Alfa Romeo GIULIA Install guide

•GIULIA AND

1750

MODELS •

•

BODY.

SHOP

MANUAL

BODY ALIGNMENT CHECKING BENCH

PREPARING THE BENCH

AND

THE BODY

•

Place

the bench

alevel

floor.

•

Fit

the

front

and rear screw jacks (do

not

lock in place those at the rear) and adjust them

the

following

height

from

the bench

top:

Front:

320

330

-Rear:

300

essential

that

each pair

jacks

set

the

same

height.

CAUTION

-Make sure the

front

jack

with

the Smarking

placed at the right side while

that

with

the

Dmarking

at the

left

side.

THIS PUBLICATION

DESIGNED TO GIVE THE

ALFA

ROMEO SERVICE NETWORK A

COMPLETE BACKGROUND OF INFORMATION ABOUT CHECKING, REPAIRING AND

REFINISHING THE BODY; FURTHER, THE REPAIR, REMOVAL AND

INSTALLATION,

INSPECTION

AND

ADJUSTMENT

MAJOR ITEMS, ESPECIALLY THOSE

THE 1750

SALOON, ARE COVERED

DETAILS.

BEST RESULTS CAN

OBTAINED ONLY WHEN CHECKING AND RECONDITIONING

WORK

PERFORMED WITH THE

AID

OF THE SUITABLY PROVIDED SPECIAL TOOLS

AND WHEN

ONLY

GENUINE

ALFA

ROMEO REPLACEMENT PARTS ARE USED.

MANUAL

SHOULD

KEPT CONTINUOUSLY

UP-TO-DATE

THE

ADDITION

NEW

SPECIFICATIONS

AND

INSTRUCTIONS ISSUED

INTERVALS

THE

TECHNICAL SERVICE DIVISION

THE REGULAR

"INFORMATION

SHEETS" AND

"MODI

FICA

TlON

INSTRUCTIONS"

Direzione Assistenza

CONTENTS

3General notes on

body

repairing

BODY

ALIGNMENT

CHECKING

BENCH

5General

6Positioning the jigs

7Component parts

8Preparing the bench and the

body

Alignment

checking

14 Diagram

dimensions

main

unit

attachments

80DY

REPAIR

Front

cross member replacement

22 Replacing the fender and

front

panels

28 Replacing the tail panel

29 Replacing the rear

wing

assembly

30 8ringing windscreen frame back

into

shape

REMOVAL

AND

INSTALLATION

Windscreen and rear

window

glass

36 Doors

37 Door

trim

panels

Door

glass

frames

Door

locks

Window

regulators

44 Door

glasses

Front

vent

windows

47 Door weatherstrips

Front

seats

50 Facia board

54 Console

Roof

trimming

Insulation padding

CHECKING

AND

ADJUSTING

Door

locks

Engine hood

72 Luggage

compartment

lid

73 Door weatherstrip leakage

74 Luggage

compartment

sealing

75 Water test

76 Sealing

Sound deadener

REFINISHING

85 General

Finish

identification

How

order finish material

Colour

matching

Painting process

Painting troubles

Painting

trouble

shooting

SPECIAL TOOLS

103 List

special tools

GENERAL NOTES ON BODY REPAIRING

When undertaking any

body

repair operation,

advisable

astandard technique

detailed in the

following

notes.

the

body

shows deep

distortions

resulting

from

acollision

accident, the damaged parts must

replaced

with

new ones;

this

will

ultimately

save

money and

will

ensure

that

both

car's

styling

and structure

are

restored.

All

body

component

parts

are

available

spares and

are

also

entered in the spare parts catalogue

the model concerned.

•For replacing, the damaged parts must be cut

off

along the

joining

lines, suitably designed

for

this purpose,

with

the aid

tin

snips,

trimming

shears, hack saws

simi lar means

suitable

for

straight

cutting

the sheet metal

without

warping

it.

drill

through

the

spot welds,

use

drills

slightly larger in

diameter than spots

(drill

0.0.

from

4mmI

avoid stressing the parts

left

while

attempting

tear

off

spot welds.

separate arc welded parts,

use

chisel

chip

off

the beads

grind

the beads

down

order

prevent

putting

structural components under undue strains;

with

the chisel,

part

then sheet metal panels

from

each other.

•

Trim

and smooth

out

the edges

cut

off

panels.

Properly

fill

all holes,

left

after

drilling

the

spot welds,

welding

with

filler

rod. Carefully

trim

with

file

the

edges

joined together

both

body

sheet metal and replacement

panel and get rid

any sign

finish material

from

areas

welded.

•

prevent the spot welds

from

oxidizing,

especially those

particularly

exposed

atmospheric agents, coat the affected

parts

with

asuitable rust

inhibiting

compound

before

welding.

WARNING

-On models featuring A.C. generators, disconnect

terminals before welding

prevent damaging the diodes.

•Keep parts properly positioned

clamping them in place;

where this

not

practicable, make some spot welds

hold

the parts together.

GENERAL NOTES ON BODY REPAIRING

•

After

ensuring

that

all parts are in

proper

alignment, weld the components together

following,

spot weld diameter and spacing

arc welding beads, the

factory's

technique.

Remove welding

scales

peening and smooth

out

any roughness.

Slight

dents

bulges in

body

panels

can

corrected

hammering.

•

imperfections

persist, smooth

out

the affected

areas

with

body

grinder,

taking care

not

reduce excessively

the thickness

sheet metal, especially

along the

edges

the stiffening ribs.

the surfaces

are

not

perfectly

flush,

fill

low

spots

with

body

solder.

•

suitable templates are

not

available, doors and lids can

checked

for

proper

fit

with

their

openings

means either

new replacement parts

doors and lids themselves

the car being

repaired provided

that

not

warped

out

shape.

•Should

opening require

brcught

back

into

alignment

with

the

use

hydraulically·controlled

straight-

ening jacks, special care must

taken

avoid stressing

out

line

other

parts

body

that

previously checked

within

alignment

limits.

Performing the repair operations in

workmanlike

manner,

aguarantee

that

the structural strength

has

not

been impaired, rests

the operator's skill and responsibility.

CAUTION

-When accomplishing repair works, always

use

suitable

clothing

and observe all safety

precautions

prescribed

safety regulations.

BODY ALIGNMENT CHECKING BENCH

GENERAL

the

body

shows sign

warping

must undergo abench check.

this purpose, remove the engine

compartment

lid and all mechanical

units:

engine,

clutch,

gearbox,

rear axle,

front

and rear suspension, steering gear, radiator, exhaust pipe.

An overhead crane

the most convenient means

for

hoisting the

body

and placing

over the bench.

the

body

does

not

fit

fits

improperly

the alignment checking jigs,

must

brought

back

into

line

the

distorted

components replaced

with

new ones.

aid

for

the

bodyman,

further

details

this

matter

are given in the

following

pages

together

with

the procedures

for

carrying

out

the checks and

some

repairs.

BODY ALIGNMENT CHECKING BENCH

POSITIONING

THE

JIGS

The

position

the jigs varies according

the car model. The dimensions specified

below

should

therefore

adhered

applicable.

•

••••

....

••

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•••••

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•

•••

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•

•••••• • • o •

..350.

1'11'1376.3

/ftm472

••

1500

2450

(1300·1600·1750

Coupe

Spider)

2535

(0)1750

S8100n@

1300

1600

17.50

SP.iderl

-.-

2595

tGiutia

Saloonsl

m/ft

2709

(1300-1600-1750

Coupe)

ml'l

2900

IGiulia

Saloons)

2900

1150

Saloon)

••

• 0

••

• 0

BODY ALIGNMENT CHECKING BENCH

COMPONENT PARTS

LIST

OF COMPONENTS

BENCH A.a.OgO'

Item

no.

Part no. Quan- Nomenclature Car model

tity

A.8.0007

1Bench

with

jig

positioning

holes

A.8.0016

2Screw jack

for

front

support

frame

All

models

A.8.00l7

2Screw jack

for

rear

support

frame

A.8.0068

Front

plate

for

resting

front

suspension jig

Jig

for

checking gearbox

support

cross-member and center

All

models

less

A.8.0083

1cross-member

attachments

17S0 Saloon

SJig

for

checking gearbox

support

cross-member and center Only

A.8.0073

1cross-member attachments

17S0

Saloon

A.8.00l3

1Cross member for resting

rear suspension jigs

A.8.00n

1Jig

for

checking R.H.

front

suspension attachments

8A.8.0071 1Jig

for

checking

L.H.

front

suspension attachments

9A.8.00S4 1Jig

for

checking

R.H.

fear suspension attachments

All

models

A.8.00SS 1Jig

for

checking L.H. rear suspension attachments

A.8.00S6

Extension

gauge

for

checking steering

box

&relay crank

1attachments

12 A.8.0801 1

Box

containing

steel dowels

,detailed

below

DOWEL

SET

Item

no.

Part

no.

Quan-

Nomenclature

Car model

tity

A.8.00S7 4Parallel dowels

for

holes

lower

arm

front

suspension

All

models

model year

Parallel dowels

for

holes

lower

arm

front

suspension

All

models

from

A.8.0064

8model year

Threaded dowels

A.8.0060

-4

which

for

gearbox

attachment

holes

8- 4

which

for

the holes in slanting rods

front

suspen-

12 sian

upper

arms

A.8.0061 6Threaded

dowels

for

center

cross·member

attachment

holes

All

models

A.8.0062 2Parallel dowels

for

radius rod

attachment

holes

A.8.0063

6Parallel

dowels

for

T·arm

attachment

holes

A.8.00S9 2Parallel

dowels

for

hole

transverse

rod

fran

tsuspension

upper

arm

NOTE

-Dowels are

not

supplied separately.

but

aset.

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