Competitors:
BMW 5 Series, Mercedes-Benz E-Class, Audi A6, Volvo S80
Design Philosophy:
Stylish Italian design, driver-focused ergonomics, luxurious interior appointments
Target Audience:
Discerning buyers seeking a premium European sedan with sporting character and distinctive styling
Primary Coverage:
Full Service, Maintenance, Repair, Troubleshooting
Estimated Pages:
Extensive (typical for full workshop manuals, often 1000+ pages)
Type:
Workshop Manual / Service Repair Manual
Format:
Digital Download (ISO/EXE)
Powertrain:
Engine mechanical, fuel injection, lubrication, cooling, exhaust systems
Drivetrain:
Manual and Automatic Transmission, Clutch, Differential, Driveshafts
Chassis:
Suspension (front and rear), Steering, Brakes (hydraulic and mechanical components)
Electrical:
Engine Control Unit (ECU), Ignition, Lighting, Instrumentation, Power Accessories, Body Control Module (BCM), Airbag system, ABS/TCS systems
Body And Interior:
Body panels, doors, windows, interior trim, HVAC system, seats, security systems
Maintenance:
Scheduled maintenance (oil changes, filter replacements, spark plug checks, belt inspections), fluid level checks and top-offs
Diagnostics:
Fault code reading and interpretation, symptom-based troubleshooting guides
Repair:
Component removal and installation, component overhaul, calibration procedures
Specifications:
Torque specifications, clearance measurements, electrical schematics, diagnostic procedures
Depth:
Comprehensive (covers everything from routine maintenance to major overhauls and electrical diagnostics)
Format:
Disc Image File (.ISO) / Application (.exe)
Printability:
Full Printable (allows users to print specific sections or the entire manual)
Binding Type:
Digital (no physical binding)
Paper Type:
Not Applicable (Digital Format)
Zoom Functionality:
Yes (allows zoom in/out for detailed diagram viewing)
Engine Type:
Inline 5-cylinder, Turbocharged Direct Injection Diesel (JTD)
Bore X Stroke:
82.0 mm x 90.4 mm
Compression Ratio:
18.0:1
Fuel System:
Common Rail Direct Injection (CDI) with multi-stage injection
Engine Management:
Bosch EDC 15/16 (typical for this era JTD)
Horsepower:
136 hp (100 kW) @ 4000 rpm (early models) / 140 hp (103 kW) @ 4000 rpm (later models)
Torque:
300 Nm (221 lb-ft) @ 1800 rpm (early models) / 314 Nm (231 lb-ft) @ 1800 rpm (later models)
Euro Ncap Score:
4 stars (overall for the 166 platform, specific to year and test configuration)
Braking System:
ABS with EBD (Electronic Brakeforce Distribution), Brake Assist (BA)
Traction Control:
ASR (Anti-Slip Regulation) / TCS (Traction Control System)
Airbags:
Driver, front passenger, side airbags (standard on most trims), curtain airbags (optional/later models)
Body Structure:
High-strength steel passenger cell, crumple zones
Head Unit:
Factory integrated CD player, radio, with optional navigation system and premium audio by Bose.
Display:
Central multi-function display for climate control, trip computer, and system status.
Cruise Control:
Standard on most variants.
Phone Integration:
Optional Bluetooth hands-free system available on later models.
Engine Oil And Filter:
Typically every 15,000 - 20,000 km or 1 year, whichever comes first (refer to manual for exact schedule).
Fuel Filter:
Every 40,000 - 60,000 km.
Air Filter:
Every 20,000 - 30,000 km or as needed.
Timing Belt:
Crucial component! Typically every 60,000 - 80,000 km or 5 years. Replacement requires replacement of tensioners and idler pulleys.
Engine Oil:
API CF/SJ or ACEA B3/B4, viscosity SAE 5W-40 or 10W-40 (check specific engine variant and climate).
Coolant:
Paraflu UP or equivalent G11/G12 antifreeze, mixed 50:50 with distilled water.
Transmission Fluid Manual:
API GL-4, viscosity SAE 75W-90 (e.g., Tutela Car Technyx).
Transmission Fluid Automatic:
Specific ATF fluid as per manufacturer's recommendation (e.g., ZF LifeguardFluid5).
Electrical Gremlins:
Common on older Alfas, often related to wiring harness degradation, ground points, or specific control modules.
Suspension Wear:
Front suspension components (wishbone bushings, ball joints) can wear prematurely due to road conditions and vehicle weight.
Diesel Particulate Filter:
Some early models may not have a DPF, but later ones might. Clogging can occur if regeneration cycles are interrupted.
Egr Valve:
Can become clogged with soot, leading to reduced performance and check engine lights.
Turbocharger Issues:
Can be susceptible to wear if oil changes are neglected or if driven hard from cold.
Brand Origin:
Italian automobile manufacturer founded in 1910.
Predecessor:
Alfa Romeo 164
Design Era:
Developed by Pininfarina, representing a modern evolution of Alfa Romeo's distinctive styling.
Production Period:
1998-2007 (marketed until 2008 in some regions)
Manufacturing Plant:
Pomigliano d'Arco, Naples, Italy
