🏷️ Basic Information Identification Make: Alfa Romeo Model: 166 Engine Variant: 2.4 JTD 10V Years Covered: 1998-2008 Codes Engine Code Group: AR32501 (common for this era JTD) 👋 Introduction Market Position Segment: Executive Sedan Competitive Analysis Competitors: BMW 5 Series, Mercedes-Benz E-Class, Audi A6, Volvo S80 Key Features Design Philosophy: Stylish Italian design, driver-focused ergonomics, luxurious interior appointments Target Audience: Discerning buyers seeking a premium European sedan with sporting character and distinctive styling 📋 Manual Details Coverage Areas Primary Coverage: Full Service, Maintenance, Repair, Troubleshooting Page Count Estimated Pages: Extensive (typical for full workshop manuals, often 1000+ pages) Manual Type Type: Workshop Manual / Service Repair Manual Language Language: English Format Format: Digital Download (ISO/EXE) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel injection, lubrication, cooling, exhaust systems Drivetrain: Manual and Automatic Transmission, Clutch, Differential, Driveshafts Chassis: Suspension (front and rear), Steering, Brakes (hydraulic and mechanical components) Electrical: Engine Control Unit (ECU), Ignition, Lighting, Instrumentation, Power Accessories, Body Control Module (BCM), Airbag system, ABS/TCS systems Body And Interior: Body panels, doors, windows, interior trim, HVAC system, seats, security systems Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, spark plug checks, belt inspections), fluid level checks and top-offs Diagnostics: Fault code reading and interpretation, symptom-based troubleshooting guides Repair: Component removal and installation, component overhaul, calibration procedures Specifications: Torque specifications, clearance measurements, electrical schematics, diagnostic procedures Technical Depth Depth: Comprehensive (covers everything from routine maintenance to major overhauls and electrical diagnostics) 📊 Manual Specifications File Format Format: Disc Image File (.ISO) / Application (.exe) Print Quality Printability: Full Printable (allows users to print specific sections or the entire manual) Binding Type Binding Type: Digital (no physical binding) Paper Type Paper Type: Not Applicable (Digital Format) Features Zoom Functionality: Yes (allows zoom in/out for detailed diagram viewing) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 5-cylinder, Turbocharged Direct Injection Diesel (JTD) Displacement: 2387 cc Bore X Stroke: 82.0 mm x 90.4 mm Compression Ratio: 18.0:1 Fuel System: Common Rail Direct Injection (CDI) with multi-stage injection Engine Management: Bosch EDC 15/16 (typical for this era JTD) Performance Horsepower: 136 hp (100 kW) @ 4000 rpm (early models) / 140 hp (103 kW) @ 4000 rpm (later models) Torque: 300 Nm (221 lb-ft) @ 1800 rpm (early models) / 314 Nm (231 lb-ft) @ 1800 rpm (later models) 🔧 Transmission Standard Transmission Type: 5-speed Manual (Type M32/M40 variants) Optional Transmission Type: 5-speed Automatic (e.g., ZF 5HP19FL, later 6-speed available on some models/markets) Features Clutch Type: Hydraulically operated single dry plate clutch 📐 Dimensions Exterior Length: approx. 4705 mm Width: approx. 1775 mm Height: approx. 1435 mm Wheelbase: approx. 2700 mm Weights Curb Weight: approx. 1580 kg 🛡️ Safety Features Ratings Euro Ncap Score: 4 stars (overall for the 166 platform, specific to year and test configuration) Active Features Braking System: ABS with EBD (Electronic Brakeforce Distribution), Brake Assist (BA) Traction Control: ASR (Anti-Slip Regulation) / TCS (Traction Control System) Passive Features Airbags: Driver, front passenger, side airbags (standard on most trims), curtain airbags (optional/later models) Body Structure: High-strength steel passenger cell, crumple zones 💡 Technology Features Infotainment Head Unit: Factory integrated CD player, radio, with optional navigation system and premium audio by Bose. Display: Central multi-function display for climate control, trip computer, and system status. Driver Assistance Cruise Control: Standard on most variants. Connectivity Phone Integration: Optional Bluetooth hands-free system available on later models. 🔧 Maintenance Service Intervals Engine Oil And Filter: Typically every 15,000 - 20,000 km or 1 year, whichever comes first (refer to manual for exact schedule). Fuel Filter: Every 40,000 - 60,000 km. Air Filter: Every 20,000 - 30,000 km or as needed. Timing Belt: Crucial component! Typically every 60,000 - 80,000 km or 5 years. Replacement requires replacement of tensioners and idler pulleys. Fluid Specifications Engine Oil: API CF/SJ or ACEA B3/B4, viscosity SAE 5W-40 or 10W-40 (check specific engine variant and climate). Coolant: Paraflu UP or equivalent G11/G12 antifreeze, mixed 50:50 with distilled water. Brake Fluid: DOT 4 Transmission Fluid Manual: API GL-4, viscosity SAE 75W-90 (e.g., Tutela Car Technyx). Transmission Fluid Automatic: Specific ATF fluid as per manufacturer's recommendation (e.g., ZF LifeguardFluid5). Known Issues Electrical Gremlins: Common on older Alfas, often related to wiring harness degradation, ground points, or specific control modules. Suspension Wear: Front suspension components (wishbone bushings, ball joints) can wear prematurely due to road conditions and vehicle weight. Diesel Particulate Filter: Some early models may not have a DPF, but later ones might. Clogging can occur if regeneration cycles are interrupted. Egr Valve: Can become clogged with soot, leading to reduced performance and check engine lights. Turbocharger Issues: Can be susceptible to wear if oil changes are neglected or if driven hard from cold. 📚 Vehicle History Brand Heritage Brand Origin: Italian automobile manufacturer founded in 1910. Model Evolution Predecessor: Alfa Romeo 164...