🏷️ Basic Information

Make:

Alfa Romeo

Model:

166

Engine:

2.5 V6 (likely 'Busso' V6)

Vehicle Codes:

Type 936

👋 Introduction

Segment:

Executive Sedan

Competitors:

BMW 5 Series (E39), Mercedes-Benz E-Class (W210), Audi A6 (C5), Volvo S80.

Design Philosophy:

Emphasized Italian styling, driver engagement, and luxury appointments, often with a focus on the 'driving experience'.

Engine Emphasis:

Known for the sonorous and powerful Alfa Romeo 'Busso' V6 engine.

Demographic:

Discerning drivers appreciating performance, style, and a distinct European driving character.

📋 Manual Details

Years Covered:

1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008

Type:

Factory Service Repair Manual

Language:

English

File Format:

ISO (for disc image)

Print Quality:

Printable without restriction

Searchability:

Likely includes searchable text within the ISO image, depending on the original source

📖 Manual Coverage

Engine:

Complete engine diagnostics, repair, overhaul, cooling system, lubrication system, fuel system, ignition system, emissions control.

Transmission:

Manual and Automatic transmission servicing, repair, rebuild, clutch, driveline components (axles, driveshafts).

Brakes:

Hydraulic brake systems, ABS, brake pad/disc replacement, fluid flushing, parking brake.

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings, wheel alignment.

Steering:

Power steering system, steering rack, column, wheel balancing.

Electrical:

Battery, charging system (alternator), starter motor, lighting systems, instrumentation, warning systems, audio system wiring, climate control electrical components.

Bodywork:

Body frame and mounting, exterior panels, interior trim, doors, windows, seals, bumpers.

Climate Control:

HVAC system, refrigerant, compressor, heater core, A/C diagnostics.

Exhaust:

Exhaust system components, catalytic converter, mufflers, pipes.

Fuel:

Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, fuel lines.

Maintenance:

Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, lubrication.

Troubleshooting:

Systematic diagnosis of faults, common problems, symptom-based troubleshooting guides.

Repair:

Step-by-step repair procedures for all major vehicle systems, including component replacement and adjustment.

Electrical Diagnostics:

Detailed wiring diagrams, electrical component testing, troubleshooting electrical issues.

Engine Rebuild:

Full engine overhaul procedures, including torque specifications, clearances, and assembly sequences.

Depth:

Comprehensive, covering from basic maintenance to advanced engine and transmission rebuilds, including detailed electrical system schematics.

📊 Manual Specifications

Format:

ISO Disk Image

Requirements:

Requires mounting software such as DAEMON Tools, PowerISO, or similar.

Printability:

High quality, printable pages for easy reference during repairs.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code Designation:

Likely the 2.5L V6 'Busso' engine (e.g., AR32401, AR32405 variations).

Horsepower Range:

Approximately 190-192 hp (at 6300 rpm).

Torque Range:

Approximately 210-215 lb-ft (at 5000 rpm).

Fuel Delivery:

Multi-point fuel injection (MPI) or Sequential Fuel Injection (SFI).

Layout:

V6, 60-degree bank angle.

Valvetrain:

DOHC, 4 valves per cylinder (24 valves total).

🔧 Transmission

Type Standard:

5-speed Manual (likely Getrag 265 or similar).

Type Optional:

4-speed Automatic (likely ZF 4HP20 or similar).

Transmission Features:

Front-wheel drive layout, sport modes on automatic transmissions.

📐 Dimensions

Length:

Approximately 4737 mm (186.5 in).

Width:

Approximately 1770 mm (69.7 in).

Height:

Approximately 1437 mm (56.6 in).

Curb Weight:

Approximately 1520-1600 kg (3350-3530 lbs).

Wheelbase:

Approximately 2700 mm (106.3 in).

🛡️ Safety Features

Crash Test Data:

Limited public Euro NCAP data available for early models; later models benefited from general safety advancements.

Braking ABS:

Standard Anti-lock Braking System (ABS).

Traction Control:

Optional or standard Traction Control System (ASR - Antipatinage)

Airbags:

Driver and front passenger airbags; optional side airbags on later models.

Seatbelts:

Pre-tensioning seatbelts.

💡 Technology Features

Audio System:

Factory radio/cassette/CD player, optional Bose sound system.

Navigation:

Optional factory navigation system on some higher-spec models.

Cruise Control:

Standard or optional cruise control.

Phone Integration:

Optional hands-free phone integration via Bluetooth on later models.

🔧 Maintenance

Oil Change:

Typically every 10,000-15,000 km (6,000-9,000 miles) or annually, refer to manual for exact spec.

Timing Belt Replacement:

Crucial for the 'Busso' V6; typically every 90,000-120,000 km (56,000-75,000 miles) or 5-6 years. Failure is catastrophic.

Engine Oil Grade:

Refer to manual for specific 'Busso' V6 recommendations (e.g., Selenia 10W-40 or 10W-50, or equivalent synthetic).

Coolant Type:

Ethylene glycol-based coolant, typically requiring specific OAT (Organic Acid Technology) or HOAT formulations as per manufacturer.

Brake Fluid Type:

DOT 3 or DOT 4.

Transmission Fluid Manual:

GL-4 or GL-5 gear oil, viscosity as per manual (e.g., 75W-90).

Transmission Fluid Automatic:

Specific ATF (Automatic Transmission Fluid) type; refer to manual for ZF 4HP20 specifications.

Engine Component Wear:

Timing belt tensioner and idler pulley reliability, camshaft/crankshaft seal leaks, potential oil consumption.

Electrical Gremlins:

Common in Italian cars of this era; issues with sensors, wiring harnesses, central locking, and dashboard warning lights.

Suspension Wear:

Worn control arm bushings and ball joints due to the car's weight and performance.

Climate Control Failure:

HVAC blower motor resistors, climate control unit faults, A/C compressor issues.

📚 Vehicle History

Heritage:

Alfa Romeo has a long and storied history in motorsport and producing stylish, driver-focused road cars, particularly known for their V6 engines.

Generation:

First generation (Type 936), succeeding the Alfa Romeo 164. Designed by Walter de Silva.

Production Years:

1998-2007 ( facelift in 2003).

Manufacturing Location:

Italy (Pomigliano d'Arco plant).

🏆 Awards & Recognition

Design Awards:

While specific 'awards' are not widely publicized for this model, its design by Walter de Silva was critically acclaimed, contributing to Alfa Romeo's reputation for styling.

Reliability Perception:

Perceived reliability can be mixed, with strong mechanicals (especially the V6 engine) offset by potential electrical and minor component issues common to some European cars of the era. Proper maintenance is key.