1986 Alfa Romeo Spider Workshop Manual PDF

The 1986 Alfa Romeo Spider Workshop Manual provides comprehensive technical information for the classic Italian sports car. This manual covers the 2.0L twin-cam engine, 5-speed manual transmission, electrical systems, suspension, brakes, bodywork, and routine maintenance procedures. Below are key sections for specifications, maintenance schedules, repair procedures, troubleshooting, and technical data.

1. Vehicle Specifications 2. Maintenance Schedule 3. Engine Systems 4. Transmission & Drivetrain 5. Electrical Systems 6. Suspension & Steering 7. Brake Systems 8. Body & Interior 9. Troubleshooting Guide 10. Technical Data 11. Wiring Diagrams

Vehicle Specifications

Key technical specifications for the 1986 Alfa Romeo Spider.

Specification	Details
Engine Type	2.0L DOHC Twin-Cam Inline-4
Displacement	1962 cc
Power Output	128 hp @ 5400 rpm
Torque	137 lb-ft @ 4000 rpm
Transmission	5-speed manual
Fuel System	Bosch L-Jetronic fuel injection
Brakes	Front disc, rear drum
Suspension	Independent front, live axle rear
Wheelbase	88.6 inches
Curb Weight	2535 lbs

Maintenance Schedule

Recommended service intervals and maintenance procedures.

Oil Change: Every 3,000 miles or 3 months
Spark Plugs: Replace every 12,000 miles
Timing Belt: Replace every 60,000 miles
Coolant Flush: Every 24,000 miles or 2 years
Brake Fluid: Replace every 12,000 miles
Air Filter: Replace every 15,000 miles

WARNING! Always use manufacturer-recommended fluids and parts. Follow torque specifications precisely.

Engine Systems

Detailed procedures for engine maintenance and repair.

Valve Adjustment: Set clearance to 0.015" intake, 0.017" exhaust
Timing Belt Replacement: Align marks on camshaft and crankshaft pulleys
Fuel Injection: Test fuel pressure (36-40 psi)
Cooling System: Check thermostat opens at 180°F
Ignition System: Set timing to 10° BTDC at idle

CAUTION! Engine components are precision parts; handle with care to avoid damage.

Transmission & Drivetrain

Transmission Type: 5-speed manual with overdrive
Gear Ratios: 1st: 3.35, 2nd: 2.09, 3rd: 1.39, 4th: 1.03, 5th: 0.82
Final Drive: 4.10:1 ratio
Clutch: Hydraulic actuation, 215mm diameter
Transmission Fluid: SAE 80W-90 GL-4 gear oil
Capacity: 2.1 quarts

Electrical Systems

Complete electrical system diagnostics and repair procedures.

Battery: 12V 45Ah, negative ground. Alternator: 65A output. Starter: 1.4kW pre-engaged type.

Fuse Box: Located under dashboard. Main fuses: 30A for headlights, 15A for ignition, 10A for instruments. Wiring: Color-coded per Italian standards. Ground points: Engine block, chassis, body panels.

Suspension & Steering

Front and rear suspension components and steering system.

Front Suspension: Double wishbone with coil springs and anti-roll bar
Rear Suspension: Live axle with trailing arms and coil springs
Steering: Rack and pinion, 3.2 turns lock-to-lock
Wheel Alignment: Toe-in 1/16", camber -0.5° to -1.0°

Tip: Always check suspension bushings for wear during routine maintenance.

Brake Systems

Hydraulic brake system maintenance and repair procedures.

Front Brakes: 10.2" ventilated discs, single piston calipers
Rear Brakes: 9.0" drums with self-adjusting mechanism
Master Cylinder: Tandem type with integrated reservoir
Brake Fluid: DOT 4, replace every 2 years
Bleeding Sequence: Right rear, left rear, right front, left front
Pad Replacement: Minimum thickness 2mm

WARNING! Brake system is critical for safety; test thoroughly after any service.

Body & Interior

Bodywork maintenance and interior component repair.

Body: Steel unibody construction with aluminum hood. Paint: Acrylic enamel finish. Interior: Vinyl and cloth upholstery. Convertible Top: Manual operation with vinyl window. Rust Prevention: Check common areas - floor pans, rocker panels, wheel arches.

Troubleshooting Guide

Common problems and diagnostic procedures.

Symptom	Possible Cause	Corrective Action
Hard starting	Fuel pressure, ignition timing	Check fuel pump, test spark, verify timing marks
Overheating	Coolant level, thermostat	Check radiator, water pump, fan operation
Poor idle	Vacuum leaks, AFM	Inspect hoses, clean throttle body, test AFM
Brake pull	Calipers, alignment	Check caliper operation, inspect pads, verify alignment
Electrical issues	Grounds, alternator	Test battery, check ground connections, verify charging

Technical Data

Torque Specifications: Cylinder head bolts: 65 ft-lbs, Main bearings: 50 ft-lbs
Fluid Capacities: Engine oil: 5.3 qt, Coolant: 9.5 qt, Fuel tank: 15.8 gal
Pressures: Oil pressure: 50-60 psi @ 2000 rpm, Fuel pressure: 36-40 psi
Clearances: Piston to bore: 0.002", Rod bearing: 0.0015"

Wiring Diagrams

Complete electrical schematics for all systems.

Color Codes: Red - power, Black - ground, Green - lighting, Yellow - ignition. Connectors: Multi-pin weatherproof type. Ground Locations: Engine block, firewall, chassis rails. Circuit Protection: Fuses and fusible links in engine compartment.

Service Support: Alfa Romeo technical assistance available through authorized dealers.