ALFA ROMEO 164 - Service Manual
Contents
1. for not experlenced operators Special attention is needed when working with spring or tension loaded fasteners and devices as clips etc as careless removal may cause personal Injury The catalytic converter reaches a high tempera ture during operation Never touch the catalytic converter unless ade quate protective equipment has been previously worn gloves etc Do not approach any easily llammable material to the catalytic converter Care should betaken when working on air condi tlong system fluid FREON Operate in a ventilated area disposing Freon In an appropriate collecting system a great amount of Freon In a restricted area can re duce the oxigen quantity thus causing soffo cation Pa ant haat Crann ahauva ES Off 498 OE dl maw http alfalover dhs 0rg 164 Sm7a0a11 jpg 1 of 2 2002 02 16 22 27 44 AS Freon should never come in contact with metal surfaces because It can cause oxida tion specially if combined with water e At ambient temperature and pressure freon evaporates quickly and therefore freezes whatever comes in contact with it avoid contact with skin or eyes Some fluids such as brake cluch fiuid or cool ant mixture may damage the paintwork Do not disperse used engine oll in the ambient Investigate where used oll Is safely collected In your area Lift properiy the vehicie Use recommended elevators and follow the safety regulations Block wheels with suitable safe2. installation and reassembly procedures are nor mally obtained reversing the order of the removal and disassembly procedures Specially marked notes headline some peculiar sieps Installation and reassembly are described and illustrated in a specific paragraph only when completely different http alfalover dhs org 164 Sm7a0a06 jpg 1 of 2 2002 02 16 22 25 38 http alfalover dhs org 164 Sm7a0a06 jpg VI http alfalover dhs org 164 Sm7a0a06 jpg 2 of 2 2002 02 16 22 25 38 http alfalover dhs org 164 Sm7a0a07 jpg INTRODUCTION 154 SYMBOLOGY s Many special symbols are largely used in this manual for gt exhaust a quick reference and localization of data warming and caution notes etc A Kar A complete list of symbology herein used is below ilus A trated O ih screw n i removal disassembly sl tightening iorque with oil i 9 m installation reassembly ES engine idie R P M tighten io torque O j ovalization D N squeeze the nut i taper El adjustment setting eccentricity EB os E visual inspection check L flatness a lubricate L diameter 4 A SE ee o weight difference linear dimension wc angular value ZA parallelism pressure E smear with grease E E temperature E heat up temperature bk om brake system air bleeding _ sealing plugging By ml surface to be machined o fill up with engine oli E inierference i grease H H ef clearance
3. lbs 0 113 Nm 1 HP SAE 1 0141 CV http alfalover dhs 0rg 164 Sm7a0a10 jpg 1 of 2 2002 02 16 22 27 16 The relevant conversions are herewith reported UNITS OF MEASURE CONVERSION TABLE S I gt American C 5 9 F 32 1 liter 0 27 gals 1 cm 0 061 cu in 1 m 35 336 cu in 1N 0 225 lbs imm 0 03937 in im 3 281 ft im 1 094 yards 1km 0 621 miles 1 kPa 0 145 psi 1 kPa 0 296 in Hg 1 Nm 0 73756 ft lbs 1 Nm 8 851 in Ibs 1 CV 0 986 HP SAE http alfalover dhs org 164 Sm7a0a10 jpg http alfalover dhs org 164 Sm7a0a10 jpg 2 of 2 2002 02 16 22 27 16 18 http alfalover dhs org 164 Sm7a0a11 jpg INTRODUCTION Workshop shuold be equipped with ali satety equipments as fire extinguishers etc Workshop safety rules must always be carried out without any exception When acting on fuel system carefully follow the instructions below e Disconnect battery negative lead Store fuel drained from ithe system into a sultable contalner with safety cap e DO NOT SMOKE if electrical components are involved in proce dure disconnect first the battery negative lead Care should be taken especially when working on the H cables of the ignition system Contact of oll or solvents with engine belts could affect elasticity rubber and cause dangerous slipping cf belts The engine compariment locates many hot and or rotating parts which could result dangerous
4. play x WARNING a IN http alfalover dhs 0rg 164 Sm7a0a07 jpg 1 of 2 2002 02 16 22 25 47 http alfalover dhs org 164 Sm7a0a07 jpg 1 intake E CAUTION VII http alfalover dhs 0rg 164 Sm7a0a07 jpg 2 of 2 2002 02 16 22 25 47 http alfalover dhs org 164 Sm7a0a08 jpg INTRODUCTION MAINTENANCE PHILOSOPHY Ali work must be performed with maximum care and attention In order to avold injury to personnel and vehicle s damage The service procedures recommended and described in this publication were developed for professional service personne and are effective methods for performing vehicle repair Following these procedures will help as sure efficient economical vehicle performance and serv ice reliability Some of this procedures require the use of special tools designed by Alfa Romeo improper or makeshift tools can damage the parts involved Toloosen tight fitting cast iron parts just lightly strike them with a lead or alluminum hammer lor light alloy parts use a wodden or plastic mallet On disassembly check if parts that should be marked do in fact have the relevant number or reference stamped on it On reassembly lubricate parts where necessary to prevent seizure during their running in period Suitably protect with adhesive tape or clean cioths all engine parts that after disassembly show orifices or drilling which are likely to let in dust orforeign matter In reassembly
5. ALFA ROMEO 164 Service Manual 164 Service Manual Page H D U U w O nl Jo U PU w p D D Di vi 7 U V D U w V DO D D mo ioo o SERVICE MANUAL 1991 1993 164 att moves 50 STATE AND CANADA VERSION ALFA ROMEO DISTRIBUTORS NORTH AMERICA http alfalover dhs org 164 alfa21b html 2002 02 16 22 24 32 http alfalover dhs org 164 Sm7a0a00 jpg SERVICE MANUAL 1991 1993 164 aL mopers 50 STATE AND CANADA VERSION ALFA ROMEO DISTRIBUTORS NOATH AMERICA http alfalover dhs org 164 Sm7a0a00 jpg 2002 02 16 22 24 44 http alfalover dhs org 164 Sm7a0a01 jpg 184 FOREWORD This manual contains service maintenance and repair information for all Alfa Romeo 164 model year 1991 USA and CANADA versions it supplies the service personnei with ali information necessary to ofier any Alfa Romeo customer a fast and precise vehicle service in any circumstance it includes procedures concerning removal and instaliation disassembly and reassembly checks and inspections all operation are extensively illustrated for an easy identification of involved parts as well as proper tools to be used Symbols are used to headlight important operations as lubrication or proper tightening Refer to the symbology tabie in the Introduction paragraph Ali data needed for adjustments and dimensional checks are bold written and quickly found throughout
6. e system s characteristics The vehicles not conforming to specified ex haust emission data because misadjusted or non properly tuned up will possibly be non contorming to the law requirements and aiso have a higher fuel consumption On this vehicle Is Installed a driver s side air bag system special care should betaken on working on this system to avoid unintentional activation When working on any electrical system In the air bag deployment zone driver s seat area dis connect the battery and remove the air bag module from the steering wheel You may then reconnect the battery if necessary for electrical diagnosis For all details reter to Group 00 and WIRING DIAGRAMS AND ELECTRICAL DIAGNOSIS Book http alfalover dhs org 164 Sm7a0a09 jpg explode http alfalover dhs org 164 Sm7a0a09 jpg 2 of 2 2002 02 16 22 27 03 http alfalover dhs org 164 Sm7a0a10 jpg UNITS OF MEASURE Measurements given in this manuai are expressec in TEMPERATURE CAPACITY WEIGHT LENGTH PRESSURE or STRESS TORQUE POWER INTRODUCTION 154 international System units S l However Commomon American Units of measure are indicated American gt S l F 9 5 C 32 1 gal 3 7 liters 1 cu in 16 387 cm 1 cu ft 0 028 m 1 Ib 0 453 kg 1 Ib 4 444 N 1 in 25 4 mm 1 f 0 305 m 1 yard 0 914 m 1 mile 1 609 krn 1 psi 6 895 kPa 1 in Hg 3 377 kPa 1 ft lbs 1 356 Nm 1 in
7. empera ture during operation Never touch the catalytic converter unless ade quate protective equipment has been previously worn gloves etc Do not approach any easily flammable material to the catalytic converter Care should be taken when working on air condi tlong system fluid FREON Operate In a ventilated area disposing Freon In an appropriate collecting system a great amount of Freon in a restricted area can re duce the oxigen quantity thus causing soffo cation Do not heat Freon above 52 C 125 F It may http alfalover dhs org 164 Sm7a0a09 jpg 1 of 2 2002 02 16 22 27 03 Freon should never come in contact with metal surfaces because it can cause oxida tion specially If combined with water e At amblent temperature and pressure freon evaporates quickly and therefore freezes whatever comes in contact with it avoid contact with skin or eyes Some fluids such as brake ciuch fluid or cool ant mixture may damage the paintwork Do not disperse used engine oll In the ambient Investigate where used oll Is safely collected in your area Lift properly the vehicle Use recommended elevators and follow the safety regulations Block wheels with suitable safety chocks and apply the parking brake Atterthe vehicle has been lifted on jacks support It using suitable safety stands The american legislation prohibits tampering of components of the anti pollution system or to alter th
8. nor vehicle safety be jeopardizes by the selected service methods GENERAL SAFETY PRECAUTIONS Alwavs wear safety aoaales whenever workina http alfalover dhs org 164 Sm7a0a08 jpg d a epee re rr were than Alfa Romeo original Spare Pars AR AECI AA 21 on vehicles or vehicle s components Vill http alfalover dhs org 164 Sm7a0a08 jpg 2 of 2 2002 02 16 22 26 04 134 http alfalover dhs org 164 Sm7a0a09 jpg INTRODUCTION Workshop shuold be equipped with ali safety equipments as fire extinguishers stc Workshop safety rules must always be carried out without any exception When acting on fuel system carefully follow the instructions below Disconnect battery negative lead Store fuel drained from the system Into a sultabie container with safety cap e DO NOT SMOKE If electrical components are Involved in proce dure disconnect first the battery negative lead Care should be taken especially when working on the H V cables of the ignition system Contact of oil or solvents with engine belts could affect elasticity rubber and cause dangerous slipping of belts The engine compartment iocates many hot and or rotating parts which could result dangerous for not experienced operators Special attention is needed when working with spring or tension loaded fasteners and devices as clips etc as careless removal may cause personal injury The catalytic converter reaches a high t
9. procedure it is vital to observe the tightening torques and adjustement data itis necessary to remind that gaskets seal rings and union copper rings must always be replaced and never re used Do not dirty or dust the internal trim The manufacturer does not assure the perfect vehicle s reliability and functioning H some items or svetems of the vehicle are ranlaced with naris other http alfalover dhs org 164 Sm7a0a08 jpg 1 of 2 2002 02 16 22 26 04 186 SAFETY MEASURES All work must be performed with maximum care and attention The person servicing an Alfa Romeo Is responsible for safety at work In order to avold Injury to personnel and vehicie s damage he is responsible for ensuring that all general and specific safety regulations are observad The following headlines are used in the manual io draw your attention to particular safety related points WARNING Used whenever insufficient care could re suk In personal Injury or even loss of life x CAUTION Indicates that failure or improper service methods could cause damage to the ve hicie or render it unsafe NOTE Highligis particular procedures or re marks These Warning and Caution cover only the situations and procedures described in this manual and recom mended by Alfa Romeo Accordingly anyone who uses a service procedure ortool thatis not recommended inthis manual must assure himself thoroughly that neither personal safety
10. strated in the figure below Refer to the Group Index for a quick localization of the group you ar interested in The symbols printed at the top corner of each page can also be used for a quick reference Each group is than divided into sections to address each component or item within the system An illustrated index and the table of contents reter to procedures and checks for each required component A short description opens each section followed by removal installation disassembly reassembly anc checks and inspections procedures Since most of the given instructions concem compiete disassembly of components they should be entirely followed only when strictly necessary After the pages of procedures all data relevant to the group are collected in the Technical Characteristics However working on engine ON Denon and Specifications section as well as the special tools right and left side are referred to an opera used in the above mentioned procedures agonia P side as illustrated below A special attention has been given to the troubleshooting procedures located at the end of each group to help even the least experienced operator in the identification and correction of possible maltunctions starting directly from the trouble reported by the customer and performing a series of tests on the affected systems These procedures also intend to teach a systematic approach to locate and correct problems The
11. the pages A special attention has been given to the troubieshooting procedures located at the end of each group Even the least experienced operator is so helped in the identification and correction of malfunctions starting directly trom the trouble reported by the customer and performing a series of tests on the affected systems More detalled information can be found In the Introduction paragraph which should be anyway read before using the Manual This publication is issued together with the WIRING DIAGRAMS AND ELECTRICAL DIAGNOSIS manual For information not covered in this publication refer 1o the above mentioned one All Information contained In this manua refers to the latest data avallable at the time of printing Alfa Romeo reserves Itself the right to make changes in design or addition to or Improvement in its products at any time without notice Manual updating issues are however to be periodically expected http alfalover dhs org 164 Sm7a0a01 jpg 1 of 2 2002 02 16 22 25 02 http alfalover dhs org 164 Sm7a0a01 jpg a nee http alfalover dhs org 164 Sm7a0a01 jpg 2 of 2 2002 02 16 22 25 02 http alfalover dhs org 164 Sm7a0a03 jpg 164 GROUP INDEX GROUP 00 COMPLETE CAR wie 01 ENGINE Hi 04 FUEL AIR SUPPLY amp EXHAUST SYSTEM 05 encine IN i ELECTRICAL UNITS 07 COOLING SYSTEM ET 12 CLUTCH E 13 MECHANICAL TRANSMISSION 16 AUTOMATIC ala TRANSMISSION PA 17 FINAL DRIVE Sf 21 s
12. ty chocks and apply the parking brake Afierthe vehicle has been lifted on jacks support it using sultable safety stands The american legisiation prohibits tampering of components of the anti pollution system or to alter the system s characteristics The vehicles noi conforming to specified ex haust emission data because misadjusted or non properly tuned up will possibly be non conforming to the law requirements and also have a higher fuel consumption On this vehicle Is Installed a driver s side air bag system special care should be taken on working on this system to avold unintentional activation When working on any electrical system in the air bag deployment zone driver s seat area dis connect the battery and remove the air bag module from the steering wheel You may then reconnect the battery il necessary for electrical diagnosis For all detalis refer to Group 00 and WIRING DIAGRAMS AND ELECTRICAL DIAGNOSIS Book http alfalover dhs org 164 Sm7a0a11 jpg MV NVI IGGLTIEMIEGGUUIE SE wylew Tiret explode http alfalover dhs 0rg 164 Sm7a0a11 jpg 2 of 2 2002 02 16 22 27 44
13. uspensions IX 22 BRAKES http alfalover dhs org 164 Sm7a0a03 jpg 1 of 2 2002 02 16 22 25 15 GROUP 23 STEERING 28 WHEELS amp TIRES EA 40 ELECTRICAL SYSTEM 43 ON BOARD INSTRUMENTS A amp ELECTRONIC DEVICES E 49 BODY a 55 DOORS A 56 HOOD amp TRUNK 2235 66 INTERNAL TRIM del 75 EXTERNAL TRIM Ese gQ HEATING VENTILATION TX amp AIR CONDITIONING http alfalover dhs org 164 Sm7a0a03 jpg gt gt http alfalover dhs org 164 Sm7a0a03 jpg 2 of 2 2002 02 16 22 25 15 http alfalover dhs org 164 Sm7a0a05 jpg SEN INTRODUCTION Jes Nd INTRODUCTION TABLE OF CONTENTS HOW TO USE THIS MANUAL vi SAFETY MEASURES VII General safety precautlons VIII SYMBOLOGY cc vit UNITS OF MEASURE nere nverenvens X MAINTENANCE PHILOSOPHY seenen VIII http alfalover dhs org 164 Sm7a0a05 jpg 1 of 2 2002 02 16 22 25 25 http alfalover dhs org 164 Sm7a0a05 jpg http alfalover dhs org 164 Sm7a0a05 jpg 2 of 2 2002 02 16 22 25 25 http alfalover dhs org 164 Sm7a0a06 jpg INTRODUCTION l 164 HOW TO USE THIS MANUAL NOTE in the presem manual procedures often re fer to L H and R H side Right and left are intended as they appear This manual is divided into chapters GROUPS related to an operator seated at the driver s place with the main group disassemblies as Illu
Download Pdf Manuals
Related Search