket
5 Backdoor opening control

56-6
Alfawiki.nl

sheath in the luggage room, inorder to prevent opening stressincrease.

INTERNAL TRIMMINGTRIM
ROOF TRIM

1

2
3
4
5
6
7
8
9
10
11

Roof
Taps
Sun screen
Sun screen
Passenger handle
Passender handle
Roof lamp
Passenger handle
Inside mirror support
Roof lamp
Inside mirror

REMOVAL AND
INSTALLATION

screws securing mirror support @.

to roof nanel and remove it.
sunscreens
5. RemoveBe careful not to stain roof.

0and @.
6. Remove weatherstrip of doors

With reference to exploded viewa n d o f backdoor in contact withabove proceed as follows:
1. Open protection of screws securing passenger h a n d l e s 0, @and @ to roof panel, unscrew themand remove handles,

pillar trim.
7. Remove roof trim @ andw i t h d r a w i t f r o m backdoor c o m -roof; move upper part of front

partment.
8. For installation, reverse order ofremoval.
C A U T I O N :For installation, it is recommended
to position roof trim starting from2.

By means of proper tool, remove

taps 0.
3. Disconnect harness and removeroof lamps @ and @I .
4. R e m o v e i n s i d e m i r r o r @) inorder to gain access to the t h r e e

May 1983

rear side and then use a cord toreposition windshield seal in its place(see: Group 75 - Windshield Installation).

66-2
Alfawiki.nl

1
2

Roof trim
Front righr

4

5

Cord
WindshieldpillarWindshield seal

6

Body

3

INTERNAL TRIMMINGFLOOR TRIM

Alfawiki.nl

INTERNAL TRIMMINGREMOVAL AND
INSTALLATIONWith reference to exploded view
above proceed as follows:
1. R e m o v e r e a r s e a t @, f r o n t
seats 0, rear console @, speed
level console @ and safety belt
@I and 0(seetheanchors
relevant paragraphs).
2. Unscrew the fourteen screws

4. Remove seals of front door
compartments in the part where they
cover floor trim and remove theadhesive tape strips securing trim tomaterial trim @ .
7. install floor trim by reversing
order of removal. After installing
handbrake cables, adjust it bybody.
5. Unscrew nut and lock nut offollowing procedures described inGroup 00 - Maintenance of Mechanicparking brake @ adjustment fork

Components and Body.

and withdraw the two cables frombracket 0.

securing kick plate @ to body andremove them.
3. By means of proper tool, withdraw plastic rivet securing to bodythe accelerator pedal end of travel 0; then remove it,

6 . R e m o v e f l o o r t r i m b y withdrawing it from parking brake and, if
necessary,removesoundproofing

CENTRAL PILLAR TRIM AND FRONT SAFETY BELTS

5

a*27 f
f 4 3(2.8 + 4 4.4.4
20.25 f 31.8)

1 Door opening seal
2 Door opening seal
3 Central pillar trim
4 Safety belt
5 Safety belr anchor on tunnel
6 Central pillar trim coverp::(2.8 +f

REMOVAL AND
INSTALLATIONWith reference to exploded viewand @ in the part where they cover

above, proceed as follows:

central pillar trim 0.

4. After removing protection, unscrew the screw securing safety

1. Move front seat completely
forward.

3.

belt @ anchor bracket to body.

2. Remove door opening seals @May 1983

Lift protection of screw securingsafety belt @ suppot~, unscrew it
and remove the support.

66-4
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INTERNAL TRIMMING

9. -Install safety belt and pillar trimby reversing order of removal. All theanchor safety belt screws, must be
tightened to the prescribed torque.
@ : Tightening torque
Safety belt anchor screws
27 + 43 N.m(2,s + 4,4 kg-m
20.25 + 31.8 ft-lb)
CAUTION:
If the vehicle is collided or overturned, replace t h e e n t i r e b e l t
assembly regardless of nature of
accident.

5.

By means of proper tool, remove

plastic rivet securing cover @ totrim @ and remove it.
6.
Removepillartrim@ bylifting it.
7. Unscrew the screw securingsafety belt @ retractor and removeit.

8. After removing protection, unscrew the screw securing safety belt
anchor 5 on tunnel and remove it.

0

FIXED PART TRIM
OF SHELF UNDERREAR WINDOW

3. Unscrew the screw securing tobody hinge @ of movable shelf,
and remove hinge.
4. Unscrew the two screws securing
to body the seat back clampings
device @ and remove it.
5. By means of proper tool, wirhdraw the two plastic rivets andunscrew the two screws securing
to body, trim @ of fixed part ofshelf under r e a r w i n d o w , t h e nremove trim.
1

Fixed part trim of shelf under fear
window
2 Movable shelf hinge
3 Seat back clamping device
4 Seat back fixed part

REMOVAL AND
INSTALLATIONWith reference to the exploded view
above proceed as follows:
1. Remove movable shelf underrear window.
2. Unscrew screw securing seatback fixed part @ to body, lift seat6.

back and remove it.

removal.

66-5
Alfawiki.nl

Install trim by reversing order of

May 1983

INTERNAL TRIMMINGREAR PILLAR TRIM

1 Back door seal

2 Rear pillar trim

3 Plastic cap
4 Door opening seal

REMOVAL AND
INSTALLATION
1. Remove door o p e n i n g s e a l @in the part where it covers trim 0.

2. Detach plastic cap
remove pillar trim 0.

@

and

3.

Install trim by reversing order ofremoval.

LUGGAGE ROOM SIDE TRIM

1
2

Luggage room side trim
Fixed part trim of shelf under rearwindow
3 Movable shelf hinge
4 Seat‘back clamping device
5 Seat back fixed part

REMOVAL AND
INSTALLATION
1. Remove seat back clamping
device @, seat back fixed part @and trim of fixed part shelf underrear window @ (see: Trim of fixed

2 . By means of proper tool, remove
plastic rivets securing side trim tobody, then remove it.

part shelf under rear window).

May 1983

66-6
Alfawiki.nl

3. Install side trim by reversing
order of removal.

INTERNAL TRIMMING(3) Remove plastic trims @REMOVAL AND
INSTALLATION

and @ .
(4) Unscrew the four screws securing to seat @ the seat back adjust-Take care not to stain seat and seatm e n t d e v i c e @J a n d h i n g e 0;

badk upholstery.

then remove seatback 0.

1eWith reference to the above exploded
view proceed as follows:
1. Move seat completely forward
and unscrew the two rear screws
securing guides @ and 0 tofloor.

(2) Remove guides by unscrewing
the four securing screws to seat @.

(5) Remove the four screws securingtrim(3) Install guides and control leverby reversing order of removal andtightening screws to the prescribed
torque.

2. Move seat completely backward
and unscrew the two front screwss e c u r i n g g u i d e s @ a n d I@ t ofloor.

@ : Tightening torqueScrews securing guides to seat
1 7 f 2 0 N.m(1.8 + 2.1 kg-m

@

to

seat

back

@

up-

holstery.
(6) Lift clamps securing seat back
upholstery, turn it inside out and lift
it until protections @ and @ ofseat back adjustment device @I
securing screws and of hinge @ areuncovered.

13.0 + 15.2 ft-lb)
5. If necessary, remove seat backadjustment device @ , hinge ~ 0,and seat back 0.
(1) Lift cover @ of seat backadjustment device @ .
( 2 ) K e e p i n g k n o b @ still, bymeans of proper plier, rotate counterclockwise the plate securing knob;
then remove it.

3. Remove seat together withguides, from car.
4. If necessary, remove guides @and 0 from seat.
(1) By means of proper tool, release
the seat turnover control lever @(7) Remove plastic protections @@I a n d u n s c r e w t h e f o u r
ands c r e w s s e c u r i n g t o seatback t h eseatback adjstment device and hinge;

from guides.

then remove them.

May 1983

66-8
Alfawiki.nl

INTERNAL TRIMMING@ : Tightening torque
Securing screws of seat backadjustment device and of hinge
17 + 29 N-m

7. Install seat on car by reversing
order of removal and tightening
screws securing seat guides to floor,
to the prescribed torque.

(1.8 + 3 kg-m

13 + 21.7 ft.lb)
6. If necessary, remove headrest byoperating on knurled part as shownin figure.

@ : Tightening torqueScrews securing seat guides tofloor
IO+11 N-m
(1.1 + 1.2 kg-m
8 + 8.7 ftdlb)(8) For installment reverse order ofremoval. Tighten the screws ofseatback adjustment device and of
hinge to the prescribed torque.

REAR SEATS

1 Seat2 Seat back fixed part
3 Seat back
4 Shelf under rear window fixed part
5 Seat back clamping device
6 Luggage room and seat back trim
7 Seat back8 Seat back hinge

Alfawiki.nl
66-9

May 7983

INTERNAL TRIMMING

4. Unscrew nut securing seatback @ to body @ and remove it.

REMOVAL AND
INSTALLATIONTake care not to stain seat and seatback upholstery.
1. Lift and remove seat.
2. Unscrew the screw securing to
body@ the seat back fixed
p a r t @ then lift seat back andremove it.

1 Seat back fixed part2 Seat back3 Body4 Door compartment seal
3.

By means of proper tool, with-draw plastic rivets securing luggage
room

upholsteryto seat back.

1 Seat back2 Kick plate
3 Door compartment seal
4 Body5. Carry out same procedure forremoval of the other seat back.
6. Install seat backs and seat, by
reversing order of removal.

CONSOLESREAR CONSOLEREMOVAL AND
INSTALLATION
1. Remove rubber bellows locatedon parking brake.
2. Remove ashtray, which is pressure secured.
3. Unscrew the screw securingconsole and remove it by moving it
first forward in order to withdraw
it from clamp located on floor
tunnel.

1 Rubber bellows 3 Ashtray
2 Console

4.

Install console by reversing orderof removal.

May 1983

66-10
Alfawiki.nl

INTERNAL TRIMMING

CE:NTRAL CONSOLE

May 1983

66-12
Alfawiki.nl

INTERNAL TRIMMING

i. Unscrew the four screws secur-

REMOVAL AND
INSTALLATION

ing heater control assembly @ toconsole 0.
8.

Remove the four screws securingconsole @ to dahsboard.

CAUTION:.
groundDisconnect
battery
cable.
.
Before removing the components fitted with harness,make sure that relevant connections have been disconnected.
5. By means of proper tool, remove
finisher 0.

With reference to exploded view

above proceed as follows:

1. Remove by pulling, knobs @and @ of heater control assembly.
2. Detach finisher @I and disconnect harness of clock @ , lighters e a t @ and lamp 0 .
3. Remove finisher @I .

4.

If necessary, remove lighter
unscrewing
ring
seat
@ by
nut @ and withdrawing bush @and ornament @ .

,l/rE==ilh6. Disconnect

harnessofs w i t c h e s 0, @, @ a n d @:then remove finisher 0.

Alfawiki.nl
66-13

0 being
9. Remove console
careful during lamp @ and harness
removal.
10. Install console and its components, by reversing order ofremoval.

May 1983

INTERNAL TRIMMINGDASHBOARD

May 1983

66-14
Alfawiki.nl

INTERNAL TRIMMING

5.

REMOVAL AND
INSTALLATION

By means of proper tool, remove

ornaments @ and @ .
6. By means of proper tool, remove
finisher @ of duct @ and unscrew
the two screws securing dashboard @ to body.

CAUTION:.
Remove battery ground cable.
.
Before removing the components fitted with harness, makesure that relevant connections
have been disconnected.

7. Unscrew the seven screws securing dahsboard @ and @ to body.
With reference to explbded view
above proceed as follows:
Remove central console (see:1.
Central Console).
2. Remove steering wheel andcolumn shell covers (see: Group 23 Steering Wheel and Column).
3. Remove cluster 0 .
(1) Unscrew the four screws securing cluster 0 to support bracket@.
-\/I
Low view

CAUTION:To remove the whole dashboard, two(2) Open cover@ pressure inset-ted, disconnect harness; thenremove cluster 0 .
4. Operating as per figure, remove
spring securing center ventilationd u c t @ control cable to heater
control assembly.

operators are required.

8. R e m o v edashwholetheboard @ and @.
9. If necessary, disassemble dashb o a r d c o m p o n e n t s @ and @.
(1) By means of a drilling machine
fitted with suitable drill, countersink
the four rivets securing upper dashboard @ to lower dashboard @.

Alfawiki.nl
66-15

May 1983

INTERNAL TRIMMINGSERVICE DATA AND SPECIFICATIONSTIGHTENING TORQUE

Unit
kg-m

N-m

ft.lb

Item

CENTRAL PILLAR TRIM AND
SAFETY BELTS
Safety belt anchor screws27+

2.8 + 4.4

43
I

20.25 + 31.8
I

FRONT SEATS
17 + 20

1.8 + 2.1

13 fdevice and of hinge

17 + 29

1.8 +. 3

13 + 21.7

Screws securing seat guides to floor

10 +

1.1

8 + 8.7

Screws securing guides to seat

15.2

Securing sraws of seat back adjustment

11

Alfawiki.nl
66-l 7+1.2

May 1983

EXTERNAL TRIMMINGCONTENTSFRONT BUMPER . . . . . . . . . . . . . . . . .
REAR BUMPER . . . . . . . . . . . . . . . . . .

75-2
75-3

DRIP COVER MOLDING . . . . . . . . . . . 75-4
GRiLLE . . . . . . . . . . . . . . . . . . . . . . . . 75-5
COWL TOP COVER . . . . . . . . . . . . . . . 75-6

Alfawiki.nl

G LASSES . . . . . . . . . . . . . . . . . . . . . . .
Windscreen . . . . . . . . . . . . . . . . . . .
Rear window . . . . . . . . . . . . . . . . . .

75-7
75-7
75-9

SPECIAL SERVICE TOOLS . . . . . . . . . 75-l 1

May 1983

EXTERNAL TRIMMINGFRONT BUMPER.

4 Fog light
5 fog light

1 Bumper2 Bracket
3 Bracket

REMOVAL AND
INSTALLATIONWith reference to exploded view
above proceed as follows:
disconnect fog
1.
If
present,
light @ and @ harness.

3. Unscrew the four screws securing brackets @ and @ to sills.

2. Operating from engine compartment inside, disconnect harnessof the two electromagnetic horns,
unscrew the nut securing each hornt o b r a c k e t , a n d remove horns.

5. Remove bumper and, if neces4.

Unscrew the two screws securing

bumper to fenders.

May 1983

75-2
Alfawiki.nl

sary, disassemble fog lights.
6 . C o n n e c t b u m p e r t o b o d y byreversing order of removal.

EXTERNAL TRIMMINGREAR BUMPER

1 Bumper2 Bracket
3 Bracket

4 Bracket
6 Nuts6 Bracket

REMOVAL AND
INSTALLATION
W ith reference to exploded view
above proceed as follows:
1. Lift luggage room upholsteryand rear trim.
2. Unscrew the four screws securing bumper brackets @ and @ tobrackets @ and @.

\3. Unscrew the two screws securing
bumper @ to body.

6. Install bumper, by reversing
order of removal.

4. Remove bumper.
5. If necessary, unscrew the eightscrews securing brackets @ and @)to rear floor.

75-3

Alfawiki.nl

May 1983

EXTERNAL TRIMMINGGRILLE

3 Hood4 Screw

1 Badge
2 Grille

4. Install grille by reversing orderof removal.

REMOVAL AND
INSTALLATIONWith reference to exploded view
above proceed as follows:
1. Open hood completely removing
it from stay.
2. By means of a magnetic screw-

CAUTION:.
Be careful not to exert excessive
force during operations, as grilledriver, unscrew screw @ securing.

grille @ to body.
3. Remove grille, by means ofis made of plastic.
Take care to keep oil away fromgrille.

suitable wooden tool.

Alfawiki.nl
75-5

May 1983

EXTERNAL TRIMMING

COWL TOP COVER

5 Windscreen washer pipings
6 Windscreen wiper arms
7 Sprayers

1 cowl top cover
2 Windscreen seal

3 Plastic nut screw
4 Seal rubber

I
i
1
I

With reference to exploded view
above proceed as follows:
1. Open hood and remove seal @.
2.
Lift protections of nuts securing
wiper arms @, unscrew the relevant
screws; then remove wiper arms.
3. By means of proper tool, remove
the five springs securing cowl top

tected by a cover, securing cowl top
cover @ to body; then lift cowl.
5. Disconnect windscreen washer\\

cover 0 to body.

May 1983

4. Unscrew the two screws, pro-

\
I

7566
Alfawiki.nl

p i p i n g s ($ s e p a r a t i n g t h e m f r o msprayers @ w h i c h a r e p r e s s u r einserted into cowl top cover, thenremove cowl top cover.

6.

Install cowl top cover by revers-

ing order of removal.

EXTERNAL TRIMMINGREMOVAL
With reference to exploded view

remove, by means of proper tool

above proceed as follows:ornament 0.
3. Remove door opening seal @1. Remove wiper arms @ andmove cowl top cover @ forward(see: Cowl-Top Cover).
2. Operating from vehicle inside,

6. Carefully pull upper part ofwindscreen, remove it from body,then remove it completely.

INSTALLATION
For installation, two operators are
required.

May 1983

p i l l a r t r i m 0, then remove it.
5. Operating as per the following
figure, set end of tool A.9.0051 out

in the part where it covers pillarof every 10 cm (4 in), starting fromtrim 0.
4. By means of proper tool, remove

centre of windscreen upper rim;
between body and windscreen seat.

CAUTION:
By means of silicone, lubricate rim ofwindscreen weatherstrip in order toallow an easy insertion of weatherstrip on body.

Alfawiki.nl

1.

Into weatherstrip rim 0, insert

two cords (A and B) arranged as per
figure in order to allow repositioningof weatherstrip @ on body.

EXTERNAL TRIMMING

Rest windscreen on lower side of
ito seat into body and verify it isproperly centered with weatherstrip @ mounted on lower side,only.
3. Slowly pull first cord startingfrom upper rim and follow positioning of weatherstrip rim by slightly
tapping, with the hand, on windscreen from outside.
4. Repear same operation withsecond cord until complete installation of windscreen.
5. Carry out installation of pillar
trim, of door compartment seal andof ornament, by reversing order ofremoval.
6. Install cowl top cover and wiper
arms.
2.

1 Roof trim
2 Windscreen seal weatherstrip
4
3 Right Cord front pillar

56

Windscreen Body

REAR WINDOW

1 Rear window

3 Backdoor
4 Movable shelf

2 Rear window
weatherstrip

Alfawiki.nl
75-9

May 1983

EXTERNAL TRIMMINGREMOVAL
With reference to exploded view
above proceed as follows:
1. Open back door and release thetwo cables supporting shelf @under rear window.
2. Disconnect electric cables ofheated rear window.
3. Operating as per the following
figure, set end of tool A-9.0051 out

INSTALLATIONCAUTION:
Do not damages filaments of heatedrear window with tool A.9.0051.

For installation; two operators are
required.

4. Carefully pull upper part of rearwindow, release it from back door
and remove.

CAUTION:
By means of silicone, lubricate rim ofrear window weatherstrip in order to

May 1983

Alfawiki.nlof every 10 cm (4 in), starting from
center of rear window upper rim,
between back door @ sheet andrear window weatherstrip seal 0.

allow an easy insertion of weatherstrip on body.
1. Into seal rim @ inset-t two
cords (A and B) arranged as per
figure in order to allow repositioningof weatherstrip on back door.

Alfawiki.nl

AIR VENTILATIONCONTENTSWIRING DIAGRAM . . . . . . . . . . . . . . . 80-2
AIR VENTILATION UNIT a. .,. . . , . . . 80-3
Removal and installation . . . . . . . . . 80-4

Heater fan switch . . . . . . . . . . . _ _ . 80-5
TROUBLE DIAGNOSIS AND
CORRECTIONS . . . . . . . . . . . . . . . _. . 80-5c:
Alfawiki.nl

May 1983

HEATER.-WIRING DIAGRAM-~

G1.5

r
i
I
I@
I
I
B
I---d
M I

111213141

I I,i,i 1

I1

G1,5

A l Battery
El Ignition switch
84 Control for headlight, flashing, low beam and full beam
F8 Air ventilation control lamp
G I Fusebox
Ql Air ventilation heater fan
Q4 Air ventilation heater fan control(IV - Low speed)(2V - High speed)

May 1983

80-2
Alfawiki.nl

HEATERAIR VENTILATION UNIT

2
3
4
5
6
7
8
9
10
11
12
13
14
15

Alfawiki.nl
80-3

Air ventilation unit shell covers
Heater fan
Door
Air ventilation unit controls
Door
Air ventilation unit shell covers
Heater core
Door
Outer air duct frame
Outer air duct
Incoming air intake nozzle
Center ventilation duct
Air ventilation unit
Engine compartment cross member
Liquid delivery pipings

May 1983

HEATERREMOVAL AND
INSTALLATION

5. Loosen metal clamps securing(3) Separate the two shell cov-

then remove pipings.

ers 0 and @.
(4) If necessary, with reference toexploded view above, release control
cables of doors @ and @ b y
operating with suitable wrench on
the screw securing levers to door
hinges as shown in figure.

CAUTION:.
Remove battery ground cable.
.
Before removing components
fitted with harness, make sure
the relevant connections havebeen disconnected.
.
Be careful when removing air
ventilation unit pipings, otherwise liquid leakages from heatercore may occur.
With reference to exploded view
above proceed as follows:
1. Remove lower finisher of central
console and unscrew the four screws
securing air ventilation unit controls @ to console (see Group 66 -(2) Remove or cut seals.

pipings @ to air ventilation unit;

6. Unscrew the two screws securing
f r a m e @ of ourer air duct @ toair ventilation unit; then remove
both.

Central Console).
2. Unscrew the four nuts securing
air v e n t i l a t i o n u n i t @) t o b o d y .

Door hinge
Lever
Door control cable
Screw(5) If required, disassemble components o f a i r v e n t i l a t i o n unit
controls operating as per figure.

7. Carefully withdraw air ventilation unit and air ventilation unit
3. Operating from engine compartment inside, disconnect harnessof heater fan 0.
4. By means of two terminals,
clamp liquide delivery pipings @to air ventilation unit 0, in orderto prevent leakages.

controls a.
8. If necessary, disassemble air
ventilation unit
in order to gain
access to its inner components.
(I) Operating as per figure, remove
the eight springs keeping together
shellcovers0 and @ of air
ventilation unit.

If necessary, o p e r a t e o n a i rventilation unit components present

9.

in the dashboard by following
the indications provided in Group 66- Dashboard.
10. Install air ventilation unit byreversing order of removal.

May 1983

80-4
Alfawiki.nl

HEATERHEATER FAN SWITCHCAUTION:.
.After restoring hydraulic connection, it is necessary to top up
header tank of engine coolingsystem.
.
Lubricate air ventilation unit
control cables by means ofproper oil.

I
E

I

I
l

LOCATION
The switch is located in the lower
ornament of central console (see:Group 66 - Consoles).

CHECK
Check switch proper functioning byverifying that continuity between
terminals occurs in compliance with
the indications provided in table.

TROUBLE DIAGNOSIS AND CORRECTIONS
Probable cause

Corrective action

Cooling water temperature too low

Check thermostat: replace if necessary

Condition

Insufficient heating performance(No heated air flow to ducts)b

D Heater care pluggedlInsufficient cooling water level

I Malfunctioning air mix door

Insufficient air flow to floor

Clean heater
RefillCheck door and adjustlBlower motor speed too lo w

Check blower motor and:-- restore poor connections- replace blower motor if necessarylMalfunctioning air floor door

Check door and adjust

Malfunctioning door control

Check control and adjustlInsufficient defrosting performance (Cold air to ducts)

Refer to “No heated air flow to ducts”

Insufficient air flow to defroster(Refer to: Group 66 - Dashboard)lBlower motor speed too low

Check blower motor and:- restore poor connections- replace blower motor if necessarylMalfunctioning air main duct door

Check door and adjustlMalfunctioning door central

Check door control and adjustl

Bad cable sliding

AdjustlControl cable bent excessively

Correct

Control lever dragsl . Air intake door not operate

Check and adjust

properly

Noise from blower motorlLoose bolt in blower motor? Broken blower blade(s)Alfawiki.nl
80-S

Check and tighten
Replace blower

May 1983

Alfawiki.nl