Market Position:
The Alfa Romeo 166 was positioned as a premium executive sedan, competing with established German luxury brands.
Competitors:
Primary competitors included the BMW 5 Series, Mercedes-Benz E-Class, and Audi A6 during its production run.
Key Features:
Distinctive Italian styling, engaging driving dynamics, luxurious interior appointments, and potent JTD diesel engines.
Purpose:
Designed for both DIY enthusiasts and professional mechanics, providing detailed instructions for service, maintenance, and repair.
Engine Mechanical:
Complete engine disassembly, assembly, diagnosis, and repair for the 2.4 JTD 20V engine.
Engine Management:
Fuel injection system (common rail), ignition system (glow plugs), emission control systems, engine control unit (ECU) diagnostics.
Transmission:
Manual and automatic transmission service, repair, and overhaul procedures.
Drivetrain:
Front-wheel drive system, axles, driveshafts, CV joints, differentials.
Brakes:
Brake system components (discs, pads, calipers, master cylinder, ABS), bleeding procedures, hydraulic system diagnostics.
Steering:
Power steering system, steering rack, tie rod ends, fluid specifications, repair procedures.
Climate Control:
Air conditioning system service, refrigerant handling, heater core, ventilation system troubleshooting.
Body And Chassis:
Body panel removal and installation, interior trim, corrosion protection, chassis components.
Suspension System:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications.
Electrical System:
Full electrical schematics, wiring diagrams, component testing, lighting, power windows, central locking.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid level checks, spark plug replacement (where applicable).
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon faults across all major vehicle systems.
Repair:
Detailed instructions for component removal, repair, and reinstallation, including major component overhauls.
Diagnostics:
Diagnostic trouble codes (DTCs), scan tool procedures, sensor testing, actuator testing.
Specifications:
Torque specifications for all fasteners, fluid capacities, clearances, and critical measurements.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds.
File Format:
Disc Image File (.ISO) / Application (.exe). Requires mounting software like Daemon Tools or MagicISO.
Printability:
Full printable, allowing users to print specific sections or the entire manual.
Binding Type:
Digital download, no physical binding. Allows for easy navigation and search.
Paper Type:
N/A (Digital format). Users can print on desired paper type.
Engine Code:
936A8 (common for 2.4 JTD 20V)
Engine Type:
Inline 5-cylinder, Turbocharged Direct Injection Diesel (Common Rail)
Bore X Stroke:
82.0 mm x 90.4 mm
Horsepower:
175 PS (173 bhp) @ 4000 rpm (typical for later models)
Torque:
330 Nm (243 lb-ft) @ 2000 rpm (typical for later models)
Fuel System Type:
Bosch Common Rail Direct Injection
Valvetrain:
DOHC (Double Overhead Camshaft), 4 valves per cylinder (20 valves total)
Turbocharger:
Variable Geometry Turbocharger (VGT)
Transmission Type Standard:
6-speed Manual Transmission
Transmission Type Optional:
5-speed Automatic Transmission (typically with Q-Tronic functionality)
Transmission Features:
Torque converter lock-up, manual override modes in automatic.
Euro Ncap Rating:
4 Stars (for the model generation, though specific crash test data for 2.4 JTD might vary slightly).
Active Safety Features:
ABS with EBD, Traction Control (ASR), Cruise Control, Xenon headlights (optional).
Passive Safety Features:
Front airbags, side airbags, curtain airbags, pre-tensioned seatbelts, deformable steering column.
Infotainment System:
Optional satellite navigation, premium audio systems (e.g., Bose), CD player, radio.
Driver Assistance Features:
Cruise control, parking sensors (optional).
Connectivity:
Limited by era, primarily analogue connectivity for audio systems, potentially hands-free phone integration (Bluetooth/wired).
Oil Change Interval:
Typically every 20,000 km (12,500 miles) or 1 year, whichever comes first (check specific vehicle handbook and manual).
Timing Belt Replacement:
Critical. Typically every 100,000 km (60,000 miles) or 5 years. Failure can cause severe engine damage. Manual will specify exact interval and procedure.
Engine Oil Type:
Fully Synthetic, API CF/CG-4/CH-4 or ACEA B3/B4, viscosity SAE 5W-40 or 10W-40. Manual will confirm precise specification (e.g., Selenia WR Diesel).
Coolant Type:
Paraflu UP (or equivalent OAT-based coolant), typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 (or DOT 4 LV for ABS systems). Manual will confirm specific requirement.
Common Issues:
Wear on suspension bushings, EGR valve issues, turbocharger problems (especially if maintenance is neglected), diesel particulate filter (DPF) issues (if equipped), minor electrical gremlins, cambelt failure risk.
Preventative Maintenance:
Regular oil and filter changes, timely timing belt replacement, cleaning of EGR valve and intake manifold, checking turbocharger for play.
