AUTOMOTIVE ELECTRICIANS

Alfa Romeo 166 2.5 V6 da 10/03 — SUPPLY — — WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION — WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION

Wiring diagram



Components
Component codeNameAssembly reference
A1Battery5530B
A5Terminal board-
A6Rear junction node-
A10Alternator-
A10Alternator5530A
A20Starter motor-
A20Starter' motor5520B
B1Junction unit-
B1Junction unit5505A
B1Junction unit5505A
B2Dashboard junction unit (CPL)-
B2General supply MAXI FUSE-
B2Junction unit-
B2Junction unit5505A
B3Relay unit5505A
B4Rear services MAXI FUSE-
B5MAXI FUSE box-
B7-MAXI FUSE) for ABS-
B8(MAXI FUSE) for engine fan-
B9Starting enablement MAXI FUSE-
B17Rear electric windows fuse-
B20Seat heating fuse-
B31ABS fuse-
B33Heated rear window fuse-
B37Spark plugs MAXI FUSE-
B38Additional heater fuse-
B39Diesel pre-heating fuse-
B42CAE supply fuse-
B60Boot opening fuse-
B61Fuel flap opening fuse-
B62Left seat adjustment fuse-
B63Right seat adjustment fuse-
B65Vehicle interior fan fuse-
B70Trailer fuse-
B80i.e. MAXI FUSE-
B90Radio amplifier fuse-
B99Battery fuses junction unit (CBA)5530B
C1Battery earth-
C10Front left earth-
C31Rear right earth-
D1Front-dashboard coupling-
D6Rear - front coupling-
D19Dashboard / battery coupling-
H1Ignition switch5520A
I50Inertial switch1040A
M40A.B.I control unit5505A
N40Fuel pump and sender unit-
Location of components

Components
Component codeNameAssembly reference
A1Battery5530B
A5Terminal board-
A6Rear junction node-
A10Alternator-
A10Alternator5530A
A20Starter motor-
A20Starter' motor5520B
B1Junction unit-
B1Junction unit5505A
B1Junction unit5505A
B2Dashboard junction unit (CPL)-
B2General supply MAXI FUSE-
B2Junction unit-
B2Junction unit5505A
B3Relay unit5505A
B4Rear services MAXI FUSE-
B5MAXI FUSE box-
B7-MAXI FUSE) for ABS-
B8(MAXI FUSE) for engine fan-
B9Starting enablement MAXI FUSE-
B17Rear electric windows fuse-
B20Seat heating fuse-
B31ABS fuse-
B33Heated rear window fuse-
B37Spark plugs MAXI FUSE-
B38Additional heater fuse-
B39Diesel pre-heating fuse-
B42CAE supply fuse-
B60Boot opening fuse-
B61Fuel flap opening fuse-
B62Left seat adjustment fuse-
B63Right seat adjustment fuse-
B65Vehicle interior fan fuse-
B70Trailer fuse-
B80i.e. MAXI FUSE-
B90Radio amplifier fuse-
B99Battery fuses junction unit (CBA)5530B
C1Battery earth-
C10Front left earth-
C31Rear right earth-
D1Front-dashboard coupling-
D6Rear - front coupling-
D19Dashboard / battery coupling-
H1Ignition switch5520A
I50Inertial switch1040A
M40A.B.I control unit5505A
N40Fuel pump and sender unit-
DescriptionThe entire electrical system has been designed and constructed in accordance with the most up-to-date guidelines concerning safety and protection, especially against fire risks.There are two main kinds of protection:active protection, aimed at reducing possible causes of faults 'at source';passive protection, aimed at minimizing the effects of a possible fault.The first kind involves the thoughtful design of wiring, attentive to location and anchorage, and the careful planning of properly protected cable routes.Modifications have therefore been made to the alternator and starter motor cables, with the adoption of protective caps, etc.Passive protection instead includes all the interventions, which have always been adopted on vehicles, to reduce high fault currents (overload and short circuit).All the fuses included in the system have been rated on the basis of the nominal absorption of the loads which cannot be served simultaneously, and so as to ensure intervention in the case of a definite short circuit.All the electrical systems are supplied by the battery at a voltage of 12. V. The battery is in turn recharged by the alternator ( 3309762SeeE5010STARTING AND RECHARING ) during engine operation. The main supply lines are protected by 'MAXIFUSES', grouped together in a container located in the engine compartment services compartment.The power supplies to all services and systems are protected by fuses grouped in the junction units, one of which is inside the passenger compartment and the other one which is in the engine compartment on the left side panel. The unattached fuses are located in the engine compartment near the rear bulkhead and in compartments protected by covers in the luggage compartment, one on the right hand side and the other on the left hand side behind the battery.All the power supplies are thus protected, except for the starter motor cable (battery-starter motor) and recharging cable (starter motor-alternator): these are protected by an additional shielded sheath.Some circuits are supplied continuously, even if the vehicle is stopped and the ignition is off, as they are connected directly to the battery.Other circuits are supplied by turning the ignition key to various different positions:when the key is inserted and turned to the first click, the ignition is turned on (MAR position) and several circuits are supplied, which are thus called 'ignition-operated' (lines 'INTE' and '15/54');the second click - AVV (starting) position - supplies the starter motor (line '50'), disconnecting certain circuits (those which absorb greater power) and thereby guaranteeing the maximum current flow to the actual starter motor; ('INT/A' line).767The lines through which the supply is distributed to the various electrical devices are shown on the wiring diagrams relating to the various functions and systems.This general diagram shows all the lines which depart from the battery and the MAXIFUSE boxes; reference should be made to the specific diagrams for greater detail.
Functional descriptionAll electrical equipment and systems are supplied by battery A1, located in the boot compartment: two junction units distribute power to the various parts of the car.junction unit A6 is located at the rear. This is protected by MAXIFUSE for rear services B4 (60A). It sends power to all services with control units or systems located in the boot compartment.terminal board A5 is located at the front - in the engine bay. This is protected by master power supply MAXIFUSE B2 (125A). It sends power to all services with control units or systems located in the engine bay.The other supply lines leading to junction unit B1 and ignition switch H1 are protected by both MAXIFUSES B5:ACC (30A) for supply to ignition switch H1 ;CENTR (60A) for supply for services via fuses for junction unit B1 Other circuits are supplied by turning ignition key H1 to various different positions:certain ignition-operated services are supplied when the key is turned to MAR;in the AVV position - the starter motor is supplied; (line '50') (3309762SeeE5010STARTING AND RECHARING);certain services which are ignition-operated except at start-up are disconnected in this position (INT/A line)

Battery



A1A



A1B



A1C



A1D



battery and leads



5530B10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314864-5530B54battery cover - r+r . Make sure that the ignition key is in theOFF position.1. Disconnect the battery negative and positive terminals.2. Undo the bolt (2a) fixing the battery retaining bracket (2b).3. Remove the battery.2010647

5530B40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314864-5530B54battery cover - r+r1. Press and release the retainers (1a), then remove the cover (1b)for the supply box on the battery. 2071303

5530B52


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314864-5530B54battery cover - r+r . 3314861-5530B10battery - r+r . 1. Remove the battery fluid collection reservoir.2010648

5530B54


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Working in the luggage compartment, undo the knob for the batterycover.2. Remove the battery cover.2010650

Terminal board



A5



A5



A5



A5



A5



A5



A5A



A5A



A5B



A5B



A5C



A5D



A5



A5



A5



A5



A5



A5



A5



A5



A5A



A5A



A5B



A5B



A5C



A5D



A5



A5



Rear junction node



A6A



A6B



A6C



A6G



A6H



A6I



A6A



A6B



A6C



A6G



A6H



A6I



Alternator



A10A



A10A



A10A



A10B



A10B



A10B



A10B



A10B



A10B



A10B



alternator and components



5530A14


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp. Make sure that the ignition is OFF (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r (right) 3315197-7040D14engine bay rear side cover (one) lh or rh - r r (left). 3314703-4450B10Front WHEEL (one) - R.R. (left). 3315300-7055B42Additional FRONT WHEEL ARCH (one), left or right- R.R. (right) 3314211-1092G10single engine belt r r . Disconnect the electrical connections fromthe alternator.1. Undo the bolts (1a) and remove the alternator (1b).2010633

5530A40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213315302-7055B54under-engine guard - r r . 3314180-1084B30engine oil filter r r . 3314703-4450B10Front WHEEL (one) - R.R. (right) 3315300-7055B42Additional FRONT WHEEL ARCH (one), left or right- R.R. (right) 3314211-1092G10single engine belt r r . 3314213-1092G20engine component single belt fixed tensioner - one- r + r . 3314858-5530A14alternator - r+r for versions with air conditioner . Undo the bolts fixing the timing belt coverto the alternator bracket/spacer.1. Undo the bolts (1a) and remove the alternator bracket/spacer(1b).2010645

Starter motor



A20A



A20A



A20A



A20B



A20B



A20B



A20B



A20B



A20B



starter motor and components



5520B10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-). Proceed with removal 3314409-1016A10sound-proofing cover- r + r . Proceed with removal 3315196-7040D12engine front side cover(one) lh or rh - r r (Left side). Proceed with removal 3315197-7040D14engine bay rear side cover(one) lh or rh - r r (Left side). 1. Disconnect the electrical connections for the starter motor.2. Undo the bolts (2a) and remove the starter motor (2b).2071296

5520B12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the lift. Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 3315302-7055B54under-engine guard - r r . 3314154-1076B50exhaust pipe attachment to engine - r + r . 1. Undo the bolts (1a) for the starter motor, release the band (1b)and remove the electrical connections protective cover (1c).2010624

Junction unit



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1B



B1B



B1B



B1B



B1B



B1B



B1B



B1B



B1B



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1D



B1D



B1D



B1G



B1E



B1E



B1E



B1E



B1E



B1E



B1E



B1E



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1H



B1H



B1H



B1H



B1H



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1X



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1B



B1B



B1B



B1B



B1B



B1B



B1B



B1B



B1B



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1D



B1D



B1D



B1G



B1E



B1E



B1E



B1E



B1E



B1E



B1E



B1E



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1H



B1H



B1H



B1H



B1H



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1X



multi-function components



5505A10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314824-5505A18multi-function controlunit - r r . 1. Undo the bolt (1a) and push back the junction unit as far asnecessary to disconnect the electrical connections (1b).767For precise identification ofthe electrical connections, see Wiring Diagrams Section.2. Remove the junction unit.2010592

5505A13


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r (left). 3315197-7040D14engine bay rear side cover (one) lh or rh - r r (left).

5505A18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 1. Unscrew bolt (1a) and open fuse access cover (1b).2. Undo the bolt (2a) and remove the integrated multiservices unit(2b) after having disconnected the electrical connections (2c),(2d), (2e), (2f) and (2g).2010595

5505A29


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Open the bonnet lid.1. Release the retainers (1a) and remove the cover (1b) for theadditional junction unit.2071293

Dashboard junction unit (CPL)



B2



B2A



B2B



B2C



B2E



B2F



B2G



B2G



B2H



B2I



B2I



B2I



B2I



B2I



B2I



B2



B2A



B2B



B2C



B2E



B2F



B2G



B2G



B2H



B2I



B2I



B2I



B2I



B2I



B2I



Relay unit



B3A



B3A



B3A



B3A



B3A



B3B



B3B



B3B



B3B



B3B



B3B



B3B



B3B



B3C



B3C



B3D



B3D



B3D



B3D



B3D



B3D



B3D



B3A



B3A



B3A



B3A



B3A



B3B



B3B



B3B



B3B



B3B



B3B



B3B



B3B



B3C



B3C



B3D



B3D



B3D



B3D



B3D



B3D



B3D



Rear services MAXI FUSE



B4



B4



MAXI FUSE box



B5A



B5C



B5D



B5D



B5A



B5C



B5D



B5D



-MAXI FUSE) for ABS



B7



B7



B7



B7



B7



B7



(MAXI FUSE) for engine fan



B8



B8



Starting enablement MAXI FUSE



B9



B9



B9



B9



B9



B9



Rear electric windows fuse



B17



B17



Seat heating fuse



B20



B20



ABS fuse



B31



B31



B31



B31



Heated rear window fuse



B33



B33



Spark plugs MAXI FUSE



B37



B37



B37



B37



Additional heater fuse



B38



B38



B38



B38



Diesel pre-heating fuse



B39



B39



B39



B39



CAE supply fuse



B42



B42



Boot opening fuse



B60



B60



Fuel flap opening fuse



B61



B61



Left seat adjustment fuse



B62



B62



Right seat adjustment fuse



B63



B63



Vehicle interior fan fuse



B65



B65



B65



B65



Trailer fuse



B70



B70



i.e. MAXI FUSE



B80



B80



B80



B80



B80



B80



Radio amplifier fuse



B90



B90



Battery fuses junction unit (CBA)



B99A



B99C



B99D



B99E



B99G



B99A



B99C



B99D



B99E



B99G



Front left earth



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10B



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10B



Rear right earth



C31



C31



C31



C31



C31



C31



C31



C31



Dashboard-i.e coupling.



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1B



D1B



D1B



D1B



D1B



D1B



D1B



D1B



D1B



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1D



D1D



D1D



D1D



D1D



D1D



D1D



D1D



D1D



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1B



D1B



D1B



D1B



D1B



D1B



D1B



D1B



D1B



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1D



D1D



D1D



D1D



D1D



D1D



D1D



D1D



D1D



Rear - front coupling



D6C



D6C



D6C



D6C



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6B



D6B



D6C



D6C



D6C



D6C



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6B



D6B



Dashboard / battery coupling



D19



D19



D19



D19



Ignition switch



H1A



H1A



H1A



H1A



H1A



H1A



H1B



H1B



H1B



H1A



H1A



H1A



H1A



H1A



H1A



H1B



H1B



H1B



ignition switch



5520A12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3314931-5580C18air bag module - r+r . 7693315174-7040A26steering column trim - r+r . 3314624-4110A11steering wheel - r+r for replacement or check forversions with air bag . 3314902-5550A12complete stalk unit - r+r for versions with air bag . 1. Release the aerial for the electronic key from the ignition switch.2. Release the electrical wiring from the fixing band and disconnectthe electrical connection for the ignition switch.2010621

5520A14


768

Inertial switch



I50



I50



I50



I50



I50



I50



I50



I50



I50



I50



I50



I50



I50



I50



I50



I50



fuel tank and components



1040A10


<anchor>1</anchor><span>Refitting</span><icon><imageid>21</imageid></icon>0Removing20.767The fuel tank is supplied by theParts Dept. together with the multifunction valves (which cannotbe dismantled) and the immersed pump assembly complete with gauge.Therefore if the tank has to be replaced it is not possible to reuse theimmsered pump assembly complete with gauge removed, but a new pre-assembledunit consisting of a tank - pump - multifunction valves suppliedby the Parts Dept. must be fitted.Move the fuel tank closer to its housingusing the hydraulic jack and connect the supply pipes to the fuel vapourseparator.Refit the fuel tank in its seating andsecure with its bolts.Remove the hydraulic jack from under thefuel tank.1. Replace the rear suspension crossmeber (1a) in its housing usingthe hydraulic jack (1b) and fix it tightening the bolts (1c) tothe recommended torque.Remove the hydraulic jack from under thecrossmember.2007293

1040A14


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213315188-7040B10load platform (luggage platform) trim - r+r . 3314100-1040A70submerged pump assembly complete with level guagecontrol - r + r . 3314706-4450B13rear wheels(2) r r . 3314094-1040A10fuel tank - r + r and decant fuel . 1. Remove the multi-purpose valve from the fuel tank.2007294

1040A30


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the lift.3315188-7040B10load platform (luggage platform) trim - r+r . 3314100-1040A70submerged pump assembly complete with level guagecontrol - r + r . Drain the fuel from the tank using suitableequipment.3314704-4450B11WHEEL (one) rear - R.R. (right) Undo the bolts and remove the rear partof the right rear wheel arch liner.1. Disconnect the connecting pipes to the valves on the tank fromthe fuel vapour separator.2. Disconnect the rapid attachment for the fuel vapour supply pipeto the canister.3. Undo the bolts fixing the fuel filler pipe to the bodyshell.2007295

1040A31


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the lift.3315188-7040B10load platform (luggage platform) trim - r+r . 3314100-1040A70submerged pump assembly complete with level guagecontrol - r + r . Drain the fuel from the tank using suitableequipment.3314704-4450B11WHEEL (one) rear - R.R. (right) Undo the bolts and remove the rear partof the right rear wheel arch liner.1. Disconnect the connecting pipes to the valves on the tank fromthe fuel vapour separator.2. Disconnect the rapid attachment for the fuel vapour supply pipeto the canister.3. Undo the bolts fixing the fuel filler pipe to the bodyshell.4. Loosen the band fixing the fuel filler pipe to the hose.2007299

1040A32


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the lift.3314704-4450B11WHEEL (one) rear - R.R. (right) 3315188-7040B10load platform (luggage platform) trim - r+r . 3314100-1040A70submerged pump assembly complete with level guagecontrol - r + r . Drain the fuel from the tank using suitableequipment.Undo the bolts and remove the rear partof the right rear wheel arch liner.1. Release the fuel reflux pipe and the fuel vapour pipes from theband on the hose joining the rigid pipe to the tank.2. Disconnect and remove the hose joining the rigid pipe to thefuel tank.2007302

1040A40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Open the access flap to the fuel fillerpipe cap.Undo and remove the fuel filler pipe cap.

1040A70


769

1040A74


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21- 7045A10 l/h or r/h front seat (one) - r+r . 1. Cut the floor carpet along the marked line.2. Undo the bolts fixing the inertia switch to the bodyshell.3. Disconnect the electrical connection (3a) and remove the inertiaswitch (3b).2007309

104A32


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the vehicle on a ramp.3314704-4450B11WHEEL (one) rear - R.R. (right). 3315188-7040B10load platform (luggage platform) trim - r+r . 3314100-1040A70submerged pump assembly complete with level guagecontrol - r + r . Drain the fuel from the tank using suitableequipment.Undo the bolts and remove the rear partof the right rear wheel arch liner.1. Release the fuel reflux pipe and the fuel vapour pipes from theband on the hose joining the rigid pipe to the tank.2. Disconnect and remove the hose joining the rigid pipe to thefuel tank.2007750

1040A66


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with removal 3315188-7040B10load platform (luggageplatform) trim - r+r . Proceed with removal 3314100-1040A70submerged pump assemblycomplete with level guage control - r + r . Remove the submerged fuel pump assemblyfuel level gauge control.

A.B.I control unit



M40A



M40A



M40B



M40B



M40C



M40A



M40A



M40B



M40B



M40C



Fuel pump and sender unit



N40



N40



N40



N40



N40



N40



N40



N40



N40



N40



N40



N40



N40



N40



N40



N40



N40



N40


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