Alfa Romeo 155 manual 1992–98 (P/N PA49780016V002)

• Alfa Romeo 155 four-door Twin Spark sedan coverage: base-manual sections for the 1.7, 1.8, and 2.0 T.Spark engines, plus the 1.6, 1.8, and 2.0 T.Spark 16V updates. Documented engine codes include AR67103, AR67102, AR67202, AR67106, AR67601, and AR67204; the 16V supplement identifies vehicle model 167000.
• 11-file, 1,181-page scanned PDF set: combines the Alfa Romeo 155 base repair volumes with the V001 and V002 16V update material. The primary factory supplement is P/N PA49780016V002 (60494598), dated December 1995.
• Covers engine removal and refitting, cylinder-head and oil-sump work, timing and counter-rotating-shaft belt service, crankshaft and camshaft seal replacement, cooling-system repair, ignition service, starter disassembly, and alternator removal.
• Documents Bosch Motronic M1.7, M2.10.3, and M2.10.4 fault diagnosis, including air-flow, injector, fuel-pressure, lambda-sensor, EGR-control, timing-variator, Alfa Romeo CODE, and starting-fault test routines.
• Details clutch controls, gearbox and differential service, axle shafts, front and rear suspension, steering, conventional brakes, Bosch 5.3 ABS, electronic instruments, HVAC, power accessories, and structural body repair.
• Supplies system wiring diagrams, connector and component-location views, troubleshooting tables, illustrated indexes, special-tool references, and the related torque, capacity, inspection, alignment, and electrical test data.

PDF page breakdown: 01—62; 02—120; 03—148; 04—140; 05—116; 06—99; 10—66; 11—136; 12—78; 13—112; 14—104.

Twin Spark Engine and Fuel-Management Coverage

Alfa Romeo organized this material as a base repair library with replacement-page supplements, rather than as one blanket model-year manual. The V002 update card identifies the original V000 issue and the V001 and V002 supplements, while later inserted pages carry service information into 1996. Matching the engine code and publication section is therefore more reliable than relying on a broad year range.

The earlier engine volume identifies the 1995 cc AR67202, 1773 cc AR67102, and 1749 cc AR67103 Twin Spark engines. The 16V supplement uses the 1970 cc AR67204 engine as its primary reference and gives the differing procedures and specifications for the 1747 cc AR67601 and 1598 cc AR67106 engines. That distinction matters because the ignition arrangement, Motronic version, cooling-fan control, sensors, and several service procedures change between builds.

Engine repair coverage goes well beyond routine maintenance. The manual addresses engine-assembly removal, on-vehicle cylinder-head work, oil-sump removal, front and rear crankshaft sealing, camshaft and countershaft seals, timing-drive access, intake and exhaust components, fuel delivery, ignition coils, the starter motor, alternator, radiator, expansion tank, and cooling fan. Technical sections add timing diagrams, component-specific torque tables, lubricants, sealants, inspection data, and Alfa Romeo special-tool references.

Fuel and ignition diagnosis is laid out as test-based workshop information rather than a list of fault codes. The earlier Twin Spark material covers Motronic M1.7, while the 16V update adds M2.10.3 and M2.10.4. The diagnostic pages trace mixture, idle, starting, sensor, injector, fuel-pressure, air-leak, lambda-feedback, EGR, and control-unit faults through wiring diagrams and corrective-action charts. Component and connector locations support checks of the hot-film air-flow meter, fuel injectors, phase and speed sensors, coolant-temperature input, timing-variator solenoid, and related control circuits.

Chassis, Electrical, and Body Repair

The mechanical-unit sections cover clutch operation, gearbox and differential removal and specifications, axle shafts, front and rear suspension geometry, steering-column and steering-gear work, brake hydraulics, and the Bosch 5.3 ABS. ABS coverage includes the hydraulic layout, wheel-speed sensing, electrohydraulic control unit, wiring, component locations, and system-specific fault tracing.

Electrical diagnosis is divided by vehicle function. Representative diagram groups cover the Check Panel, windshield and headlight washer/wiper circuits, heating and air conditioning, starting and charging, Alfa Romeo CODE and Motronic engine control, and Bosch 5.3 ABS. Power windows, central locking, the sunroof, heated mirrors, and related accessories are handled in the same test-oriented format. Each major system is supported by some combination of a functional description, wiring diagram, connector table, component-location view, troubleshooting chart, and individual component checks.

The bodywork volumes are more detailed than a trim-removal guide. They cover panel removal and installation, mating-surface preparation, spot and MIG welding, body-squaring tables and diagrams, paint and corrosion-protection processes, and replacement of the hood, trunk lid, front and rear doors, fenders, structural supports, and underbody sections. These chapters provide structural repair and restoration data for the sedan body, not just component-removal information.

Scope and Workshop Notes

Complete bench engine overhaul is referred to Alfa Romeo’s PA493600000000-series overhaul instructions, and internal mechanical-unit overhaul is referred to PA494200000000. Those dedicated overhaul books are not part of this set. The material here is strongest for removal and refitting, on-car repair, fault isolation, system testing, specifications, electrical diagnosis, and body repair.

Several manual-specific repair traps deserve attention. The 16V Twin Spark uses different center and side spark-plug types; mixing positions or substituting the wrong plug can damage the engine. During starter repair, burrs at the retaining-ring groove can damage the inverter shaft. Cylinder-head installation also depends on the specified fastening order and staged angle procedure, so a single torque figure is not a substitute for the full factory table.

Pressurized fuel lines, ABS hydraulics, air-conditioning refrigerant, electrical isolation, and under-vehicle work all require appropriate workshop precautions. Use each diagram or specification in the context of the complete factory procedure before disconnecting lines, lifting assemblies, or applying final torque.