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Alfa Romeo 166 Complete Workshop Service Repair Manual 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
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Basic Information Identification Make: Alfa Romeo Model: 166 Generation First Generation Years: 1998-2007 Codes Chassis Code: 936 Introduction Market Position Segment: Executive/Luxury Sedan Competitive Analysis Key Competitors: BMW 5 Series,...
Type: Cars
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Sku: 163548
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166
Alfa Romeo
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| Basic Information | |
| Identification | |
| Make: | Alfa Romeo |
| Model: | 166 |
| Generation | |
| First Generation Years: | 1998-2007 |
| Codes | |
| Chassis Code: | 936 |
| Introduction | |
| Market Position | |
| Segment: | Executive/Luxury Sedan |
| Competitive Analysis | |
| Key Competitors: | BMW 5 Series, Mercedes-Benz E-Class, Audi A6, Volvo S80, Jaguar S-Type |
| Key Features | |
| Design Philosophy: | Italian design flair, luxurious interior, powerful engines, advanced chassis dynamics for its era |
| Value Proposition | |
| Diy Savings: | Enables owners to perform maintenance and repairs, potentially saving significant costs on dealership labor |
| Manual Details | |
| Coverage Areas | |
| Years Covered: | 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 |
| Models Covered: | All models, engines, trim levels, and transmission types |
| Page Count | |
| Estimated Page Count: | Extensive (exact number not specified, but described as 'complete' and 'A-Z' coverage) |
| Manual Type | |
| Type: | Complete Workshop Service Repair Manual |
| Language | |
| Language: | English (implied by product description and target market) |
| Format | |
| Delivery Format: | Downloadable Digital File (PDF) |
| Accessibility: | Downloadable to multiple devices (PC, MAC, tablet, smartphone), allowing for flexible access in the workshop or on the go. |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Complete engine overhaul, diagnostics, timing belt/chain, lubrication, cooling system, fuel system, ignition system |
| Transmission: | Manual and automatic transmission service, repair, fluid changes, clutch service, differential service |
| Drivetrain: | Front-wheel drive components, axles, CV joints, driveshafts |
| Suspension: | Front and rear suspension systems, shock absorbers, springs, bushings, alignment specifications |
| Steering: | Power steering system, steering rack, tie rods, steering column |
| Brakes: | Brake system diagnostics, service, repair, ABS, brake fluid specifications, pad and rotor replacement |
| Electrical: | Wiring diagrams, lighting systems, starter, alternator, battery, fuses, relays, comfort systems, diagnostic trouble codes (DTCs) |
| Bodywork And Chassis: | Body panel repair, door mechanisms, glass replacement, interior trim, chassis components, welding procedures |
| HVAC: | Air conditioning system diagnosis, service, refrigerant handling, heater core, climate control |
| Fuel System: | Fuel pumps, injectors, lines, tanks, evaporative emission control |
| Exhaust System: | Exhaust manifold, catalytic converter, mufflers, pipes, oxygen sensors |
| Safety Systems: | Airbag system diagnosis and service, seatbelt mechanisms |
| Procedures Included | |
| Maintenance: | Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement |
| Troubleshooting: | Step-by-step diagnostic procedures for common and uncommon faults, guided troubleshooting trees |
| Repair: | Detailed instructions for component removal, installation, and repair across all vehicle systems |
| Diagnostics: | Information on diagnostic tools, reading fault codes, sensor data interpretation |
| Rebuilds: | Comprehensive engine and transmission rebuild procedures, including component specifications and tolerances |
| Adjustments: | Adjustment procedures for various components, e.g., parking brake, clutch linkage |
| Wiring Diagrams: | Detailed electrical wiring schematics for all vehicle systems |
| Technical Depth | |
| Depth: | Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds) |
| Level Of Detail: | Includes step-by-step instructions, diagrams, illustrations, torque specifications, clearances, and diagnostic flowcharts |
| Diagnostic Tools Coverage: | Includes guidance for using diagnostic tools to read and interpret ECU data, sensor readings, and fault codes specific to Alfa Romeo's diagnostic protocols of the era. |
| Manual Specifications | |
| File Format | |
| Format: | PDF (Portable Document Format) |
| Searchable: | Likely searchable text content due to PDF format, allowing quick access to information |
| Print Quality | |
| Printability: | Printable pages (user can print specific chapters or the entire manual) |
| Binding Type | |
| Binding: | Not applicable (digital download) |
| Paper Type | |
| Paper Type: | Not applicable (digital download) |
| Software Requirements | |
| Required Software: | Adobe Reader (free download available) |
| Engine Specifications | |
| Primary Engine | |
| Engine Options: | V6 Petrol (2.0, 2.5, 3.0, 3.2 litre), 4-cylinder Diesel (2.4 JTD), V6 Diesel (2.4 JTD) |
| Specific Engines Covered: | Includes details for engines such as the 3.0 V6 24v Busso (166.160) and 2.4 JTD 10-valve and 20-valve diesel engines. |
| Performance | |
| Typical Hp Range: | 150 hp (2.0 TS) to 240 hp (3.2 V6 24v) |
| Typical Torque Range: | 250 Nm (2.0 TS) to 285 Nm (3.2 V6 24v) |
| Fuel System | |
| Fuel Injection: | Multi-point fuel injection (MPI) for petrol engines, Common Rail Direct Injection (CRDI) for JTD diesel engines |
| Engine Management | |
| ECU Systems: | Details on Bosch Motronic and other ECU systems for engine control and diagnostics |
| Transmission | |
| Standard | |
| Standard Transmission: | 5-speed Manual Transmission (for most petrol variants), 6-speed Manual Transmission (for some performance variants) |
| Optional | |
| Optional Transmission: | 4-speed or 5-speed ZF automatic transmission (e.g., 'Q-System' or 'Comfortronic') |
| Features | |
| Transmission Fluid Spec: | Specific ATF (Automatic Transmission Fluid) types and manual gearbox oil specifications are detailed for each transmission type. |
| Clutch | |
| Clutch Type: | Hydraulically operated single dry plate clutch for manual transmissions. |
| Dimensions | |
| Exterior | |
| Length: | Approx. 4720 mm |
| Width: | Approx. 1795 mm |
| Height: | Approx. 1430 mm |
| Weights | |
| Curb Weight: | Varies by engine/transmission, typically from 1500 kg to 1750 kg |
| Gross Weight: | Detailed GWV specified for each model variant. |
| Cargo | |
| Trunk Volume: | Approx. 510 litres |
| Safety Features | |
| Ratings | |
| Euro Ncap Rating: | Euro NCAP: 4 stars (for 1999 testing) |
| Active Features | |
| Active Safety: | ABS with EBD (Electronic Brakeforce Distribution), Traction Control (ASR), Vehicle Stability Control (VDC/ESP) on later models |
| Passive Features | |
| Passive Safety: | Front airbags, side airbags, curtain airbags (optional/later models), pre-tensioned seatbelts, ISOFIX child seat anchors |
| Technology Features | |
| Infotainment | |
| Infotainment System: | Optional integrated navigation system, CD player, radio, premium audio system options (e.g., Bose). |
| Driver Assistance | |
| Driver Assistance Features: | Cruise control, parking sensors (rear), automatic climate control with dual-zone functionality. |
| Connectivity | |
| Connectivity Options: | Limited by era. Typically included phone integration via Bluetooth or optional hands-free kits on later models. |
| Lighting | |
| Headlight Types: | Halogen projector headlights, with optional Xenon HID headlights on higher trims or later models. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Typically 10,000-15,000 km or 12 months, depending on engine oil specification and driving conditions. |
| Timing Belt Replacement: | For V6 engines, replacement interval is usually around 100,000 km or 5 years. Diesel engines use timing chains, requiring less frequent replacement. |
| Fluid Specifications | |
| Engine Oil Spec: | Covers various API/ACEA specifications depending on engine (e.g., SAE 10W-40, 10W-50, 5W-40). Includes detailed capacity for each engine. |
| Coolant Spec: | Paraflu UP or equivalent antifreeze/coolant, typically a 50/50 mix with distilled water. Capacity around 8-9 litres. |
| Brake Fluid Spec: | DOT 4 brake fluid is standard. Capacity approx. 1 litre. |
| Power Steering Fluid Spec: | Specific hydraulic fluid (e.g., Tutela GI/R or equivalent) is required. Capacity approx. 1-1.5 litres. |
| Known Issues | |
| Common Wear Items: | Front suspension components (bushings, ball joints), Alfa Romeo V6 'Busso' engine timing belt tensioners and water pump, catalytic converter, electronic control module (ECU) issues on some models, electrical gremlins. |
| Diesel Engine Quirks: | DPF issues (if fitted), injector seal leaks on 2.4 JTD. |
| Vehicle History | |
| Brand Heritage | |
| Alfa Romeo Legacy: | Alfa Romeo's long history of producing stylish, performance-oriented, and engaging cars, known for their engines and handling characteristics. |
| Model Evolution | |
| 166 Development: | Successor to the Alfa Romeo 164, based on the Tipo 4 platform shared with Lancia Kappa, Fiat Croma, and Saab 9000. Styled by Centro Stile Alfa Romeo, with significant input from Pininfarina for the exterior styling. |
| Production | |
| Production Period: | 1998 - 2007 |
| Production Location | |
| Manufacturing Plant: | Grugliasco, Turin, Italy |
| Awards & Recognition | |
| Recognitions | |
| Automotive Journalism Awards: | While specific awards are not widely publicized for the 166, it was generally praised by automotive press for its styling, handling, and comfort, often winning 'best Italian car' accolades in its segment. |