Alfa Romeo GTV | Spider 1995-2006 Service Workshop Manual

The Workshop Service Manual set for the Alfa Romeo GTV | Spider is a must-have for any Alfa owner, an invaluable resource for carrying out work on the GTV/Spider. This manual covers every component and repair procedure in full Alfa Romeo factory specification for the vehicle, including those hard-to-locate items such as the crankshaft speed sensor etc. This manual set is by far the most comprehensive available for the Alfa type 916 it covers every item for all variants and updated models for both Left and Right-hand drive vehicles, including individual engine overhaul manuals for 1.8 twin spark, 2.0 twin spark, 2.0 V6 turbo, 3.0 V6.

1995-2006 Alfa Romeo GTV & Spider:  

The Manual Covers The Following Items:

Variants For Gtv 1996 Tb
Variants For Spider 1996 Tb
Variants For Gtv 2959 24V
Variants For Euro3 1970 T-spark 16V
Variants For Euro3 2959 24V

GTV 1.8 T. Spark
GTV 2.0 T. Spark
GTV 2.0 V6 Turbo
GTV 3.0 V6

Engine Model Codes Covered
16101
16102
16202
32201
33503
67106
67601

Tightening Torques
Specific Tools
Maintenance

Overhauling Engine Out The Vehicle:
Introduction:
Crankcase
Cylinder Head
Crankshaft
Main & Rod Bearings Halves
Flywheel
Pistons & Connecting Rods
Valve Gear Timing
Valves
Timing Variator
Camshafts
Lubrication
Oil Pump
Climate Control Compressor
Coolant Manifold
Water Pump
Intake Manifold
Timing Gear Drive Belt
Ignition Coils

Engine Disassembly:
Cylinder Head Disassembly
Checks And Inspection Cylinder Head
Checks And Inspection Crankcase
Instructions For Reassembly
Checking The Electric Components Of The Lubrication Circuit
Removal/Refitting
Description
Removal
Refitting
Guard Under Engine
Wheelhouse Guards

Overhauling Engine Items Possible Whilst Fitted In Vehicle
Cylinder Head
Oil Sump
Crankshaft Front Oil Seal Replacement
Counter-rotating Shaft Oil Seal Replacement
Camshaft Oil Seal Replacement
Engine Damper Connecting Rod Anchoring
Bracket Rubber Bushing· Replacement
Crankcase Rear Cover Replacement
(With Built-in Oil Seal)

Engine Electrical Components
Phase Sensor
Rpm And Phase Sensor
Engine Coolant Temperature Sensor (Ntc)
Knock Sensor
Phase Variator Electromagnet
Inertia Switch
Tachometer Sensor

Clutch System
Description
Clutch Plate And Pressure Plate
Removal/Refitting
Checks And Inspections
Clutch Control
Clutch Pump
Clutch Control Pedal
Removal/Refitting
Clutch Control Cylinder
Relieving The Air From The Hydraulic System
Minimum Brake-clutch Fluid Level Sensor
Removal / Refitting
Exhaust Gas Recirculation
Description
Egr Valve
Egr Modulating Solenoid Valve
Exhaust System
Description
Catalytic Converter
Lambda Sensor
Exhaust Emission Control

Gearbox Unit
Differential Carrier Oil Seal Gearbox Side
Differential Carrier Oil Seal Engine Side
Outside Gearbox Controls
Version With Rods And Tie-rods
Synchronized Reverse Gear
Gearshift Control Tie-rods
Gearshift Control Rod
Gearshift Lever.
Cable Control
Reversing Gear Release Cable
Gearshift Lever Knob
Axle Shafts:
Gearbox Side Constant Velocity Joint
Wheel Side Constant Velocity Joint
Intermediate Shaft
Left Axle Shaft Damping Masey

Brake System:
Description
Brake Pedal
Brake-clutch Fluid Reservoir
Brake – Clutch Fluid Minimum Level Sensor
Abs Bosch 2Si Hydraulic Unit/Electronic Control Unit
Bosch 5.3 Abs With Ebd
Servobrake
Braking Load Proportioning Valve
Brake System Pipes
Checks And Inspections
Bleeding The Air From The System
Recovery In The Case Of Air In The Piston
Stop Lights Switch
Front Inductive Sensors
Rear Inductive Sensors
Right Front Active Sensor
Left Front Active Sensor
Rear Active Sensors
Front Brake Disk
Front Brake Caliper
Changing The Front Brake Pads
Rear Brake Disk
Rear Brake Caliper
Changing The Rear Brake Pads
Parking Brake
Control Lever
Front Control Cable
Rear Control Cables
Adjusting The Control Cables
Handbrake On Warning Switch

Steering Control:
Steering Wheel
Steering Column
Steering Lock
Power Steering Box
Power Steering Pump
Checks And Inspections
Filling The Power Steering Circuit And
Bleeding Air
Power Steering Oil Reservoir

Suspension:
Front Suspension
Checks And Inspections
Coil Spring And Shock Absorber Assembly
Wishbone
Front Crossmember
Anti-roll Bar
Rear Multilink Suspension
Complete Suspension Frame
Shock Absorbers
Coil Springs

Electrical System:
Electrical System Fault Diagnosis
Wiring Diagrams
Ignition
Ignition Coils
Spark Plugs
Starter Motor
Battery
Alternator
Lighting
Upper Front Light Clusters
Headlamp Aiming Switch
Lower Front Light Clusters
Tail Light Cluster
Number Plate Lights
Direction Indicator Side Repeaters
Third Stop Light – Spider
Third Stop Light – Gtv
Third Brake Light Gtv On Rear Spoiler
Passeger Compartment Roof Lamp
Glove Box Light
Dashboard Light
Door Light
Luggage Compartment Light
Bulb Table
Fusebox
Ignition Switch
Windscreen Wiper Unit
Windscreen Washer Pump
Horns
Cigar Lighter
Sound System (’98 Versions)
Speakers
Electric Aerial
Instrument Cluster
Main Panel
Auxiliary Panel
Controls And Switches
Steering Colum Lever Unit
Hazard Warning Lights Control Switch
Hazard Light/ Fog Light / Rear Fog Light Switches
Sets Of Switches At Side Of Panel
Power Window Switches
Sun Roof Control Switch (Gtv)
Top Control Switches (Spider)
Double Door Mirror Adjustment Switch
Alarm System
Control Unit-siren
Remote Control Receiver Unit
Bonnet Open Detection Switch
Air Bag Control Unit
System Components
Air Bag Control Unit
Driver’s Seat Air Bag
Clock Spring Device
Passenger’s Side Air Bag
Passenger Side Airbag Disable Switch
Front Seat Belt Pre-tensioners
Electronic Control Units/Modules
Injection-ignition Control Unit
Abs Control Unit
Alarm System Control Unit.
Air Bag And Pre-tensioner Control Unit
Power Window Control Unit
Alfa Romeo Code Control Unit.
Alfa Romeo Code Aerial (’98 Versions)
Climate Control Unit.

Fuel System:
Fuel Supply
Description Of The System
Fuel Pipe Fittings (John Guest)
Fuel Pipe Fittings (Huron)
Fuel Tank
Fuel Level Gauge
Fuel Pump
Fuel Filter
Fuel Pressure Regulator
Pulse Damper
Fuel Distribution Manifold
Electroinjectors
Checking The Pressure And Tightness Of The Fuel Circuit
Description Of The Fuel Vapour Recovery System
Fuel Vapour Separator
Fuel Vapour Filter (Canister)
Fuel Vapour Solenoid Valve
Fuel Pressure And Circuit Tightness Check

Air Supply System:
Air Supply And Oil Vapour Recovery System
Air Cleaner Cartridge Replacement
Intake Manifold
Boost-drive Management
Throttle Body
Throttle Potentiometer
Fluxing Test
Air-flow Meter
Intake Air Temperature Sensor (Ntc)
Throttle Position Sensor
Intake Box
Air Intake Resonators
Constant Idle Speed Actuator
Oil Vapour Separator
Turbocharger

Wheels And Hubs:
Front Wheel Upright
Caulking The Front Wheel Hub
Fastening Nut
Adjusting The Position Of The Front Suspension Upright
Dis-assembly
Checks And Inspections
Reassembly
Rear Wheel Hub
Removing / Refitting
Checks And Inspections
Versions With Abs Active Sensors
Front Steering Knuckle
Staking Front Wheel Hub Fixing Nut
Adjusting Front Suspension Steering Knuckle Position
Rear Wheel Hub (Inc 6 Cylinder Version)
Wheels
Rims
Tyres
Tyre Pressure And Wear
Wheel Balancing
Checking The Front Wheel Geometry
Checking The Rear Wheel Geometry
Checking The Characteristic Angles
Checking The Front Wheel Toe-in
Checking The Front Wheel Camber And Caster
Checking The Rear Wheel Toe-in
Checking The Rear Wheel Camber

Heating And Ventilation:
General
Refrigerant Fluid: R13 4A
Air Flow And Distribution Unit
Operating Layout.
Recirculation Function
Air Flows In The Passenger Compartment
Location Of Components On The Ducting/Distribution Unit
Air Conditioning Circuit
Operating Principle
Location Of Components
Condenser
Evaporator
Drier Filter
Expansion Valve
Three-level Pressure Switch (Trinary)
4-level Pressure Switch
Minimum Pressure Switch (Antifrost)
Compressor
Ducting/Distributor Uni
On-vehicle Operations
Climate Control Unit Controls
Fan
Fan Resistance
Radiator And Heater
Recirculation Port Control Motor
Three/Four Levels Pressure Switch
Defrosting Pressure Switch
Compressor Pipes
Evaporator Pipes
Pollen Filter
Emptying And Recharging The System
Emptying The System And Recovering The Coolant Fluid
Recharging The Coolant Fluid
Topping Up The Compressor Oil Level
Washing The System
Automatic Temperature Climate Control
Ecu Operating Logic Climate Control System
Air Conditioner Unit
Adjustable Air Vent On Dashboard
Climate Control System Control Assembly
Fan Electronic Variator
Recirculation Flap Motor
Air Distribution Flap Motor
Air Mixing Flap Motor
Microswitch For Inhibiting Air Conditioning With Hood Open (Spider)
Upper Mixed Air Sensor
Lower Mixed Air Sensor

Closing Panels:
Doors
Door Striker (Spider Only)
Lock Striker
Door Mirror
Door Panel
Lock Unit
Window Guides
Window
Window Adjustment
Window Winding Device
Window Wiper Seal
Up-down Device
Up-down Device Cam
Up-down Device Microswitch
Front Wind Seal
Mirror Triangle Seal
Door Lower Moulding
Bonnet
Telescopic Props
Bonnet Closing Device
Bonnet Inner Cover
Shield
Front Badging
Bonnet Opening Control Cable
Wheel Arch Liner
Complete Spider Boot Lid
GTV Complete Boot Lid
Telescopic Props
Boot Lid Closing Device
Boot Moulding
Hood Compartment Cover And Hinges (Spider)

Interior Trim Spider & GTV:
Front Seats Complete Seat Strip Down & Rebuild
Electric Front Seats Complete Seat Strip Down & Rebuild
Dashboard
Instrument Cluster Hood
Central Unit Frame (’98 Versions)
Glovebox Lid & Lock
Dashboard Trim Panel
Tunnel Console
Centre Console
Sound System Compartment (’98 Versions)
Sun Visors
Door Surround Moulding
Upper Windscreen Trim
Inner Rearview Mirror
Windscreen Frame Seal
Seat Belts
Hood Compartment Lid
Hood Compartment Upper Trim Panel
Boot Lid
Hood Compartment Inner Partition
Luggage Net (’98 Versions)
Rear Shelf Trim
Heel Board
Outer Door Surround Seal
Engine Compartment Guards
Engine Compartment Rear Seal
Rear Luggage Compartment Trim
Luggage Compartment Floor Trim
Luggage Compartment Interior Trim
Floor Trim
Boot Compartment Flap Catch
Passenger’s Grab Handle
Roof Lining
Rear Seats
Rear Headrest
Side Panel
Parcel Shelf
Centre Pillar Trim
Rear Pillar Trim

Fixed Body Components
All Exterior And Interior Body Panels