🏷️ Basic Information

Make:

Alfa Romeo

Model:

166

Year:

1999-2003

Platform Code:

Type 936

👋 Introduction

Positioning:

The Alfa Romeo 166 was positioned as a premium executive sedan, competing with established German rivals like the BMW 5 Series and Mercedes-Benz E-Class. It was known for its distinctive Italian styling, engaging driving dynamics, and luxurious interior.

Rivals:

Key competitors included the BMW 5 Series (E39), Mercedes-Benz E-Class (W210), Audi A6 (C5), Jaguar S-Type, and Volvo S80. The 166 offered a more passionate and design-led alternative.

Distinguishing Features:

Striking Pininfarina design, advanced 'Motional'` chassis control system (optional), comfortable and well-appointed interior, potent V6 engine options, and engaging handling characteristics characteristic of Alfa Romeo.

Design Philosophy:

Embodies Alfa Romeo's 'La meccanica delle emozioni' (the mechanics of emotion) philosophy, emphasizing driver engagement, sophisticated styling, and a connection between the driver and the machine.

📋 Manual Details

Primary Coverage:

Maintenance, Service, Repair

Secondary Coverage:

Troubleshooting, Wiring Diagrams, Electrical System, Chassis, Bodywork

Specific Component Coverage:

Includes detailed sections on specific components like fuel injectors, spark plugs, brake calipers, clutch master cylinders, radiators, alternators, starter motors, and more.

Estimated Pages:

Thousands of pages (as indicated by comprehensive coverage)

Type:

Factory Service Manual / ELearn Manual

Type Description:

eLearn is an electronic diagnostic and repair information system, often more interactive and data-rich than traditional printed manuals, providing diagnostic flowcharts and component data.

Language:

Likely English (based on product description and keywords, though original ELearn systems could be multi-lingual)

Format:

Digital (PDF, potentially ISO for ELearn software)

📖 Manual Coverage

Engine Mechanical:

Engine removal/installation, cylinder head, cylinder block, crankshaft, camshafts, pistons, connecting rods, timing systems (belts/chains), lubrication system, cooling system.

Engine Electrical:

Ignition system, starting system, charging system, engine control system (ECU diagnostics, sensor/actuator testing), fuel injection system (injectors, pumps, sensors).

Transmission:

Manual transmission (clutch, gear selection, internal components), Automatic transmission (torque converter, valve body, electronic controls, fluid service).

Driveline And Axle:

Front axle, rear axle, driveshafts, CV joints, differentials.

Suspension:

Front suspension (struts, control arms, ball joints), Rear suspension (shocks, springs, trailing arms), wheel alignment, road wheels and tires.

Brakes:

Brake system hydraulics, disc and drum components, ABS system, parking brake system, brake fluid specifications and bleeding procedures.

Steering:

Power steering system (pump, rack, fluid), steering column, steering wheel, tie rods.

Restraint System:

Seat belts, Supplemental Restraint System (SRS) including airbags (sensors, control modules, deployment precautions), seat belt pretensioners.

Body And Chassis:

Body structure, panels, doors, locks, security system, glass, windows, sunroof, interior trim, instrument panel, chassis components.

HVAC:

Heater, ventilation, air conditioning (compressor, condenser, evaporator, refrigerant, control systems).

Electrical And Electronics:

Complete wiring diagrams, lighting system, audio-visual system, navigation system, telephone system, power supply, body control module (BCM), instrument cluster, switches.

Fuel System:

Fuel pump testing, fuel filter replacement, fuel line repair, fuel pressure specifications, and injector diagnostics.

Exhaust System:

Information on exhaust system components, troubleshooting leaks, and component replacement.

Cooling System:

Radiator, water pump, thermostat, cooling fans, hoses, coolant capacity, and troubleshooting overheating issues.

Maintenance:

Scheduled maintenance, periodic lubrication, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, tune-up procedures.

Repair:

Step-by-step repair instructions for all major systems, including disassembly, inspection, repair, and reassembly of components.

Troubleshooting:

Diagnostic procedures for common problems, fault code interpretation, symptom-based troubleshooting guides.

Diagnostics:

Procedures for using diagnostic tools, understanding sensor data, and identifying electrical faults.

Engine Rebuild:

Detailed procedures for complete engine disassembly, inspection, repair, and reassembly, including torque specifications and tolerances.

Transmission Overhaul:

Comprehensive instructions for overhauling both manual and automatic transmissions, including component replacement and adjustment.

Body Repair:

Information on body panel repair, welding procedures, and corrosion protection. Also covers glass replacement and door mechanism repair.

Emission Control:

Details on emission control systems, including catalytic converters, oxygen sensors, and related diagnostic procedures.

Wheel Alignment:

Specifications and procedures for front and rear wheel alignment.

Lubrication Points:

Specific points and types of lubricant required for various components.

Airbag Service:

Critical safety procedures for working with the SRS system, including battery disconnection, airbag module handling, and system testing.

Depth:

Comprehensive, factory-level detail suitable for professional service centers and experienced DIY mechanics. Covers everything from basic fluid checks to full engine and transmission rebuilds.

Diagnostic Tools:

Information on required diagnostic tools, scan tool connections, and interpretation of fault codes specific to Alfa Romeo's diagnostic systems of the era.

Specifications And Tolerances:

Extensive lists of technical specifications, torque values, clearances, and tolerances for all major components and systems.

📊 Manual Specifications

Primary Format:

PDF

Secondary Format:

Possibly ISO if it's the full ELearn software package.

Quality:

High resolution, suitable for printing. Assumed to be scannable from original factory documentation.

Binding:

N/A (Digital format implies no physical binding)

Paper:

N/A (Digital format implies no physical paper type)

⚙️ Engine Specifications

Engine Options:

2.0 L Twin Spark (4-cylinder), 2.5 L Busso V6, 3.0 L Busso V6, 3.2 L Busso V6 (later models). Diesel options included 2.4 L JTD (5-cylinder).

V6 Busso Specs:

2.5L: Approx. 190 hp, 2.5L. 3.0L: Approx. 220-228 hp, 280-300 Nm. 3.2L: Approx. 240 hp, 300-330 Nm.

Injection Type:

Multi-point fuel injection (MPI) for Twin Spark, sequential multi-point fuel injection for V6 models. Common Rail Direct Injection (CRDI) for JTD diesel.

🔧 Transmission

Manual Transmission:

5-speed and 6-speed manual transmissions were available, depending on the engine variant.

Automatic Transmission:

Available on V6 models, often a 4-speed automatic (e.g., 'Q-System' with sport mode).

Gear Ratio Info:

Specific gear ratios for each engine and transmission combination are detailed within the manual.

📐 Dimensions

Length:

Approximately 4735 mm (186.4 in)

Width:

Approximately 1785 mm (70.3 in)

Height:

Approximately 1440 mm (56.7 in)

Curb Weight:

Varies by engine and specification, typically between 1500-1650 kg (3300-3638 lbs)

🛡️ Safety Features

Euro Ncap Rating:

Achieved a respectable 4-star Euro NCAP rating for its class at the time of release.

Active Safety:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Traction Control System (TCS), and optional Vehicle Dynamic Control (VDC) on some models.

Passive Safety:

Multiple airbags (front, side, and optional curtain), seat belt pretensioners, reinforced body structure.

💡 Technology Features

Infotainment System:

Early models featured basic audio systems, while later models offered optional navigation systems, CD players, and Bose sound systems. Controls were typically integrated into the center console.

Driver Assistance Features:

ABS, EBD, TCS, VDC (optional), cruise control, parking sensors (on some later models).

Connectivity Features:

Optional integrated mobile phone preparation on some models.

🔧 Maintenance

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 1 year for petrol engines, or as recommended by specific oil viscosity. Diesel models might have different intervals.

Timing Belt Interval:

Crucial for Twin Spark and V6 engines. Typically every 60,000 km (37,000 miles) or 4-5 years, due to interference engine design. This manual will detail the exact procedure and recommended intervals.

Engine Oil Type:

Refer to manual for specific grades (e.g., Selenia 20K for Twin Spark, Selenia Racing/Star for V6). Typically SAE 10W-40 or 10W-60 synthetic or semi-synthetic.

Coolant Type:

Paraflu UP or equivalent long-life coolant concentrate mixed with distilled water.

Transmission Fluid:

Specific ATF fluid for automatic transmissions (e.g., Tutela XG-31), manual transmission fluid (e.g., SAE 75W-90 GL-4/GL-5).

Common Problems:

Worn suspension bushings, issues with the electronic climate control system, aging electrical connectors, timing belt service criticality (especially on V6 engines), minor oil leaks from V6 engines, and potential for ECU faults.

📚 Vehicle History

Heritage:

Alfa Romeo boasts a rich motorsport heritage dating back to 1910, renowned for its passionate engineering and distinctive styling. This legacy influenced the development and character of models like the 166.

Evolution Timeline:

The 166 succeeded the Alfa Romeo 164. It was produced from 1998 to 2007, with a significant facelift in 2003. This manual covers the pre-facelift models from 1999-2003.

Production Location:

Primarily produced in Italy.

🏆 Awards & Recognition

Awards:

While not a major award winner in the same vein as some German competitors, the 166 was praised for its styling and driving dynamics by automotive journalists.