Alfa Romeo 166 2.4 JTD 20V 1998-2008 Service Repair Manual

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The Alfa Romeo 166, produced from 1998 to 2008, is an executive sedan renowned for blending distinctive Italian style with sporty handling and a refined ride. Designed by Pininfarina, its...

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Art.-Nr: 153003

Stichworte: 166 166 2.4 JTD 20V 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 Alfa Romeo Car Cars

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Beschreibung

The Alfa Romeo 166, produced from 1998 to 2008, is an executive sedan renowned for blending distinctive Italian style with sporty handling and a refined ride. Designed by Pininfarina, its elegant and flowing lines set it apart in a segment often dominated by more conservative designs. Under the hood, the 2.4 JTD 20V engine offers a powerful and torquey driving experience, characteristic of Alfa Romeo's focus on performance and driver engagement. This model represented a significant evolution from its predecessor, the 164, and competed with established luxury sedans of its era, offering a compelling alternative for those seeking a blend of luxury, performance, and unique design. This comprehensive service repair factory manual provides detailed information essential for the maintenance and repair of the Alfa Romeo 166 2.4 JTD 20V. It covers a wide array of systems, including general information, specifications, technical features, rigging, troubleshooting, the electrical system, fuel system, power unit, drivetrain, suspension, chassis, and bodywork. Within its pages, you will find detailed maintenance and repair procedures, diagnostic steps, and technical specifications, all presented in a clear, step-by-step format with accompanying diagrams. This manual is an invaluable resource for owners, mechanics, and technicians alike, ensuring the proper upkeep and repair of the vehicle.

🏷️ Basic Information

Identification

Make:

Alfa Romeo

Model:

Engine Variant:

2.4 JTD 20V

Production Years Covered:

1998-2008

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Executive Sedan

Brand Philosophy:

Known for blending Italian style, performance, and sporty handling.

Competitive Analysis

Competitors:

BMW 5 Series, Mercedes-Benz E-Class, Audi A6, Volvo S80, Jaguar S-Type of its era.

Key Features

Design:

Distinctive Pininfarina styling, elegant and flowing lines.

Powertrain:

Powerful and torquey 2.4-liter common rail turbodiesel engine.

Handling:

Renowned for its engaging driving dynamics and refined ride quality.

📋 Manual Details

Coverage Areas

Systems Covered:

• General Information

• Specifications

• Technical Features and Description

• Rigging Information

• Troubleshooting

• Electrical System

• Fuel System

• Power Unit (Engine)

• Lower Unit (Transmission/Drivetrain)

• Bracket Unit (Suspension/Chassis)

• Maintenance

• Index

• Appendix

Procedures Included:

• Maintenance Procedures

• Repair Procedures

• Troubleshooting Guides

• Diagnostic Steps

Manual Type

Type:

Service Repair Factory Manual

Language

Languages:

Multilanguage

Format

File Format:

Disc Image File (.ISO) / Application (.exe)

Compatibility:

Windows 32 bit

Requirements:

DAEMON Tools / MagicISO etc. for ISO file

Print Quality

Printability:

Printable without any restriction

Delivery

Method:

Download link after payment

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed procedures for cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system.

Engine Management:

Coverage of electronic engine control unit (ECU), fuel injection system (common rail direct injection), ignition system (glow plugs), emissions control.

Fuel System:

Components of the common rail system: high-pressure pump, injectors, fuel rail, pressure regulator, fuel filter replacement, bleeding procedures.

Electrical System:

Wiring diagrams, component locations, fuses, relays, battery, alternator, starter motor, lighting system, accessory circuits, starting and charging system diagnostics.

Transmission Drivetrain:

Manual and automatic transmission servicing, clutch replacement, driveshaft, differential, propeller shaft, axle shafts.

Suspension Steering:

Front and rear suspension component diagnosis and replacement (struts, shock absorbers, control arms, bushings), steering rack, power steering system.

Braking System:

Front and rear brake inspection, pad and rotor replacement, caliper servicing, brake fluid bleeding, ABS system components and diagnostics.

Body And Chassis:

Body panel removal/installation, door mechanisms, glass replacement, structural components, underbody protection.

HVAC System:

Air conditioning system servicing, heater core replacement, ventilation system.

Troubleshooting:

Systematic diagnostic procedures for common faults, fault codes, symptom-based troubleshooting.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, fuel filter replacement, spark plug/glow plug replacement, coolant changes, brake fluid flush.

Component Replacement:

Detailed step-by-step instructions for replacing major and minor components across all vehicle systems.

Diagnostic Procedures:

Methods for identifying the root cause of malfunctions, including electrical testing and mechanical checks.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to advanced repair and diagnostics.

Detail Level:

Step-by-step instructions with accompanying diagrams and illustrations for clarity.

📊 Manual Specifications

File Format

Type:

Digital (ISO/EXE)

Scalability:

Zoomable on computer for enhanced detail viewing.

Print Quality

Reproduction:

Can be printed without restriction.

Binding Type

Format:

Electronic (no physical binding)

Paper Type

Format:

Digital (no physical paper type)

Completeness

Completeness:

Factory original content, providing complete service and repair information.

⚙️ Engine Specifications

Primary Engine

Engine Code:

841C.000 (typical for 20V JTD)

Configuration:

Inline 5-cylinder, turbocharged diesel

Displacement:

2387 cc

Bore X Stroke:

82 mm x 90.4 mm

Compression Ratio:

18.0:1

Performance

Horsepower:

136-140 hp (approx. @ 4000 rpm, depending on variant)

Torque:

305-330 Nm (approx. @ 1800-2000 rpm, depending on variant)

Fuel System

Injection Type:

Common Rail Direct Injection (JTD)

Turbocharger:

Variable Geometry Turbocharger (VGT)

Emissions Control:

Euro 3/Euro 4 compliant (depending on model year), often with particulate filter (DPF).

🔧 Transmission

Standard

Type:

5-speed Manual

Optional

Type:

5-speed Automatic (Q-System)

Features

Drive Type:

Front-Wheel Drive (FWD)

Gear Ratios:

Refer to manual for specific gear ratios by transmission type.

📐 Dimensions

Exterior

Length:

Approx. 4778 mm

Width:

Approx. 1795 mm

Height:

Approx. 1436 mm

Wheelbase:

Approx. 2700 mm

Weights

Curb Weight:

Approx. 1590-1650 kg (depending on transmission and equipment)

Gross Vehicle Weight:

Refer to manual for specific GVW.

Cargo

Boot Capacity:

Approx. 510 liters

🛡️ Safety Features

Ratings

Euro Ncap:

4 Stars (Euro NCAP 2001, for early models, refer to specific test data)

Active Features

Standard Anti-lock Braking System

Standard Electronic Stability Program (VDC - Vehicle Dynamic Control)

Traction Control:

Standard Traction Control System (ASR)

Passive Features

Airbags:

Driver, passenger, side airbags (standard or optional depending on trim and year).

Seatbelts:

Pretensioner seatbelts with load limiters.

Chassis Design:

Crumple zones, reinforced passenger cell.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette/CD player, Bose sound system optional on higher trims.

Navigation:

Optional integrated satellite navigation system.

Driver Assistance

Cruise Control:

Standard or optional depending on trim level.

Parking Sensors:

Optional rear parking sensors available on some models.

Connectivity

Phone Integration:

Optional Bluetooth hands-free kit on later models.

🔧 Maintenance

Service Intervals

Engine Oil Filter Change:

Typically every 15,000 km or 1 year, whichever comes first (refer to manual for precise interval based on driving conditions).

Air Filter Replacement:

Typically every 30,000 km or 2 years.

Fuel Filter Replacement:

Typically every 45,000 km or 3 years.

Timing Belt Replacement:

Critical maintenance item for JTD engines. Typically every 90,000 km or 5 years. Failure can cause severe engine damage. Refer to manual for exact interval and procedure.

Coolant Change:

Typically every 60,000 km or 4 years.

Brake Fluid Change:

Typically every 2 years.

Fluid Specifications

Engine Oil:

API CI-4/CH-4, ACEA B3/B4, SAE 5W-40 or 10W-40 (synthetic or semi-synthetic diesel engine oil). Check manual for specific viscosity and approvals.

Coolant:

Paraflu UP or equivalent (Ethylene Glycol based coolant, blue color). Mix 50/50 with distilled water.

Brake Fluid:

DOT 4

Transmission Fluid Manual:

API GL-4, SAE 75W-90 (synthetic manual transmission fluid).

Transmission Fluid Automatic:

Refer to manual for specific automatic transmission fluid (e.g., ATF Dexron III/VI equivalent).

Known Issues

Diesel Particulate Filter:

DPF regeneration issues, clogging, requiring forced regeneration or replacement.

Glow Plugs:

Can fail, leading to difficult cold starts.

Suspension Bushings:

Wear and tear on front control arm bushings, leading to knocking noises and steering vagueness.

Mass Airflow Sensor:

Can become faulty, affecting engine performance and fuel economy.

Window Regulators:

Can fail, particularly the driver's side window.

E-Grille:

Issues with the electric parking brake mechanism (if equipped).

📚 Vehicle History

Brand Heritage

Legacy:

Alfa Romeo has a rich history in motorsport and creating driver-focused, stylish vehicles.

Model Evolution

Predecessor:

Alfa Romeo 164

Generation 1:

Launched in 1998, designed by Pininfarina, replacing the Alfa Romeo 164.

Production

Manufacturing Plant:

Pomigliano d'Arco, Italy

Production End:

2007 (for model year 2008)

🏆 Awards & Recognition

Recognitions

Styling:

Praised for its distinctive and elegant Italian design, a strong selling point.

Driving Dynamics:

Often noted for its sporty handling and comfortable ride, a hallmark of Alfa Romeo.