Alfa Romeo 166 Workshop Service Repair Manual download
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🏷️ Basic Information Identification Make: Alfa Romeo Model: 166 Generation: First Generation (936) Production Years: 1998-2007 Codes Chassis Code: 936 👋 Introduction Market Position Segment: Executive Sedan Competitive Analysis Competitors: BMW 5 Series, Mercedes-Benz E-Class, Audi A6, Jaguar S-Type Key Features Design Philosophy: Emphasized Italian design, performance, and luxury Unique Selling Points: Distinctive styling, powerful V6 and V8 engines, engaging driving dynamics 📋 Manual Details Coverage Areas Market Regions: Global (primarily Europe) Page Count Estimated Page Count: Extensive (typical workshop manuals are 1000+ pages) Manual Type Manual Type: Workshop Service Repair Manual Language Languages Included: Italian, English, German, Spanish, Dutch, French, Portuguese Format Digital Format: Software (downloadable) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, diagnosis, and repair of all engine variants Engine Control System: ECU diagnosis, sensor testing, and system calibration Fuel System: Fuel pump, injectors, lines, tank, and evaporative emission control Cooling System: Radiator, thermostat, water pump, hoses, and fan operation Exhaust System: Catalytic converter, mufflers, pipes, and emission control components Ignition System: Spark plugs, coils, wiring, and ignition timing Charging System: Alternator, voltage regulator, and battery diagnostics Starting System: Starter motor, solenoid, and ignition switch Transmission Manual: Clutch system, gearbox overhaul, and driveline components Transmission Automatic: Automatic transaxle diagnosis, repair, and fluid management Suspension Front: Struts, control arms, bushings, and alignment procedures Suspension Rear: Shock absorbers, springs, trailing arms, and alignment procedures Steering System: Power steering pump, rack and pinion, and steering column components Brake System: Disc brakes (front/rear), calipers, pads, rotors, fluid, and ABS Wheel And Tire System: Wheel and tire specifications, mounting, and balancing Lighting System: Headlights, taillights, indicators, and interior lighting Wiper And Washer System: Wiper motors, blades, washer fluid pump, and control switches Electrical System: Complete wiring diagrams, component testing, and diagnostic procedures Supplemental Restraint System: Airbag system diagnosis, sensor location, and replacement Climate Control System: Air conditioning, heater, ventilation, and blower systems Body Repair: Panel replacement, rust repair, and structural integrity Interior Trim: Seat removal, dashboard, door panels, and headliner Audio Visual System: Radio, amplifier, speakers, and antenna system Sun Roof System: Operation, maintenance, and repair of the sunroof mechanism Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements Troubleshooting: Diagnostic flowcharts and symptom-based repair guidance Repair: Step-by-step instructions for component replacement and repair Overhaul: Detailed procedures for complete engine, transmission, and major component rebuilds Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems Technical Specifications: Torque values, clearances, fluid capacities, and electrical values Technical Depth Depth: Professional Mechanic Level (suitable for professional workshops and advanced DIY enthusiasts) Diagnostics: In-depth diagnostic procedures, including fault code interpretation and sensor testing Calibration: Procedures for calibrating sensors and control modules 📊 Manual Specifications File Format File Type: Software Application (likely with interactive diagrams and search functionality) Print Quality Print Readability: High (designed for clarity of diagrams and text) Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Variants: 2.0L Busso V6, 3.0L Busso V6, 3.2L Busso V6, 2.5L GM V6, 3.0L GM V6, 3.2L GM V6, 2.2L JTD Diesel, 2.4L JTD Diesel, 2.0L JTD Diesel Performance Horsepower Range: 140 HP (2.0 JTD) to 240 HP (3.2 V6) Torque Range: 260 Nm (2.0 JTD) to 330 Nm (3.2 V6) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI), Direct Injection (for some diesel variants) Engine Layout Busso V6 Configuration: 60-degree V6 Engine Codes Common Busso Engine Codes: AR161.02 (2.0 V6), AR307.01 (3.0 V6), AR161.05 (3.2 V6) Common Jtd Engine Codes: 17541 (2.4 JTD), 937A5000 (2.4 JTD 20v) 🔧 Transmission Standard Manual Transmission: 5-speed, 6-speed (depending on engine) Optional Automatic Transmission: 4-speed Automatic (often referred to as 'Sportronic') Features Drive Type: Front-Wheel Drive (FWD) Clutch Type: Hydraulically actuated single dry plate clutch 📐 Dimensions Exterior Length: Approx. 4,720 mm (185.8 in) Width: Approx. 1,757 mm (69.2 in) Height: Approx. 1,427 mm (56.2 in) Weights Curb Weight: Approx. 1,400 kg - 1,600 kg (depending on engine and options) Gross Vehicle Weight Rating: Typically around 2,000 kg 🛡️ Safety Features Ratings Euroncap Rating: 3 Stars (original test) Active Features ABS: Standard Anti-lock Braking System Esd: Optional Electronic Stability Program (ESP) Traction Control: TCS (Traction Control System) Passive Features Airbags: Frontal airbags, optional side and curtain airbags Seatbelts: Pretensioner seatbelts with load limiters 💡 Technology Features Infotainment Audio System: Bose audio system available on higher trims, with CD player and optional navigation. Driver Assistance Cruise Control: Standard on most models. Connectivity Power Mirrors: Electrically adjustable and heated mirrors standard. Comfort Features Power Windows: Full electric window operation. Keyless Entry: Available on some models. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 15,000 km or 1 year, whichever comes first (consult manual for specific engine). Oil Specifications Engine Oil Type: API SN/SM/SL, ACEA A3/B4, SAE 5W-40 or 10W-40 (e.g., Selenia K Star 5W-40) Fluid Specifications Coolant Type: Ethylene glycol based coolant,...
4-speed Automatic (often referred to as 'Sportronic')
Features
Drive Type:
Front-Wheel Drive (FWD)
Clutch Type:
Hydraulically actuated single dry plate clutch
📐 Dimensions
Exterior
Length:
Approx. 4,720 mm (185.8 in)
Width:
Approx. 1,757 mm (69.2 in)
Height:
Approx. 1,427 mm (56.2 in)
Weights
Curb Weight:
Approx. 1,400 kg - 1,600 kg (depending on engine and options)
Gross Vehicle Weight Rating:
Typically around 2,000 kg
🛡️ Safety Features
Ratings
Euroncap Rating:
3 Stars (original test)
Active Features
ABS:
Standard Anti-lock Braking System
Esd:
Optional Electronic Stability Program (ESP)
Traction Control:
TCS (Traction Control System)
Passive Features
Airbags:
Frontal airbags, optional side and curtain airbags
Seatbelts:
Pretensioner seatbelts with load limiters
💡 Technology Features
Infotainment
Audio System:
Bose audio system available on higher trims, with CD player and optional navigation.
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
Power Mirrors:
Electrically adjustable and heated mirrors standard.
Comfort Features
Power Windows:
Full electric window operation.
Keyless Entry:
Available on some models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 15,000 km or 1 year, whichever comes first (consult manual for specific engine).
Oil Specifications
Engine Oil Type:
API SN/SM/SL, ACEA A3/B4, SAE 5W-40 or 10W-40 (e.g., Selenia K Star 5W-40)
Fluid Specifications
Coolant Type:
Ethylene glycol based coolant, recommended antifreeze (e.g., Paraflu UP).
Brake Fluid Type:
DOT 4
Automatic Transmission Fluid Type:
Specific ATF, refer to manual (e.g., Tutela GI/A)
Known Issues
Busso V6 Timing Belt:
Crucial to adhere to strict replacement intervals (often 90,000 km or 5 years) due to catastrophic failure risk.
Busso V6 Oil Consumption:
Can be prone to higher oil consumption, requiring regular checks.
Electrical Gremlins:
Older models can suffer from intermittent electrical issues, often related to aging wiring or connectors. The manual's wiring diagrams are essential for diagnosis.
Suspension Bushings:
Wear on suspension bushings is common, affecting ride quality and handling.
Diesel Dpf:
Diesel Particulate Filter (DPF) issues on later diesel models if not maintained or used for short journeys.
📚 Vehicle History
Brand Heritage
Alfa Romeo Legacy:
Renowned for sporty driving dynamics, distinctive Italian styling, and passionate engineering.
Model Evolution
Predecessor:
Alfa Romeo 164
Facelift:
Minor facelift around 2003 (e.g., revised front grille, updated interior).
Production
Manufacturing Plant:
Pomigliano d'Arco, Naples, Italy
🏆 Awards & Recognition
Recognitions
Design Awards:
The 166's styling was critically acclaimed and often cited as a highlight.