Alfa Romeo Alfetta Workshop Manual Download Page 3

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Summary of Contents for Alfetta

Page 1: ...TRANSMISSION SUSPENSION VEHICLE HEIGHT AND GEOMETRY STEERING GEAR BRAKES Alfawiki nl...

Page 3: ...nents Only by this means can the complete interchangeability and perfect performance of the various parts be ensured When ordering please specify not oniy the type of car and the part number from the...

Page 4: ...steering column to car 29 Re building 76 Partial operations 31 Re fitting the suspension 80 Tools 32 Partial operations 83 Tightening torques 36 Tools 83 Lubricants and sealants 40 Tightening torques...

Page 5: ...excessive contamination of the cleaning fluid Then wash the parts with paraffin or a suitable fluid Remove any surplus with a compressed air jet Dry the parts immediately after washing to avoid corros...

Page 6: ...______o_VE _RH_AU_L_____ TRA NS MI SS ION A B 4 November 1975 Public nO 2064 Workshop Manual Alfawiki nl...

Page 7: ...f a two piece propell er shaft The connection at either end is achieved by means of a flexible coupl ing The location on the body is by means of a central support fitted with ball bearings The drive f...

Page 8: ...and remove the bolts connecting the flanges 4 which retain the exhaust pipe 5 against the manifold slacken and remove bolt 6 fixing the exhaust pipe to the bracket situated on the rear engine mountin...

Page 9: ...ual Remove the flywheel locking tool and unscrew the remaining fixing bolts on the propeller shaft using the same procedure Unlock and remove the nuts and washers fix ing the propeller shaft centre su...

Page 10: ...ws Suitably mark the respective positions of the front and rear shaft Fit tool no A 2 0263 to the flexible coupling Release the bolts 8 November 1975 between shaft and flexible coupling and remove the...

Page 11: ...to 4 9 to 5 3 kgm if the transmission is of the type with interference mounted bolts fixing nuts must be tightened to 4 4 to 4 9 kg m Remove tool no A 2 0263 Fit protective cap and fill the front bush...

Page 12: ...ntrifugal cap Remove the centre support using a press and the semi circular plates no A 2 0247 at this stage the other centrifugal cap is damaged and must be replaced when re assembling 10 November 19...

Page 13: ...id Centre coupling on rear shaft Clamp the rear shaft in a vice Mark the position of the coupling in relation to the shaft Public nO 2064 Workshop Manual Remove the protecting rubber cap from the fron...

Page 14: ...ealing cap to the bush of the rear flexible coupling and secure by means of the special ring Re assemble the flexible coupling align the marks previously made and ensure that the locating holes are al...

Page 15: ...nuts of the coupling Engage 5th gear and tighten the nuts to the above mentioned torque Remove tool no A 2 0290 and fit in its place the small cover plate on the flywheel housing Reconnect the rear e...

Page 16: ...use special tool no 2 A 5 0190 and torque wrench Rear bolts use special tool no 3 A 5 0191 and torque wrench 14 November 1975 To check tightening torque of bolts on front coupling Front bolts use spec...

Page 17: ...Remove the outer cover from the joint and carefully clean the external part of the joint with rags Do not use solvents Remove the circlip retaining the constant velocity joint using suitable pliers Ma...

Page 18: ...to prevent in time loss of grease It is also recommended that only the clamping clips of the type supplied by our Part Department be used in order to prevent any out of balance condition of the half s...

Page 19: ...TOOLS TIGHTENING TORQUES LUBRICANTS AND SEALANTS Alfawiki nl...

Page 20: ...d rear bolts of centre coupling A 5 0192 SPANNER 17 mm Bi hexagon spanner L shaped for front bolts of rear coupling and rear bolts of front coupling A 2 0247 SEMI CIRCULAR PLATES for removing the cent...

Page 21: ...peller shaft A 3 0246 FITTING TOOL for the front spherical bearing of the front propeller shaft A 3 0261 EXTRACTOR for rear spherical bearing and spherical seat of the front propeller shaft and spher...

Page 22: ...for propeller shaft A 3 0479 EXTRACTOR for extracting half shaft from constant velo city joint use with A 3 0487 and A 2 0247 A 3 0487 BASE for extracting and fitting constant velocity joints on half...

Page 23: ...brake disc spacer and hub shaft 2 8 3 With grease Fixing bolts for propeller shaft with torque wrench directly applied 4 9 5 3 Dry Fixing nuts for propeller shaft with use of special spanner and 300...

Page 24: ...ring and bush for taking up front clearance of propeller shaft ISECO MOLYKOTE COMPOUND G RAPID Working surfaces of spherical bearing and centre and rear spherical seat of propeller shaft Sealant liqui...

Page 25: ...ched at the front to the lower wishbones and at the rear to the body Public nO 2064 Workshop Manual The suspension also comprises hydraulic double acting shock absorbers passing through the upper wish...

Page 26: ...e of the car it is necessary to disconnect the expansion tank 24 November 1975 Disconnect the shock absorbers from the lower wishbones by removing the retaining bolts To remove the lower wishbone and...

Page 27: ...steering linkage from the stub axle by using tool no A 3 0376 after removing the castellated nut and split pin Disconnect the stub axle from the upper wishbone after removal of the retaining nut by fr...

Page 28: ...g from the hub using tool no A 3 0379 and a press or vice as illustrated 26 November 1975 Check bearings for signs of wear or seizure Check condition of hub and stub axle and replace these if necessar...

Page 29: ...f the wishbone and remove nuts 3 with corresponding washers securing the bushes to the wishbone mounting 4 Insert in the torsion bar seat the serrated ring tool no A 3 0373 and secure to the threaded...

Page 30: ...of tool A 3 0435 28 March 1978 At this stage ensure that the alignment mark on the ball joint coincides with that on the seat of the wishbone to prevent misalignment damage which would adversely affec...

Page 31: ...OLEO BLITZ Apply similar markings on the new compo nents as on the discarded ones Clamp the anti roll bar in a vice and insert the link on the bar s pin using tool A 3 0346 Ensure that the previously...

Page 32: ...to 2 5 kgm At the same time rotate the hub to assist the seating of the bearings in their seats and to prevent the rollers causing damage to the races Slacken the nut and tighten it again using a tor...

Page 33: ...hbone Position the lower wishbone against the body locating the respective spacers between the longitudinal member and the mounting pin of the wishbone in line with the retaining bolt holes Insert the...

Page 34: ...is necessary to remove the road wheel on the side of the car in question It is not necessary to remove the brake caliper 32 November 1975 It is not necessary to weight the car stati cally It is suffi...

Page 35: ...elease the bottom wishbone as detailed on page 24 Public nO 2064 Workshop Manual Disconnect the shock absorber completely Disconnect the brake caliper Disconnect the steering linkage and proceed as de...

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Page 37: ...TOOLS TIGHTENING TORQUES LUBRICANTS ANTI SEIZING COMPOUNDS Alfawiki nl...

Page 38: ...tening and releasing torsion bars to be used together with A 2 0069 A 3 0328 FITTING TOOL for front hub outer taper bearing outer race A 3 0329 FITTING TOOL for front hub inner taper bearing outer rac...

Page 39: ...r link to be used with A 3 0367 A 3 0372 EXTRACTOR FITTING TOOL for lower wishbone bush to be used with A 3 0373 A 3 0373 RING serrated ring for extracting the bushes from the lower wishbone to be use...

Page 40: ...outer race A 3 0422 PUNCH for extracting rubber mountings for cross member to be used with A 3 0423 A 3 0423 BASE for extracting and fitting crossmember rubber mountings to be used with A 3 0422 A 3...

Page 41: ...shbone A 3 0442 RING for extracting ball joint on lower wishbone A 3 0459 FITTING TOOL for front hub oil seal R 7 0010 JACK column type for car hoisting if Tools marked with an asterisk are also used...

Page 42: ...QUIVALENTS Grease for AGIP FI GREASE 33 FD Internal cavity of hub 50 g SHELL RETINAX AX IP AUTO GREASE FD Grease for Lip of oil seal for hub and working area ISECO MOLYKOTE BR 2 on stub axle Sufficien...

Page 43: ...hich is of tubular con struction and triangular shape is connected at the front to a crossmember by means of rubber mountings This crossmember in turn is bolted to the body Public nO 2064 Workshop Man...

Page 44: ...d from the lever on the clutch cover proceeding as detailed on page 6 42 November 1975 To remove the rear axle Disconnect the half shaft on the hub side by slackening and removing the bolts 3 also ass...

Page 45: ...it tool R 4 0150 6 to the gearbox rear axle unit Support the assembly by means of a column type jack and proceed as follows Disconnect the propeller shaft from the clutch spider by slackening and remo...

Page 46: ...removing the securing bolts Slacken and remove the bolt securing the anti roll bar mountings to the body Withdraw mountings Disconnect the handbrake cable from the brake caliper levers Fit the column...

Page 47: ...the Watts linkage from the pivot by removing the securing nut for the balance lever after breaking the caulking Where fitted remove also the washer Disconnect the Watts linkage from the balance lever...

Page 48: ...her using tool A 3 0435 operated by a spanner Place the lower washer in its seat Insert the new rubber mounting using tool A 3 0435 complete with guide tunnel Fit the upper washer Caulk the edge of th...

Page 49: ...p Manual Road springs To check the efficiency of the springs mea sure under static load the distance between the spring cup and the bump rubber pad see page 59 If spring replacement is necessary fit s...

Page 50: ...r complete with rubber mountings and bushes in position and secure to body Raise the gearbox differential unit using a column type jack in conjunction with tool R 4 0150 previously fitted and secure t...

Page 51: ...drive cable the electric wires and adjust the hand brake cable Check the correct vehicle suspension height Check rear wheels geometry Public nO 2064 Workshop Manual PARTIAL OPERATIONS For refitting th...

Page 52: ...securing the Watts linkage to the balance lever and withdraw the linkage Replace the rubber bushes on the bench as detailed on page 46 Reassemble the Watts linkage by connecting the linkage to the ba...

Page 53: ...shaft and hub it is only necessary to carry out the first sequence of operations whereas it is necessary to carry out the complete sequence of operations if the hub bearing is to be replaced The fitm...

Page 54: ...2 45 19 35 20 32 47 65 53 72 47 66 HIGH 1 1 SPEED I EXTENSION 157 205 84 127 83 118 98 135 94 130 145 190 I 11600 25070 06 11600 25070 17 SHOCK ABSORBER 11600 25070 11 11600 25070 10 11604 25070 01 11...

Page 55: ...TOOLS TIGHTENING TORQUES LUBRICANTS AND ANTI SEIZING COMPOUNDS Alfawiki nl...

Page 56: ...SUPPORT for raising car A 2 0131 STOP Wheel hub tool A 2 0269 CAULKING TOOL for caulking upper washer on rear axle rubber mounting A 2 0281 SPACER for extracting rear wheel hubs A 3 0327 EXTRACTOR fo...

Page 57: ...g and fitting rubber bush on transverse linkage for rear axle A 3 0444 EXTRACTOR FITTING TOOL for rubber bushes on transverse linkage for rear axle A 3 0445 EXTRACTOR FITTING TOOL for balance lever ru...

Page 58: ...ing nut on rear wheel bearings A 5 0192 SPANNER 17 mm hexagon spanner for propeller shaft flexible coupling retaining bolts R 4 0150 SUPPORT for fitting and removing clutch unit to gearbox differentia...

Page 59: ...propeller shaft with 200 to 400 mm torque spanner 4 1 to 4 5 Dry and tool spanner Bolts retaining axle crossmember 4 to 4 5 Dry LUBRICANTS AND ANTI SEIZING COMPOUNDS DESCRIPTION Grease for Internal su...

Page 60: ...sorbers and slacken the bolts securing the Watts linkage to the body Bounce the car a few times to settle the suspension 58 November 1975 To check front vehicle height Measure dimension A from the low...

Page 61: ...A 4 0149 along the inner surface of the ruler and after removing the pointer and slackening bolt C withdraw graduated rod until the head of screw D lightly touches the lower part of the wishbone moun...

Page 62: ...from the rear DIRECTION OF ROTATION OF TORSION BARS FOR SUSPENSION HEIGHT ADJUSTMENT Suspension height low The car is raised Anti clockwise Clockwise Suspension height high Car is lowered Clockwise An...

Page 63: ...on for the front end Using tool A 3 0374 remove the torsion bar from its seat rotate it in a CLOCKWISE direction and locate it again in its rear seat Ensure that the marked spline lines up with the as...

Page 64: ...adjust caster angle Check the caster angle on both front wheels which should be ex 4 30 30 The maximum difference between the two sides is 0 20 62 November 1975 Where the caster angle is outside the...

Page 65: ...itting it check that the notch controlling the cancellation of the direction indicator lever is in line with the pawl of this lever If this condition is not correct discon nect the steering column fro...

Page 66: ...___ To check rear wheel camber angle Check the camber angle on the LH and RH rear wheel This angle which is not adju stable should be 3 0 30 whilst the maximum difference between the two sides should...

Page 67: ...TOOLS Alfawiki nl...

Page 68: ...thus are also common to other models 66 November 1975 A 2 007S SUPPORT for raising car A 3 0374 EXTRACTOR for torsion bar A 4 0146 RULER for checking car suspension height A 4 0149 TOOL for checking...

Page 69: ...d the driver increased protection in the event of a frontal impact the steering rack has been mounted in a rearward position Public nO 2064 Workshop Manual For the same reason a two piece steering col...

Page 70: ...wing the retaining bolts Disconnect the steering column tube 1 from the top mounting 2 by removing the adjusting lever 3 after unscrewing the retaining nut and washer Extract the upper half of the shr...

Page 71: ...ate its removal TO DISMANTLE THE STEERING RACK Clamp the steering rack in a vice Remove the ball joints from the steering tie rods as follows Public nO 2064 Workshop Manual Slacken the locknut fixing...

Page 72: ...ng Extract the guide bush from the rack from the far end of the housing using tool A 3 0291 70 March 1978 Inspection and checks Carefully clean all dismantled parts checking that The piniOn the rack a...

Page 73: ...Department in various thicknesses Fit the needle roller bearing to the housing using tool A 3 0456 Fit the rubber ring in its seat Public nO 2064 Workshop Manual Prepare approx 90 g of BP Energrease...

Page 74: ...ding Where this condition is not met rectify by replacing the shim which are available from our Spare Division in various thicknesses Remove again the cover spacers and the bush Fit sealing ring to th...

Page 75: ...ng steering wheel to column Extract the steering wheel from the splines using tool A 3 0451 Publ ic nO 2064 Workshop Manual Disconnect from the steering column tube the lower shroud and steering assem...

Page 76: ...olumn 1 from the upper flange of the flexible coupling Withdraw the column from this flange working from the passenger compartment of the car Extract the flange from the boots If necessary remove boot...

Page 77: ...head shears Public nO2064 Workshop Manual Fit the rubber bush to the lower lug using a press tool A 3 0501 and base A 3 0492 Prior to fit the roller cages to the steering column lubricate their seats...

Page 78: ...ive endfloat 76 November 1975 PARTIAL OPERATIONS In the event of repairs being required it is possible to work on the steering rack and the steering without completely removing and dismantling the uni...

Page 79: ...joints from the stub axle as detailed on page 68 Unscrew the locknuts If necessary use a spanner on the flats of the tie rods To replace the boots on the steering tie rods In order to replace the boot...

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Page 81: ...TOOLS TIGHTENING TORQUES LUBRICANTS AND SEALANTS Alfawiki nl...

Page 82: ...3 0291 EXTRACTOR for rack bush A 3 0353 EXTRACTOR for ball bearing on steering rack pinion use with tool no A 2 0239 A 3 0376 EXTRACTOR for ball joint on steering lever A 3 0393 FITTING TOOL for pinio...

Page 83: ...nds of steering column tube A 3 0451 EXTRACTOR for steering wheel A 3 0455 EXTRACTOR for needle roller bearing on steering rack pinion A 3 0456 FITTING TOOL for needle roller bearing on steering rack...

Page 84: ...ge bottom side A 3 0501 EXTRACTOR FiniNG TOOL for rubber bush for steering column tube to be used with tool A 3 0492 A 5 0202 SPANNER for steering tie rods A 3 0346 FITTING TOOL for rack guide bush To...

Page 85: ...COMMERCIAL PRODUCTS Grease for BP ENERGREASE HT EP OO ZF steering box 90 g Oil for ERGON RUBBER GREASE N 3 ISECO Steering column roller cages SFERUL B2 AR REINACH Lubricant for Top support brackets fi...

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Page 87: ...ic circuit is fed by a tandem brake master cylinder mounted co axially on the vacuum brake servo unit The circuit is of the dual line tipe i e it con sists of two independent circuits one front and on...

Page 88: ...means of a centre punch Withdraw the brake pads If necessary use pliers Mark the assembly position of the pads 86 November 1975 Push back the brake cylinders using tool A 2 0147 To remove brake disc...

Page 89: ...Proceed as follows Unscrew the adaptor 1 of the metal pipe connecting it to the caliper Unscrew the adap tor 2 and remove the connecting pipe Public nO 2064 Workshop Manual Disconnect the caliper from...

Page 90: ...surface finish of the disc must be as fol lows 0 4 to 0 9 J I measured in a circumferential direction 0 5 to 1 2 J I measured in a radial direction 88 November 1975 To replace brake caliper dust cove...

Page 91: ...e front suspension Refit the brake pads in accordance with the marks previously applied providing they are not replaced and no rectification work is required on the brake disc On completion of the ass...

Page 92: ...ing surfaces of both brake discs The amount of metal removed which must be the same on both surfaces of each disc must not exceed 0 5 mm on each side After machining the thickness of the rear discs mu...

Page 93: ...Fit the caliper feed pipe adaptor Ut the three way adaptor and tighten to 0 8 to 1 kg m Bleed the brakes as detailed on page 100 on completion of the assembly Public nO 2064 Workshop Manual To replace...

Page 94: ...t to a nominal torque of 0 7 to 1 kg m using tool A S 0194 92 November 1975 Inner brake pads Turn the adjusting screw 2 until the required end float of 0 1 0 15 mm between disc and pad measured with a...

Page 95: ...e order noting the follow ing Check the seals 4 for wear Replace the seals if necessary Ensure that the sealing ring is fitted between the brake master cylinder and the brake servo unit Tighten the nu...

Page 96: ...pedal bracket by removing the fixing nuts 3 Dismantle the pedal assembly as follows 94 f Jovember 1975 Remove the pivot pin securing the fork of the clutch master cylinder to the pedal Remove the anch...

Page 97: ...cylinder operating the fork is 10 6 to 12 2 mm If necessary the stroke can be adjusted by varying the number of adjustment plates Vacuum system The vacuum system consists of a non return valve fitted...

Page 98: ...to bleed the brakes as detailed on page 100 even in the case of a partial removal of the brake pipes Front circuit To remove brake pipe A Raise the car Remove the front LH road wheel and unscrew the u...

Page 99: ...e car Remove the front RH road wheel and disconnect the union between brake pipe B and the flexible pipe D Feed again into the engine compartment the end of the pipe that has just peen disconnect ed R...

Page 100: ...8 November 1975 completely This allows the crossmember to be lowered sufficiently for the pipe to pass through From underneath the car remove the metal brake pipe E withdrawing it towards the rear and...

Page 101: ...pe by unscrewing the adaptor connecting it to the brake caliper Proceed in a similar manner for the opposite side of the car Publ ic nO 2064 Workshop Manual To remove flexible pipe H Raise the car Dis...

Page 102: ...he bleed screws and operate repea tedly the brake pedal allow the brake pedal to return slowly and pause a few seconds between each stroke Continue with this operation until the fluid emerging is free...

Page 103: ...cting bottles which should be partially filled with fluid to the bleed screws or the calipers in question Ensure that the flexible tubes are immersed in the fluid Raise the pressure to the level previ...

Page 104: ...DBRAKE ASSEMBLY To remove the handbrake cable Raise the car and working below it discon nect the front part of the exhaust pipe as detailed below Slacken the clamp 2 securing the front pipe to the tai...

Page 105: ...her from the pin Public nO 2064 Workshop Manual Separate the cable from the anchoring plates Withdraw the handbrake outer cable from the mounting plate near the rear flexible propeller shaft coupling...

Page 106: ...d and replace them as required Assemble the lever in the reverse order noting the following Adjust the handbrake lever travel by recon necting the flexible cable to the rear calipers as detailed on pa...

Page 107: ...TOOLS TIGHTENING TORQUES LUBRICANTS FLUIDS AND SEALANTS Alfawiki nl...

Page 108: ...for brake cali per pistons A 2 0355 PLIERS for extracting front caliper pistons A 2 0149 GAUGE for checking front caliper piston position A 5 0194 SPANNER for rear caliper endfloat adjustment A 5 0201...

Page 109: ...TECNICA Centro Direzionale 20020 ARESE Milano Publ ie 2064 R 5 78 000 Printed in Italy All rights reserved This book or parts thereof may not be reproduced in any form without permission of ALFA ROME...

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