1998-2007 Alfa Romeo 166 Workshop Repair & Service Manual (680MB CD, Searchable, Printable)

This workshop service and repair manual is for the Alfa Romeo 166, covering production years 1998-2007. It includes all models and engines and is available on a 680MB CD in searchable and printable format. This comprehensive manual is complete and intact, ensuring that you have all the necessary information to repair your vehicle with confidence.

PRODUCT DETAILS:

• Total Size: 680MB
• File Format: ISO
• Delivery: Instant download link displayed on checkout page and emailed after payment
• Protection: DRM-free, no restrictions
• Printable: Yes

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This official full workshop service repair manual includes:

• Detailed sub-steps for repair procedures
• Notes, cautions, and warnings for critical information
• Numbered instructions for easy navigation
• Bold figure numbers for quick reference to illustrations
• Detailed illustrations, drawings, and photos
• Enlarged inset for detailed part examination
• Numbered table of contents for easy access to information
• Diagnosis and repair of electrical problems with detailed wiring diagrams

This manual is completely missing pages and is an official source of reliable service information. Customer satisfaction is guaranteed.

EXCERPT (1998-2007 Alfa Romeo 166 Service/Repair Manual):

1. Undo the bolts and remove the flanges on the differential, complete with seals.
2. Remove the adjustment shim.
3. Undo the bolts and remove the support for the differential internal housing.
4. Remove the differential.
5. Remove the differential bearing outer races.
6. Remove the magnet.
7. Remove the bolt for the Reverse gear shaft.
8. Undo the bolts and remove the gearbox casing. The casing is sealed to the bell housing and can be released using a wooden or resin hammer.
9. Unscrew the bolts and remove the 5th speed control rod from the Reverse gear selector fork and the 5th speed selector.
10. Remove the 5th speed selector fork from the control rod.
11. At the same time, remove the main shaft, layshaft, reverse shaft, and 1st, 2nd, 3rd, and 4th speed selector fork assemblies. Keep the units assembled until they are placed on the workbench. Separate the selector forks from the rods.
12. Remove the clutch release bearing fork.
13. Remove the outer non-slip bush.
14. Undo the nut fixing the rear power unit rigid support to the flexible mounting.
15. Undo the bolts fixing the power unit rear flexible mounting to the front suspension frame.
16. Undo the bolts and remove the bracket connecting the power unit rigid rear support to the crankcase sump.
17. Undo the bolts and remove the power unit rigid rear support, removing it through the wheel arch.
18. Clutch release HYDRAULIC SYSTEM: Bleed air and restore level.
19. Hose from clutch fluid reservoir to rigid intermediate pipe for master cylinder: Remove and replace with pedal unit removed for right hand drive versions.
20. Hose from rigid intermediate pipe to master cylinder (pump): Remove and replace with pedal unit removed for right hand drive versions.
21. Pipe from inlet and outlet from master cylinder (pump) and hydraulic damper: Remove and replace with pedal unit removed for right hand drive versions.
22. (Pump) - MASTER CYLINDER R.R.
23. (Pump) - MASTER CYLINDER R.R. for right hand drive versions.
24. OPERATING CYLINDER/CLUTCH HYDRAULIC ACTUATOR: Remove and replace.
25. FLEXIBLE PIPE from clutch reservoir to (pump) - master cylinder: Remove and replace.
26. RIGID supply PIPE from (pump) - master cylinder: Remove and replace.
27. FLEXIBLE supply PIPE to operating cylinder: Remove and replace.
28. Rigid pipe from vibration damper to slave cylinder: Remove and replace.
29. Clutch hydraulic circuit vibration damper: Remove and replace.
30. Remove the two plastic buttons and remove the soundproof protection.
31. Disconnect the flexible hose from the clutch fluid reservoir to the intermediate rigid pipe for the master cylinder, rigid pipe side.
32. Working from the engine bay, disconnect the flexible hose from the clutch fluid reservoir to the intermediate rigid pipe for the master cylinder, reservoir side, and remove.
33. Remove the flexible hose from the clutch fluid reservoir to the intermediate rigid pipe for the master cylinder, taking it out of the engine compartment.
34. Refitting (Removing): Place the flexible hose from the clutch fluid reservoir to the intermediate rigid pipe for the master cylinder back in its housing and connect it. Place the soundproof cover back in its housing and secure it using the plastic pins.