Alfa Romeo 166 2.4 JTD 10V 1998-2008 Service Repair Manual

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UGS: 152321

Mots clés: 166 166 2.4 JTD 10V 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 Alfa Romeo Car Cars

Variantes de produits

Description

The Alfa Romeo 166, produced between 1998 and 2008, is an executive luxury sedan renowned for its distinctive Pininfarina styling, sporty handling, and passionate driving experience. Powered by a torque-rich 2.4-liter five-cylinder JTD diesel engine, this model offered a compelling blend of performance and Italian design, positioning it as a stylish alternative to its German competitors. Its elegant lines and sophisticated road presence, coupled with engaging driving dynamics and a comfortable ride, made it a standout in its segment. This comprehensive Factory Service Repair Manual / Workshop Manual is designed to assist both do-it-yourself enthusiasts and experienced mechanics in the maintenance and repair of the Alfa Romeo 166 2.4 JTD 10V. It covers a wide array of critical areas, including general information, periodic maintenance, detailed engine overhaul procedures for the 2.4 JTD 10V, fuel and cooling system servicing, chassis component repair, electrical system diagnostics, and emission control information. The manual provides step-by-step instructions, troubleshooting guides, technical specifications, wiring diagrams, and essential safety guidelines to ensure the vehicle remains in optimal condition.

🏷️ Basic Information

Identification

Make:

Alfa Romeo

Model:

Engine:

2.4 JTD 10V

Production Years:

1998-2008

👋 Introduction

Market Position

Model Segment:

Executive/Luxury Sedan

Brand Philosophy:

Known for sporty handling, stylish Italian design, and passionate driving experience.

Competitive Analysis

Key Competitors:

BMW 5 Series, Mercedes-Benz E-Class, Audi A6, Volvo S80.

Key Features

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.

📋 Manual Details

Coverage

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

Language:

Multilanguage

Intended Audience:

Do-it-yourselfer and experienced mechanic

Completeness:

Complete and intact, no missing/corrupt parts or pages.

Format

File Format:

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

Delivery Method:

Instant download

Software Requirements:

DAEMON Tools / MagicISO or similar for .ISO files

📖 Manual Coverage

Systems

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.

Procedures

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.

Technical Depth

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.

📊 Manual Specifications

Print Quality

Printability:

Printable without any restriction.

Binding Type

Binding Type:

Digital Download (PDF/ISO/EXE)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

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)

Performance

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).

Fuel System

Fuel Type:

Diesel

Ignition System:

Compression Ignition

Fluids

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

Standard

Transmission Type:

5-speed manual transmission (often denoted as 'M5' or similar for the JTD variant).

Optional

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.

Features

Clutch Type:

Hydraulically operated single dry plate clutch.

Fluids

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).

📐 Dimensions

Exterior

Length:

Approx. 4775 mm

Width:

Approx. 1790 mm

Height:

Approx. 1450 mm

Wheelbase:

Approx. 2700 mm

Weights

Curb Weight:

Approx. 1550-1650 kg (depending on specification)

Gross Vehicle Weight:

Refer to vehicle's VIN plate or manual.

Cargo

Trunk Capacity:

Approx. 510 liters

🛡️ Safety Features

Passive Features

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.

Active Features

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.

Ratings

Euroncap Rating:

4 stars (for the original 166 model, specific year may vary).

💡 Technology Features

Infotainment

Audio System:

Factory fitted Clarion or Blaupunkt radio/cassette/CD players, often with steering wheel controls and Bose sound system option.

Navigation System:

Optional integrated satellite navigation system available on some higher trims.

Driver Assistance

Cruise Control:

Standard on most models.

Connectivity

Phone Integration:

Optional Bluetooth hands-free system on later models.

🔧 Maintenance

Service Intervals

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.

Fluid Specifications

Brake Fluid Type:

DOT 4

Power Steering Fluid Type:

Refer to manual; typically a Pentosin CHF 11S or equivalent hydraulic fluid.

Fluid Capacities

Engine Oil Capacity:

Approx. 5.7 - 6.5 liters (including filter, refer to manual).

Coolant Capacity:

Approx. 7.0 - 8.0 liters.

Known Issues

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.

📚 Vehicle History

Brand Heritage

Brand Origin:

Italian automotive manufacturer founded in 1910, known for performance and design.

Model Evolution

Predecessor:

Alfa Romeo 164

Successor:

Alfa Romeo Giulia (in a broader sense of the executive sedan lineage).

Production

Manufacturing Plant:

Pista factory in Arese, Italy, and initially at the Pomigliano d'Arco plant.

Design House:

Pininfarina

🏆 Awards & Recognition

Recognitions

Design Awards:

While not specific awards for the 166 model itself, it consistently received praise for its elegant and timeless design.