Alfa Romeo GIULIA Install guide
•GIULIA AND
1750
MODELS •
•
BODY.
SHOP
MANUAL
BODY ALIGNMENT CHECKING BENCH
PREPARING THE BENCH
AND
THE BODY
E
E
•
Place
the bench
on
alevel
floor.
•
Fit
the
front
and rear screw jacks (do
not
lock in place those at the rear) and adjust them
to
the
following
height
from
the bench
top:
-
Front:
320
to
330
mm
-Rear:
300
mm
It
is
essential
that
each pair
of
jacks
is
set
to
the
same
height.
CAUTION
-Make sure the
front
jack
with
the Smarking
is
placed at the right side while
that
with
the
Dmarking
is
at the
left
side.
S
r
THIS PUBLICATION
IS
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
OF
MAJOR ITEMS, ESPECIALLY THOSE
OF
THE 1750
SALOON, ARE COVERED
IN
DETAILS.
BEST RESULTS CAN
BE
OBTAINED ONLY WHEN CHECKING AND RECONDITIONING
WORK
IS
PERFORMED WITH THE
AID
OF THE SUITABLY PROVIDED SPECIAL TOOLS
AND WHEN
ONLY
GENUINE
ALFA
ROMEO REPLACEMENT PARTS ARE USED.
TH
IS
MANUAL
SHOULD
BE
KEPT CONTINUOUSLY
UP-TO-DATE
BY
THE
ADDITION
OF
NEW
SPECIFICATIONS
AND
INSTRUCTIONS ISSUED
AT
INTERVALS
BY
THE
TECHNICAL SERVICE DIVISION
IN
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
12
Alignment
checking
14 Diagram
of
dimensions
of
main
unit
attachments
80DY
REPAIR
15
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
31
Windscreen and rear
window
glass
36 Doors
37 Door
trim
panels
38
Door
glass
frames
39
Door
locks
43
Window
regulators
44 Door
glasses
45
Front
vent
windows
47 Door weatherstrips
49
Front
seats
50 Facia board
54 Console
57
Roof
trimming
65
Insulation padding
CHECKING
AND
ADJUSTING
66
Door
locks
69
Engine hood
72 Luggage
compartment
lid
73 Door weatherstrip leakage
74 Luggage
compartment
sealing
75 Water test
76 Sealing
84
Sound deadener
REFINISHING
85 General
86
Finish
identification
87
How
to
order finish material
87
Colour
matching
88
Painting process
95
Painting troubles
96
Painting
trouble
shooting
SPECIAL TOOLS
103 List
of
special tools
2
GENERAL NOTES ON BODY REPAIRING
When undertaking any
body
repair operation,
it
is
advisable
to
follow
astandard technique
as
detailed in the
following
notes.
If
the
body
shows deep
distortions
resulting
from
acollision
or
an
accident, the damaged parts must
be
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
as
spares and
are
also
entered in the spare parts catalogue
of
the model concerned.
•For replacing, the damaged parts must be cut
off
along the
joining
lines, suitably designed
for
this purpose,
with
the aid
of
tin
snips,
trimming
shears, hack saws
or
simi lar means
suitable
for
straight
cutting
the sheet metal
without
warping
it.
To
drill
through
the
spot welds,
use
drills
slightly larger in
diameter than spots
(drill
0.0.
from
3
to
4mmI
so
as
to
avoid stressing the parts
to
be
left
in
while
attempting
to
tear
off
spot welds.
To
separate arc welded parts,
use
chisel
to
chip
off
the beads
or
grind
the beads
down
in
order
to
prevent
putting
structural components under undue strains;
with
the chisel,
part
then sheet metal panels
from
each other.
•
Trim
and smooth
out
the edges
of
cut
off
panels.
Properly
fill
all holes,
left
after
drilling
the
spot welds,
by
welding
with
a
filler
rod. Carefully
trim
with
a
file
the
edges
to
be
joined together
both
of
body
sheet metal and replacement
panel and get rid
of
any sign
of
finish material
from
areas
to
be
welded.
•
To
prevent the spot welds
from
oxidizing,
especially those
particularly
exposed
to
atmospheric agents, coat the affected
parts
with
asuitable rust
inhibiting
compound
before
welding.
WARNING
-On models featuring A.C. generators, disconnect
terminals before welding
to
prevent damaging the diodes.
•Keep parts properly positioned
by
clamping them in place;
where this
is
not
practicable, make some spot welds
to
hold
the parts together.
3
GENERAL NOTES ON BODY REPAIRING
•
After
ensuring
that
all parts are in
proper
alignment, weld the components together
following,
as
to
spot weld diameter and spacing
or
arc welding beads, the
factory's
technique.
Remove welding
scales
by
peening and smooth
out
any roughness.
Slight
dents
or
bulges in
body
panels
can
be
corrected
by
hammering.
•
If
imperfections
persist, smooth
out
the affected
areas
with
a
body
grinder,
taking care
not
to
reduce excessively
the thickness
of
sheet metal, especially
along the
edges
or
the stiffening ribs.
If
the surfaces
are
not
perfectly
flush,
fill
low
spots
with
body
solder.
•
If
suitable templates are
not
available, doors and lids can
be
checked
for
proper
fit
with
their
openings
by
means either
of
new replacement parts
or
doors and lids themselves
of
the car being
repaired provided
that
not
warped
out
of
shape.
•Should
an
opening require
to
be
brcught
back
into
alignment
with
the
use
of
hydraulically·controlled
straight-
ening jacks, special care must
be
taken
to
avoid stressing
out
of
line
other
parts
of
body
that
previously checked
within
alignment
limits.
Performing the repair operations in
workmanlike
manner,
as
aguarantee
that
the structural strength
has
not
been impaired, rests
on
the operator's skill and responsibility.
CAUTION
-When accomplishing repair works, always
use
suitable
clothing
and observe all safety
precautions
as
prescribed
by
safety regulations.
4
BODY ALIGNMENT CHECKING BENCH
GENERAL
If
the
body
shows sign
of
warping
it
must undergo abench check.
To
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
is
the most convenient means
for
hoisting the
body
and placing
it
over the bench.
If
the
body
does
not
fit
or
fits
improperly
to
the alignment checking jigs,
it
must
be
brought
back
into
line
or
the
distorted
components replaced
with
new ones.
As
an
aid
for
the
bodyman,
further
details
on
this
matter
are given in the
following
pages
together
with
the procedures
for
carrying
out
the checks and
some
repairs.
5
BODY ALIGNMENT CHECKING BENCH
POSITIONING
THE
JIGS
The
position
of
the jigs varies according
to
the car model. The dimensions specified
below
should
therefore
be
adhered
to
as
applicable.
•
••••
..
-
....
••
:...:; ••
•••••
..~
..
•
•••
-
CD CD
50
CD
'.~~
...
•
.I
~
•••••• • • o •
..350.
1'11'1376.3
/ftm472
,
••
1500
mm
2450
(1300·1600·1750
Coupe
&
Spider)
mm
2535
(0)1750
S8100n@
1300
.
1600
.
17.50
SP.iderl
-.-
mm
2595
tGiutia
Saloonsl
m/ft
2709
(1300-1600-1750
Coupe)
ml'l
2900
IGiulia
Saloons)
mm
2900
t
1150
Saloon)
--
••
• 0
.0
o.
••
• 0
6
BODY ALIGNMENT CHECKING BENCH
COMPONENT PARTS
/'
"
LIST
OF COMPONENTS
OF
BENCH A.a.OgO'
Item
no.
Part no. Quan- Nomenclature Car model
tity
,
A.8.0007
1Bench
with
jig
positioning
holes
2
A.8.0016
2Screw jack
for
front
support
of
frame
All
models
3
A.8.00l7
2Screw jack
for
rear
support
of
frame
4
A.8.0068
1
Front
plate
for
resting
of
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
6
A.8.00l3
1Cross member for resting
of
rear suspension jigs
7
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
10
A.8.00SS 1Jig
for
checking L.H. rear suspension attachments
A.8.00S6
Extension
gauge
for
checking steering
box
&relay crank
11
1attachments
'-
12 A.8.0801 1
Box
containing
36
steel dowels
as
,detailed
below
./
/'
DOWEL
SET
Item
no.
Part
no.
Quan-
Nomenclature
Car model
tity
A.8.00S7 4Parallel dowels
for
holes
of
lower
arm
of
front
suspension
All
models
up
to
model year
68
Parallel dowels
for
holes
of
lower
arm
of
front
suspension
All
models
from
A.8.0064
8model year
68
Threaded dowels
A.8.0060
-4
of
which
for
gearbox
attachment
holes
8- 4
of
which
for
the holes in slanting rods
of
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
of
transverse
rod
of
fran
tsuspension
upper
arm
.
"-
NOTE
-Dowels are
not
supplied separately.
but
as
aset.
7
BODY ALIGNMENT CHECKING BENCH
PREPARING THE BENCH
AND
THE BODY
*
*
*
•
Secure
in place the
front
plate
and
the rear cross-member making certain they
are
exactly at right
angle
with
the rails.
WARNING -The accuracy
of
results depends closely upon the correct setting
of
plate
and
cross-
member.
9
BODY ALIGNMENT CHECKING BENCH
PREPARING
THE
BENCH AND
THE
BODY
.. -
..
...
~.
,
II
10
•Secure in place the centre jig
for
checking the gearbox
su
pport
cross
member and centre cross member
attachments.
•Hang the
body
over the bench then
lower
it
slowly on the rear jacks.
Adjust
the position
of
the rear jacks
lengthwise and secure them in place.
Lower
the
body
further
so
that
it
rests
on the
four
jacks.
•
Act
on the adjusting. screws
of
jacks
until
there
is
aclearance A
of
4
to
5
mm
between the
body
and the centre
jig.
BODY ALIGNMENT CHECKING BENCH
PREPARING THE BENCH
AND
THE BODY
•Bring the suspension
attachment
checking jigs close
to
the
body
after
having placed them on the
suitable surfaces
of
the bench cross members. Secure in place
only
after
the
body
has
been
definitively
positioned. .
CAUTION
-Should
any
difficulty
arise in
mounting
the rear jigs, slightly raise the
body.
•
Lower
the
four
jigs
until
there
is
aclearance A
of
1
to
2mm between the
body
and the centre jig.
The
body
is
definitively
positioned when the attaching holes are in line
with
those in the jigs.
•
Firmly
secure
the
jigs
to
the supporting cross members.
11
BODY ALIGNMENT CHECKING BENCH
ALIGNMENT CHECKING
Usually, the procedure
for
checking the
body
alignment starts
with
the checking
of
front
suspension
attachments
first,
then
with
that
of
rear suspension attachments. However, this sequence may
not
be
followed
strictly
as
it
depends much on the
type
of
work
to
be
performed.
For
example,
if
the rear end
of
the
body
has
been repaired, the
front
end
will
be
set
first
and then the check carried
out
on the rear
end; conversely,
if
the
front
is the end affected
by
repairs
or
any
doubt
exists on the alignment
of front
suspension attachments, the
order
of
operations shall
be
reversed.
If
the repairs have been
skillfully
carried
out,
all dowels should match freely the respective holes or, at
the most,
after
aslight pressure
is
applied
by
hand, Never deliver blows
to
the dowels
or
apply pressure
on them
other
than manually. The diameter
of
each dowel
is
much smaller than the bore
of
the
corresponding hole in the jig; this clearance corresponds
to
the
maximum
tolerance allowed
for
the
positioning
of
the
hole.
The
illustration
below
shows the dowels
as
fitted
for
checking the alignment
of
the
1750
Saloon
body.
A.8.0062
A.8.0061
A.B.0060------------,
A.8.0064
A.B.0059
The dowels
as
fitted
are the
same
on
both
sides and symmetrical
about
the longitu-
dinal centreline.
'2
A
BODY ALIGNMENT CHECKING BENCH
ALIGNMENT CHECKING
o5
For checking the steering
box
and the
relay crank attachments,
use
the
extension
gauge, special tool P.N. A.8.0056, and,
acting
from
inside the engine com·
partment,
proceed
as
follows:
•
Hold
the extension
gauge
in such a
way
that
the
wing
nut
A
is
pointing
upward
and make sure
that
the end
flanges bearing the markings
Sand
D
are positioned respectively at the
left
and
at
the
right
skirt.
•Slacken the
wingnut
Aand extend the
gauge
so
that
the dowels on the end
flanges can be inserted in the holes in
the skirts.
•Check
that
the reference marks on the
two
gauge tubes
are
aligned perfectly
or
within
a
maximum
tolerance
of
!0.5 mm.
0)
....
__
·_--1fA
13
DIAGRAM OF DIMENSIONS OF MAIN UNIT ATTACHMENTS
DIAGRAM OF DIMENSIONS OF MAIN UNIT ATTACHMENTS
I
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1750 Saloon
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EFGHIL
Giulia Saloons
23765
872.5 280.5 187.9 25 98.5 30 133.9 74.6
1750 Saloon 2436.5 870 283
..J
wCoupe 1300·1600 872.5 280.5
c2216.5
cCoupe 1750 909 244
::;
190.5 34.2 101.25 33.25 131.15 70.5
Spider 1300·1600 872.5 280.5
Spider 1750 2116.5 909 244
,I
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58
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-
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--
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Dimensions in millimetres
14
BODY
REPAIR
FRONT CROSS MEMBER REPLACEMENT
/0
I
16
•Break
off
the
seams
between
skirt
inner
panel and cross member through the
opening
so
obtained.
•Chip
off
the spot welds on
skirt
inner
panel (shock absorber
mounting
side).
•
From
inside
the
engine
compartment
chip
off
the spot welds along
the
gusset.
•Start removing the cross member
by
tapping
lightly
with
a
mallet
so
as
not
to strain the
adjoining
structural
components; then, take
out
the cross
member
by
raising the
body.
REINSTALLATION
•
Cut
the opening Ain the shock
absorber
moun
ting.
•Place the new cross member on the
positioning
fixture
and secure in place.
• L
ower
the
body
on the frame
alignment
checking bench.
•Check
for
the
proper
fitting
of
cross
member
with
fender
skirt
panels.
•Secure the cross member
to
the
body
with
clamps and
spot
welding; then,
take away the
positioning
fixture.
•Spot
weld
as
shown through the
opening Apreviously made.
BODY REPAIR
FRONT CROSS MEMBER REPLACEMENT
17
BODY
REPAIR
FRONT CROSS MEMBER REPLACEMENT
18
•
Arc
weld the
bottom
edges
of
skirt
inner panel
to
the cross member.
•With suitable tools, close the opening
in
skirt
outer
panel
as
shown.
•Clamp
properly
the.
edges
of
skirt
panel
to
the cross member.
•Spot weld the
edge
of
sk
irt
panel
to
the suspension arm attachment.
BODY
REPAIR
FRONT
CROSS
MEMBER REPLACEMENT
•Complete
the
arc welding
of
the
remaining
skirt
panel
edges.
•Secure in place
the
front
gussets
with
suitable clamps and spot weld them
to
the cross member.
•Flatten and close
by
welding the openings previously
cut
through.
19
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7
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1
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