engine Alfa Romeo 166 2006 Owner handbook (in English)

171
Front direction indicators
To replace the bulb (Type B – PY21W,
21W, coloured):
– Remove the engine compartment cov-
er after turning the fastening pins.
– Turn counter-clockwise and remove
the bulb holder (A- fig. 35) without
disconnecting the connector.
– Remove the bulb (B- fig. 36) from
the bulb holder, pushing it slightly and
turning it counter-clockwise.– Fit the new bulb into the bulb holder,
pushing it slightly and turning it clock-
wise.
– Fit the bulb holder and lock it by turn-
ing it clockwise.
– Refit the engine compartment cover
and secure it by turning the fastening
pins.FRONT LIGHT UNITS –
HALOGEN BULB HEADLIGHTS
(optional for versions/markets where
applicable)
The front light units with halogen bulb
headlights contain low beam, high beam,
sidelight and direction indicator bulbs.
The bulbs are arranged inside the light
unit as follows (fig. 37-38):
A.Direction indicator
B.High beam headlight and sidelight
C.Low beam headlight.
A0D0070m
fig. 35
A0D0071m
fig. 36
A0D0054m
fig. 37

172
Low beam headlights
To replace the bulb (Type D – H7,
55W):
– Remove the engine compartment cov-
er after turning the fastening pins.
– Remove the rubber cap (A- fig.
39) by pulling the tab (B).
– Disconnect the snap-fitted connector
(C- fig. 40).
–- Release the clip (D).
– Remove the bulb (E- fig. 41).– Fit the bulb in the headlight reflector
making the notch coincide with the corre-
sponding groove.
– Lock the bulb with the clip.
– Fit the connector to the new bulb.
– Fit the rubber cap.– Refit the engine compartment cover
and secure it by turning the fastening
pins.
A0D0036m
fig. 38
A0D0072m
fig. 39
A0D0074m
fig. 41
A0D0073m
fig. 40

173
High beam headlights
To replace the bulb (Type D – H7,
55W):
– Remove the engine compartment cov-
er after turning the fastening pins.
– Turn counter-clockwise and remove
the direction indicator bulb holder (A-
fig. 42) without disconnecting the con-
nector to widen the working space.
– Remove the rubber cap (B) by
pulling the tab (C).– Disconnect the snap-fitted connector
(D- fig. 43) and release the clip (E).
– Remove the bulb (F- fig. 44).– Fit the new bulb in the headlight re-
flector making the notches coincide with
the corresponding grooves.
– Lock the bulb with the clip.
– Fit the connector to the bulb.
– Fit the rubber cap.
– Fit the direction indicator bulb holder
and lock it by turning it clockwise.
– Refit the engine compartment cover
and secure it by turning the fastening
pins.
A0D0075m
fig. 42
A0D0076m
fig. 43
A0D0077m
fig. 44

174
Front sidelights
To replace the bulb (Type B – H6W,
6W):
– Remove the engine compartment cov-
er after turning the fastening pins.
– Turn counter-clockwise and remove
the direction indicator bulb holder (A-
fig. 45) without disconnecting the con-
nector to widen the working space.
– Remove the rubber cap (B) by pulling
the tab (C).– Press the two retaining tabs and re-
move the bulb holder (D- fig. 46).
– Remove the bulb (E- fig. 47) from
the bulb holder, pushing it slightly and
turning it counter-clockwise.– Fit the new bulb into the bulb holder,
pushing it slightly and turning it clock-
wise.
– Push the bulb holder down in its seat.
– Fit the rubber cap.
– Fit the direction indicator bulb holder
and lock it by turning it clockwise.
– Refit the engine compartment cover
and secure it by turning the fastening
pins.
A0D0075m
fig. 45
A0D0078m
fig. 46
A0D0079m
fig. 47

175
Front direction indicators
To replace the bulb (Type B – PY21W,
21W, coloured):
– Remove the engine compartment cov-
er after turning the fastening pins.
– Turn counter-clockwise and remove
the bulb holder (A- fig. 48), without
disconnecting the connector.
– Remove the bulb (B- fig. 49) from
the bulb holder, pushing it slightly and
turning it counter-clockwise.– Fit the new bulb into the bulb holder,
pushing it slightly and turning it clock-
wise.
– Fit the bulb holder and lock it by turn-
ing it clockwise.
– Refit the engine compartment cover
and secure it by turning the fastening
pins.FRONT FOGLIGHTS
To replace the bulb (Type D - H3, 55W)
proceed under the car as follows:
– Disconnect the connector (A- fig.
50) from the light unit.
– Turn the cover (B) counter-clockwise
and remove it.
– Disconnect the connector (C- fig.
51) from the bulb.
– Release the clip and remove the bulb
(D- fig. 52).
A0D0080m
fig. 48
A0D0081m
fig. 49
A0D0082m
fig. 50

188
FUSES AND RELAYS IN
ENGINE BAY
The fuses and relays in the engine bay
are housed:
– In a box set next to the left side pan-
el (fig. 88).
– On a bracket set behind the left
headlight (fig. 91).To gain access to the box, remove the
cover (A-fig. 87), releasing it from the
retaining clips.
The devices protected by the fuses in
the engine bay are listed in the tables on
next pages.IMPORTANTThe arrangement of the
relays may vary depending on the ver-
sions and markets. In the event of a sus-
pected anomaly, contact Alfa Romeo Au-
thorized Services.
A0D0093m
fig. 87
A0D0094m
fig. 88 fig. 89
A0D0095m

189
Circuits operated by relays are the fol-
lowing (fig. 89):
A.Dipped beam headlight
B.Climate control fan
C.Horn
D.Front fog light
F.. Petrol versions (single fan): engine
cooling radiator (high speed)
JTD versions (two-fan): engine cooling
radiator (high speed)
G.Conditioner compressor
H.Petrol versions: engine cooling radia-
tor (low speed)
JTD versions (two-fan): engine cooling
radiator (high speed)L.Fuel pump
M.Electronic injection main relay
N.Starter motor
P.Diesel filter warming (JTD versions)
JTD versions (two-fan): engine cooling
radiator (low speed)
To gain access to relays on the bracket
set behind the left headlight (fig. 91),
remove the cover (A-fig. 90) after
turning the fastening pins (B).Circuits operated by relays are the fol-
lowing (fig. 91):
– Brown base relay: additional heater
(JTD versions)
– Black base relay: engine cooling radi-
ator relay, high speed (JTD versions).
A0D0096m
fig. 90
A0D0110m
fig. 91

192
System/Component Fuse no. Ampere Location
Conditioner compressor 13 7.5A fig. 89
Cruise Control 5 10A fig. 86
Diesel fuel filter warming 23 30Afig. 89
(JTD versions) 5 40Afig. 89
Door mirror defrosting 2 7.5A fig. 93
Electrochromic driving mirror 15 10A fig. 93
Electronic injection control unit 20 10A fig. 89
21 15A fig. 89
22 20A fig. 89
Electronic injection system 16 5A fig. 86
Engine control unit 18 7.5A fig. 89
Engine cooling control unit 16 5A fig. 86
Engine cooling radiator fan 4 60A fig. 89
System/Component Fuse no. Ampere Location
Engine cooling radiator fan 5 40A fig. 89
EOBD system (socket) 18 5A fig. 86
Front LH power window
(ABI control unit) 18 20Afig. 93
Front RH power window
(ABI control unit) 3 20Afig. 93
Front LH seat electric adjustment 6 30A fig. 93
Front RH seat electric adjustment 5 30A fig. 93
Front LH seat warming 9 10A fig. 93
Front RH seat warming 8 10A fig. 93
Fuel pump 19 15A fig. 89
Fuel pump relay coil
(engine bay box) 16 5Afig. 86
Glow plug (JTD versions) 8 60A fig. 89
Headlight washer (intermittent) 12 20A fig. 86
Horns 11 15A fig. 89
I.C.S. system 5 10A fig. 86
6 7.5A fig. 86
7 20A fig. 86
18 5A fig. 86
Instrument panel 6 7.5A fig. 86
18 5A fig. 86

194 IN THE EVENT
OF A FLAT BATTERY
STARTING WITH AN
AUXILIARY BATTERY
If the battery is flat, it is possible to start the
engine using an auxiliary battery (B-fig.
96) with the same electrical characteristics
as the original battery (A-fig. 96) (see
chapter “Technical specifications”).
The battery is housed on the left-hand
side of the boot, protected by a cover.
If the battery is low, the servocontrol
operating when the luggage compart-
ment opens from inside or by the key
does not work. However, it is always pos-
sible to open the luggage compartmentto reach the battery. Just rotate the key
wider simultaneously pressing on the bon-
net edge by the hand.
IMPORTANTApply a moderate pres-
sure only on the bonnet edge, immediate-
ly above the lock.
On versions without navigation system and
without CD player, access to the battery is
gained by slackening the knob (A-fig. 94)
and removing the battery cover.
On versions with navigation system and
/or CD player, access to the battery is
gained by slackening the knobs (A-fig.
95) and removing the cover (B).
Starting with an auxiliary battery does
not damages the Alfa Romeo CODE sys-
tem and must be carried out as follows:– Switch off all the not strictly neces-
sary electric devices.
– Connect a jump lead to the positive
terminals (1-fig. 96) of the two batter-
ies (+ sign next to the terminal).
– Connect another jump lead to the
negative terminals (2) of both batteries
(– sign next to the terminal).
– Start the engine.
– When the engine has started, remove
the cables reversing the sequence de-
scribed for connecting them.
– If after a few attempts, the engine
fails to start, do not insist pointlessly and
contact the nearest Authorized Alfa
Romeo Services.
fig. 96
A
B
fig. 94
A0D0107m3052CAm
fig. 95
341PGSm

195
To avoid damaging the
vehicle’s electrical sys-
tem follow the manu-
facturer’s system instructions ac-
companying the jump leads. The
jump leads must be of a suffi-
cient cross-section and long
enough to ensure that the two
vehicles do not touch.
Never use a quick bat-
tery charger to start
the engine in an emer-
gency as this could damage the
electronic systems of your vehi-
cle, particularly the control units
which manage the starting and
supply functions.
The battery terminal
connecting and discon-
necting operations gen-
erate current that may cause
problems to the car’s electronic
systems. Therefore, this opera-
tion should be carried out by
skilled personnel.
At the end of the operation refit the bat-
tery cover.
IMPORTANT If the battery was com-
pletely drained, it may be necessary to
carry out the Alfa Romeo I.C.S. “self-
teaching” operation as follows:
– Let the engine idle to allow the bat-
tery to recharge and make sure it will
start next time.
– Switch the engine off.
– Turn the ignition key to MARand
leave it in this position for 30 seconds to
1 minute, then turn it to STOPfor about
5 to 10 seconds, after which the engine
can be started.
This starting procedure
must be carried out by
qualified personnel as incorrect op-
erations may provoke electrical
discharge of great intensity. The
liquid contained in the battery is
toxic and corrosive. Avoid contact
with skin and eyes.
Keep naked flame, and lighted cig-
arettes away from the battery. Do
not cause sparks.
WARNING