Alfa 164 Technical Service Bulletin 80.93.02

Information: Stepper Motor Replacement Video

Models: 1991 thru 1993 164 Models

Date: 03/30/93

THE FOLLOWING ARE WRITTEN INSTRUCTIONS TO SUPPLEMENT THE 1991 THRU 1993 164 STEPPER MOTOR REMOVAL VIDEO - PART NUMBER 608- 97496.

NOTE !

VERY EARLY PRODUCTION 1991 MODELS HAVE TWO BOLTS WHICH MUST BE REMOVED TO PULL BACK THE DASH. THESE BOLTS ARE LOCATED IN THE GLOVE BOX AREA. ALSO THERE IS A MODIFICATION TO THE DASHBOARD DEFROSTER OUTLET AREA WHICH MUST BE PERFORMED ON THESE EARLY PRODUCTION MODELS. SEE VIDEO TAPE FOR COMPLETE DETAILS.

THE LONG REACH - CLOSE CLEARANCE OFFSET SCREWDRIVER SHOWN IN THE VIDEO WAS MADE USING A LONG 6mm BOX END WRENCH AND A #2 PHILLIPS POWER DRIVE BIT. A CRAFTSMAN WRENCH - PART NUMBER 42952 AND A #2 PHILLIPS BIT FORM A BLACK & DECKER 5 PACK - PART NUMBER 71-468 CAN BE USED.

MAKE THE MODIFIED SEARS RATCHETING OFFSET SCREWDRIVER USING SEARS - PART NUMBER 41121. REMOVE ANY SHARP EDGES AND RINSE THE TOOL OFF WHEN YOU ARE DONE TO REMOVE GRINDING DUST. AIR DRY AND LUBRICATE SO THAT THE RATCHET WORKS SMOOTHLY.

AFTER YOU HAVE FABRICATED YOUR TOOLS AS PER THE TRAINING VIDEO - PART NUMBER 608-97496, PROCEED AS FOLLOWS. REFER TO THE VIDEO FOR CLARIFICATIONS AS NECESSARY.

DISASSEMBLY

  1. FIRST, RUN BOTH FRONT SEATS ALL THE WAY BACK AND DOWN - ALSO MAKE SURE THAT THE SEAT BACKS ARE NEAR VERTICAL.
  2. NEXT, WRITE DOWN ALL OF THE OWNERS RADIO STATION PRESETS. WE MUST DISCONNECT THE BATTERY AND THE PRESETS WILL BE LOST. AS A PROFESSIONAL YOU WANT TO RE-ENTER THE PRESETS AND RETURN THE VEHICLE TO THE OWNER JUST AS YOU FOUND IT.
  3. NOW DISCONNECT THE BATTERY - BUT REMEMBER - IF THE VEHICLE HAS A FACTORY ALARM - YOU MUST USE THE OWNERS ALARM KEY TO DISABLE THE SYSTEM.
  4. REMOVE THE BATTERY COVER AND REMOVE THE GROUND CABLE.
  5. TO REMOVE THE PASSENGER SIDE "A" PILLAR TRIM. REMOVE THE TWO SCREWS FROM THE GRAB HANDLE - REMOVE THE HANDLE AND SLIP OUT THE TRIM PIECE.
  6. NEXT, POP UP AND REMOVE THE DASH DEFROSTER VENT TRIM PIECE.
  7. INSPECT THE VIN PLATE TO SEE IF IT SHOWS SIGNS OF RUBBING ON THE GLASS. IF IT DOES, BEND IT OWN SLIGHTLY SO THAT WHEN YOU PUT THE CAR BACK TO TOGETHER IT WILL NOT RUB ON THE GLASS. THIS WILL HELP PREVENT DASH BOARD SQUEAKS.
  8. NEXT, TEAR TWO STRIPS OF DUCT TAPE SO THAT THEY ARE 16 INCHES LONG BY 1 INCH WIDE. USE THESE STRIPS TO COVER THE DASH VENT WINDSHIELD DEFROSTER OUTLETS. IF YOU DO NOT TAPE THEM YOU WILL DROP SOME PARTS DOWN THEM SOONER OR LATER! ALSO IT IS A GOOD IDEA TO LAY SOME RAGS AT THE VERY BASE OF THE WINDSHIELD WHERE THERE ARE SEVERAL OPEN AREAS WHICH WILL SWALLOW ANY DROPPED PARTS.
  9. NOW USING THE LONG HANDLE OFFSET SCREWDRIVER BREAK, LOOSE THE 2 LARGE CENTER PHILLIPS SCREWS. THEN USE THE SHORT PHILLIPS BIT WITH THE SAFETY WIRE ON IT TO REMOVE THE SCREWS THE REST OF THE WAY.
  10. NEXT, REMOVE THE FOUR SMALL SCREWS AT EACH DEFROSTER OUTLET (EIGHT SCREWS IN ALL). THE SCREWS CLOSEST TO THE WINDSHIELD WILL HAVE TO BE REMOVED USING THE LONG REACH OFFSET PHILLIPS AND THE BIT WITH THE SAFETY WIRE. THE SCREWS FARTHER FROM THE WINDSHIELD CAN BE REMOVED USING THE MODIFIED RATCHET.
  11. NOW REMOVE THE LARGE PHILLIPS SCREWS IN EACH CORNER OF THE DASH.
  12. SLIDE BACK THE FLOOR CONSOLE. TO DO THIS - REMOVE THE REAR ASH TRAY BY PRESSING DOWN ON THE SPRING TABS. THEN REMOVE THE TWO SCREWS THAT HOLD DOWN THE BACK OF THE CONSOLE.
  13. SLACKEN THE ADJUSTER FOR THE EMERGENCY BRAKE LEVER SO THAT IT CAN BE PULLED TO A NEAR VERTICAL POSITION. BE MINDFUL OF THE SPRING TANG FOR THE ADJUSTER NUT. IT MUST STAY POSITIONED TO THE REAR OR IT CAN INTERFERE AND DAMAGE THE FLOOR CONSOLE. PULL THE LEVER UP ALL THE WAY.
  14. IF THE VEHICLE HAS A MANUAL TRANSMISSION SHIFT IT INTO REVERSE AND SLIDE THE CONSOLE BACK AS FAR AS POSSIBLE.

    OR

    IF IT IS AN AUTOMATIC TRANSMISSION - SELECT DRIVE ONE AND THEN PULL OFF THE SHIFT HANDLE - THEN SLIDE THE CONSOLE BACK AND LIFT IT UP AND OFF OF THE SHIFTER AND SLIDE IT BACK FURTHER. GENTLY REST THE CONSOLE ON TOP OF THE SHIFT LEVER.

  15. TO REMOVE THE PASSENGER SIDE CENTER CONSOLE SIDE PANEL FIRST LOOSEN THE FRONT INNER SEAT TRACK BOLT AND ROTATE THE METAL TAB UNDER THE TRACK OUT OF THE WAY. REMOVE THE TWO RETAINING SCREWS. SLIDE THE BOTTOM EDGE OF THE PANEL FORWARD AND DOWN - THEN SLIP THE PANEL OUT. REMOVE THE DRIVERS SIDE IN EXACTLY THE SAME FASHION.
  16. REMOVE THE SCREW AT THE BOTTOM OF THE VERTICAL TRIM PIECE NEAR THE RADIO - SLIDE THE TRIM DOWN AND REMOVE IT.
  17. REMOVE THE 2 SCREWS AT THE SIDE OF THE A/C ECU. OPEN THE GLOVE BOX AND REMOVE THE SCREW GOING INTO THE SIDE OF THE ECU.
  18. POP OUT THE ACCESS PANEL AND DISCONNECT THE STEPPER MOTOR WIRING CONNECTOR. CLOSE THE GLOVE BOX.
  19. NOW PRY OUT THE LEFT SIDE OF THE A/C ECU. LIFT UP ON THE CORNER OF THE INSTRUMENT CLUSTER AS NECESSARY TO . PREVENT THE ECU FROM DAMAGING THE VINYL - ROTATE THE UNIT OUT OF THE CONSOLE. DEPRESS THE LOCK TAB AND UNPLUG THE WIRING CONNECTOR. REMOVE THE ECU.
  20. REMOVE THE FOUR SCREWS LOCATED BEHIND THE A/C ECU. TWO DIRECTLY BEHIND - AND TWO JUST ABOVE. THEN REMOVE THE TWO 6mm BOLTS ON EITHER SIDE OF THE BOTTOM OF THE RAO(Q CONSOLE. PUSH THE GOLD BRACKETS OUTWARD TO MAKE IT EASIER TO LIFT OUT THE CONSOLE. PULL THE RADIO CONSOLE UP AND OUT FAR ENOUGH TO ACCESS THE CONNECTORS ON THE BACK OF THE RADIO. LIFT UP THE LOCK TABS ON BOTH OF THE ELECTRICAL CONNECTORS AND UNPLUG THEM - UNPLUG THE ANTENNA LEAD. THEN REMOVE THE GROUND CABLE. REMOVE THE RADIO CONSOLE ASSEMBLY.
  21. LOOSEN THE INSTRUMENT CLUSTER BY REMOVING THE TWO TRIM PIECES USING THE CROOKED PICK FROM THE SNAP-ON PICK SET PART NUMBER A5A204A. THEN REMOVE THE SCREW BEHIND EACH TRIM PIECE.
  22. DROP DOWN THE FUSE BOX DOOR AND REMOVE THE SCREW ON EITHER SIDE ON THE STEERING COLUMN.
  23. UNSNAP THE CLUSTER LOWER TRIM PIECE BY PUTTING BOTH OF YOUR THUMBS UNDER THE MIDDLE OF THE PIECE - PRESS UP AND PULL BACK TO UNSNAP IT. LAY IT ON THE FUSE BOX DOOR. DO NOT DISCONNECT THE WIRES.
  24. REMOVE THE 2 BOLTS WHICH RETAIN THE BOTTOM EDGE OF THE CLUSTER. PULL UP AND BACK TO DISLODGE THE CLUSTER ASSEMBLY. IT IS NOT NECESSARY TO UNPLUG AND REMOVE THE CLUSTER.
  25. TILT THE CLUSTER BACK AT THE TOP - REACH OVER THE CLUSTER AND REMOVE THE LARGE PHILLIPS SCREW DIRECTLY BEHIND IT.
  26. REMOVE THE SMALL PHILLIPS SCREW AT THE TOP LEFT CORNER OF THE CENTER VENT ASSEMBLY. UNSNAP THE TOP RIGHT CORNER OF THE VENT ASSEMBLY AND DISLODGE IT. DO NOT UNPLUG IT - JUST LET IT DOWN GENTLY TO THE FLOOR.
  27. REMOVE THE 2 SCREWS ON EITHER SIDE OF THE UNDER DASH LIGHT - ON THE PASSENGER SIDE OF THE CAR. LET THE ECU DOWN TO THE FLOOR - IT IS NOT NECESSARY TO UNPLUG IT.
  28. REMOVE THE 10 mm NUT FROM THE STUD LOCATED JUST ABOVE THE UNDER DASH LIGHT.
  29. REMOVE THE 13 mm NUT ON THE STUD LOCATED IN THE BOTTOM RIGHT CORNER OF THE DASH.
  30. REMOVE THE RIGHT CORNER COVER. REMOVE THE 2 SCREWS WHICH RETAIN THE RIGHT VENT. TURN THE VENT TO THE CLOSED POSITION TO PREVENT IT FROM BEING DAMAGED UPON ITS REMOVAL. CAREFULLY PRY UP AND OUT ON THE VENT (do not pull on it) AND REMOVE IT.
  31. REMOVE THE SIDE DEFROST VENT ESCUTCHEON BY ACTING ON THE FOUR RETAINING TABS WITH THE CROOKED PICK.
  32. LIFT UP AND GENTLY START TO PULL BACK ON THE DASH. AS YOU DO, YOU MUST GUIDE THE DASH OVER THE WINDSHIELD DEFROSTER OUTLETS WHICH WILL REMAIN BEHIND. IT IS VERY IMPORTANT THAT THE DASH DOES NOT HANG UP ON THESE VENTS. ALSO BE CAREFUL THAT YOU DO NOT LOSE THE SPEED NUTS ON THE DEFROSTER OUTLETS.
  33. PULL THE DASH BACK APPROXIMATELY 4 INCHES. SUPPORT THE DASH AT THE CORNER USING THE MILANO ABS TOOL PART NUMBER 182-0074 OR USE A GENERIC ALIGNMENT RACK BRAKE PEDAL APPLICATION TOOL.
  34. REMOVE THE CORNER VERTICAL FOAM BRICK.
  35. REMOVE THE SMALL SIDE OUTLET DEFROSTER ELBOW TUBE.
  36. REMOVE THE LARGE HORIZONTAL FOAM LOG. YOU WILL HAVE TO BREAK IT LOOSE AS IT IS USUALLY PARTIALLY GLUED IN PLACE.
  37. REMOVE THE LARGE A/C VENT TUBE.
  38. REMOVE THE SMALL DEFROSTER TUBE AND THE "C" CLIP.
  39. USING A LONG PHILLIPS SCREWDRIVER - GO THROUGH THE HOLE IN THE TOP LEFT CORNER OF THE GLOVE BOX AND REMOVE THE SCREW WHICH RETAINS THE PASSENGER SIDE WINDSHIELD DEFROST TUBE. SLIDE THE TUBE OUT FROM BEHIND THE DASH - AGAIN BE CAREFUL NOT TO LOOSE THE SPEED NUTS-
  40. REMOVE THE ESCUTCHEON JUST BELOW THE STEPPER MOTORS.
  41. REMOVE THE 3 SCREWS WHICH RETAIN THE STEPPER MOTOR ASSEMBLY - DISLODGE THE ASSEMBLY. ROTATE THE ASSEMBLY AND CUT OFF THE SPEED CLIP FROM THE HEATER FLAP CONTROL CABLE. REMOVE THE CABLE FROM THE ARM - REMOVE THE MOTOR ASSEMBLY.

NOTE !

WHEN INSTALLING THE NEW MOTOR ASSEMBLY - YOU MUST INDEX THE NEW MOTOR DRIVE WITH THE AIR DISTRIBUTION DRUM. TO DO THIS, ROTATE THE DRUM FULLY CLOCKWISE - GENTLY PRESS THE MOTOR DRIVE UP AGAINST THE DRUM FEMALE RECEPTACLE. USING YOUR THUMB INSERTED THROUGH THE LOWER AIR OUTLET - ROTATE THE DRUM UNTIL IT INDEXES WITH THE MOTOR DRIVE AND YOU FEEL THE DRIVE SLIP INTO PLACE. YOU DO NOT NEED TO FORCE IT. IF IT IS IN THE DRUM YOU CAN LET GO OF THE MOTOR AND IT WILL STAY 1N PLACE.

RE-ASSEMBLY

  1. NOW INSTALL THE THREE STEPPER MOTOR RETAINING SCREWS.

    NOTE !

    IF YOU DO NOT PROPERLY INDEX THE MOTOR YOU COULD STILL PUT IN THE RETAINING SCREWS BUT YOU WILL LIKELY BREAK THE DISTRIBUTION DRUM. ALSO WHEN INSTALLING THE MOTOR ASSEMBLY BE SURE TO ROUTE THE HEAT FLAP CABLE IN FRONT OF THE MOTOR BRACKET. INSTALL THE CABLE ONTO THE MOTOR LEVER AND INSTALL SPEED CLIP - PART NUMBER 608-05430. BE SURE TO USE THE ALFA PART. IF YOU USE ANOTHER CLIP YOU MAY SACRIFICE THE SUCCESS OF THIS REPAIR.

  2. RE-INSTALL THE HEATER OUTLET ESCUTCHEON.
  3. RE-INSTALL THE WINDSHIELD DEFROSTER VENT.
  4. HANG THE "C" CLIP ONTO THE DASH FRAME AND INSTALL THE SMALL DUCT TUBE.
  5. INSTALL THE LARGE VENT TUBE.
  6. INSTALL THE SMALL DUCT ELBOW.
  7. INSTALL THE LARGE HORIZONTAL FOAM LOG. PUSH IT IN SO THAT THERE IS ABOUT 4" SPACE FROM IT TO THE CORNER OF THE DASH. THIS WILL LEAVE ROOM FOR THE FOAM BRICK.
  8. INSTALL THE CORNER VERTICAL FOAM BRICK.
  9. NOW LIFT UP ON THE DASH AND PRESS THE DASH FORWARD - HOOK THE TOP EDGE INTO PLACE.

    NOTE !

    YOU MUST GUIDE THE DASH OVER THE WINDSHIELD DEFROSTER OUTLETS. CAREFULLY TUCK THEM DOWN AS YOU SLIDE THE DASH lNTO PLACE.

  10. HOLD THE DASH IN PLACE BY LOOSELY INSTALLING THE LARGE PHILLIPS SCREW IN THE FAR CORNER OF THE DASH.
  11. INSTALL THE 10 MM NUT ONTO THE STUD WHICH IS .lUST ABOVE THE UNDER DASH LIGHT. DO NOT TIGHTEN IT AT THIS TIME.

    NOTE !

    THERE IS A BLACK PLASTIC SPACER WHICH LIKELY FELL OFF THE STUD ABOVE THE LIGHT. BE SURE TO RE-INSTALL IT. LEAVE THE 10 MM NUT ON THE STUD

  12. POSITION THE BOTTOM RIGHT CORNER OF THE DASH INTO THE MOUNTING STUD BE CAREFUL OF THE WIRES NEAR BY - LOOSELY INSTALL THE 13 MM NUT.
  13. RE-INSTALL THE LARGE PHILLIPS SCREW BEHIND THE INSTRUMENT CLUSTER.
  14. RE-INSTALL ALL OF THE SCREWS IN THE TOP OF THE DASH - USE A PICK TO ALIGN THE SPEED NUTS ON THE DEFROSTER OUTLETS.
  15. TIGHTEN ALL THE SCREWS ON TOP OF THE DASH. REMOVE THE DUCT TAPE FROM THE DEFROSTER VENTS AND REMOVE THE RAGS.
  16. TIGHTEN THE LARGE SCREW BEHIND THE INSTRUMENT CLUSTER.
  17. TIGHTEN THE 10 MM AND THE 13 MM NUTS YOU LEFT LOOSE, UNDER THE DASH.
  18. POSITION THE LARGE VENT TUBE SO THAT IT IS CENTERED WITH THE DASH OUTLET AND RECESSED APPROXIMATELY 2 INCHES. USE A 3l8 EXTENSION TO POKE AND PROD THE FOAM AND TUBE TO GET IT PROPERLY POSITIONED. LUBRICATE WITH SILICONE AND INSTALL THE RIGHT VENT ASSEMBLY. 7/8 YOU SHOULD NOT HAVE TO FORCE IT. RE-POSITION THE DUCT TUBE AS NECESSARY TO ACHIEVE AN EASY FIT.
  19. INSTALL THE SIDE OUTLET ESCUTCHEON.
  20. INSTALL THE DASH CORNER COVER.
  21. ) RE-INSTALL THE CENTER VENT.
  22. RE-INSTALL THE INSTRUMENT CLUSTER AND RELATED TRIM.
  23. RE-INSTALL THE RADIO CONSOLE. PLUG IN BOTH ELECTRICAL CONNECTORS AS WELL AS THE ANTENNA LEAD AND ATTACH THE GROUND WIRE. INSTALL THE TOP 4 SCREWS AND THE 2 BOTTOM BOLTS.
  24. RE-INSTALL THE AlC ECU. BE CAREFUL NOT TO DAMAGE THE VINYL AT BOTTOM RIGHT CORNER OF THE INSTRUMENT CLUSTER. OPEN THE GLOVE BOX AND INSTALL THE SCREW ON THE SIDE - PLUG IN THE STEPPER MOTORS - RE-INSTALL THE ACCESS COVER.
  25. RE-INSTALL BOTH OF THE CONSOLE SIDE COVERS.
  26. RE-POSITION THE METAL TABS UNDER EACH SEAT TRACK AND TIGHTEN THE TRACKS.
  27. RE-INSTALL THE FLOOR CONSOLE.
  28. RE-INSTALL THE WINDSHIELD DEFROSTER VENT TRIM PIECE.
  29. RE-INSTALL THE "A" PILLAR TRIM.
  30. ON AUTOMATIC TRANSMISSION EQUIPPED VEHICLES, RE-INSTALL THE SHIFT LEVER
  31. ADJUST THE EMERGENCY BRAKE LEVER - BE MINDFUL THAT THE SPRING CLIP IS PROPERLY POSITIONED AND DOES NOT INTERFERE WITH THE CONSOLE WHEN THE LEVER IS ENGAGED.
  32. RE-CONNECT THE BATTERY AND ACTIVATE THE ALARM SYSTEM.
  33. PROGRAM THE RADIO WITH THE STATION SETTINGS YOU RECORDED EARLIER AND SET THE CLOCK TO THE PROPER TIME.
  34. TEST ALL INTERIOR SYSTEMS AND CONTROLS FOR PROPER OPERATION.

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