Alfa Romeo 166 2.0 TS 1998-2008 Full Service Repair Manual

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Distributeur:

UGS: 158134

Mots clés: 166 166 2.0 TS 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 Alfa Romeo Car Cars

Variantes de produits

Description

The Alfa Romeo 166, produced from 1998 to 2008, is an executive sedan renowned for its distinctive Italian styling, sport-focused driving dynamics, and luxurious interior appointments. Featuring the 2.0 TS (Twin Spark) engine, this chassis code 936 model offers a blend of performance and refinement, positioning it within the premium segment against competitors like the BMW 5 Series and Mercedes-Benz E-Class. Alfa Romeo's heritage of passionate design and advanced engineering is evident throughout the 166, making it a compelling choice for those who appreciate automotive artistry and engaging driving experiences. This comprehensive full service repair manual provides extensive information for the Alfa Romeo 166, covering all major mechanical and electrical systems. It details scheduled maintenance, including critical procedures like timing belt replacement for the 2.0 TS engine, alongside engine, transmission, brake, suspension, and electrical system repairs. The manual also includes troubleshooting guides, technical data, and specifications, making it an invaluable resource for owners, independent mechanics, and automotive enthusiasts. With its dealership-level information, this manual is designed to assist in maintaining and repairing the vehicle effectively, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Alfa Romeo

Model:

Engine:

2.0 TS (Twin Spark)

Generation

Production Years Covered:

1998-2008

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Executive Sedan (premium segment)

Competitive Analysis

Key Competitors:

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

Key Features

Design Philosophy:

Distinctive Italian styling, sport-focused driving dynamics, luxurious interior appointments

Manual Value Proposition:

Provides dealership-level repair and maintenance information for DIY or professional use, saving time and money.

User Base:

Owners of Alfa Romeo 166 2.0 TS, independent mechanics, automotive enthusiasts

📋 Manual Details

Coverage Areas

Market:

Global (primarily European market focus implied)

Page Count

Estimated Pages:

Extensive (specific number not provided, described as 'most complete' and 'packed with all the information')

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Delivery Method:

Instant Download

File Type:

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

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions control, starting and charging systems

Transmission:

Manual transmission (clutch, gearbox, driveshafts), Automatic transmission (if applicable to 2.0 TS variant, details likely included)

Brakes:

Hydraulic system, ABS, brake discs and pads, calipers, master cylinder, lines, parking brake

Suspension:

Front and rear suspension, shock absorbers, springs, control arms, bushings, steering system components

Electrical:

Wiring diagrams, lighting, power windows, locks, mirrors, instrument cluster, body control modules, ECU diagnostics

Bodywork:

Body panels, doors, hood, trunk, bumpers, glass, interior trim, seals

HVAC:

Heating, ventilation, and air conditioning systems

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacements, fluid checks), fluid specifications, lubrication points

Troubleshooting:

Diagnostic procedures for common and uncommon faults, fault codes, symptom analysis

Repair:

Step-by-step repair instructions for all major mechanical and electrical components, including complete disassembly and reassembly

Technical Data:

Torque specifications, clearances, alignments, electrical resistance values, component testing procedures

Technical Depth

Depth:

Comprehensive (covers everything from basic maintenance to complete rebuilds, suitable for both DIY and professional mechanics)

📊 Manual Specifications

File Format

Requirements:

Requires software like DAEMON Tools or MagicISO for .ISO file, or capable of running .exe application.

Print Quality

Printability:

Full Printable

Zoom Functionality

Zoom:

YES (allows zooming in/out on diagrams and text)

Binding Type

Binding:

Digital (downloadable, no physical binding)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

AR32301 (typical for 2.0 TS)

Displacement:

1970 cc (2.0 Liters)

Configuration:

Inline 4-cylinder, DOHC, 16 valves (4 valves per cylinder)

Bore X Stroke:

83.0 mm x 91.0 mm

Compression Ratio:

10.3:1 (typical)

Performance

Horsepower:

150-155 PS (148-153 bhp / 110-114 kW) at 6300 rpm (depending on market and specific tune)

Torque:

187-192 Nm (138-142 lb-ft) at 4300 rpm (depending on market and specific tune)

Fuel System

Fuel Delivery:

Multi-point sequential fuel injection (Bosch Motronic or similar)

Fuel Type:

Unleaded gasoline (Octane rating typically 95 RON recommended)

Engine Features

Variable Valve Timing:

Yes (Variable Valve Timing, VVT)

Engine Management System:

ECU controlled, with diagnostic capabilities

🔧 Transmission

Standard

Type:

5-speed Manual Transmission

Optional

Type:

4-speed Automatic Transmission (Pro-Gear/Q-Tronic)

Features

Clutch:

Hydraulically operated, single dry plate

Fluid Specifications

Manual Gearbox Oil:

API GL-4, SAE 75W-85 (typical, refer to manual for exact spec)

Automatic Transmission Fluid:

Dexron III/VI or equivalent (typical, refer to manual for exact spec)

📐 Dimensions

Exterior

Length:

Approx. 4705 mm (185.2 in)

Width:

Approx. 1762 mm (69.4 in)

Height:

Approx. 1425 mm (56.1 in)

Wheelbase:

Approx. 2700 mm (106.3 in)

Weights

Curb Weight:

Approx. 1420-1470 kg (3130-3240 lbs) (depending on transmission and equipment)

Cargo

Trunk Capacity:

Approx. 510 liters (18.0 cu ft)

🛡️ Safety Features

Ratings

Euro Ncap Score:

4 Stars (for models tested in its era, specific results may vary for 2.0 TS variants)

Active Features

Standard

Traction Control:

Optional or standard depending on trim level (ASR)

Brake Assist:

Likely included in later models

Passive Features

Airbags:

Front airbags (driver and passenger), side airbags (optional or standard)

Seatbelts:

Pre-tensioning seatbelts

💡 Technology Features

Infotainment

Audio System:

Factory fitted CD player/radio, optional Bose sound system

Navigation:

Optional factory navigation system (early generation)

Driver Assistance

Cruise Control:

Standard or optional depending on trim

Connectivity

Auxiliary Input:

Not typically standard, may require aftermarket modification for aux/USB

🔧 Maintenance

Service Intervals

Oil Change:

Typically 15,000 km (9,300 miles) or 12 months (whichever comes first), or 20,000 km for specific synthetics (consult manual)

Timing Belt Replacement:

Critical: 60,000 km (37,000 miles) or 5 years (whichever comes first) for 2.0 TS engine.

Spark Plug Replacement:

Typically 100,000 km (62,000 miles) due to Twin Spark system's dual plugs per cylinder.

Fluid Specifications

Engine Oil:

API SL or ACEA A3/B3, SAE 10W-40 or 10W-50 (fully synthetic recommended) - consult manual for exact specification and capacity (approx. 4.5 liters)

Coolant:

Ethylene Glycol based coolant, OAT (Organic Acid Technology) type, 50% mixture with distilled water. Capacity approx. 8.5 liters.

Brake Fluid:

DOT 4

Known Issues

Timing Belt Wear:

Critical failure if not replaced on schedule, can cause catastrophic engine damage.

Electrics:

Can be prone to minor electrical gremlins, wiring harness issues, and sensor failures, common in older European cars.

Suspension Wear:

Bushings and control arms can wear over time, leading to steering looseness or noise.

Rust:

Body rust, particularly around wheel arches and sills, can be an issue depending on climate and care.

📚 Vehicle History

Brand Heritage

Marque Origin:

Italy, founded in 1910

Brand Focus:

Known for sporty driving, passionate design, and advanced engineering

Model Evolution

Predecessor:

Alfa Romeo 164

Design Era:

Late 1990s to late 2000s executive car design, with updates in 2003.

Production

Manufacturing Plant:

Pomigliano d'Arco, Italy

Production Volume:

Moderate, not a mass-market vehicle

🏆 Awards & Recognition

Recognitions

Design Awards:

While specific awards for the 166 are not widely publicized, it was recognized for its distinctive Giugiaro-designed exterior.