The 1968 Alfa Romeo Spider is a charming Italian roadster with the robust 1.6L twin-cam engine, but age and deferred maintenance create predictable engine wear and fuel system issues that can get expensive quickly. Most survivors today are 55+ years old, so expect problems related to decades of use rather than design flaws.
Worn Engine Bottom End (Main Bearings & Crankshaft)
Common · high severityTypical onset: 80,000-150,000 mi
Symptoms: Deep knocking sound on cold start that may diminish when warm, Low oil pressure at idle, Metallic rattling under acceleration, Metal shavings in oil filter
Fix: Full engine-out rebuild with crankshaft machining, new main bearings, rod bearings, and seals. Expect 40-50 hours labor for proper R&R and rebuild on this twin-cam engine. Many shops send the bottom end to a machine shop for crank grinding.
Estimated cost: $5,500-9,000
Piston Ring Wear and Cylinder Bore Scoring
Common · medium severityTypical onset: 100,000-180,000 mi
Symptoms: Blue smoke on startup and deceleration, Excessive oil consumption (1 quart per 500-800 miles), Loss of compression across multiple cylinders, Fouled spark plugs
Fix: Requires cylinder honing or boring oversized, new pistons and rings. Often combined with valve job since engine is already out. Total 45-55 hours including removal, machine work, and reassembly.
Estimated cost: $6,000-10,000
Valve Guide Wear and Valve Job Needed
Common · medium severityTypical onset: 60,000-120,000 mi
Symptoms: Blue smoke during warmup, Rough idle and misfires, Poor fuel economy, Oil fouling on intake valves visible during compression test
Fix: Head removal, valve guide replacement, valve seat machining, new valve seals, and lapping. Twin-cam heads are time-intensive. Plan on 25-35 hours labor depending on whether engine stays in car.
Estimated cost: $3,500-5,500
Worn Transmission Mounts
Common · low severitySymptoms: Excessive shifter vibration especially at idle, Clunking when engaging clutch or shifting, Visible drooping of transmission tailshaft, Difficulty finding gears
Fix: Rubber mounts deteriorate badly over decades even with low miles. Replace all transmission and engine mounts as a set. 3-5 hours labor.
Estimated cost: $400-800
Worn Synchros and Manual Transmission Rebuild
Occasional · medium severityTypical onset: 70,000-140,000 mi
Symptoms: Grinding into second gear especially when cold, Difficulty downshifting, Popping out of gear under load, Gear clash even with clutch fully depressed
Fix: Full transmission rebuild with synchro rings, bearings, and seals. These Alfa gearboxes need experienced hands familiar with Italian layshaft designs. 18-25 hours including removal and reinstallation.
Estimated cost: $2,800-4,500
Clogged Fuel System and Carb Varnish Buildup
Common · low severitySymptoms: Hard starting when cold, Stumbling and hesitation during acceleration, Stalling at idle, Rough running that improves after driving
Fix: Complete fuel system service: new fuel filter, tank cleaning if rusty, carb disassembly and ultrasonic cleaning, rebuild with new jets and gaskets. Plan 8-12 hours for thorough dual-carb work on Weber or Solex setups.
Estimated cost: $800-1,500
Cooling System Corrosion and Overheating
Occasional · medium severitySymptoms: Running hot in traffic or on hills, Coolant loss with no visible external leaks, Rusty or muddy coolant, Heater blowing cold air
Fix: Old coolant turns acidic and eats aluminum. Requires radiator recore or replacement, water pump, thermostat, all hoses, and thorough block flushing. If neglected, can cause head gasket failure. 10-15 hours.
Estimated cost: $1,200-2,200
Buy one only if it has documented recent engine work or you have $8-12K set aside for a full rebuild — charming cars, but 55-year-old engines don't owe you anything.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.