Workshop Manuals Factory service & repair Alfa Romeo
01 Introduction and contents02 00 Technical data and maintenance03 10 Engine – T. Spark 16V04 10 Engine – 3.0 V605 18 Clutch06 21 Gearbox07 27 Front axle08 33 Brakes09 41 Steering10 44 Suspension and wheels11 Variants – 2.0 V6 Turbo (GTV and Spider)12 Variants – 3.0 V6 24V13 Variants – Euro 3 models14 50 Heating, ventilation and air conditioning15 70 Bodywork16 Variants – heating and air conditioning (2.0 V6 Turbo and 3.0 V6 24V)17 55 Electric system18 Electric system diagnosis – 1995-96 cars (incl. V6 Turbo and 24V)19 Electric system diagnosis – from May '97 cars20 Electric system diagnosis – '98 to 2000 cars21 Right-hand drive variants
Alfa Romeo GTV and Spider (916) Factory Service Manual (1995-2000)15 · 70 Bodywork
15 · Body & interior

Surfacing or filling

Make
Alfa Romeo
Model
GTV / Spider GTV and Spider (916) Factory Service Manual
Year
1995–2000
Section
Body › Surfacing or filling
70 BodyworkSurfacing or filling

Surfacing or filling

Repair operations on sheet metal (or plastic parts) usually require a surfacing and/or filling stage. It is very important to blend the product well, then apply a coating sufficient to cover the existing ondulations without exceeding the specified thickness.

Sanding

Dry sanding may be carried out by hand or using an electric or pneumatic sander fitted with the specified sandpaper.

A person wearing protective gear is sanding a metal part with a sander connected to a dust extraction system.

Masking

The areas surrounding the parts to be repaired should be masked with sheets of paper fixed to the surface with adhesive tape.

The importance of this operation should not be underestimated and it should be carried out, like all the others, taking all the necessary precautions to avoid painting parts not involved in the operation. Masking should be applied:

  • before coating with Primer;
  • before undercoating;
  • before coating with paint.

Coating with Primer

Primer is to be applied to bare metal surfaces, as protection against corrosion.

Sealing

Sealing must be carried out on sheet metals, to prevent the penetration of water or damp and is carried out with the use of different products.

Sealants are products that fill, insulate and protect and are to be used on sheet metal joints. Sealant should be applied with a brush or suitable spray gun.

Undercoating

Due to its thickness, the undercoating eliminates any imperfections of the layer beneath.

The undercoat must be prepared and applied following the instructions given in the corresponding painting cycle.

Sanding the undercoat

Sanding is necessary due to the thickness of the undercoat.

During this operation, to locate and remove any imperfections and waviness, it is advisable to spray a fine film of enamel (spy coat) on the surface concerned.

Preparation of paints

For the catalysis and dilution proportions for the preparation of painting products, closely adhere to the Manufacturer’s Instructions.

A paint storage cabinet with multiple shelves holding paint cans and a spray gun station on top.

Parts & tools for this job For 1995 Alfa Romeo GTV / Spider

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