AUTOMOTIVE ELECTRICIANS

Alfa Romeo 166 2.4 JTD 10v da 03/02 a 09/03 — MAIN BEAM HEADLAMPS — — WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION — WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION

Wiring diagram

Components
Component codeNameAssembly reference
A5Terminal board-
B1Junction unit5505A
B2Dashboard junction unit (CPL)-
B2Junction unit-
B2Junction unit5505A
B3Relay unit5505A
B5MAXI FUSE box-
B99Battery fuses junction unit (CBA)5530B
C10Front left earth-
C11Right front earth-
C13Front earth on left side panel5505A
C15Facia earth, driver's side-
C21Dashboard earth on Air Bag bracket-
C21Passenger side dashboard earth-
D1Front-dashboard coupling-
D6Rear - front coupling-
D19Dashboard / battery coupling-
E50Instrument panel-
E50Instrument panel5560B
F10Left headlamp5540B
F10Left headlamp5540B
F11Right headlamp5540B
F11Right headlamp5540B
H1Ignition switch5520A
H5Steering column switch unit5550A
M45Electronic Check device-
M45Electronic Check device5560C
Location of components

Components
Component codeNameAssembly reference
A5Terminal board-
B1Junction unit5505A
B2Dashboard junction unit (CPL)-
B2Junction unit-
B2Junction unit5505A
B3Relay unit5505A
B5MAXI FUSE box-
B99Battery fuses junction unit (CBA)5530B
C10Front left earth-
C11Right front earth-
C13Front earth on left side panel5505A
C15Facia earth, driver's side-
C21Dashboard earth on Air Bag bracket-
C21Passenger side dashboard earth-
D1Front-dashboard coupling-
D6Rear - front coupling-
D19Dashboard / battery coupling-
E50Instrument panel-
E50Instrument panel5560B
F10Left headlamp5540B
F10Left headlamp5540B
F11Right headlamp5540B
F11Right headlamp5540B
H1Ignition switch5520A
H5Steering column switch unit5550A
M45Electronic Check device-
M45Electronic Check device5560C
DescriptionThe car is equipped with two main beam headlamps.The main beam headlamps are switched on:when the dipped beam headlamps are on, by pressing the lever towards the dashboard (stable mode)in 'flash' mode, by pulling the lever towards the steering wheel (unstable mode)The circuit is protected by two fuses, one for the right hand headlamp, one for the left hand headlamp.A warning light in the panel signals that the main beam headlamps have been switched on.
Functional description The main beams are controlled by electronic Check device M45 , which receives control signals from the switches and controls the bulbs while also checking the various lines. The supply for the Check device M45 arrives directly from the battery (maxifuse CENTR of B5 ) to pins 1 and 6 of connector C, via fuse F11 of junction unit B1 . The supply controlled by the ignition (INT/A) arrives via fuse F1 of junction unit B1 at pin 9 of connector C: pin 7 of connector C is earhed. The circuit for the main beam headlamps is operated by the steering column switch unit H5 , placing the switch in the main beam headlamps position or closing the 'flasher' contact. In the first case, the supply arrives from the dipped headlamps control H6 , ( 3309117SeeE2011DIPPED HEADLAMPS ). In the second case, on the other hand, the supply arrives directly from the line controlled by the ignition (INT/A) at pin 4, via fuse F1 of junction unit B1 . When the lights are on, the steering column switch unit H5 controls the supply of the main beam headlamps from pin 3 of connector A. This signal energizes the relay R4 , located in the relay control unit B3 , which supplies the headlamps F10 (left) and F11 (right). Each circuit is protected by a fuse in relay control unit B3 : F2 for the left hand headlamp and F1 for the right hand headlamp. The left hand headlamp supply line also lights up the 'main beams on' warning light inside instrument panel E50 - pin 6 of connector C - while pin 16 of connector A acts as an earth.

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



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



MAXI FUSE box



B5A



B5C



B5D



B5D



B5A



B5C



B5D



B5D



Battery fuses junction unit (CBA)



B99A



B99C



B99D



B99E



B99G



B99A



B99C



B99D



B99E



B99G



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

Front left earth



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10B



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10B



Right front earth



C11



C11



C11



C11



C11



C11



Dashboard earth on Air Bag bracket



C21



C21



C21



C21



C21



C21



C21



C21



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



Instrument panel



E50A



E50A



E50A



E50A



E50A



E50A



E50A



E50A



E50A



E50A



E50A



E50A



E50B



E50B



E50B



E50B



E50B



E50B



E50C



E50C



E50C



E50C



E50C



E50C



E50C



E50C



E50C



E50C



E50D



E50D



E50A



E50A



E50A



E50A



E50A



E50A



E50A



E50A



E50A



E50A



E50A



E50A



E50B



E50B



E50B



E50B



E50B



E50B



E50C



E50C



E50C



E50C



E50C



E50C



E50C



E50C



E50C



E50C



E50D



E50D



analogue control panel



5560B06


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314917-5560B11analogue control panel- r+r or replace . 1. At the bench, remove the bulbs from the panel using suitablepliers.2010702

5560B11


<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 ). Lower the steering wheel and move it back.1. Undo the bolts (1a) and remove the upper half casing for thesteering column (1b).2010703

5560B12


<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 ). Open the fuse carrier compartment flap.1. Using the tool (1a) and pushing the fuse carrier compartment,remove the surround (1b) complete with switches.2. Disconnect the elelectrical connections (2a), (2b) and (2c) andremove the surround complete with switches.2010706

Left headlamp



F10



F10



F10A



F10A



F10B



F10B



F10B



F10B



F10C



F10C



F10C



F10D



F10D



F10



F10



F10A



F10A



F10B



F10B



F10B



F10B



F10C



F10C



F10C



F10D



F10D



headlamps



5540B16


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on thelift. Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 3315300-7055B42Additional FRONT WHEEL ARCH (one), left or right- R.R. . 3315286-7055A43central front grille - r r . 3315285-7055A41RIGHT FRONT GRILLE - R.R. . 1. Undo the lower bolts fixing the bumper to the lower radiatorcrossmember.2. Unscrew the bolts retaining the bumper to the body.3. Unscrew the upper bolts securing the bumper to the body.2010660

5540B22


<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. Release the retaining spring (1a) and remove the protective cover(1b).2. Disconnect the electrical connection from the lamp.3. Release the retaining spring (3a) and remove the lamp (3b) fromthe light cluster.767If the lamp is working properly,avoid touching the bulb with your hands. If this does happen, cleanthe bulb with alcohol.2010662

5540B26


<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. Rotate the bulb holder (1a) in an anti-clockwise direction untilit is released from the light cluster (1b).2. Disconnect the electrical connection (2a) and extract the bulbholder.3. Separate the lamp from the bulb holder (press fit).767If the lamp is working properly,avoid touching the bulb with your hands. If this does happen, cleanthe bulb with alcohol.2010663

5540B38


Prepare the vehiclecomplete with spare wheel, tools, fluids, fuel reserve.Check that the tyre inflation pressureis correct.Place the headlamp alignment switch inposition '0'.Position the vehicle on a flat surface,perpendicular to a screen with an opaque surface, 10 metres away, whichcontains the following lines.1. V - V: vertical corresponding to the trace of the vehicle symmetryplane.2. C - C: traces of the vertical planes passing through the referencecentres of the light clusters.3. HC - HC: horizontal corresponding to the height from the groundof the reference centres for the light clusters.4. AC - AC: horizontal 11 cm below the HC - HC line.5. Lines inclined at 15° as illustrated in the diagram.2010664

5540B40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on theramp. 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 . 1. Disconnect the electrical connection from the exhaust gas headlampcontrol unit.2. Disconnect the electrical connection from the headlamp alignmentmotor.2010666

5540B42


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on theramp. 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 . 3315298-7055B39front additional wheel arch half (one), lh or rh,front element - r r . 3315285-7055A41RIGHT FRONT GRILLE - R.R. . 3315286-7055A43central front grille - r r . 3315293-7055B10Front BUMPER - R.R. . 3314879-5540B40Gas discharge LEFT LIGHT CLUSTER CONTROL UNIT (one)- R.R . . 1. At the bench, rotate the exhaust gas headlamp control unit torelease it from the fastening on the light cluster.2010668

5540B43


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Undo the control unit fixing bolts.2071307

5540B44


<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 . 1. Disconnect the electrical connection from the exhaust gas headlampcontrol unit.2010672

5540B46


<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 . 1. Disconnect the electrical connection from the exhaust gas headlampcontrol unit.2010675

5540B48


<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 . 1. Disconnect the electrical connection from the exhaust gas headlampcontrol unit.2010678

5540B81


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213315196-7040D12engine front side cover (one) lh or rh - r r (rightand left) 3315198-7040D30engine bay front beam cover - r r3315284-7055A40radiator shield - r r3315285-7055A41RIGHT FRONT GRILLE - R.R. (right andleft) 3315298-7055B39front additional wheel arch half (one), lh or rh,front element - r r (right and left) 3315293-7055B10Front BUMPER - R.R.1. Undo the light cluster fixing bolts.2. Move the light cluster assembly slightly.2071316

5540B82


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213315196-7040D12engine front side cover (one) lh or rh - r r (rightand left) 3315198-7040D30engine bay front beam cover - r r3315284-7055A40radiator shield - r r3315285-7055A41RIGHT FRONT GRILLE - R.R. (right andleft) 3315298-7055B39front additional wheel arch half (one), lh or rh,front element - r r (right and left) 3315293-7055B10Front BUMPER - R.R.1. Undo the light cluster fixing bolts.2. Move the light cluster assembly slightly.2071318

Right headlamp



F11



F11



F11



F11A



F11A



F11B



F11B



F11B



F11B



F11B



F11C



F11C



F11D



F11D



F11



F11



F11



F11A



F11A



F11B



F11B



F11B



F11B



F11B



F11C



F11C



F11D



F11D



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

Steering column switch unit



H5A



H5A



H5A



H5B



H5B



H5B



H5C



H5C



H5D



H5D



H5D



H5A



H5A



H5A



H5B



H5B



H5B



H5C



H5C



H5D



H5D



H5D



stalk unit



5550A12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314931-5580C18air bag module - r+r . 7693315174-7040A26steering column trim - r+r . 3314624-4110A11steering wheel - r+r for replacement or check forversions with air bag . 1. Undo the bolts (1a) and remove the complete steering column switchunit (1b) after having disconnected the electrical connections (1c),(1d), (1e) and (1f).2010691

Electronic Check device



M45A



M45A



M45A



M45A



M45B



M45B



M45B



M45B



M45C



M45C



M45C



M45C



M45C



M45C



M45C



M45D



M45D



M45D



M45D



M45D



M45D



M45D



M45E



M45E



M45E



M45E



M45A



M45A



M45A



M45A



M45B



M45B



M45B



M45B



M45C



M45C



M45C



M45C



M45C



M45C



M45C



M45D



M45D



M45D



M45D



M45D



M45D



M45D



M45E



M45E



M45E



M45E


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