Model Segment:
Executive/Luxury Sedan
Brand Philosophy:
Known for sporty handling, stylish Italian design, and passionate driving experience.
Key Competitors:
BMW 5 Series, Mercedes-Benz E-Class, Audi A6, Volvo S80.
Design Language:
Distinctive Pininfarina styling, elegant lines, and a sophisticated road presence.
Engine Type:
Powerful and torque-rich 2.4-liter five-cylinder JTD (Turbocharged Direct Injection) diesel engine.
Driving Dynamics:
Renowned for its engaging handling, communicative steering, and comfortable ride.
Product Name:
Alfa Romeo 166 2.4 JTD 10V 1998-2008 Service Repair Manual
Coverage Areas:
General Information, Periodic Maintenance, Engine, Fuel System and Throttle Body, Cooling and Lubrication System, Chassis, Electrical System, Servicing Information, Emission Control Information, Wiring Diagram, and more.
Manual Type:
Factory Service Repair Manual / Workshop Manual
Intended Audience:
Do-it-yourselfer and experienced mechanic
Completeness:
Complete and intact, no missing/corrupt parts or pages.
File Format:
Disc Image File (.ISO) / Application (.exe)
Delivery Method:
Instant download
Software Requirements:
DAEMON Tools / MagicISO or similar for .ISO files
Engine Overhaul:
Detailed procedures for disassembly, inspection, and reassembly of the 2.4 JTD 10V engine.
Fuel System Service:
Covers fuel injectors, fuel pump, fuel filter replacement, and throttle body cleaning/adjustment.
Cooling System Maintenance:
Radiator, water pump, thermostat, coolant flushing, and leak detection procedures.
Lubrication System Service:
Oil filter replacement, oil change procedures, oil pressure checks, and lubrication system components.
Chassis Component Repair:
Suspension, steering, brakes, wheel alignment, and bodywork repair information.
Electrical System Diagnostics:
Detailed wiring diagrams, component testing, troubleshooting for lighting, ignition, starting, and charging systems.
Emission Control Information:
Details on emission control systems, sensors, and diagnostic procedures for compliance.
Routine Maintenance:
Step-by-step instructions for oil changes, filter replacements, fluid checks, and inspections.
Troubleshooting Guides:
Diagnostic flowcharts and symptom-based troubleshooting for common issues.
Component Replacement:
Detailed instructions for replacing major and minor components.
Rebuilding Procedures:
Complete disassembly and reassembly guidance for key mechanical assemblies.
Diagnostic Tools:
Information relevant to using OBD-II scanners and specialized Alfa Romeo diagnostic equipment.
Torque Specifications:
Precise torque values for critical fasteners throughout the vehicle.
Clearances And Tolerances:
Specifications for engine component clearances, bearing tolerances, and other critical measurements.
Engine Code:
Often referred to by displacement and valve count (e.g., 2.4 JTD 10V)
Configuration:
Inline 5-cylinder
Displacement:
2387 cc (2.4 Liters)
Bore X Stroke:
Approx. 82.0 mm x 90.4 mm
Valve Train:
SOHC (Single Overhead Camshaft), 2 valves per cylinder (10 valves total)
Fuel Delivery:
Common Rail Direct Injection (CRDI)
Turbocharger:
Yes, variable geometry turbocharger (VGT)
Horsepower Range:
Approximately 136-140 hp (earlier models), up to 150-175 hp (later revisions).
Torque Range:
Approximately 310-330 Nm (earlier models), up to 360-400 Nm (later revisions).
Ignition System:
Compression Ignition
Engine Oil Type:
API CG-4 or ACEA B3/B4 specification, SAE 5W-40 or 10W-40 recommended (refer to manual for specific grades).
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives.
Transmission Type:
5-speed manual transmission (often denoted as 'M5' or similar for the JTD variant).
Optional Transmission Type:
Some models were available with a 4-speed automatic transmission (e.g., ZF 4HP20), though the 2.4 JTD was more commonly paired with the manual.
Clutch Type:
Hydraulically operated single dry plate clutch.
Manual Transmission Fluid Type:
API GL-4 or GL-5 specification gear oil, SAE 75W-90 or 80W-90 recommended.
Automatic Transmission Fluid Type:
Refer to manual for specific ATF specification (e.g., Dexron III or equivalent).
Airbags:
Driver, passenger, side airbags, and optional curtain airbags.
Seatbelts:
Pre-tensioning front seatbelts with load limiters.
Body Structure:
Designed with crumple zones and a reinforced safety cell.
Braking System:
Front ventilated discs, rear solid discs, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution).
Traction Control:
ASR (Anti-Slip Regulation) available on some models.
Stability Control:
ESP (Electronic Stability Program) often available or standard on later models.
Euroncap Rating:
4 stars (for the original 166 model, specific year may vary).
Oil Change Interval:
Typically every 15,000 - 20,000 km or 12 months, whichever comes first (refer to manual for exact specification).
Timing Belt Interval:
Crucial for JTD engines. Typically around 100,000 - 120,000 km or 5 years. This manual will provide precise intervals and procedures.
Air Filter Replacement:
Recommend inspection every 15,000 km and replacement as needed or per manual schedule.
Fuel Filter Replacement:
Critical for diesel engines. Typically every 30,000 - 40,000 km. Manual will specify the exact interval and procedure.
Power Steering Fluid Type:
Refer to manual; typically a Pentosin CHF 11S or equivalent hydraulic fluid.
Engine Oil Capacity:
Approx. 5.7 - 6.5 liters (including filter, refer to manual).
Coolant Capacity:
Approx. 7.0 - 8.0 liters.
Common Engine Issues:
Potential for injector issues, EGR valve problems, swirl flap issues, timing belt failure if not replaced on schedule.
Common Electrical Issues:
Minor electrical gremlins, issues with window regulators, central locking, and dashboard warning lights are sometimes reported.
Common Chassis Issues:
Wear on front suspension components (wishbones, bushings), potential for rust in certain areas.
Brand Origin:
Italian automotive manufacturer founded in 1910, known for performance and design.
Predecessor:
Alfa Romeo 164
Successor:
Alfa Romeo Giulia (in a broader sense of the executive sedan lineage).
Manufacturing Plant:
Pista factory in Arese, Italy, and initially at the Pomigliano d'Arco plant.
Design House:
Pininfarina
