Alfa 164 Technical Service Bulletin 66.94.01

Information: 164 Dashboard R & R

Models: 1991 thru 1994 164 ALL

Date: 02/23/94

For the purpose of illustration, the instructions listed below refer to 1991 thru 1993 164 models. These instructions therefore, do not apply to the console/dash variations of the 1994 model. Refer to the '94 manual for console/dash disassembly.

STEP ONE

1. Remove the drivers seat.
   
2. Move the passenger seat down and to the rear-most position.
   

STEP TWO

1. DISCONNECT THE BATTERY.
   
   
2. Open the hood and remove the rubber weather-strip (Item #1) and plastic bulkhead cowl (Item #2). Note the rubber caps at the ends of the weather-strip and insure that they are re-installed at the end of the job.
   
3. Discharge the Freon from the Air Conditioning system in an environmentally safe manner.
   

STEP THREE

1. Remove the power wires from the four studs on connector G56, (Fig. B #1 & #2). Count & label the wires at each of the terminals. UPON REASSEMBLY. THE WIRES MUST ALL BE REINSTALLED TO THEIR CORRECT POSITION.
   
2. Disconnect connectors G151 & G154 (#3 & #4) and push the rubber grommet through the fire-wall.
   
3. Remove the bolts on the lower wiring insulator (#5).
   
4. Remove the air cleaner top cover/air flow meter assy.
   
5. Remove the 2 fire-wall partition screws on the right and the 1 on the left.
   
6. Remove the wiper arms.
   
7. Remove the fire-wall support bracket (#6) and release the fuel pipes from the clip on the right side.
   
8. Slightly raise the fire-wall partition and cut the tie strap on the right and remove the strap that secures the wiring harness on the left (#8). (On later production cars there is an identical strap on the right).
   
9. Unplug the brake light relay.
   
10. Remove the partition taking care to not damage the center harness clip.
    

STEP FOUR

1. Disconnect all 6 Air Conditioning component electrical connectors (#1) noting their locations. If a connector has a securing tie strap make sure that it gets a new one on assembly.
   
2. Disconnect the low pressure A. C. hose from the evaporator, (#2). Remove the nut that secures the E.P~R. valve bracket, (#6).
   
3. Disconnect the high pressure A. C. hose from the receiver drier,
   (#3);
   
4. Cap all open fittings and lay the hoses across the engine.
   

STEP FIVE

1. Carefully remove the evaporator group. Removal of the intake air plenum from the engine makes this easier.
   
2. Remove the air mixing flap cable from the fan assy., release the clips and remove the fan.
   
3. With the heater hoses still connected, pull the heater core out of the housing and rest it on the engine.
   
4. Disconnect the Wiper motor electrical connector, remove the remaining 2 bolts and remove the wiper assy.
   
5. Release the Fan Relay block from its clip.
   
6. Disconnect the hood button for the Alarm if so equipped.
   
7. Remove the~2 ground wire nuts on the left-inner side of the fire- wall. Record the amount of wires on each stud to help with reassembly.
   
8. Disconnect the 2 Air Bag sensor connectors and carefully thread them through the fire-wall sides. It will be necessary to remove the cooling system reservoir hold down screws to access the clip below it. Keep track of all tie strap and grommet locations.
   
9. All the afore-mentioned wires will stay with the dashboard assy.
   
10. Remove the 8 securing nuts for the dash assy., leave 1 on each side (finger tight) until actual dash removal.
    

STEP SIX

1. Remove the rear ashtray and remove the 2 phillips screws.
   
2. Place the shifter in "N", pull off the shift handle (automatic) or unsnap shift boot neck (5 speed). Fully engage the handbrake.
   
3. Pop up the window switch assembly and disconnect the wires. Remove assembly.
   
4. Remove the carpeted coin tray that is behind the switches and remove the fuse holder for the rear windows. Lift the wiring harness out of its clip.
   
5. Disconnect the cigarette lighters and shift indicator bulbs on the automatic.
   
6. Remove the console taking special care not to damage the handbrake trim on the console or the handbrake handle cover.
   

STEP SEVEN

1. Remove the screw that secures the trim to the left of the radio and A.C. panel.
   
2. Remove both carpeted tunnel trim pieces, (it may be necessary to loosen the front inner bolt on the passenger seat to swing the black metal tab out of the way).
   
3. Remove the air duct tubes.
   
4. Working from the left side, remove the phillips screw for the radio wedge. With a 10 mm. and an 8 mm. wrench remove the ground strap and mounting screw at the rear of the radio. Unplug the wiring and antenna. Remove the radio.
   
5. Remove the 3 screws that secure the A.C. panel and remove it, taking care to not scuff the instrument cluster shroud.
   
6. Remove the 2 phillips screws behind the hazard switch panel, the
   2 phillips screws below them and the bolts (#1 & #2). Cut any tie straps and remove the upper console.
   
7. Disconnect any wiring connectors that link the dash to the rear wiring, note the connector for the check eng. light that goes forward.
   

STEP EIGHT

1. Remove the nut securing the wiring connector panel below the fuse box door. Disconnect the first 4 connectors, leave the green one connected, push the wires clear and re-attach the panel.
   
2. Disconnect the 4 cruise control connectors, the brake light switch plug. There are 4 loose connectors; 4 pin white, 2 pin black, 2 pin black and a 3 pin white.
   
3. Insure that the steering wheel 15 straight, remove the bolt shown in Fig. G and scribe the steering shaft.
   
4. Disconnect the Air Bag E.C.U. plugs and remove the bolt securing the ground strap.
   
5. Remove the screw securing the lid to the right of the glove box and remove the lid.
   
6. Disconnect all the connectors and push them, the A.B.S. relay and the large connector with the yellow clip (G124) through to the back side of the dash.
   
7. Remove the nut near the hood release that secures the dash, also remove the nut on the right that is in a similar location.
   

STEP NINE

1. Remove the screws that secure the assist grips on both left and right sides.
   
2. Remove both "A" pillar trim pieces.
   

STEP TEN

1. Remove the two finger tight nuts on the fire-wall.
   
2. Remove the dashboard.
   
3. Place the dashboard, steering wheel side down on a soft fender cover on a workbench.
   

INSTALLATION 15 REVERSAL OF THE ABOVE.

DISASSEMBLY OF DASHBOARD

If a dashboard has been removed, and further disassembly is nessesary, proceed as follows. The numbering sequence corresponds to the numbers in Fig. J on page 10/10.

1. Release the wire retaining clip. Cut the tie straps for the cruise control harness.
   
2. Remove the 2 cap nuts.
   
3. Remove the windshield grid.
   
4. Remove the large dash to frame screws and the defrost vent screws.
   
5. Release the vent holding clips.
   
6. Unbend the tabs around the mounting bracket on the drivers side of the dash. Lift off the frame, noting its position at the bottom of the air box.
   
7. Remove the duct-work, replace screws #7 with a speed nut clip on the defroster duct and insert the screw from the opposite direction of factory installation to improve future serviceability.
   
8. Lift out the air box.