ALFA ROMEO

INSTRUCTS

Beware of the dangers of carbon

Never run the engine The exhaust deadly in an enclosed carbon is

monoxide
space. monoxide u

gases contain

gas. Carbon

monoxide

particularly and to tasteless. ascertain.

dangerous and

as it colorless, odorless is eery difficult

its presence

Make a careful note of the symbol stamped on the key handle

Ignition key.

SYMBOL

Key to doors, dashboard locker, trunk lid, fuel filler cover. Keys SYMBOL

When ordering duplicate keys, please quote the symbol ; duplicate keys w i l l be supplied in a semifinished state.

The operation and maintenance handbook

instructions contained

in this

must be carefully observed by every user w h o desires to get the best f r o m this vehicle and to ensure a long life for every component. Users are recommended, in their o w n interest, to entrust all maintenance and repair w o r k to an authorized A l f a Romeo Service Station of our After-Sales Department, as such Stations are equipped w i t h the proper tools and jigs and staffed by trained mechanics w h o ave kept up-to-date by means of our factory instructions. Users are r e m i n d e d that A l f a Romeo cannot be responsible for any errors made by unauthorized service stations or for any damage resulting f r o m the use of lubricants other than those recommended.

ALFA ROMEO

Direzione Assistenza Clienti

The data relating lo weights, consumptions and speeds are approximate o n l y ; Alfa Romeo reserves the right to change w i t h o u t notice any features and data given in this book.

Contents

Page

3 4 6 10

Vehicle Features

identification Page 47

CHASSIS MAINTENANCE Clutch Gearbox Propeller Rear axle Suspensions Steering gear Steering linkage Front wheels (camber and toe-in) Brakes Wheels Tires (maintenance) shaft

Controls and instrument SPRINT Controls and instruments SPIDER

48 50 51 52 53 54 55 57 63 64

HOW TO USE YOUR CAR

14 15 16 17 18 20

Breaking in Starting the engine Precautions ( w h i l e d r i v i n g and p a r k i n g )

Winter precautions Ventilating and heating system Lowering and raising the top

BODY MAINTENANCE LUBRICATION

67

Washing, polishing, etc

22 24 26 28 29

Periodical

lubrication lubric;

Recommended

ELECTRIC SYSTEM 69 69 70 70 Genera Battery Starting motor and generator

Engine lubrication Oil p u m p Oil filter

Inside lighting, SPRINT Headlamps and tail Fusebox W i r i n g d i a g r a m , SPRINT W i r i n g d i a g r a m , SPIDER lights

MAINTENANCE 30 Periodical maintenance

71 73 74 76

ENGINE MAINTENANCE 33 34 37 40 44 Tightening torque specifications Valve timing

TOOL KIT

79

Tools
WARRANTY

Fuel feed Ignition Cooling system 80

Free service coupons

Vehicle identification

DATA PLATE AND CHASSIS NUMBER

Sprint

&

>

Spider

ENGINE NUMBER

Main features

SPRINT Engine Number and layout of cylinders Bore and stroke Total displacement . . . . Max. power at 6200 r.p.m.
4 in line

SPIDER

mm cc. CV HP mm mm mm mm mm mm mm Kg.

78 x 82 1570 92 ( D I N ) 104(SAE) 1292 1270 2380 11,000 3980 1535 1320 905 2+ 2 155-15

Chassis

Front wheel track Rear wheel track Wheel base M i n . t u r n i n g circle Overall length Overall w i d t h Overall height Dry weight, incl. tools and jack . Number of seats Tires Pirelli C i n t u r a t o S

2250 10,000 3900 1580 1335' 885 2

* w i t h top

1st

Performance after b r e a k i n g in

w ith 8 : 4 1

bevel drive

period

2nd . 3rd . 4th . 5th . reverse

. . . . .

. . . . . .

. . . . . .

41 69 102 137 172 46

km/h km/h km/h km/h km/h km/h

26 43 64 85 107 29

m.p.h. m.p.h. m.p.h. m.p.h. m.p.h. m.p.h.

To avoid damaging engine, do not exceed these maximum speeds. The performances shown are intended for use in ambient as f o u n d in center Europe.
Imp.

conditions

U.S.

Fuel

consumption Fuel, oil and water

Per 100 Km (62.5 mi.) to Italian C U N A standards Water (engine and radiator)

Sprint Spider

a p p r o x . 9.4 It (1.97 gals) (2.48 gals) a p p r o x . 8.8 It. (1.93 gals) (2.32 gals) approx. 7.5 It (1.65 gals) (1.98 gals)

Fuel: for best e n g i n e p e r f o r m a n c e , we recommend premium-grade fuel w i t h an octane n u m b e r of not less than 92 (RM)

53 It. (11.7 gals) (14.0 gals)

Oil
(sump and filter) when full d a n g e r level approx. approx. approx. approx. approx. 5.7 3.7 1.65 1.25 0.25 Kgs Kgs Kgs Kgs Kgs

Gearbox Rear axle Steering box

(5.6 (3.6 (3.2 (2.5 (0.5

qts) qts) pints pints) pints)

(6.7 (4.3 (3.8 (3.0 (0.6

qts) qts) pints) pints pints;

GIULIA

1600
SPRINT

GIULIA

1600
% ~

SPIDER

Controls and instruments

14 15 16 1/

18 19

Controls and instruments

SPRINT

I 2 3

Headlamp d i p p e d / u n d i p p e d control lever Direction indicator control lever Headlamp signalling control Horn control knob (flashing)

Controls

18 20

Ignition

switch

Headlamp switch knob. Pull out this knob to light p a r k i n g l i g h t s ; by t u r n i n g clockwise f u r t h e r , the dipped headlamps light up.

22 26 27 29 30

Windshield wiper control Engine hood release

knob.

Windshield washing b u t t o n Choke lever T h r o t t l e lever Hand brake handle T r i p mileage recorder zero setting

38 40 41 42 43

Dashboard light switch lever Clutch peda Brake pedal Throttle peda Gear shift lever and shifting diagram

Controls and instruments

2 3 4

18

19

20 21

Controls and instruments

SPRINT

Direction indicator w a r n i n g

light

Instruments

6 7
8

Oil temperature

indicator light

Parking lamp w a r n i n g

Water temperature indicator Fuel reserve w a r n i n g light

10 11 12 13 14 15 16 17 19 21 24

Fuel level

indicator

Revolution counter. Oil pressure gauge Heater-blower unit w a r n i n g light Speedometer Main mileage recorder T r i p mileage recorder Generator w a r n i n g light Undipped headlamp w a r n i n g Choke w a r n i n g light Rearview m i r r o r light

Cigarette 25 28 33 34 35 36 37 39 44

lighter

Luxury

fittings

Radio set compartment Ram air intake control Heating and ventilating air flow Air temperature adjusting lever Heating and ventilating air outlet Heater-blower unit control Ceiling light switch Dashboard locker control

Seat positioning lever ( t o tilt the seat back, adjust the two screws at the sides of lunges)

45

Ash tray

Controls and instruments

10

12

Wj^ 2 q f

33

34 35 36

Controls and instruments

SPIDER

1 2 3 17 22 23 24 26 27 30 32 33 34 35

Direction indicator control lever Horn operating knob Headlamp signalling control Ignition switch Windshield washing b u t t o n Headlamp d i p p e d / u n d i p p e d control b u t t o n Engine hood release Hand brake lever T r i p mileage recorder zero setting Dashboard light switch lever (flashing)

Controls

Windshield wiper control lever Choke control knob T h r o t t l e control knob

Headlamp switch knob. Pull out this knob to light p a r k i n g lamps By t u r n i n g f u r t h e r clockwise the dipped headlamps light up

38 39 40 41

Clutch pedal Brake pedal T h r o t t l e pedal Gear shift lever and shifting diagram.

11

Controls and instruments

2 3

Controls and instruments

SPIDER

4 5 6 7 8 9 10 11 12 13 14 15 16 18 19

Oil temperature indicator Direction indicator w a r n i n g light Water temperature indicator Parking lamp w a r n i n g light. Fuel level indicator Fuel reserve w a r n i n g light Revolution counter Oil pressure gauge Speedometer Blower-heater unit w a r n i n g light Main mileage recorder T r i p mileage recorder Generator w a r n i n g light

Instruments

Undipped headlamp w a r n i n g light Rearview m i r r o r w i t h d a y / n i g h t tab

20 21 25 28 29 31 36 37 42

Radio set compartment Dashboard locker Ram air intake control Heating and ventilating air f l o w control Air temperature adjusting lever Blower-heater unit control Cigarette lighter

Luxury fittings

Heating and ventilating air outlet Seat positioning lever ( t o tilt the seat back, adjust the two screws at the sides of hinges) Ash tray

43

13

SPECIAL CARE FOR FIRST 3,000 KM. ( 2 , 0 0 0 MILES)

BREAKING
In order to allow the various main units of the car, particularly the engine, gearbox and differential, to bed down gradually, a breaking in period of special care must be observed and during that time the maximum performance must never be demanded of the car. Before moving off, allow the engine to run at around 1,500 r.p.m. for one minute in summer and two to three minutes in winter. Push down the choke lever as soon as possible.

O n starting

W h i l e in motion

Never exceed or maintain the maximum speeds shown in the table for long periods ; never press throttle pedal to the f l o o r ; release throttle pedal from time to t i m e ; for the first 1,000 Km. (600 miles) braking. avoid prolonged and intensive

1st gear

2nd gear
1

3rd gear 67 Km/h

4th gear 91 Km/h

5th gear 115 Km h (71 mph 141 Km h (87 mph

Maximum speeds

1st 1,000

km.

27 Km h (16 mph) 34 Km/h

46 K m / h (28 mph 56 Km/h

(600 miles) 1,000 to 3,000 Km. (600 to 1,900 miles)

(41 mph) 82 Km/h

(56 mph) 111 Km h (69 mph)

(21 mph)

(34 mph)

(51 m p h ;

Changing engine oil

1 st change : after the first 800-1,100 km (500-680 miles) 2nd change including filter element and oil replacement: not later than 3,000-4,000 km (1,900-2,500 miles)

Changing oil in gearbox and differential housing Tightening cylinder head nuts

after the first 800-1,100 Km (500-680 miles). Oil change should be made with mechanical parts at normal operating temperature, in practice after a m i n i m u m distance of 20 Km. ( 13 m i . ) . After the first 800-1,100 Km (500-680 miles) and 3,000-4,000 Km ( 1,900-2,500 miles) retighten cylinder head nuts to a torque of 6.2-6.4 Kgm. (44.8-46.2 f t . l b s ) , (unscrew and retighten when cold without ubricating). * After the first 800-1,100 Km. (500-680 miles) and 3,000-4,000 Km. (1,900-2,500 miles) adjust the backlash of worm and roller in the steering box.

Adjusting steering box backlash

How to use your car

STARTING THE ENGINE

Before starting the engine make sure the gear shift lever is in neutral. Pull up choke lever, insert the key in the ignition switch and start the engine. To facilitate s t a r t i n g , p a r t i c u l a r l y in cold weather, press in the clutch pedal. As soon as engine fires release the ignition key. If engine fails to start at once, do not keep the starting motor running ( o r the battery w i l l soon become discharged) but wait a few minutes and try again. If it w i l l still not start, look f o r the cause as f o l l o w s : the battery charge may be too weak to rotate the starting m o t o r sufficiently fast to start the engine; the ignition equipment may be defective ( d i r t y plugs, excessive spark gaps, oxydised contact points, wet d i s t r i b u t o r cap, damaged d i s t r i b u t o r or c o i l ) ; the carburetor may be d i r t y and jets be clogged; electric circuits may be broken or fuses b l o w n . When the engine has started move choke lever halfway back for a time enough to w a r m the engine up, and then push it d o w n . Do not accelerate the engine until it has w a r m e d u p ; when the engine is cold the oil cannot reach all points requiring l u b r i c a t i o n . Make sure that the oil pressure shown by the gauge is as prescribed. Make sure the generator warning light goes off as soon as engine speed exceeds 1,100 r.p.m. Particularly when starting f r o m cold in w i n t e r , it is advisable, in order to facilitate starting, to press the t h r o t t l e pedal through about one quarter of its stroke while at the same time operating the choke lever.

Cold e n a m e

In summer, or when the engine is already hot do not use the choke. When the engine is hot, starting w i l l be f a c i l i t a t e d , if the t h r o t t l e pedal is depressed slowly until the carburetor t h r o t t l e is opened halfway or more in order to lean the m i x t u r e .

Hot e n g i n e

15

PRECAUTIONS

H o w to use y o u r car

While

driving

Take care not to r u n the engine beyond the m a x i m u m

revolutions.

Make a practice of checking the oil pressure gauge from time to time Stop the engine if the pressure with a hot engine and at maximum revolutions should fall below 3.5 K g / c m 2 ( 5 0 psi ) (see page 2 8 ) . Do not rest y o u r f o o t on c l u t c h pedal when not actually using it. Do not drive at high speed until the oil in the engine, in the gearbox and in the differential housing has warmed up properly. The level of the r a d i a t o r w a t e r s h o u l d be 2 to 3 c m . ( a b o u t 1 inch) below the b o t t o m r i m of the f i l l e r orifice. If the level s h o u l d d r o p to 4 to 5 cm ( 2 inches) when the engine is r u n n i n g , it is unnecessary to top up p r o v i d e d that the d r o p does not c o n t i n u e . When checking the r a d i a t o r water level when the engine is h o t , and the p a r t i c u l a r l y w h e n gauge shows a t e m p e r a t u r e a r o u n d 100"C, it is essential to t u r n the r a d i a t o r cap only as far the first notch to allow pressure w i t h i n the r a d i a t o r to d r o p . If a large q u a n t i t y of w a t e r has to be added to a hot engine, the w a t e r s h o u l d be added s l o w l y and the engine left r u n n i n g so as to prevent any sudden c o o l i n g and the poss i b i l i t y of damage.

While parking

Never leave the key in the on p o s i t i o n in o r d e r to prevent

battery

f r o m d i s c h a r g i n g and coil f r o m d a m a g i n g . A p p l y the hand b r a k e and, w h e n p a r k i n g the car u p h i l l or d o w n h i l l , shift i n t o a low gear and steer the f r o n t wheels in such a d i r e c t i o n as to cause the car, should
1

the

"

h a n d b r a k e disengage accidentally, to move t o w a r d the roadside.

How to use your car

WINTER PRECAUTIONS

In places where the temperature frequently falls below freezing point, a suitable antifreeze must be added to the engine cooling water to prevent the water in the radiator f r o m freezing while the car is in m o t i o n and the water in the engine f r o m freezing d u r i n g prolonged stops. The quantities of SHELL or BP Energol antifreeze to be used, depending on the lowest anticipated temperature, a r e :

Antifreeze

C
Antifreeze: Agip SHELL Energol

F
50 32 12 5 23

10 0
10 2 0 3 0

1.5 litres (.33 Imp. gal.) (.4 U.S. gal.) 2.25 litres (.5 Imp. gal.) (.6 U.S. gal.) 3 litres (.66 Imp. gal.) (.79 U.S. gal.)

In icy weather even a short stop may be enough to freeze up the engine water if an antifreeze has not been added. If no antifreeze is used, to avoid very serious damage is it essential to drain not only the radiator but also the engine and the heating system by opening the cocks positioned at the b o t t o m of the radiator, on the left-hand side of the engine.

D r a i n i n g off the w a t e r

Radiator

Engine

17

VENTILATING AND HEATING SYSTEM

How to use vour car

Sprint

oo

H o w to use your car J

VENTILATING AND HEATING SYSTEM

Air comes into car through : A to defrost the windshield w i t h cold or w a r m air B for ventilation by ram intake C for ventilation by ram intake for forced ventilation by blower for heating

The controls are the following : 1 Ram intake t h r o t t l e adjusting lever for air through B 2 Air f l o w adjusting lever for outlets A and C ( w h e n C is closed, there w i l l be f u l l f l o w through A ) 3 A i r temperature a d j u s t i n g lever f o r outlets A and C 4 Blower control lever for air through A and C ( w h e n the blower is operating a w a r n i n g light on dashboard w i l l go o n ; for w a r n i n g light location see no. 13 on page 8 for Sprint and on page 12 for Spider)

19

LOWERING AND RAISING THE TOP

How to use your car

Lowering the top Release the press-studs securing the side edges of the top to the body and the hooks that secure it to the windshield posts.

Release the rear cross member and f o l d the top

Slightly raise the t o p ; at the same time occurs the disengagement of the lower arms.

20

How to use your car

LOWERING AND RAISING THE TOP

Lower the housing.

top

into

its

Fix the top to the car w i t h the straps provided.

Cover the top w i t h the protective cover and secure it w i t h the pressstuds.

Raising the top To raise the top reverse the order of lowering.

21

PERIODICAL LUBRICATION

Lubrication

Check oil level and replenish, if necessary Every 5 0 0 Km. ( 3 0 0 miles) Every 4 , 0 0 0 Km. ( 2 , 5 0 0 miles) 1 Engine 2 Gearbox 3 Rear axle 4 Steering box 5 Brake fluid reservoir

6 Engine (and filter)

7 Upper king pins 8 Lower king pins 9 Front suspension arm pins 10 Rear axle reaction triangle ball joint 11 Universal joints and sliding sleeve of propeller shaft 12 Steering linkage ball joints

Control linkage joints 13 Clutch 14 Carburetor 15 Service brake 16 Parking brake Door & hood locks and hinges Windshield wiper push-pull rod loints Every 8 , 0 0 0 Km. ( 5 , 0 0 0 miles) 17 Ignition distributor

Every 1 2 , 0 0 0 Km. ( 7 , 5 0 0 miles)

18 Gearbox 19 Rear axle

22

Flexible shafts of mileage blower unit controls

recorder,

revolution

counter

and

heater

Lubrication

PERIODICAL LUBRICATION

Lubrication diagram

E
^

E
^

E
*

E
o o ir>

o o o
(N
>

o o o_ oo"
>

o o o
> L. >

OJ
>

ai
>

o
LU

a>
>

> L.

23

LU

LU

LU

RECOMMENDED LUBRICANTS

Lubrication

Part

API-NLGI-SAE Numbers

R e c o m m e n d e d commercial

equivalent

Engine

SAE 20 W 40 API MS

AGIP

Energol

Shell

X-100

Viscostatic

AA.O. 20 W 40

Gearbox

SAE 9 0

AGIP

Energol

Shell Dentax

90

Gear O i l SAE 90

Steering box & rear axle

SAE

90

AGIP

Energol

Shell Spirax 90 EP

API EP

Gear O i l SAE 90 EP

Front & rear suspension ball joints Steering l i n k a g e joints SAE NLGI Front s u s p e n s i o n a r m pins Propeller shaft universal joints 1

AGIP AGIP

Energrease A 1 Energrease A 0

Shell Retinax G Shell Darina Grease A X

AGIP Front w h e e l bearings SAE NLGI 2 / 3

Energrease L 3 Shell A l v a n i a Grease 3

A G I P Energrease L 2 Multipurpose

Brake f l u i d reservoir

SAE 70 R 3

AGIP Brake

Energol Fluid

Shell Donax B 70 R 3 Shell Super Safety Brake Fluid

The regular lubrication operations f r o m 5,000 to 30,000 miles are scheduled in the table on the f o l l o w i n g page. This w i l l enable the user to f o l l o w regularly and easily the prescribed l u b r i c a t i o n . In countries where the recommended lubricant is not found, it is possible to replace it with products of other lubricant manufacturing Companies provided that in accordance with the prescribed specifications. * To avoid damage, the SAE 90 oils prescribed for the gearbox unit should not be confused with oils of the same grade but different in type, EP, which are prescribed for steering box and rear axle units.

24

Lubrication

REGULAR LUBRICATION SCHEDULE

MILEAGE OPERATIONS
O

COVERED o o o o
O

1 ^1
CD

o o

o1 o
IT)

o o os
o

o o m cs

o o

LO

; o o m
,

o
LO CN
N

o o
<D LO CM

o r^
CN

r1
o o
CO

r^
~~

**

(N

1 Change the

oil

1
1 1

c
LU

1 Change the filter element

Fill up

o
5 o)
0> O

1 Change the

oil

I Fill up
1 Change the oil

Steering box

1 Fill up

|
1

Brake fl uid reservoir Fill up Ignition distributor Upper and lower pins and f r o n t suspension pins king

Rea r axle reaction triangle ball joint Universal joints and rooeller s haft sleeve

u
Steering linkage joints Clutch, brake and carburetor linkage joints Windshield wiper push-pull ro joints; hinges and locks exible shafts of: mileage recorder, revolution counter and blower-heater unit controls

W A R N I N G ! Check the engine oil level with the dipstick every 300 miles.

25

PERIODICAL LUBRICATION

Lubrication

Lubricating system diagram

1 Filler 2 Oil 3 Oil 4 Oil

plug suction d u c t , w i t h pump filter valve valve strainer

7 Oil 8 Idle

passage gear lubricating lubricating for oil oil passage passages the gears igni-

9 Camshaft 10 Passage tion

lubricating driving duct

5 Relief

distributor gauge

26

6 Bypass

11 Pressure

Lubrication

ENGINE LUBRICATION

The oil level should never drop below the lower m a r k on the d i p s t i c k , or to be above the top m a r k .

Oil level

W a r m up the engine to normal operating temperature. Drain off old oil thoroughly. Remove the filter body and clean off oil and sludge. Replace the filter element. Replenish with new oil.

O i l change

In the event the recommended engine lubricating oil of m u l t i g r a d e type is not f o u n d on the m a r k e t , it can be replaced by the f o l l o w i n g o i l s : Above 10"C ( 5 0 " F ) AGIP Energol SAE 40 or SHELL X-100 M.O. 40 Below 10"C ( 5 0 " F ) AGIP Energol SAE 30 or SHELL X-100 M.O. 30

Use of nond e t e r g e n t oils

If the engine has been run f o r a long time w i t h non-detergent o i l , detergent oil must not be added as deposits, adhering to various parts of the engine and flushed off by the detergent o i l , quickly clog the oil f i l t e r ; the consequence is damage to main and connecting rod bearings and to other parts lubricated by the circulating engine o i l . To replace non-detergent oil w i t h detergent oil proceed as f o l l o w s : 1 Drain off old oil and replace it f o l l o w i n g the above said procedure. 2 After 200-500 Km. ( 1 3 0 to 300 miles) depending on the distance covered by the car w i t h non-detergent o i l , change oil and filter element again. 3 Then follow the standard lubrication schedule.

Replacement of n o n - d e t e r g e n t oils w i t h d e t e r g e n t oils

W i t h a reconditioned engine f o l l o w the instructions given for breaking in period.

Oil replacement after e n g i n e reconditioning

27

OIL

PUMP

Lubrication

The oil pressure is adjusted by a valve on the p u m p body If the pressure falls below the m i n i m u m values, an authorised Alfa Romeo Service Station must be consulted to trace and remedy the fault

n u m .5-1

Kg

cm

Oil pressures w i t h hot e n g i n e

Idle

'Aa*

(7 to m i n i m u m 3.5 "

p-

(50 ps.)
m a x i m u m 4.5-5 K

revs

(65 to

\r

To increase the oil pressure a shim of suitable thickness must be inserted between the spring and the plug in the p u m p body. If the pressure is still less than that prescribed, check the pressure gauge w i t h a master gauge; if the trouble persists, check 'he p u m p gears and the main and connecting rod bearings for wear.

28

Lubrication

OIL

FILTER

Maintenance

Oil flow w i t h normal operation

Oil f l o w in an emergency

To remove impurities the engine oil is filtered by a full-flow filter in series with the delivery circuit. The filter is fitted with a valve that bypasses the element if it should become clogged. When replacing the filter element, thoroughly clean the case. It should be remembered that the periodical replacement of the element the perfect cleaning and assembly of the filter are essential if the engine is to give its best performance. On reassembling the filter, make sure that the gasket is in a good condition. After refitting the filter to the engine, make sure that there are no oil leaks. 29

PERIODICAL MAINTENANCE

Maintenance

Every 5 0 0 K m . ( 3 0 0 miles)

1 Check water level in radiator 2 Check tire inflation pressure

Every 4 , 0 0 0 Km. ( 2 , 5 0 0 miles)

3 Check fan and generator belt tension 4 Clean air cleaner 5 Adjust brake shoe/drum running clearance 6 Fili up battery 7 Cross o\/er tires 8 Check and adjust spark plug gap 9 Check valve timing chain tension

Every 8 , 0 0 0 Km. ( 5 , 0 0 0 miles)

10 Check steering r o l l e r / w o r m clearance 11 Check ignition distributor timing and contact-breaker points 12 Check valve clearance 13 Clean fuel filters and carburetor jets 14 Adjust clutch oedal free travel Lubricate throttle and choke control flexible shafts

Every 1 2 , 0 0 0 Km. ( 7 , 5 0 0 miles)

15 Front wheels : check and adjust toe-in check camber angle

Every 1 6 , 0 0 0 Km. ( 1 0 , 0 0 0 miles) Every 2 4 , 0 0 0 Km. ( 1 5 , 0 0 0 miles)

16 Adjust and grease front wheel bearings

Check tightening of all bolts, nuts and studs

30

The regular maintenance operations, f r o m 5,000 to 30,000 miles, are scheduled in the table on page 32. This will enable the user to follow regularly and easily the prescribed maintenance operations.

Maintenance

PERIODICAL MAINTENANCE

Maintenance diagram

VO

(N

00

0>
>

0
>

0)
>
>

31

>

UJ

REGULAR MAINTENANCE SCHEDULE

Maintenance

OPERATIONS

A d j u s t tension of g e n e r a t o r and f a n Clean air filter

driving

belt

A d j u s t brake clearance

shoe/drum

Fill u p

battery

Cross

over

tires

Check and adjust spark p l u g g a p

Check camshaft chain tension Check steering clearance

drive

roller/worm

Check i g n i t i o n d i s t r i b u t o r t i m i n g and contact-breaker p o i n t s

Check valve

clearance

Clean f u e l filters and carburetor jets

Adjust

clutch

pedal

free

travel

Lubricate t h r o t t l e and choke c o n t r o l f l e x i b l e shafts Check and adjust f r o n t w h e e toe-in and camber angle A d j u s t and grease w h e e l bearings Check all bolts r tightness front

and

nuts

W A R N I N G ! Check radiator water level and tire pressure every 300 miles.

Engine maintenance

NUT TIGHTENING

To avoid stressing the metal, tighten as follows with a torque wrench set to the prescribed torque.

Main bearing caps: lubetorque to Connecting rod bearing caps : lubetorque to

4.7-5 Kgm. (34-36 ft-lbs) 5-5.3 Kgm. (36-38 ft-lbs)

Tightening torque specifications

Camshaft journal caps: lubetorque to2-2.2 Kgm. (14.5-15.9 ft-lbs)

Cylinder head nut tightening order

1 After

reconditioning, lubetorque when cold t o : 6.2-6.4 Kgm. (44.7-46.2 ft-lbs)

2 Warm up the engine and when hot retighten without unscrewing to 6.6-6.7 Kgm. (47.7-48.5 ft-lbs) 3 When the cylinder head gasket is replaced relock after the first 500 Km. (300 miles). Unscrew by one quarter turn and retighten when cold to 6.2-6.4 Kgm.

Tightening torque specifications for cylinder head nuts

(44.7-46.2 ft-lbs)

33

VALVE

TIMING

Engine maintenance

The V-mounted overhead valves are directly operated by two camshafts acting through oil bath cups.

inlet Valve clearance w i t h cold engine exhaust

3.475-0.5 mm. (.0187-.0197 in.) 0.525-0.550 m m . [.0206-.0216 in.)

T i m i n g data

Inlet

valves

opening starts closing ends

24" 40' before T.D.C. 72" 40' after B.D.C.

Exhaust

valves

opening starts closing ends

66" before

B.D.C.

18" after T.D.C.

Valve

clearance adjustment

When the engine is cold, carefully measure the clearance w i t h a feeler gauge. If the clearance is incorrect, remove camshafts and valve cups measure the thickness of shim on each valve stem and replace it w i t h another of proper thickness so that the clearance is the correct one for normal operation. To facilitate this adjustment the shims are made available in a series of thicknesses ranging f r o m 1.5 to 2.8 m m . (.06 to .11 in.) in increments of 0.025 m m . (.0099 i n . ) .

34

Engine maintenance

VALVE TIMING

The valve timing is correct w h e n , no. 1 cylinder on compression stroke, the t i m i n g m a r k cut in the crankshaft pulley ( a n d marked P = TDC) is in line w i t h the reference plate and when the t i m i n g marks cut on the camshaft f r o n t journals are in line w i t h those cut on the journal bearings.

Checking and timing

No. 1 cylinder cams must be positioned as shown in the i l l u s t r a t i o n , i.e. pointing outward.

35

VALVE

TIMING

Engine maintenance

If, due to chain stretching or for any other reason, the t i m i n g marks on camshaft journals are misaligned in relation to the journal bearing marks by more than 2 ' (about 1 m m . - .04 i n . ) , unscrew the nuts and remove the locating bolts securing sprockets to camshaft flanges and, while holding one sprocket stationary, rotate its camshaft ( b y a suitable spanner wrench acting on the d r i l l e d flange keyed to the camshaft) until the t i m i n g marks line u p ; then reinstall the locating bolts and retighten the nuts.

Chain tension adjustment

To adjust t i m i n g chain tension, proceed as f o l l o w s : unlock w i t h o u t removing the setscrew securing chain tensioner; run engine at idling speed for a few seconds to allow the tensioner to tight the chain ; lock chain tensioner setscrew f i r m l y .

36

Engine maintenance

FUEL FEED

The fuel supply is ensured by a mechanical p u m p located on the righthand side of the engine and actuated by the d i s t r i b u t o r d r i v i n g shaft. Should the fuel p u m p operation prove f a u l t y , first make sure that there are no leaky unions or damaged gaskets, and then : check the condition of the filter, and clean it w i t h gasoline and an air b l a s t ; check the condition of the inlet and outlet valves and their s p r i n g s ; clean them w i t h gasoline and an air blast. If damaged, fit news ones; check the condition of the diaphragm and fit a new one if it is w o r n or damaged. The presence of leaks is shown by drops of gasoline appearing at the drain hole in the bottom of pump body.

Fuel p u m p

37

FUEL FEED

Engine maintenance

Solex 3 2 P A I A 5 carburetor The t w i n vertical d o w n d r a f t carburetor is provided w i t h a choke and an accelerating p u m p . The t h r o t t l e in the second chamber (on the engine side) is controlled by a vacuum capsule connected to the two venturi t u b e s ; the 2nd t h r o t t l e opens when 1st t h r o t t l e opening is enough to create sufficient suction in the vacuum capsule. This results in p o w e r f u l acceleration and i m p o r t a n t fuel economy at medium speeds.

1 I d l i n g jet. 2 M a i n jet no. 1. 3 Accelerating pump. for minimum screw. opening

4 A d j u s t i n g screw o f 1st t h r o t t l e . 5 Idling mixture

adjusting lever.

6 Choke c o n t r o l 7 Vacuum

capsule.

8 M a i n jet no. 2. 9 Idling 10 Filter. 11 A d j u s t i n g of 2nd screw for minimum opening throttle. jet.

1 t chamber s Adjusting the

Venturi Main jet . . . . I d l i n g jet . . . M a i n air m e t e r i n g jet I d l i n g air m e t e r i n g jet Acceleration p u m p jet Choke jet . . . .

2nd chamber 23 135 70 200 60

_
M M B

carburetor jets

38

23 125 45 220 100 45 120

Engine maintenance

FUEL FEED

If the engine runs unevenly at idling speed or tends to stall, the carburetor must be a d j u s t e d ; this must be done when engine is hot and after making sure that spark plugs are not defective. To adjust idling proceed as f o l l o w s : screw in the screw 11 for a quarter t u r n to prevent binding of the 2nd t h r o t t l e ( l o c k in the jam nut of screw 1 1 ) ; screw in the 1st t h r o t t l e m i n i m u m opening adjusting screw 4 for about half a t u r n to make the engine run f a s t e r ; unscrew the screw 5 until the engine begins to hunt , then gradually crew it in until the engine runs s m o o t h l y ; slowly unscrew the t h r o t t l e adjusting screw 4 u n t i l the engine speed is approximately 500-600 r . p . m . ; if the engine again begins to hunt , slightly tighten screw 5 ; in no case must this screw be tightened to its maximum extent. Clean float chamber and jets. Jets must always be cleaned w i t h compressed air only and never w i t h metal objects which could easily alter the orifice diameter.

Idling adjustment

Carburator maintenance

Further d i s m a n t l i n g , overhaul or adjustment must be done only by an authorized Alfa Romeo Service Station.

It consists of a silencer and a star-shaped felt element designed provide the m a x i m u m cleaning surface.

to

A i r cleaner

Cleaning Remove the air cleaner co^er and w i t h draw the element. Cleanse the element carefully by blowing low-pressure air inside it.

IGNITION

Engine maintenance

The ignition system is of the battery-and-coil type w i t h a centrifugal advance governor incorporating a vacuum advance regulator. The advance regulator corrects the advance as necessary and thereby reduces the consumption of fuel when the engine is running at reduced power.

Bosch Ignition Distributor

F Fixed Advance

Max.

M Advance

Advance

data
VJU 4 BR 41 mk

3 2
before TDC

43 ' 3 " at 5,000 rpm

Lubrication

At the prescribed lubrication schedule: Apply some drops of oil to the suitably provided lubricator located in the d i s t r i b u t o r body. Remove the rotor arm and apply some drops of oil both in the cam spindle and around the contact-breaker plate in order to lubricate the centrifugal advance governor beneath the plate. Smear a thin coating of grease on the contact-breaker cam follower.

40

Distributor point gap: 0 35 to 0.4 m m . ( .0138 to .0157 i n . ) . This gap can be adjusted by means of the adjusting screw 1. The contact-breaker points must alwais be perfectly c l e a n ; if necessary, they may be smoothed w i t h a very fine file. Clean using a lint-free cloth soaked w i t h gasoline.

Engine maintenance

IGNITION

To check the ignition t i m i n g , proceed as follows : 1 rotate the crankshaft to b r i n g no. 1 cylinder piston to the compression stroke, that is w i t h both valves closed; 2 by slightly rotating the crankshaft, b r i n g the fixed advance mark ( F ) cut in the drive pulley into line w i t h the reference plate. 3 remove the d i s t r i b u t o r cover and check whether the contact-breaker points begin to open when the engine is turned slightly in its normal direction of r o t a t i o n .

C h e c k i n g the ignition t i m i n g

A more accurate check can be made w i t h a stroboscopic gun as f o l l o w s : disconnect the rubber pipe f r o m the vacuum advance r e g u l a t o r ; run the engine at about 5,000-5,300 r.p.m. and direct the light f r o m the stroboscopic gun onto the p u l l e y ; if the t i m i n g is correct, the M ( m a x . advance) stamped on the pulley w i l l be seen in line w i t h the reference plate. If it is f o u n d that the max. advance is greater or less than the prescribed value, adjust the fixed advance accordingly, as it is better to have correct t i m i n g at high speeds. M

41

IGNITION

Engine maintenance

Timing correction

If the t i m i n g requires correction proceed as f o l l o w s : 1 unscrew the nut on bolt securing the d i s t r i b u t o r b o d y ; 2 rotate the d i s t r i b u t o r body counterclockwise or clockwise according to whether it is necessary to advance ( A ) or retard ( P ) the i g n i t i o n ; 3 retighten the nut, taking care not to move the d i s t r i b u t o r body.

T i m i n g the distributor after r e m o v i n g it from engine

After removing the d i s t r i b u t o r f r o m engine, time it as f o l l o w s : 1 rotate the crankshaft to bring no. 1 cylinder piston to the compression stroke, that is w i t h both valves closed; 2 by slightly rotating the crankshaft, b r i n g the fixed advance mark ( F ) into line w i t h the reference m a r k on the t i m i n g chain cover; 3 remove the d i s t r i b u t o r cover and t u r n the d r i v i n g spindle by hand so as to position the rotor arm towards the contact for ignition in cylinder no. 1 ; 4 make sure that in such position the contact-breaker points are about to begin opening ; 5 then, w i t h o u t moving the spindle, mount the d i s t r i b u t o r on its bracket and tighten the nut on the bolt which locks the d i s t r i b u t o r body to its bracket ;

42

6 check the ignition t i m i n g as described previously.

Engine maintenance

IGNITION

Spark plugs:

LODGE 2 HLN

This type of spark plug gives the best performance and requires a m i n i m u m of maintenance. It w i l l be enough to check and clean the electrodes periodically adjusting the electrode gap t o : 0.55-0.65 mm. (.022-.025 i n . )

The spark plugs should be locked when cold to a torque of 2.5-3.5 Kgm. (1825.3 f t - l b s ) ; lubricate the spark plug threaded shank w i t h graphite grease before installing on engine.

mm 0,55 -7 0,65

43

COOLING SYSTEM

Engine maintenance

Water pump

Engine cooling is assured by a forced water circulation. The water p u m p is b u i l t into the fan bracket and is driven by the belt that also drives the fan and the generator.

1 Fan 2 Pump body 3 Pump impeller

Thermostat

The thermostat is fitted in the intake m a n i f o l d . To ensure the quick w a r m i n g up of tne engine, the thermostat open at the prescribed t e m p e r a t u r e : Opening temperature 82 -87 C ( 1 80 1 89'F )

must

As the water can reach a temperature of 100'-105"C (212-221F) cooling circuit is under pressure even in the radiator.

the

44

Engine maintenance

COOLING SYSTEM

If, in spite of the precautions taken water consumption is encountered, f r o m the rubber hoses; also check that the spring, the rubber seal and case of d o u b t , fit a new cap.

when f i l l i n g the radiator, excessive make sure that there are no leaks the radiator cap, and make sure the valve are in good order. In the

Radiator

In order to maintain the original cooling efficiency, the radiator and engine must be flushed out f r o m time to time to remove any scale and other deposits. Proceed as f o l l o w s : drain engine and radiator f r o m water thoroughly;

C l e a n i n g the cooling circuit

fill the engine and radiator w i t h a solution of about 8 liters (1.8 Imp. gals) (2.1 U.S. gals) of water and 300 grammes ( 1 0 . 6 ozs) of sodium carbonate ; run the engine slowly for 10-15 m i n u t e s ; drain off the s o l u t i o n ; allow the engine to cool down and then circulate running water while leaving the drain cock open ; refill the engine and radiator w i t h water and run the engine slowly for a few minutes ; rain the circuit once more and then fill up again. It is advisable to flush the cooling circuit as described above before adding antifreeze.

45

COOLING SYSTEM

Engine maintenance

Adjusting

the

t e n s i o n of f a n , water pump and generator belt driving

If the tension is insufficient, the belt w i l l w e a r ; in a d d i t i o n :

slip and suffer

premature

the c o o l i n g action w i l l be reduced because of the d r o p in speed of the fan and water p u m p ; the b a t t e r y c h a r g i n g c u r r e n t w i l l be reduced o w i n g to the slower gene r a t o r speed. If the tension is excessive, the generator and w a t e r p u m p bearings w i be overloaded w i t h the consequent risk of damage. T h e r e f o r e , it is necessary to check the belt tension at the distances. The tension is correct when : A = 1-1.5 cm. ( a p p r o x . '2 i n . ) scheduled

To tighten the belt unscrew the nut on the a d j u s t i n g a r m pivot p i n , the nut of the securing b o l t and move the generator o u t w a r d s . Carefully retighten the nuts after a d j u s t i n g the belt tension.

'

46

Checking the belt tension

Adjusting the belt tension

Chassis maintenance

CLUTCH

The c l u t c h is of the single plate d r y type. Its o p e r a t i o n is ensured by 9 helical springs. The pedal free travel s h o u l d b e : Pedal free travel

approx. 23 m m . ( 1 i n c h ) .

before actual disengagement begins. W i t h this a m o u n t of free travel the actual clearance between the t h r u s t r i n g and the disengagement r i n g is 2 m m . (.079 i n . ) . W h e n , o w i n g to wear on the d r i v e n plate f a c i n g , the pedal free travel is reduced to 10-12 m m . ( Vi i n c h ) , the free travel must be restored by means of the a d j u s t i n g rod T. This is done by u n s c r e w i n g the a d j u s t i n g nuts 1 u n t i l the o r i g i n a l free travel is o b t a i n e d . A f t e r a d j u s t m e n t c a r e f u l l y secure the a d j u s t i n g nut w i t h its l o c k n u t . When it is no longer possible to restore the free travel to 23 m m . ( 1 i n c h ) by this means, and if the c o n t r o l linkage is u n d a m a g e d , the cause w i l l be excessive wear of the c l u t c h f a c i n g . It w i l l then be necessary to consult an a u t h o r i s e d Alfa Romeo Service Station f o r the replacement of the facing or the d r i v e n plate. A d j u s t i n g the pedal free travel

47

GEARBOX

Chassis maintenance

synchromesh gears and reverse

48

r ^

Chassis maintenance

GEARBOX

The casing proper, w h i c h houses the gears and shaft, consists of t w o cast half-shells to facilitate d i s m a n t l i n g and reassembling. Each synchroniser is a bevel spring ring mounted on the boss of the driven gear and w h i c h , at the moment of engagement, becomes compressed radially and displaced by f r i c t i o n by the outer sliding sleeve. The bevel spring ring by means of a pawl causes the gear to rotate w i t h it, and the gear thus develops the same speed as the engaging sleeve; in this way the inner teeth of the engaging sleeve mesh easily w i t h the f r o n t teeth on the driven gear. Two retaining strips positioned inside the bevel spring ring increase the latter's synchronising efficiency.

GEARS

1st . 2nd . 3rd . 4th . 5th . Reverse

. . . . .

. . . . .

. . . . . .

. . . . . .

3.304 1.988 1.355 1 0.791 3.010

1 1 1 1 Transmission ratios

Any adjustment of the gearbox, whether because of difficult engagement or for any other reason, must be done only by an authorized Alfa Romeo Service Station.

1 Filler plug. Check that gearbox is full of oil to the b o t t o m edge of the filler orifice. 2 Drain p l u g .

49

PROPELLER SHAFT

Chassis maintenance

Engine side

The propeller shaft is in two sections and has an intermediate support flexibly attached to the body. The f r o n t shaft is provided w i t h a rubber coupling at the gearbox e n d ; an universal joint is provided at each end of the rear shaft. If a propeller shaft should become noisy, arrangements should be made to have the flexible rubber coupling, the bearing in the intermediate support, the universal joints and the shaft alignment checked by an Alfa Romeo authorised station.

Grease the universal joints and the sliding sleeve on rear section of propeller shaft at the scheduled distances.

1 Rubber

coupling.

Differential side 50

2 Front 3 Rear

shaft. shaft. joint.

4 Universal

5 Grease seal. 6 Intermediate support

Chassis maintenance

REAR AXLE

The rear axle is attached longitudinally to the supporting structure by means of two radius rods w i t h rubber bushes at the e n d s ; trasverse attachment is effected by means of an upper reaction triangle w i t h arms hinged to the body and to the rear axle through rubber bushes. The bevel drive is of the hypoid type.

Overall gearbox/rear axle ratios w i t h 41 : 8 bevel drive

in in in in in in

1st gear 16.933 2nd gear 10.189 3rd gear 6.944 4th gear 5.125 5th gear 4.054 Reverse 15.426

1 1 1 1 1 Overall ratios

Check oil level or replace oil in the differential housing at the scheduled distances. When an overhaul is necessary, consult only an authorised Alfa Romeo Service Station.

51

SUSPENSIONS

Chassis maintenance

Front Independent suspension is p r o v i d e d f o r each f r o n t wheel ; the wheels are secured to the body by transverse a r m s . Coil springs and double-acting hyd r a u l i c telescopic shock absorbers are located between the lower arms and the body. The suspension system is c o m p l e t e d by a transverse stabiliser r o d w h i c h improves the s t a b i l i t y of the vehicle o n bends. U p w a r d s r o t a t i o n of the arms is res t r i c t e d by pads in the shock absorbers. Rotation d o w n w a r d s is restricted by a r e b o u n d cable one end of w h i c h is connected to the body and the o t h e r to the lower a r m . When accomplishing the scheduled lubrication, take care to lubricate the steering knuckle with the wheels lifted from ground.

Rear The rear suspension consists of coil springs and large d i a m e t e r shock absorbers coaxial w i t h the springs. The r e b o u n d of rear axle is l i m i t e d u p w a r d by a r u b b e r pad and d o w n w a r d w i t h a f a b r i c and vulcanized rubber s t r a p .

To lubricate, follow the regular lubrication schedule. Whenever the shock absorber d a m p i n g action appears to be uneven, have the shock absorbers checked by an a u t h o r i z e d Alfa Romeo Service Station.

52

Chassis maintenance

STEERING GEAR

The steering gear is of the w o r m - a n d - r o l l e r type. Stable steering requires that : there is no a b n o r m a l play in the steering gear ( t h e bearings in steering box, the w o r m - a n d - r o l l e r c o u p l i n g and the ball j o i n t s ) ; the

the f r o n t wheels are perfectly balanced and the t i r e i n f l a t i o n pressures are as p r e s c r i b e d ; the f r o n t suspension m e m b e r s are in perfect c o n d i t i o n s .

Check oil level and plays at the scheduled distances.

Check oil level t h r o u g h plug 3. To a d j u s t w o r m - a n d - r o l l e r c o u p l i n g act on the screw 1 . On c o m p l e t i n g the a d j u s t m e n t , lock this screw w i t h the l o c k n u t . To a d j u s t the end play of w o r m bearings insert a suitable s h i m between the bearing and the b o t t o m cover of the steeering box. 2

Tl above a d j u s t m e n t s must take up all play but must not give rise to any b i n d i n g . It is recommended that this work should always be carried out by an Alfa Romeo Service Station.

53

STEERING LINKAGE

Chassis maintenance

The steering arms are connected by ball j o i n t s .

Maintenance

At the scheduled distances : Grease the steering linkage ball j o i n t s t h r o u g h the p r o p e r grease f i t t i n g using the p r e s c r i b e d grease. Check the ball j o i n t p l a y ; if an excessive play is f o u n d , replace the ball j o i n t s . If necessary, a d j u s t the t u r n i n g circle by means of '.he a d j u s t i n g screw 5.

1 Steering 2 Bellcrank

box. bracket

3 Track r o d . 4 Later arms. circle

5 Screw for a d j u s t i n g the t u r n i n g

54

Ball joints w i t h grease

fitting.

Chassis maintenance

FRONT WHEELS

To prevent uneven and premature tire wear, and to ensure smooth and stable steering, f r o n t wheel toe-in and camber must be set to the prescribed values. Toe-in and camber vary according to the vehicle load : the values should be checked w i t h a normal load, w i t h the car standing on level g r o u n d , w i t h f u l l sump, tank and radiator, and w i t h the tires inflated to the prescribed pressures.

and w i t h : spare w h e e l , tools and all systems replenished

50 Kg = 110 lbs 20 Kg = 44.1 lbs

Load specifications for checking c a m b e r a n d toe-in

The check should be carried out by specialised mechanics using suitable equipment. It is recommended that it should only be entrusted to an authorised Alfa Romeo Service Station.

With

the

car

loaded == B

as

above,

Camber and

check

there should be :

adjustment

The camber is adjusted by varying the number of shims S between the upper suspension arms and their attachment to the body.

55

FRONT WHEELS

Chassis maintenance

Toe-in

With the car in the load conditions as prescribe'

4 mm

58 in.

3 mm -

8 il

Toe-in adjustment

bring and lock the steering wheel in the central position (i.e. with the spokes symmetrically disposed in relation to the vertical ) ;

starting with the lateral arm 1 on the steering box side, place the corresponding wheei in the straight-ahead position (toe-in n i l ) ; measure the length thus obtained of the lateral arm on the steering be side and adjust the arm 2 on the other side to the same length; bring the right-hand wheel to the straight-ahead position by ad) ng the track rod 3 ; shorten both lateral arms equally until the prescribed toe-in is obtained. Length of steering arms as measured between ball joint centres, should fall w i t h i n the following imits :

O 0

265-285 mm = 10.4-11.2 in. Q

470-490 mm

18.5-19.3 in.

56

If these values cannot be restored, the cause will probably be found in distortion resulting f r o m a collision.

Chassis maintenance

BRAKES

1 Brake f l u i d 3 Front w h e e l 4 Rear w h e e l 5 Brake pedal

reservoir cylinder cylinder for stop lights

7 Stop 8 Hand

lights brake handle lever,

2 Master c y l i n d e r

9 Rear w h e e l c y l i n d e r control o p e r a t e d by hand brake h a n d l e 10 Hand brake adjuster control cable slack

6 Pressure s w i t c h

Brake shoes w i t h s u p p o r t plates

Rea

2 shoes

Front: 3 shoes

57

BRAKES

Chassis maintenance

General

The

brake

system

consists

of

hydraulically-operated

service

brakes and

acting on all f o u r The b r a k i n g

wheels and of

mechanically-operated is applied through

parking

emergency b r a k e acting on rear wheels o n l y . action on rear wheels self-centering shoes and on f r o n t wheels t h r o u g h a three-shoe u n i t . The b r a k e d r u m s are p r o v i d e d w i t h c o o l i n g fins to dissipate r a p i d l y the heat generated by f r i c t i o n d u r i n g b r a k i n g .

Parking emergency

and

The hand p a r k i n g b r a k e is mechanically-operated t h r o u g h a w i r e cable w h i c h , when p u l l i n g the handle, acts d i r e c t l y on rear wheel b r a k e shoes. If the p a r k i n g b r a k e is p r o p e r l y a d j u s t e d , the rear wheels s h o u l d become locked w h e n the lever of is moved through half its total travel. only Usually the a d j u s t m e n t parking brake control is p e r f o r m e d

brake

when b r a k e shoe a d j u s t m e n t is r e q u i r e d f o r l i n i n g wear o r , exceptionally, f o r cable slackening. To a d j u s t the travel act on the slack a d j u s t e r 10 ( see figure on page 57 ).

Hydraulic

brake

Restore the level of h y d r a u l i c f l u i d in the b r a k e system reservoir at the scheduled distances. The level s h o u l d never d r o p below the f u l l of f l u i d (see page 2 4 ) . Mineral oil must not be used, as it would damage the rubber seals in the master and wheel cylinders. For efficient o p e r a t i o n of the h y d r a u l i c b r a k e , the pipes must be f u l l of f l u i d and free of air bubbles. Excessive and resilient always brake level by m o r e than a q u a r t e r ; it is m a n d a t o r y to use o n l y the prescribed type

Dedal travel is an almost certain i n d i c a t i o n of the presence of air bub58 bles in the system.

Chassis maintenance

BRAKES

Fill the fluid reservoir w i t h the correct type of fluid and ensure that d u r i n g the bleeding operation the level does not d r o p below the f u l l by more than a quarter.

Air bleeding

Rear wheel cylinders

By acting on pins P, move the shoes all the way apart. Push a rubber pipe over the bleed screw S; the other end of the pipe w i l l lead to a glass bottle for collection of fluid ; Unscrew the bleed screw S ; Depress the brake pedal several times, allowing it to return slowly until the rubber pipe discharges fluid free f r o m air b u b b l e s ; Hold the pedal down and screw in the air bleed screw S. Front wheel cylinders

When all air has been bled off, reset the r u n n i n g clearance as specified on the f o l l o w i n g page. If the bleeding operation has been carefully p e r f o r m e d , it w i l l be f o u n d that, when the brake pedal is operated, direct action on the f l u i d can be felt, free of resilience, immediately at the end of the free travel.

59

BRAKES

Chassis maintenance

M a s t e r cylinder push rod stroke

The brake pedal before actuating the master cylinder must travel through a free stroke corresponding to a master cylinder push rod stroke of :

1-1.5 m m .

(3/64"-l/16")

To adjust the pedal travel tighten the push rod on the clevis connecting pedal to push rod and secure it w i t h the locknut. The brake pedal travel should be adjusted when, as a result of wear of the brake linings, the pedal travels ( w h e n b r a k i n g h a r d ) through more than two-thirds of the total possible distance.

Rear

brakes

Front brakes

P - Running clearance a d j u s t i n g

pins.

V - S h o e / d r u m squareness a d j u s t i n g screws.

R u n n i n g clearance adjustment

To adjust the brake/shoe d r u m running clearance, proceed as f o l l o w s : Rear wheels : rotate the pin P which acts simultaneously on the brackets of brake shoes; Front wheels : both

60

rotate the pins P which act on each shoe.

Chassis maintenance

BRAKES

The adjustments of the three-shoe brake running clearance are quite similar to those performed on two-shoe brakes. However being description w i l l be given. Raise the wheel and make certain it spins freely by unscrewing all the three adjusting pins P, if necessary. Rotate each pin one notch a time in the same direction of rotation as the wheel and check the wheel for free spinning each time. As soon as one of the pins brings its shoe in contact w i t h the d r u m , unscrew the adjusting pin of t w o notches and then set the shoe by p u m p i n g the brake pedal. This procedure allows to compensate the pedal free travel also. When it is no more possible to reduce the pedal free travel by adjusting the pins P, replace the shoe linings w i t h new ones. this a procedure requiring great care to get m a x i m u m efficiency, a detailed

61

BRAKES

Chassis maintenance

Stopping distances

M.p.h. 31 37 43 50 56 62 68 74 80 87 93 100 105 110 176 151 126 101 76 51 25 yards

The distance in which a car can be brought to a stop after application of its brakes increases considerably as the speed increases; the distance also varies according to the road surface and is much greater when the road is wet, slippery, etc. The diagram shows stopping distance for various speeds, intended for ideal conditions, i.e. flat, dry, asphalt roads, good tires, well adjusted brakes and loads properly d i s t r i b u t e d over the car. For safety's sake always bear these stopping distances in mind at a times.

62

Chassis maintenance

WHEELS

The dimensions of the pressed sheet steel wheels are

4 % J X15

Raise the car by inserting the jack arm in the appropriate socket on the body longitudinal member. Before operating the jack, apply the hand b r a k e ; as the hand brake affects the rear wheels only, put chucks under the f r o n t wheels when raising the rear wheels. Left-hand wheels: t u r n the nuts clockwise to unscrew them. Right-hand wheels: t u r n the nuts counterclockwise to unscrew them. When replacing wheels, tighten the nuts carefully in diagonal Check again for tightness after lowering the jack. order.

Wheel removing

At the scheduled distances, lubricate front wheel bearings. The rear wheel bearings are sealed and factory packed, and do not require l u b r i c a t i o n . The front wheel bearing lubrication must be performed with great care and only by trained mechanics using suitable equipment. The correct procedure is the f o l l o w i n g : w i t h d r a w the hub to grease the inner b e a r i n g ; check the condition of the bearings c a r e f u l l y ; adjust the end play on the basis of the prescribed preload.

Maintenance

63

WHEELS

Chassis maintenance

Each wheel, complete w i t h its pneumatic tire, is dynamically balanced at the factory by means of suitable plates and blocks. Whenever a tire is changed, the wheel must be rebalanced on a suitable balancing machine. It should be remembered that unbalanced wheels mean unstable steering, abnormal steering gear wear and uneven tire wear.

Balancing

Balance w e i g h t S Static

location D Dynamic

TIRES
PIRELLI CINTURATO Front

SPRINT Rear Front

SPIDER Rear

Inflation pressures w i t h tires cold

Touring riding up to 160 K m / h (100 mph)

1.6 Kg cm (22.7 psi)

1.7Kg cm (24.1 psi)

1.6 Kg/cm (22.7 psi)

1.7Kg/cm (24.1 psi)

Sport r i d i n g u f t i/ /u above U 160 K m / h

(100 m p h )

. J. 1 . 7 K3g c m (24.1 psi)

. 1.8 Kg/cm3 (25.6 ps.)

. 1.7Kg cm 3 (24.1 psi)

. 1.8 Kg/cm3 (25.6 psi)

Cn

track

2 Kg/cm (28.4 psi)

2.1 Kg/cm (29.8 psi)

2 Kg cm (28.4 psi)

2.1 Kg/cm (29.8 psi)

64

Chassis maintenance

TIRES

Pressure

correct

The tire gives o p t i m u m p e r f o r m a n c e , the tread w o r k s over its e n t i r e w i d t h , the tire wear is uniform and tire life is long.

too low

The tire w i l l heat excessively; the sides of the tread will wear quickly and the tire plies w i l l t e n d to separate.

too high

The result w i l l be an u n c o m f o r t a b l e r i d e , excessive wear in the center of the t r e a d and tire vulnerability to knocks.

65

TIRES

Chassis maintenance

Crossing over

To ensure even and uniform tire wear and long tire life, the wheels should be crossed over as shown in the diagram below, at the scheduled distances. The spare wheel must be included in the scheme.

Pirelli crossing over diagram

66

Body maintenance

EXTERNALLY

Avoid washing the car in the sun or when the body is still hot. Start washing f r o m the bottom of the car, without letting water get into the brake drums and then move upwards. Be careful not to let the water strike too hard against the paintwork. After washing, wipe down with a sponge, which must be frequently rinsed and use plenty of water. Use chamois leather to dry the car. It may happen, during washing, that a little water does get onto the working surfaces of brake drums. It is advisable to apply the brakes lightly for fairly long intervals. This w i l l heat the brake linings and dry out any water they may have absorbed.

Washing the car

To put fresh gloss on the paintwork, rub down once or twice a year w i t h a polish suitable for synthetic or nitrocellulose paint, according to the type of paintwork on the car. On the chromework use rectified petrol to remove grease and a suitable paste to take out any scratches. Use only wollen rags for polishing. Do not use gasoline or solvents on rubber mouldings. Use only a very soft chamois leather for cleaning the windshield and windows. If the panes are very d i r t y , use window cleaning fluid or water mixed with alcohol or ammonia.

Polishing

Cleaning the windows

Grease, oil

and tar stains may be removed from

the paintork

by

Removing stains

soaking the stained area with petrol, and then by rubbing it down with a dry cloth. If tar deposits have hardened, use one of the preparations available on the market. To avoid serious damage to the paintwork, do not use polyvinyl-type tarpaulins. When refueling or lubricating, be careful not to splash gasoline or brake fluid onto the paintwork, as these liquids are highly corrosive. 67

INTERNALLY

Body maintenance

Upholstery

Remove dust f r o m the inside upholstery at intervals, using a vacuum cleaner if possible. To get rid of oil and grease stains, use diluted ammonia on the cloth parts, water w i t h neutral soap on the artificial leather and vaseline oil on the leather. Use trichloroethylene or neutral soap to remove stains f r o m the carpets. Gasoline should be used for cleaning the steering wheel and control

knobs.

When laying the car up

If the car w i l l be left unused f o r any length of time the protective steps should be taken : drain all water engine is hot ; from the engine and radiator, preferably

following

while

the

empty the fuel tank, the fuel p u m p and the carburetor float c h a m b e r ; clean the oil filter and the fuel f i l t e r ; inject a little engine oil into the cylinders through the spark plug holes and t u r n the engine over by hand several times in order to spread a film of oil over the cylinder w a l l s ; remove the battery, store it away f r o m frost, and recharge it once a m o n t h ; never allow it to become f u l l y discharged or plate sulfation w i l l result ; jack up the car, clean the tires and slightly lower their pressures; if the tires are removed, dust them internally ( a n d their tubes) talcum p o w d e r ; store them in a dark and airy but dry place; smear rust preventive grease on all unpainted metal p a r t s ; dust the seats and upholstery w i t h moth preventive; with

68

cover the car w i t h a dust sheet.

Electric system

GENERAL

The 12-volt electric system is w i r e d w i t h protected and insulated cable in order to reduce the risk of short circuit to a m i n i m u m . The negative battery terminal is grounded. If any instrument fails to operate or any lamp fails to light up, first check the corresponding f u s e ; if the fuse is sound, check to ensure that the cable terminals are tight and that the bulbs are not loose or burned out. If the trouble persists, the electric system should be checked by a competent electrician.

Generator Voltage regulator . Starting Coil gnition d i s t r i b u t o r Windshield wiper . Battery . . . . motor

LJ/GEG 2 0 0 / 1 2 / 2 7 0 0 R 32 m r RS/VA 2 0 0 / 1 2 A2 AL/EEF 0 , 7 / 1 2 TK 12 A3 VJU 4 BR 41 mK DR 2 (Lucas) 50 A m p . hour Rll

Electric components (Bosch)

BATTERY
The battery water level should never be more than 3 / 1 6 " above the plates and must never leave them uncovered; When filling up the battery, use only distilled water stored in glass container; never add acid. W a t e r level

Make sure that terminals are tight and are sufficiently coated w i t h pure vaseline, to avoid oxidising.

Terminals

The state of charge can be checked by measuring the specific gravity of the electrolyte w i t h a suitable hydrometer. The specific g r a v i t y / c h a r g e ratio is as f o l l o w s : specific gravity 1.28 ( 3 2 Be) = specific gravity 1.23 ( 2 7 Be) = battery c h a r g e d ; battery half c h a r g e d ; battery discharged.

State of charge

specific gravity 1.11 to 1.14 ( 1 5 " to 18 Be) =

I distilled water has been added to a battery, the measurement of the specific gravity should not be measured u n t i l m i x i n g is c o m p l e t e ; to facilitate m i x i n g charge the battery for 30 minutes. In tropical climates where the temperature is nearly always above 30"C (85 ( ) F), the specific gravity of the electrolyte, when the battery is f u l l y charged, must be lower than the normal figure, viz. 1.21 (25 B e ) .

69

STARTING MOTOR AND GENERATOR

Electric system

Regularly : nspect c o m m u t a t o r and brushes of generator and starting m o t o r . The brushes must be clean and must slide freely in their h o l d e r s ; brush w o r k i n g face must be cleaned w i t h a cloth soaked w i t h gasoline; the brush spring must apply effective pressure. When one brush has to be replaced, it is a good rule to replace the other at the same time. Always fit new original brushes of the prescribed type. After replacing the brushes, run the generator ( o r starting m o t o r ) w i t h no load and for such time as is necessary to bed the brush w o r k ing face to the c o m m u t a t o r . If the c o m m u t a t o r is burned or elongated, it must be turned on a lathe taking care to decrease the diameter of the m i n i m u m required o n l y ; after machining, lower the mica between the blades. The above maintenance work, like all other repair work, must only be undertaken by Alfa Romeo Service Stations.

INSIDE LIGHTING

The Sprint model is provided w i t h ceiling lights f o r lighting the inside w h i c h are switched on by opening the doors or by operating the lever switch on dashboard (see page 8, no. 3 7 ) .

Electric system

HEADLAMPS AND TAIL LIGHTS

Headlamps

Sprint

1 Headlamps, d i p p e d and undipped

beams.

4 0 / 4 5 Watts double filament 5 / 2 0 Watts double filament 5 Watts

2 Parking lights and direction indicators, f r o n t 3 Direction indicators, side. 4 Direction indicators, rear. 5 Parking and stop lights. 6 Reverse lights: They light up w h e n reverse gear is engaged and parking lights are on. 7 Reflector.

5 Watts 5 / 2 0 Watts double filament

20 Watts

Tail lights

Sprint

Spider

71

HEADLAMP BEAMS

Electric system

Replacing a bulb

To replace a headlamp bulb proceed as follows : remove the screw securing the outer r i m ; then slacken the three screws 1 securing the retaining ring 2 ; rotate the retaining ring until the screw heads will pass through the holes, and draw it off; remove the reflector unit, fit a new bulb and reassemble the unit.

1 Retaining 2 Retaining

ring ring

screw

3 Screw for a d j u s t i n g the beam in the vertical plane 4 Screw for a d j u s t i n g the beam in the horizontal plane

SPIDER SPRINT

10.2 in. 11.8 in.

10 metri =

33 feet undipped beams

Anabbaglianti = dipped beams Abbaglianti =

Beam

alignment
-

10 metri
72

SPIDER 0.26 SPRINT 0.50

Anabbaglianti Abbaglianti

Electric system

FUSEBOX AND AUXILIARY CURRENT FEED

Sprint

Spider

73

Giulia 1600 Sprint

1 Battery 2 Starting 3 Voltage 4 Generator motor regulator

32 Reverse l i g h t 33 H e a d l i g h t 34 D i r e c t i o n switch 35 Horn c o n t r o l distributor

switch switch

change-over indicator

change-over

5 Coil
6 Ignition 7 Fusebox unit, directional

knob button pedal

36 H e a d l i g h t flashing push 37 W i n d s h i e l d operated 38 H e a d l i g h t s y **" washer

switch,

8 Flasher
rt

. i - i l T 9 Terminal f o r miscellaneous services 10 Solenoid s w i t c h 11 Hand l a m p socket

39 Front d i r e c t i o n indicator and parking light bulb

40 Direction i n d i c a t o r , side 12 W i n d s h i e l d wiper 41 Engine c o m p a r t m e n t 13 Blower-heater unit 42 C e i l i n g light between en43 Tail lights plate and bulb parking light light light light undipped headlight light

Legend

14 G r o u n d gine and

connection body indicator horn

15 Fuel level 16 W a r n i n g

44 Licence 45 D i p p e d beam 46 Front

17 Water t e m p e r a t u r e g a u g e b u l b 18 O i l t e m p e r a t u r e g a u g e 19 O i l h e a t i n g resistance 20 Speedometer bulb

47 I n s t r u m e n t dial

48 Generator w a r n i n g 49 Heater w a r n i n g

21 R e v o l u t i o n counter and oil pressure indicator tempe'ature

light light light

50 Fuel reserve w a r n i n g 51 Direction indicator

22 Panel for oil & w a t e r and f u e l 23 I g n i t i o n level switch light switch

warning light

indicators

52 Parking w a r n i n g 53 Rear d i r e c t i o n

indicator

bulb bulb

24 Dashpanel

54 Parking and stop light control 55 Reverse l i g h t 56 License plate bulb light bu'b

25 Parking and h e a d l i g h t switch 26 W i n d s h i e l d w i p e r 27 Blower-heater 28 C e i l i n g light unit switch

switch switch 57 C i g a r e t t e lighter switch light light

58 C h o k e c o n t r o l 59 Choke 29 C e i l i n g light s w i t c h , on 30 Thermal switch switch door 60 H e a d l a m p warning

warning

74

31 Stop l i g h t

Connections

= n

2 8
Z
<

s 3
o
z
<

ROSSO BIANCO VERDE GIALLO GRIGIO NERO BIANCO VERDE NERO GRIGIO VERDE ROSSO VERDE NERO NERO NERO

NERO GIALLO GRIGIO NERO

B I A N C O - NERO

VEROE

Note
NERO

Where

no

cross

section

s h o w n , the w i r e gauge is 1 mm

ELECTRIC SYSTEM WIRING DIAGRAM

SPRINT

Verde Bianco

= =

green white red grey black = blue

Rosso = Grigio Nero = =

Azzurro Rosa =

pink = brown yellow black and y e l l o w black and w h i t e

Marrone Giallo =

Giallo-nero = Bianco-nero Verde-nero Rosso-nero =

black and g r e e n black and red

75

%^^fSr^

Giulia 1600 Spider

Battery motor regulator

28 H e a d l i g h t and p a r k i n g light s w i t c h 29 W i n d s h i e l d wiper switch

2 Starting 3 Voltage

30 Blower-heater unit s w i t c h 31 Horn c o n t r o l knob button

4 Generator 5 Coil 6 Ignition 7 Fusebox directional distributor

32 H e a d l i g h t flashing push 33 License plate 3 4 Thermal 35 H e a d l i g h t 36 Stop l i q h t r = * light

switch change-over switch switch switch

8 Flasher unit,
n

-r i r ,i 9 Terminal tor miscellaneous services 10 S o l e n o i d 11 Hand switch socket

37 Reverse l i g h t

lamp

38 Direction i n d i c a t o r s , side 39 D i p p e d and u n d i p p e d headlight

Legend

12 G r o u n d

connection body bulb beam bulb and direction

between engine and

13 Water t e m p e r a t u r e g a u g e 14 O i l t e m p e r a t u r e g a u g e 15 O i l h e a t i n g 16 W a r n i n g 17 W a r n i n g 18 Headlight light light resistance

40 Front p a r k i n g indicator bulb

bulb 41 Rear d i r e c t i o n 42 Rear indicator bulb bulb

p a r k i n g and stop l i g h t light plate bulb light bulb light light light

horn horn

43 Reverse 44 License

45 Generator w a r n i n g 46 Heater unit w a r n i n g

19 Front p a r k i n g 20 Rear p a r k i n g 21 Speedometer

47 Fuel reserve w a r n i n g 48 P a r k i n g w a r n i n g and oil 49 Direction 50 I n s t r u m e n t indicator light warning wiper light

22 R e v o l u t i o n pressure

counter

warning

light

indicator temperature 51 H e a d l a m p 52 W i n d s h i e l d 53 indicators Heater switch, light

23 Panel for oil & w a t e r a n d f u e l level 24 D i r e c t i o n switch 25 Fuel level 26 I g n i t i o n

indicators change-over

indicator

54 W i n d s h i e l d washer pedal operated lighter

switch light switch

76

27 Dashboard

55 C i g a r e t t e

o CK
UJ

UJM/

z o
-J
-J

()

<

3
E E
eg
UJ

UJ

o o

o
u
Z

2
UJ

o
Q
UJ >

u
_..,...

<

0
- ^

C
a O

c
a
UJ

u z
<

Z O
-J -J

o
o

<

BIANCO BIANCO BIANCO VERDE GRIGIO NERO BIANCO - NERO VERDE NERO GIALLO NERO BIANCO VERDE ROSSO VERDE VERDE NERO GRIGIO BIANCO BIANCO

GRIGIO

Note Where no cross section is shown, the wire gauge is \ mm

ELECTRIC SYSTEM WIRING DIAGRAM

SPIDER

Verde Rosso Grigio Nero

= green = red =-- grey = black = == = pink yellow black and y e l l o w black and white blue white brown

Azzurro Bianco Marrone Rosa =

Giallo =

Giallo-nero = Bianco-nero =

77

Tool kit

TOOLS

Q 0 0 >

o o o o o o o o o
1 Wrench, wheel 2 Wrench, 3 Wrench, 18 x 21 14 x 17 hub cap tightening 8 Pin, t u b e wrench

9 Jack
10 S c r e w d r i v e r , 11 S c r e w d r i v e r 12 W r e n c h , plug 13 W r e n c h , 14 W r e n c h , plug, 14 x 17 cross-tipped

4 Lever, w h e e l 5 Pliers, cutting

6 W r e n c h , t u b e , spark 7 Hammer

11x15 8x10

79

FREE SERVICE COUPONS

Warranty

Alfa

Romeo take steps to ensure the o p t i m u m special

p e r f o r m a n c e of

their life

cars by p r o v i d i n g clients w i t h of their vehicles.

services d u r i n g the e n t i r e

The w a r r a n t y c a r d , supplied w i t h every new vehicle, bears the c o n d i tions that govern the p r o v i s i o n of Alfa Romeo Services and the replacement of damaged parts d u r i n g the p e r i o d covered by the Every purchaser of an Alfa Romeo motorcar is s u p p l i e d warranty. with two

coupons c o v e r i n g c e r t a i n free maintenance d u r i n g the w a r r a n t y p e r i o d , and he must use these coupons on completion of the mileage figures as stated thereon. The labor cost of the maintenance w o r k listed on the coupons is free, but the l u b r i c a n t s used are to users account. Any w o r k not covered by the free coupons b u t f o u n d necessary d u r i n g the inspection w i l l be subject to the General Terms of Guarantee. The coupons s h o u l d be used whenever possible at the garage of the Agent that sold the car and d u r i n g n o r m a l w o r k i n g h o u r s .

80

ALFA ROMEO - Via Gattamelata, 45 - MILANO DIASS. Public, no. 838 - 9/1962 (2000)

Printed in Italy

Arti Grafiche Crespi & C. - Milano

alfa romeo - milano