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#1 · (Edited)
Spider Technical FAQ Digest - Version 2

🙏 RIP Tifosi - 1966-2013 🙏

The FAQ is dedicated to Darren Gates = Tifosi who was so important to this forum



We have developed a Spider (much of it is also helpful to the GTV) specific FAQ for the Forum. There are many excellent threads that have answered the most common and some not so common problems. Searching the forums can be difficult due to the huge amount of information found. Browsing is still very informative for those new to the BB or to the Spider. All of those that have added to the FAQ have certainly helped many Alfa Spider Owners and maybe some of the other models too!! Keep up the good work.

This is a group effort and if you see a good thread, go ahead and put a link to it in THIS thread by hitting reply and adding it to the end. Don't be shy about adding any items!!! I will add it to the first index page when I do maintenance.


Complete Car - Unit 00

#8 Chassis Stiffener Dicsussion
#21 Emergency Release Cables - Hood & Trunk
#25 Homemade Wind Deflector
#67 Wheel Stud Length
#71 MUST Have Spider Manuals
#73 Spider FAQ (non Alfa BB)
#109 Get your Alfa's History


Engine Main Mechanical - Unit 01

#9 Oil Seperator
#12 Engine Oil Viscosity Debate (Oil Jihad!)
#18 Replace Motor Mounts
#29 VVT Rubber Bushing repair
#40 Plenum Vacuum Fittings
#57 VVT O-Ring
#70 Lower Oil Pan Removal
#84 Series 3 Drive belts
#87 Head Gasket Replacement with Pictures!
#88 Motronic Top Dead Center - TDC
#120 Replace Pistons and Cylinder With Engine in Car
#114 Series 4 Trouble Codes
#129 Retorque Cylinder Head

Fuel System - Unit 04

#2 Fuel Injector Cleaning
#3 Gas Smell in Trunk or Interior/High Pressure in Gas Tank
#4 3 Series Spider L-Jet Diagnostics
#10 Fuel Vapor recovery (Gas Smell in Car)
#14 Resetting EXH Sensor
#39 Thermo Time Switch (TTS) Diagnostics
#42 SPICA Starter Run-On
#43 Dummy Thermostatic Actuator
#48 Testing L-Jet air flow meter
#52 L-jet Throttle Body stop screw
#55 L-Jet Throttle Body Throttle Shaft
#56 Manually Operated AAV
#63 Hose Clamps for Fuel Injection
#64 Fuel Injector Replacement
#74 Throttle Linkage Info
#77 Vacuum manifold pressure sensor in L-jet
#89 Fuel Injector Hose
#113 In Tank Fuel Pump
#122 Repair VVT Bushing
#124 How to Fix Mechanical Section of VVT
#126 Lots of SPICA Info
#127 Pressurized Fuel Tank
#128 VVT Wiring Harness
#146 Spica Throttle Body Rebuild
#151 Fuel Pump Inertia Relay Options

Ignition, Starting, Charging System - Unit 05

#7 Starter Removal S4 series
#20 Oxygen Sensor Info
#99 Cap and Rotor Information
#121 Soldering Oxygen Sensor Wires


Engine Cooling System - Unit 07

#23 Thermostat Bypass Valve
#27 Engine Cooling Fans
#72 Aux Fan Temp Sensor
#94 Water Pump Replacement with PICTURES


Clutch - Unit 12

#108 Replace Clutch Pedal Pivot
#22 Clutch Master Rod Adjustment
#61 Clutch Replacement
#85 Light Weight Clutch


Gearbox - Unit 13

#54 Trans Mount
#116 Trans Mount Replacementl
#68 Transmission Oil
#69 Trans Mount Puller
#102 Transmission Rebuilding
#104 Transmission Removal
#115 Transmission Mount
#117 Fix the First Gear CRUNCH


Propellor Shaft - Unit 15

#110 Drive Shaft info
#115 Propellor (Drive) Shaft Info

We needs some links for this section! Do you have any???


Rear Axle - Unit 17

#46 Pinion Nut Socket Plans
#47 More Pinion Nut Info
#59 Limited Slip Diff vs Open Differential housing differences
#92 Rebuild Limited Slip Differential Clutch Pack
#95 Rear Wheel Bearing Info


Front Suspension - Unit 21

#28 Front Wheel Bearing Info
#35 Front End Alignment
#78 Ride Height & Springs
#97 Front Spring Install
#98 Front Suspension Rebuild with PICTURES
#111 Upper A-Arm Info


Front and Rear Brakes - Unit 22

#80 Hydraulic Bleeder Screw Specs
#96 Sticking Brake Calipers
#103 Rebuilding Brake Calipers
#107 Replacing REAR Brake Pads with PICTURES!
#144 Hand Brake Rebuild


Steering - Unit 23

#17 Replace Steering Box Seal
#34 Steering Box Adjustment
#143 Steering Box Disassembly


Rear Suspension - Unit 25

#37 Rear Shock R&R
#78 Ride Height & Springs
#90 Rebuild Rear Suspension with PICTURES


Electrical System - Unit 40

#5 Headlight Relay Info
#6 Fuses and Relays Info
#11 Ignition Switch Removal
#14 Resetting EXH Sensor
#24 Warning Buzzer Locations
#30 Fuse Box Upgrade
#32 Fuel Sender Wiring
#33 S3 Ignition Switch disassembly
#38 Install Starter Relay
#39 Thermo Time Switch (TTS) Diagnostics
#41 Make Your Instruments BRIGHTER
#45 Removal Turn Signal Indicator
#48 Testing L-Jet air flow meter
#50 The Key switch goes bad for the starter
#51 S2 dash warning lights ~ lamps
#58 Fitting headlight covers onto series 3 and series 4 spiders
#79 Remove the Flywheel Sensor
#81 Headlight Replacement
#82 Lighted Ignition Switch
#112 Jaeger Gauge Test-Setup-Data
#123 How to Fix Slow Speedometer or Tachometer
#151 Fuel Pump Inertia Relay Options


Doors - Unit 65

#13 S3 Power Window Cable Adjustment
#16 Door Handles/Locks/Panels
#19 Door Limit Strap
#31 Vent Window Latches
#65 Door Latch Spring
#83 Door Lock Info
#100 Remove/Replace Vent Windows
#119 Electric Mirror Fix


Hoods - Unit 56

#21 Emergency Release Cables - Hood & Trunk


Internal Trimming - Unit 66

#26 Steering Wheel removal
#36 S3 Console removal
#62 Glove Box Door Straightening
#60 Series 3 dual pod center console
#66 Cowl Drain Hose
#86 Dashboard Cap
#93 Early vs. Late S2 Vent Differences


External Trimming - Unit 75

#44 Factory Convertible Top Manual
#53 Bumper Conversion Mysteries Revealed!
#58 Fitting headlight covers onto series 3 and series 4 spiders
#66 Cowl Drain Hose
#75 Convertible Top Replacement
#125 Rubber Bumper Repair


Ventilation, Heating and A/C System - Unit 80

#49 AC Maintenance
#76 AC/Air Conditioning system wiring


DO NOT post new questions or comments here!!

If you have a question or comment about the FAQ, send me a PM and I will respond.
 
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#131 ·
Replacement for Original Electronic VVT Harness

The link below provides a low-cost alternative for replacing the electronic VVT harness, which are no longer available new and becoming harder to find used at a reasonable price.

http://www.alfabb.com/bb/forums/spider-1966-up/361529-replacement-electronic-vvt-harness.html

Obviously, it isn't original, so if that is a concern, this isn't a solution for you. But with people asking over $100 for used harnesses, this is an inexpensive alternative.
 
#132 ·
#140 ·
#139 ·
If not already here somewhere- here is an old IAP video showing how to properly remove/re-install the spider In tank pump/sender assembly for those needing to service any of the pertaining parts;
 
#142 ·
Wondering if there is such a 'thing' as a diagnostic tool, or maybe an 'app', for a Series 4 Spider? And if there is where would the 'thing' hook-up to my Alfa?
I know this sounds like a stupid question, but when it comes to mechanical 'stuff' I'm a dope.

Regards
not sure this is the right section to post...maybe admin can move it... but anyways...

no app thats for sure!!;)
there was an alfa diagnostics machine for the S4, but basically forget trying to find that.
What you can do (when a fault occurs) is read off the fault codes.
Under the rear compartment (only USA S4's) is a red button on the side of the ECU.
Pressing that will cause the engine light to flash a certain sequence, you 'read off' the sequence and that is the fault code.

codes here: http://www.alfabb.com/bb/forums/693108-post3.html
how to get them here: http://www.alfabb.com/bb/forums/270850-post2.html

just for fun, this is what the diagnostics tool looks like and what it can do for the Motronic ML4.1 system:
http://www.alfabb.com/bb/forums/164-168-1991-1995/303137-fiat-lancia-tester-motronic-ml4-1-a.html
 
#143 ·
#144 ·
#145 ·
OK - maybe this one has a place, too...the nitty gritty on how to inspect an oil pump to figure if rebuild or replacement is necessary.

 
#147 ·
Here's a link on how to fabricate a VVT bushing with pictures. Scroll to #10.
 
#149 ·
Hi Jon -

After a defective oil pump fouled my engine, there was a long 'Metal In The Oil' thread. Several posters helped identify the subpar aftermarket pumps that are prone to failure, and I've summarized the info. I think it's worth adding to the FAQs. Thank you!

David OD
Laguna CA



There have been some durability issues with marginal aftermarket oil pumps. In particular, pump drive gears made from softer metal have failed, fouling the oil system with metal particles. It’s possible some of these marginal pumps are still for sale from vendors who must rely on manufacturer’s QC, several steps up the supply chain.

Some characteristics of marginal pumps are:


Drive gear is shiny brass instead of darker factory phosphor-bronze (Pic 1).

Marginal gear tooth root diameter is visibly less than the factory root diameter (Pics 2 & 3).

The reduced diameter portion of the gear is fully machined, while that part of most factory gears is not completely machined. A raw cast surface is proof the gear is not made from bar stock (Pic 4).

The holes in the screen on the pickup are larger - 2.0 mm vs 1.25 mm

Star lockwashers under the four nuts.

The cotter pin hole is double-drilled (Pic 4).

Black threaded hex socket plug on the bypass port.

The three pump base holes are larger 10.5 mm diameter, vs the 9.9 mm original factory holes (Pic 5).



Not all traits occur in every pump that has failed, but these are pretty consistent and should help identify faulty pumps before they're installed. Look twice before installing any new aftermarket pump, so you can leave that AAA Roadside Service card in your wallet.

Finally, with all oil pumps, correct installation is critical. See the attached factory bulletin to avoid shaft misalignment (Pic 6). And be sure the distributor drive offset pins align with the offset slot in the pump shaft. Product Auto part Plumbing Nozzle Pipe
Auto part Tool accessory Valve Machine Metal
Tool accessory Rotor Gear Auto part Machine
Auto part Tool accessory Metal Machine Machine tool
Text Document Font Line Paper
 
#150 ·
I don't think this bulb list ever made it to the Table of Contents

 
#156 ·
Excellent! I've been looking for this. The exterior bulbs will be converted to LED, especially the brake lights. Anything to make these little cars more visible.
 
#153 ·
 
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