gearbox Alfa Romeo 166 2007 Owner handbook (in English)

66
Resetting the speed memorised
The memorised speed is automatically
reset:
– turning off the engine;
or
– moving the switch (A) to the OFF
position.
When travelling with the
cruise control engaged,
never move the gearshift lever to
neutral and do not move the au-
tomatic gearshift lever to N.
You are advised to engage the
cruise control only when the traf-
fic and road conditions permit un-
der completely safe conditions, i.e.:
straight, dry road, dual carriage-
way or motorway, flowing traffic
and smooth tarmac. Do not engage
the device in town or in heavy traf-
fic conditions.
WARNING
The Cruise Control can
only be engaged with
speed over 30 km/h and, just for
certain versions up to 180 km/h.
The device must only be engaged
in 4
th, 5thor 6thgear, depending on
the vehicle speed. On cars with
electronic automatic gearbox it
must be engaged only with the
lever at position D in the automatic
mode without then moving the
gearshift lever by hand or with 3
nd
or 4thgear engaged inthe sequen-
tial manual mode.
Moving downhill with the device
engaged, the car speed might be
slightly higher than the speed
memorised due to the change in en-
gine load.
WARNING
Should the device not be
working properly or fail
to operate, move the switch (A-fig.
78) to the OFF Position and contact
Authorized Alfa Romeo Services
after checking that the protection
fuse is intact.
The switch (A-fig. 78) may be left
constantly at ON without damag-
ing the device. You are however
advised to deactivate the device
when not in use, moving the switch
(A) to OFF, to avoid accidentally
memorising the speed.
WARNING

137
– Check the operation of the horn.
– Check the operation and degree of
wear of the windscreen wipers.
– Check the operation of the external
lights and if necessary, clean the light
units.
– Above all when driving at night,
check the alignment of headlight beams
before starting off.
– Check that no oil or other liquid is
leaking out under the car.
– Ensure that luggage is stowed away
correctly.
– Ensure that, in addition to yourself,
all passengers have fastened their seat
belts.
– Ensure that the handbrake is re-
leased and that the warning lights on the
instrument panel do not indicate a mal-
function. To avoid accidental movements
of the car, disengage the handbrake
keeping the brake pedal pressed.
The following should also be noted:
– Long distances should be tackled
when in good health and should where
possible be programmed, especially when
the roads are busy.– A light meal containing easily assimil-
able foods will help keep reflexes ready
and aid concentration for a safe journey.– Use the direction indicators when
changing direction.
– Switch on the external lights at sun-
set.
– Keep a safe distance from the vehicle
in front. A “safe” distance will vary ac-
cording to the speed of the vehicle,
weather conditions and road-traffic condi-
tions.
– Never drive with one hand resting on
the gear lever. The involuntary movement
of the gear lever which this causes, even
if slight, will cause avoidable wear to the
internal elements of the gearbox.
– Never drive with the gearbox in neu-
tral.
– Do not drive with your foot resting on
the clutch pedal as this habit leads to
rapid wearing of the clutch.
– Do not drive for long periods without
a break. During a break get out of the ve-
hicle and move around a bit to shake off
drowsiness.
– Ensure that the air in the vehicle is
changed constantly using the many possi-
bilities offered by the heating-ventilation
and climate control system.
WHEN TRAVELLING
– Driving with care also means being
able to predict the actions of other road
users, respecting the speed limits and oc-
cupying the near-side lane on motorways.
Driving under the influ-
ence of alcohol, drugs
and/or some medicines is highly
dangerous.
Never drive when drunk or under
the effect of drugs or medicines.
WARNING

155 VEHICLE INACTIVITY
If the vehicle is to be left inactive for
long periods the following precautions
should be noted:
– House the vehicle under a cover in a
dry and possibly ventilated place.
– Engage a gear.
– Release the handbrake.
– Clean and protect the paintwork by
applying silicon wax.
– Cover the rubber windscreen wiper
blades with talcum powder and raise
them off the glass.
– Open the windows slightly.
– Cover the vehicle with a cloth or per-
forated plastic cover. Do not use compact
plastic covers which prevent the humidity
on the surface of the vehicle from evapo-
rating.
– Inflate the tyres to a pressure of 0.5
bars above normal. If possible rest the
tyres on wooden planks and periodically
check the pressure.– Switch off the alarm system (if fit-
ted) with the remote control, then deacti-
vate it with the emergency key.
– Disconnect the terminals from the
battery poles (negative pole first) and
check the battery charge. When the vehi-
cle is in storage, this check should be car-
ried out once a month. If the no-load volt-
age is less than 12.5V, recharge the bat-
tery.
REMOVING FROM STORAGE
Before using your vehicle after a long
period of inactivity the following opera-
tions should first be carried out:
– Do not dust the outside of the vehi-
cle.
– Visually check that there are no
leaks (oil, brake and clutch fluid, engine
coolant etc.).
– Replace the engine oil and filter.
– Check:
Gearbox-differential oil level
Brake-clutch fluid level
Level of engine coolant fluid.– Check the air cleaner and replace if
necessary.
– Check tyre pressure and ensure that
they are not damaged, cracked or cut. If
they are they must be replaced.
– Check the state of the drive belts in
the engine bay.
– Connect the cables of the battery af-
ter checking that the charge is adequate.
– Re-activate the alarm system, if fit-
ted, using the emergency key.
– With the gear lever in neutral start
the engine and allow the engine to run
for a few seconds whilst repeatedly
pumping the clutch pedal.

159
Do not use the jack for
higher capacities than
stated on its label.
Absolutely never tam-
per with the inflation
valve. Do not insert
tools of any kind be-
tween the rim and the tyre.Routinely check that the
pressure of tyres and s-
pare wheel is as speci-
fied in the “Technical specifica-
tions” chapter. Raise the car only
laterally. The car must absolutely
never be raised placing the plate
of the workshop lift arm under
the aluminium crossmember of
the rear suspension.CHANGING A WHEEL
Please be informed that:
– The jack mass is 2.100 kg.
– The jack requires no adjustment.
– The jack cannot be repaired, in the
event of breakage it must be replaced by
another original one.
– No tools other than its operating
crank can be fitted to the jackTo change a wheel proceed as follows:
– Stop the car in such a position that it
is not dangerous for the traffic where it is
possible to change the wheel safely.
Where possible, park on a level, compact
surface.
– Engage the handbrake
– Engage 1st gear or reverse. For cars
with automatic gearbox set the lever to
positionP.
– Open the boot.
– Fold forward the boot mat (A-
fig. 1).
– Slacken the ring nut (A-fig. 2) and
remove the spare wheel.
– Take the tool bag (A-fig. 3) and
bring it near to the wheel to be changed.
The jack only serves for
changing wheels on the
car with which it is provided or on
cars of the same model. It must not
be used for other purposes such as
for instance raising cars of other
models. In no case should it be used
for repairs under the vehicle.
WARNING
P4C00057564PGSm
fig. 1

162
REFITTING A NORMAL WHEEL
Refit the wheel as described below:
– Stop the car in such a position that it
is not dangerous for the traffic where it is
possible to change the wheel safely.
Where possible, park on a level, compact
surface.
– Engage the handbrake
– Engage 1st gear or reverse. For cars
with automatic gearbox set the lever to
positionP.
– Open the boot.
– Fold back the boot mat (A-fig. 1).– Take the tool bag (A-fig. 3) and
the spare wheel and bring them near to
the wheel to be changed.
– Remove the wheel cap (A-fig. 4)
(if present) levering on the edge with the
flat-tipped screwdriver provided in the tool
bag.– Using the L-wrench (B-fig. 5) pro-
vided, loosen the fastening bolts (A) by
about one turn.
– Position the jack under the car next
to the wheel to be replaced (fig. 6):
Position1: changing a rear wheel;
Position2: changing a front wheel.
– Turn the knob (A-fig. 7) of the jack
to extend it until the pin (B), on the on
the upper part of the jack inserts correctly
in the seat on the body (C).
– Fit the L-wrench (A-fig. 8) on the
jack pin (B).
392PGSm
fig. 10
1026PGSm
fig. 11
A0D0134m
fig. 9
A0D0135m
fig. 12

191
System/Component Fuse no. Ampere Location
ABI control unit 13 10A fig. 86
ABI control unit – Central locking 19 20A fig. 93
ABI control unit – Front LH power window 18 20Afig. 93
ABI control unit – Front RH power window 3 20A fig. 93
ABI control unit – Rear LH power window 14 20Afig. 93
ABI control unit – Rear RH power window 17 20Afig. 93
ABS control unit 9 5A fig. 86
7 40A fig. 89
3 40A fig. 89
Additional heater (JTD versions) 17 20A fig. 89
13 10A fig. 93
Alarm system (control unit) 12 10A fig. 93
15 10A fig. 93
Alfa Romeo Code System 20 5A fig. 86
16 5A fig. 86
Cell phone (handset) 18 5A fig. 86
5 10A fig. 86
Central locking (ABI control unit) 19 20A fig. 93
Cigar lighter 7 20A fig. 86
Climate control fan 2 30A fig. 89
Climate control unit 19 5A fig. 86
External lights Fuse no. Ampere Location
Brake lights (switch) 9 5A fig. 861 15A fig. 86
Direction indicators 12 10A fig. 93
External lights (control) 5 10A fig. 86
Front fog lights 16 15A fig. 89
Headlights and headlight position
sensor (gas discharge headlights) 6 7.5A fig. 86
IGE control unit:
- brake light switch 1 15A fig. 86
- brake lights 9 5A fig. 86
- headlight spot 11 15A fig. 86
- left side lights 17 10A fig. 86
- rear light units 15 10A fig. 86
- right side lights 8 10A fig. 86
Left dipped beam headlight 12 15A fig. 89
Reversing lights (only versions with
manual gearbox) 13 10A fig. 86
Right dipped beam headlight 10 15A fig. 89
Internal lights Fuse no. Ampere Location
Dashboard light dimmer 5 10A fig. 86
Door mirror control light 15 10A fig. 93
Glovebox light 5 10A fig. 86
Seat warming control light 15 10A fig. 93
Sun visor lights 15 10A fig. 93

205
thousands of kilometres 20 40 60 80 100 120 140 160 180
Change fuel filter (diesel versions)•••••••••
Change air cleaner cartridge (petrol versions)••••
Change air cleaner cartridge (diesel versions)•••••••••
Check and top up, if required, fluid levels (brakes/hydraulic clutch, power steering,
windscreen washer, battery, engine coolant, etc.)•••••••••
Replacement of timing gear drive belt (*) and Poly-V accessory drive belt•
Replacement of spark plugs (petrol versions)•
Check operation of engine control systems (through diagnostics socket)••••
Check manual gearbox and differential oil level (petrol versions)••
Change engine oil and oil filter •••••••••
Change brake fluid (or every 24 months)•••
Check dust/pollen filter•••••••••
(*)Or every 4 years in harsh conditions (cold climates, stop and go city traffic).
Or every 5 years, regardless of the mileage.

206 ANNUAL INSPECTION
PLAN
An annual inspection plan has
been established for cars that cov-
er less than 20,000 km a year
(e.g. 10,000 km). It consists of
the following:
– Checking the condition/wear of tyres,
and adjusting pressure (including the com-
pact spare wheel, where applicable).
– Checking the lighting system (head-
lights, turn indicators, hazard warning
lights, boot light, passenger compart-
ment, warning lights of instrument panel,
etc.).
– Checking the working order of the
windscreen wiper-washer and adjusting
the nozzles.
– Checking the positioning/wear of the
windscreen wipers.
– Checking the condition and wear of
the front brake pad.– Sight inspect the conditions of: en-
gine, gearbox, transmission, pipes and
hoses (exhaust - fuel - brakes), rubber
parts (boots, sleeves, bushes, etc.).
– Check for bonnet and boot lock clean-
ness, lever cleanness and lubrication.
– Check battery charge and fluid level
(electrolyte).
– Visually checking the condition of the
belts and various controls.
– Checking and topping up, if neces-
sary, the level of liquids (coolant, brake
fluid, windscreen washer fluid, battery
etc.).
– Change engine oil and oil filter, if re-
quired.
– Check and replace pollen filter, if re-
quired.
– Check and replace air cleaner, if re-
quired.
ADDITIONAL OPERATIONS
Every 1000 kmor before long jour-
neys check and if necessary top up:
– the engine coolant fluid level
– brake fluid/hydraulic clutch control
fluid level
– power steering fluid level
– windscreen washer and headlamp
washer fluid level
– tyre pressure and conditions.
– check light system operation (head-
lights, direction indicators, hazard lights,
etc.).
– check windscreen wiper/washer op-
eration and windscreen/rear window
blade position/wear.
Every 3000 kmcheck the level of
the engine oil and top up if necessary.
Every 5000 km(only for fuel oil en-
gines): drain the condensation water
from the filter. You are recommended to
use products of the FL Selenia, de-
signed and developed expressly for Alfa
Romeo cars (see the table “Fluids and lu-
bricants” in the Technical specifications”
chapter).

211
PROTECTIVE SHIELD UNDER
ENGINE
The car is fitted with a protective shield
under the engine.
IMPORTANTWhen changing the en-
gine oil and filter, checking and changing
the gearbox and differential oil, this pro-
tection should be removed. This operation
should be carried out by Alfa Romeo Au-
thorized Services.
CHECKING ENGINE OIL LEVEL
Fig. 3:3.2 V6 24V version
Fig. 4:JTD 20V Multijet version
The engine oil level should be checked
when the vehicle is standing on a level
surface a few minutes (about 5) after the
engine has been switched off.
Remove the dipstick (A), clean it, then
re-insert it completely, remove it once again
and check that the level is between the
MIN and MAX marks on the dipstick.The interval between the MIN and MAX
marks corresponds to approximately 1
litre of oil.
Max. engine oil consumption is usually
400 grams every 1000 km.
When the car is new, the engine needs
to run in, therefore the engine oil con-
sumption can only be considered sta-
bilised after the first 5000-6000 km.
fig. 3 - 3.2 V6 24V version
424PGSm
fig. 4 - JTD 20V Multijet version
A0D0113m

232 IDENTIFICATION DATA
The identification data should be record-
ed. The identification data is carried on la-
bels in the following positions (fig. 1):
1- Identification label
2- Body label
3- Bodywork paint identification label
4- Engine label.
BODY LABEL
The body label carrying the following in-
formation is located in front of the right
front seat concealed by the lid (A-
fig. 2), it is printed with the body identi-
fication (fig. 3) including:
– Type of vehicle
– Manufacturer’s serial number (chassis
number).
ENGINE LABELS
On the rear left-hand side, gearbox side.
BODYWORK PAINT
IDENTIFICATION LABEL
(fig. 4)
This is applied to the inner part of the
luggage compartment and carries the fol-
lowing data:
A- Paint manufacturer
B- Name of colour
C- Colour code
D- Colour code for touching up and re-
spraying.
A0D0105m
fig. 1
3224CAm
fig. 4
353PGSm
fig. 3
352PGSm
fig. 2