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.
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mm 2450 (1300·1600·1750 Coupe & Spider)
mm 2535 (0)1750 S8100n@ 1300 . 1600 .
17.50 SP.iderl
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mm 2595 tGiutia Saloonsl
m/ft 2709 (1300-1600-1750 Coupe)
ml'l 2900 IGiulia Saloons)
mm 2900 t 1150 Saloon)
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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