Alfa Romeo Giulia 1600 1972-1975 Workshop Service Manual | PDF Download

The last of the 1600 twin-cams are the Giulia Super 1.6 and the GT Junior 1.6, and this workshop manual covers both. It goes through each system, from lifting the engine out and overhauling, to setting the carburettors, fixing the clutch and gearbox and bleeding the brakes and so much more.

Models covered

• Alfa Romeo Giulia Super 1600
• Alfa Romeo GT Junior 1600

Engine

• 1570cc (the “1600”) four-cylinder twin cam

Transmission

• Five-speed gearbox, clutch, propeller shaft and rear axle, with removal, dismantling and refit

What’s included

• Taking the engine out, stripping it, checking every part and putting it back together
• Cylinder liner, piston, piston ring and crankshaft sizes, with undersize and oversize figures for rebuilds
• Cylinder head removal, valve servicing, valve clearances and valve timing
• Timing chain and camshaft drive overhaul
• Oil pump, oil strainer and external oil filter
• Fuel pumps, air cleaner, and Dellorto DHLA 40 and Weber 40 DCOE carburettors, with stripping, setting and jet sizes
• Distributor, ignition timing, sparking plugs and the distributor drive shaft
• Radiator, water pump, fan belt and thermostat
• Clutch overhaul and operating mechanism adjustment
• Gearbox removal, stripping and rebuilding, and the gearchange mechanism
• Propeller shaft, rear axle and rear suspension
• Front suspension, wheel hubs, dampers and anti-roll bar
• Steering box, steering linkage and adjustments
• Disc brakes, master cylinder, vacuum servo and bleeding
• Battery, alternator, starter and control box
• Wiring diagram for the Giulia Super 1600
• Bodywork: door trim, hinges and locks, window winding, bonnet and boot locks, and fitting windscreen and rear window glass
• Tightening torques, conversion tables and a fault diagnosis section at the end of each chapter