🏷️ Basic Information

Make:

Alfa Romeo

Model:

Spider

Generation:

916

Model Year:

2004

Chassis Code:

916

👋 Introduction

Target Audience:

Alfa Romeo Spider 916 owners, mechanics, and restorers seeking comprehensive, official repair information.

Authenticity:

Genuine factory service manual, providing accuracy and detail superior to third-party alternatives.

Content Depth:

Detailed substeps, notes, cautions, warnings, numbered instructions, and bold figure numbers for clarity.

Visual Aids:

Includes hundreds of illustrations, drawings, and photos, with enlarged insets for detailed part examination.

Usability:

Easy to navigate with a numbered table of contents and search functionality for quick access to information.

Labor Savings:

Enables DIY servicing, potentially saving $50-$60 per hour in shop labor costs.

📋 Manual Details

General Maintenance:

True

Troubleshooting:

True

Engine Service Repair:

True

Transmission Service Repair:

True

Brake System:

True

Wiring Diagram:

True

Electrical System:

True

Suspension:

True

Periodic Lubrication:

True

Steering:

True

Cooling System:

True

Fuel Injection Fuel System:

True

Emission System:

True

Heater Air Conditioning:

True

Engine Control System:

True

Chassis Body:

True

Restraint System:

True

Interior:

True

Differential Drive:

True

Axle:

True

Estimated Pages:

Hundreds (Specific count not provided in product info, but implied to be extensive)

Type:

Factory Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Comprehensive service and repair for engine components, including disassembly, inspection, assembly, and troubleshooting.

Transmission:

Detailed procedures for manual and automatic transmission service, repair, and adjustments.

Brakes:

In-depth coverage of the hydraulic brake system, including ABS components, diagnostics, and repair procedures.

Electrical:

Extensive electrical system coverage with detailed wiring diagrams, component location, diagnostics, and repair of circuits.

Suspension Steering:

Complete guide to front and rear suspension systems, steering mechanism, alignment procedures, and component replacement.

Fuel System:

Detailed information on fuel injection, fuel pump, injectors, fuel filter replacement, and emission control systems.

Cooling Ac:

Service and repair for the cooling system (radiator, thermostat, fans) and HVAC system (compressor, refrigerant, climate control).

Chassis Body:

Body repair, structural components, doors, windows, and interior trim procedures.

Restraint Systems:

Information on airbags, seatbelts, and associated control modules.

Diagnostic Procedures:

Advanced troubleshooting guides and diagnostic flowcharts for identifying and resolving issues.

Repair Procedures:

Step-by-step repair instructions for virtually all vehicle components and systems.

Maintenance Procedures:

Routine maintenance tasks, fluid changes, filter replacements, and general upkeep.

Rebuild Procedures:

Comprehensive instructions for complete engine, transmission, and component rebuilds.

Lubrication Schedule:

Detailed information on periodic lubrication points and specifications.

Depth:

Factory-level technical details, suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

Format:

PDF

Searchability:

Searchable text for quick information retrieval.

Printability:

Fully printable, allowing users to print specific pages or the entire manual.

Binding:

Digital Download (printable)

Paper Type:

N/A (Digital)

Reader Software:

Adobe PDF Reader

⚙️ Engine Specifications

Engine Options:

This manual covers the 2004 Alfa Romeo Spider 916, which typically came with a 2.0 L Twin Spark or a 3.0 L or 3.2 L Busso V6 engine. Specific engine variants are detailed within the manual.

Performance Data:

The manual provides specifications for horsepower, torque, and other performance metrics relevant to each engine option.

Injection Type:

Bosch Motronic or similar multi-point fuel injection systems (specifics depend on engine variant).

ECU System:

Details on engine control unit (ECU) functions, diagnostic trouble codes (DTCs), and sensor data interpretation.

🔧 Transmission

Transmission Type:

Likely includes coverage for a 5-speed manual transmission. Automatic transmission options may also be present depending on market and specific engine configuration.

Optional Transmission:

Potential coverage for an automated manual transmission (Selespeed) or a traditional automatic transmission depending on the specific 2004 model variant.

Clutch System:

Detailed procedures for clutch inspection, replacement, and hydraulic system service.

Transmission Fluid:

Specific fluid types and capacities for manual and automatic transmissions will be listed in the manual.

📐 Dimensions

Body Styles:

The 916 Spider is a two-door convertible.

Curb Weight:

Curb weight varies by engine. For context, the 2.0L Twin Spark models typically weigh around 1400-1450 kg, while V6 models are slightly heavier. Specific figures are within the manual.

🛡️ Safety Features

Crash Test Data:

The manual likely contains information related to the vehicle's safety structure and restraint systems as designed by the manufacturer, but official crash test ratings from organizations like Euro NCAP or NHTSA for the 2004 model year would need separate verification.

ABS:

Anti-lock Braking System (ABS) diagnostics and repair.

Airbags:

Details on airbag system components, deployment logic, and servicing procedures.

Seatbelts:

Information on seatbelt pre-tensioners and operation.

💡 Technology Features

Audio System:

The 2004 model likely features a factory CD player, possibly with steering wheel controls. Manual covers its operation and basic troubleshooting.

Cruise Control:

Coverage for cruise control system operation and diagnostics.

Diagnostics:

Information on diagnostic port (OBD-II) location and basic communication protocols for accessing engine management data.

🔧 Maintenance

Oil Change Interval:

Typical intervals for this era Alfa Romeo are around 10,000-15,000 km (6,000-9,000 miles) or 1 year, whichever comes first. The manual will provide the definitive schedule.

Timing Belt:

Crucial for Twin Spark engines (typically 100,000 km or 5 years) and V6 engines (typically 100,000 km or 5 years). The manual specifies exact intervals and replacement procedures.

Engine Oil Type:

Likely requires a high-quality synthetic engine oil, such as Selenia Star 5W-40 or equivalent API SN/ACEA C3 specification oils. Specific viscosity and API/ACEA ratings are detailed in the manual.

Coolant Type:

Paraflu UP (blue color) or an equivalent G12/G12+ compliant coolant is typically specified. Capacity and change intervals are in the manual.

Brake Fluid Type:

DOT 4 brake fluid is standard. Replacement every 2 years is recommended for optimal performance and to prevent moisture absorption.

Electrical Gremlins:

Early Alfa Romeos, including the 916 generation, are known for occasional electrical issues, particularly with wiring harness integrity and sensor failures. The manual's diagnostic section is invaluable here.

Engine Maintenance:

For Twin Spark engines, regular attention to spark plug replacement (often 4 per cylinder) and the timing belt are critical. Busso V6 engines require diligent maintenance, especially regarding the timing belt and oil changes.

📚 Vehicle History

Alfa Romeo Legacy:

Alfa Romeo has a long history of producing sporting roadsters, with the Spider nameplate being iconic and synonymous with Italian design and performance.

916 Generation:

The 916 generation Spider, launched in 1995, replaced the previous 110 Spider. It featured a distinctive Pininfarina design and shared its platform with the GTV coupe. The 2004 model represents a later iteration within this generation, likely incorporating minor updates.

Manufacturing Location:

The 916 Spider and GTV were primarily manufactured in Italy.

🏆 Awards & Recognition

Design Awards:

The 916 Spider and its GTV sibling received numerous design accolades, including being recognized as one of the most beautiful cars in the world upon their introduction. While not directly related to the manual, it speaks to the vehicle's pedigree.