Alfa Romeo 166 2.0 TS da 04/01 a 02/02 – PETROL ENGINE ELECTRONIC MANAGEMENT – – Right hand drive – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION

Wiring diagram

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Components

Component code	Name	Assembly reference
A5	Terminal board	-
A30	Ignition coil	5510C
B1	Junction unit	-
B1	Junction unit	5505A
B1	Junction unit	5505A
B2	Dashboard junction unit (CPL)	-
B2	Junction unit	-
B2	Junction unit	5505A
B5	MAXI FUSE box	-
B40	Fuel injection services supply fuse	-
B41	Fuel injection control unit supply relay	-
B80	i.e. MAXI FUSE	-
B99	Battery fuses junction unit (CBA)	5530B
C10	Front left earth	-
C15	Facia earth, driver's side	-
C21	Dashboard earth on Air Bag bracket	-
C21	Passenger side dashboard earth	-
C30	Rear left earth	-
C31	Rear right earth	-
C40	Chassis earth for I.E system.	-
C40	Engine earth	5505A
D1	Dashboard-i.e coupling.	-
D1	Front-dashboard coupling	-
D4	Engine front connection	-
D4	Front-engine prewiring coupling	-
D5	ABS plus ANTISPIN coupling	-
D5	ABS plus antispin connection	-
D6	Rear - front coupling	-
D19	Dashboard / battery coupling	-
D23	Dashboard-i.e coupling.	-
D24	Engine-i.e coupling.	-
D25	Dashboard-left rear coupling	-
D25	Dashboard-rear coupling left	-
D49	Pedal assembly join	1060G
D80	Coils and fuel injectors connection	-
D83	Front-automatic transmission coupling	-
E50	Instrument panel	-
E50	Instrument panel	5560B
H1	Ignition switch	5520A
I30	Brake pedal switch	5550D
I31	Clutch pedal switch	1060G
I31	Clutch pedal switch	5550D
I31	Clutch pedal switch	5580A
I50	Inertial switch	1040A
J10	Fuel injection main relay	1056B
J10	Fuel injection main relay	1060G
J15	Fuel pump relay	1056B
K15	Lambda sensor on pre-catalyzer	-
K16	Lambda sensor on pre-catalyzer-2	-
K17	Lambda sensor on post-catalyzer	-
K18	Lambda sensor on post-catalyzer-2	-
K36	Engine coolant temperature sensor-sender unit	1088E
K40	Lambda sensor	1080B
K41	Air flow meter	1056B
K41	Air flow meter	1060G
K42	Air temperature sensor	1056B
K46	Rpm sensor	5510C
K47	Cam angle sensor	5510C
K49	Altitude sensor	1056B
K50	Detonation sensor	5510C
K51	Knock sensor 2	5510C
K55	Accelerator pedal potentiometer	1068A
K58	Steering sensor	-
L10	Fuel vapour recovery solenoid	1080E
L15	Variable geometry control solenoid	1080E
L35	Overboost solenoid	1064B
M10	Engine management control unit	-
M10	Engine management control unit	1056B
M11	Fuel injection main relay diode	-
M20	CODE control unit	5580E
M50	ABS control unit	-
M50	ABS control unit	3340A
N40	Fuel pump and sender unit	-
N40	Fuel pump and sender unit	5540B
N70	Injector	1056B
N70	Injector	1060F
N75	Integrated throttle body actuator	1056B
N76	Timing variator actuator	1056B
R10	Multiple tester connection	-
R51	I.E. control unit additional socket	-

Location of components

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Components

Component code	Name	Assembly reference
A5	Terminal board	-
A30	Ignition coil	5510C
B1	Junction unit	-
B1	Junction unit	5505A
B1	Junction unit	5505A
B2	Dashboard junction unit (CPL)	-
B2	Junction unit	-
B2	Junction unit	5505A
B5	MAXI FUSE box	-
B40	Fuel injection services supply fuse	-
B41	Fuel injection control unit supply relay	-
B80	i.e. MAXI FUSE	-
B99	Battery fuses junction unit (CBA)	5530B
C10	Front left earth	-
C15	Facia earth, driver's side	-
C21	Dashboard earth on Air Bag bracket	-
C21	Passenger side dashboard earth	-
C30	Rear left earth	-
C31	Rear right earth	-
C40	Chassis earth for I.E system.	-
C40	Engine earth	5505A
D1	Dashboard-i.e coupling.	-
D1	Front-dashboard coupling	-
D4	Engine front connection	-
D4	Front-engine prewiring coupling	-
D5	ABS plus ANTISPIN coupling	-
D5	ABS plus antispin connection	-
D6	Rear - front coupling	-
D19	Dashboard / battery coupling	-
D23	Dashboard-i.e coupling.	-
D24	Engine-i.e coupling.	-
D25	Dashboard-left rear coupling	-
D25	Dashboard-rear coupling left	-
D49	Pedal assembly join	1060G
D80	Coils and fuel injectors connection	-
D83	Front-automatic transmission coupling	-
E50	Instrument panel	-
E50	Instrument panel	5560B
H1	Ignition switch	5520A
I30	Brake pedal switch	5550D
I31	Clutch pedal switch	1060G
I31	Clutch pedal switch	5550D
I31	Clutch pedal switch	5580A
I50	Inertial switch	1040A
J10	Fuel injection main relay	1056B
J10	Fuel injection main relay	1060G
J15	Fuel pump relay	1056B
K15	Lambda sensor on pre-catalyzer	-
K16	Lambda sensor on pre-catalyzer-2	-
K17	Lambda sensor on post-catalyzer	-
K18	Lambda sensor on post-catalyzer-2	-
K36	Engine coolant temperature sensor-sender unit	1088E
K40	Lambda sensor	1080B
K41	Air flow meter	1056B
K41	Air flow meter	1060G
K42	Air temperature sensor	1056B
K46	Rpm sensor	5510C
K47	Cam angle sensor	5510C
K49	Altitude sensor	1056B
K50	Detonation sensor	5510C
K51	Knock sensor 2	5510C
K55	Accelerator pedal potentiometer	1068A
K58	Steering sensor	-
L10	Fuel vapour recovery solenoid	1080E
L15	Variable geometry control solenoid	1080E
L35	Overboost solenoid	1064B
M10	Engine management control unit	-
M10	Engine management control unit	1056B
M11	Fuel injection main relay diode	-
M20	CODE control unit	5580E
M50	ABS control unit	-
M50	ABS control unit	3340A
N40	Fuel pump and sender unit	-
N40	Fuel pump and sender unit	5540B
N70	Injector	1056B
N70	Injector	1060F
N75	Integrated throttle body actuator	1056B
N76	Timing variator actuator	1056B
R10	Multiple tester connection	-
R51	I.E. control unit additional socket	-

DescriptionAn electronic management system supervises and governs all engine parameters. It optimises performance and fuel consumption by responding in real time to different service conditions.The system is managed by a single control unit that controls the twin spark ignition (static and lost spark), and the injection (phased).The system uses signals received from numerous sensors to control actuators. It is connected to the following systems:fuel supply;air supply system;engine cooling;exhaust with catalytic converter;fuel vapour recirculation; For further details, see DESCRIPTION AND OPERATION 1056Supply lines to the control unit and the various system components (sensors and actuators) are protected by a special maxifuse and another protects the steering wheel fuses, located with the relays in a service tank (behind the engine bulkhead).

Functional description Engine control unit M10 manages the electronic ignition and injection system. System power is distributed by main injection relay J10. When ignition key sends an INT/A supply via fuse F16 of control unit B1, power is sent to pin 47 connector A of control unit M10 and the coils of relays J10 and J15. The control unit then energises the coil of relay J10 via pin 31 of connector A and fuel pump relayJ15 from pin 30 of connector A. The connector contact takes power from the battery vai MAXIFUSE B80 that supplies fuel pump N40 via F3 of B1. The pump earth is supplied by inertia switch I50, which cuts off the fuel flow in the case of impact. The contact of main relay J10, supplied from the battery via MAXIFUSE B80, distributes power to the following devices:via fuse B41 to:1) control unit M10 at pins 16-32-48, 2) injectors N70, 3) ignition coils A30; via fuse B40 to:4) fuel vapour recovery solenoid L10, 5) variable geometry control solenoid L15, 6) variable valve timing actuator N76, 7) pre and post converter lambda sensors K15-K16-K17, 8) air flow meter K41. Control unit M10 controls the various engine service parameters by means of input signals from the following sensors:rpm sensor K46 on pins 10 and 59 of connector B; this supplies a frequency signal proportional to engine rpm.timing sensor K47; this is supplied from pin 26 of connector B (positive) and receives an earth signal from pin 42. pin 51 receives a frequency signal proportional to engine phaseengine temperature sensor K36 at pin 25 connector B; this supplies a signal proportional to engine coolant temperature. It is supplied via pin 26 of connector B. It also contains the transmitter for the instrument panel (see E4010 - STRUMENTO ON-BOARD INSTRUMENT).lambda sensor on preconverter K15 at pins 2-7-39 connector B; lambda sensor on preconverter -2 K16 at pins 23-34-55 connector B; lambda sensor on post converter K17 at pins 28-50-36 connector B. This supplies control unit M10 with information on the correct air-fuel mixture composition:knock sensor K50 at pins 22 and 54 connector B; this sends the control unit a signal representing engine knock conditionsair flow sensor K41 at pins 25-54-57-63; This sends a signal proportional to the air flow rate. Accelerator pedal K55 is fitted with two built-in potentiometers (a main one and a safety back-up). These are connected to control unit M10 via pins 7-8-24-25-40-56 connector A.The purpose of the above potentiometers is to notify the control unit of accelerator pedal position and thus the engine power requirement. On the basis of signals received from the accelerator pedal and the various sensors, control unit M10 drives injectors N70 via pins 3-19-35-52, ignition coils A30 via pins 14-16-30-31 and the built-in throttle body actuator N75 at pins 1-17-24-26-33-40-49-58.The throttle body is fitted with two potentiometers connected in parallel; this controls throttle opening via a step motorOn the basis of input parameters, control unit M10 controls variable valve timing actuator N76 (pin 36 connector B), fuel vapour recovery valve10 (pin 5 connector B) and the variable geometry control solenoid L15 of the turbine (pin 4 connector B). Table E5030 shows other electrical/electronic systems on the vehicle that interact with control unit M10:pins 9-41-50-62 connector A control ENGINE COOLING E5020;pin 3 connector A receives a signal from the ALFA ROMEO CODE control unit E7010;pins 6-13 connector A refer to ACTIVATION OF COMPRESSOR E6021 to adjust engine speed to the load increase whenever this is activated or compressor deactivation when engine speed and load is high.pins 12 and 29 connector A refer to the ASR/TCS E7021 system (antislip function).pins 19-22-35 connector A interact with ON-BOARD INSTRUMENT panel E4010.pin 27 connector A receives a signal from the brake pedal (see E7020 - ABS without VDC). Control unit M10 is fitted with a self-diagnostic system; it is connected to pin 7 of connector R10 via pin 53 connector A. this system can be used to analyse the injection system using external diagnostic instruments. Control unit M10 also sends an earth signal via pin 46 of connector A to turn on the injection fault warning light on instrument panel E50.

Terminal board

A5

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A5

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A5

A5 - Terminal board ( ABS ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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A5

A5 - Terminal board ( ICS ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

A5D - Terminal board ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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A5

A5 - Terminal board ( RECHARGING ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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A5

Ignition coil

A30

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A30A

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A30A

coil, ecu, sensors

5510C10

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 1. Disconnect the high tension leads from the ignition coil.2. Disconnect the electrical connection from the ignition coil.3. Undo the bolts (3a) and remove the ignition coil (3b).2010599

5510C14

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is OFF (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 3314048-1016A40ignition coil cover on cylinder head- r+r . 1. Disconnect the electrical connections from the ignition coils.2. Disconnect the electrical connection for the air conditioningcompressor electro-magnet coupling.3. Disconnect the earth lead from the ignition coils mounting bracket.Release the electrical wiring from thebands on the tappet cover and move it aside.2010600

5510C16

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 3314293-1016A42left hand cylinder head ignition coil cover - r+r . 1. Disconnect the electrical connections from the ignition coils.1. Undo the bolts (1a) and remove the electrical wiring securingbrackets (1b).Move the electrical wiring to the side.2010607

5510C18

5510C34

5510C42

5510C46

5510C48

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 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 . 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). 3314249-1048B44heat exchanger/manifold pipe - r r . 3314191-1088C40thermostat- r + r . 3314285-1088C36thermostat support - r + r . 3315298-7055B39front additional wheel arch half (one), lh or rh,front element - r r . 3314195-1088D26rigid intake pipe to water pump - r+r for versionswith a/c . 3314270-1072B42left hand or right hand inlet manifold (one) - r+r . 3314269-1072B12intake manifold (one) lh or rh - r r and replacegasket (right) 1. Undo the bolt (1a) and remove the timing side knock sensor (1b).2010619

Junction unit

B1A

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B1A

B1A - Junction unit ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

B1B - Junction unit ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B1B

B1B - Junction unit ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

B1C - Junction unit ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

B1C - Junction unit ( LEFT LONGITUDINAL ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B1C

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B1C

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B1C

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B1C

B1C - Junction unit ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B1D

B1D - Junction unit ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B1D

B1D - Junction unit ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B1D

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B1G

B1G - Junction unit ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B1E

B1E - Junction unit ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B1E

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B1E

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B1E

B1E - Junction unit ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B1E

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B1E

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B1E

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B1E

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B1F

B1F - Junction unit ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B1H

B1H - Junction unit ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B1H

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B1H

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B1H

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B1H

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B1I

B1I - Junction unit ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B1I

B1I - Junction unit ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

multi-function components

5505A10

<anchor>0</anchor>Removing<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

5505A18

<anchor>0</anchor>Removing<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>Removing<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)

B2I

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B2I

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MAXI FUSE box

B5A

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B5C

B5C - MAXI FUSE box ( BATTERY POSITIVE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B5D

B5D - MAXI FUSE box ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

B40

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B40

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B40

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B40

B40 - Fuel injection services supply fuse ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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B40

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B40

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B80

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Battery fuses junction unit (CBA)

battery and leads

5530B10

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

Rear left earth

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Rear right earth

C31

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C31

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C31

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C31

C31 - Rear right earth ( REAR ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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C31

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C31

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C31

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C31

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Chassis earth for I.E system.

C40

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C40

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C40

C40 - Chassis earth for I.E system. ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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C40

Dashboard-i.e coupling.

D1

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D1

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D1

D1A

D1A - Dashboard-i.e coupling. ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D1A

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D1A

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D1B

D1B - Dashboard-i.e coupling. ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D1B

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D1B

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D1B

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D1B

D1B - Dashboard-i.e coupling. ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D1B

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D1B

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D1B

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D1B

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D1C

D1C - Dashboard-i.e coupling. ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

D1C - Dashboard-i.e coupling. ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D1C

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D1C

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D1C

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D1C

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D1C

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D1D

D1D - Dashboard-i.e coupling. ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D1D

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D1D

Engine front connection

D4

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D4

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D4

D4 - Engine front connection ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D4

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D4

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D4

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D4

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D4

D5

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D5

D5 - ABS plus ANTISPIN coupling ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

D6 - Rear - front coupling ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D6

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D6

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D6

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D6

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D6

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D6

D6 - Rear - front coupling ( REAR ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D6B

D6B - Rear - front coupling ( REAR ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D6B

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Dashboard / battery coupling

D19

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D19

D19 - Dashboard / battery coupling ( BATTERY POSITIVE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D19

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D19

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Dashboard-i.e coupling.

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D23A

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D23B

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D23A

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D23B

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D23B

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D23B

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Engine-i.e coupling.

D24

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D24

D24 - Engine-i.e coupling. ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D24

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D24

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Dashboard-left rear coupling

D25A

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D25A

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D25A

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D25B

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D25B

D49

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D49

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D49

D49 - Pedal assembly join ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

1060G22

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 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 (right) 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 . 3315302-7055B54under-engine guard - r r . 3314201-1092A12crankshaft pulley - r+r for versions with air conditioner . 3314213-1092G20engine component single belt fixed tensioner - one- r + r . 3314042-1008C10power unit upper reaction link r r . 3314043-1008C16body link bracket - r r . 3314077-1032B14toothed timing belt - r + r for timing adjustmentor replacement versions with air conditioner . 3314336-1032B61timing belt pulley - r r . 3314337-1032B62a/c duct pulley - r r . 1. Undo the bolts (1a) and remove the left side protection (1b)for the timing belt.2. Disconnect the electrical connection for the cam angle sensor.3. Undo the bolts (3a) and remove the cam angle sensor (3b).2008721

1060G28

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-). Proceed with removal 3314409-1016A10sound-proofing cover- r + r . 1. Disconnect the electrical connection from the fuel pressure sensoron the fuel manifold.2. Undo and remove the fuel pressure sensor on the fuel manifold.2070776

1060G30

1060G38

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). Disconnect the electrical connection fromthe switch on the brake pedal.Rotate and remove the switch on the brakepedal.

1060G42

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). Disconnect the electrical connection fromthe switch on the clutch pedal.Rotate and remove the switch on the clutchpedal.

1060G50

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Proceed with the removal 3314409-1016A10sound-proofing cover- r + r . 1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold (1b), throttle body connectorside.2. Loosen the band (2a) and disconnect the vacuum pipe (2b) fromthe vacuum unit.2008725

1060G52

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Proceed with the removal 3314409-1016A10sound-proofing cover- r + r . Proceed with the removal 3314376-1060G50Electro-pneumaticallycontrolled THROTTLE CASING - R.R. . 1. Undo the bolts (1a) and separate the pneumatic throttle body(1b) from the connector (1c).2. Remove the gasket.2008728

1060G58

1060G70

1060G72

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal ( 3314861-5530B10battery - r+r ). Proceed with the removal 3314409-1016A10sound-proofing cover- r + r . 1. Disconnect the electrical connection from the solenoid on thevacuum tank.2. Disconnect the vacuum pipes from the solenoid on the vacuum tank.3. Undo the upper bolt (3a), loosen the lower bolt (3b), then releaseand remove the solenoid valve on the vacuum reservoir (3c), completewith lower pad. Recover the upper bolt pad.2008735

1060G80

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is OFF (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 1. Remove the buttons (1a) using the tool (1b) and remove the protection(1c).2. Open the two protective covers (2a) and undo the nuts (2b) underneathfixing the control unit cover.3. Undo the bolts (3a) and remove the control unit cover (3b).2008736

1060G90

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Ensure that the ignition key is in stopposition, then disconnect the battery negative terminal ( 3314861-5530B10battery - r+r ). Proceed with the removal 3315196-7040D12engine front side cover(one) lh or rh - r r (Right and leftsides). Proceed with removal 3315198-7040D30engine bay front beamcover - r r . Proceed with the removal 3315197-7040D14engine bay rear sidecover (one) lh or rh - r r (Right andleft sides). 1. Connect the electrical connections to the diesel electronic injectioncontrol unit.2008740

Coils and fuel injectors connection

D80

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D80

D80 - Coils and fuel injectors connection ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D80

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D80

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CAE-front coupling

D83

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D83

D83 - CAE-front coupling ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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D83

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D83

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D83

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D83

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D83

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D83

D83 - CAE-front coupling ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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E50D

analogue control panel

H1B

H1B - Ignition switch ( FACIA ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

5520A12

<anchor>0</anchor>Removing<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

brake and reversing lights

1040A10

<anchor>1</anchor>Refitting<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>Removing<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>Removing<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

1040A32

<anchor>0</anchor>Removing<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>Removing<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>Removing<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

1056B68

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting211. Remove the clips (1a) and remove the injectors (1b) from thesingle fuel manifold pipe.2. Remove the seals from the injectors.2007338

1056B70

3314123Refer to op..1056B68set of injectors - r+ r with fuel manifold pipe removed - includes seal replacement .

1056B81

Make sure that the ignition key is in theOFF position. Check that: the air conditioning is switchedoff, the accelerator pedal is never pressed and the accelerator cableis correctly positioned (refer to op. 33141321068A30accelerator control cable - r + r ). Connect the tool to the diagnostic socketand place the knob in position 3.Connect the Examiner diagnostic equipment.Connect the Examiner diagnostic equipment.Using the Examiner, enter the "ControlUnit Test" ambient.Place the ignition key in the ON position.Using the Examiner, enter the "ActiveDiagnosis" ambient, then select "Reset self-adjustmentparameters" and "Idle actuator".Using the Examiner, press "Carry outactive diagnosis".Place the ignition key in the OFF positionand wait for 30 seconds.Place the ignition key in the ON positionand wait for 30 seconds.Using the Examiner, re-establish the dialoguewith the engine control system.Using the Examiner, enter the "Parameters"ambient and select the following tests from the menu - "Idle recognitiontest - carried out" and "Idle recognition signals - synchronized".767If at least one of the parametersdoes not conform, place the ignition key in the OFF position andrepeat the procedure. If this non conformity persists, check thatthe diagnostic cable is correctly connected and check the operationof the instrument.Place the ignition key in the OFF positionand wait for 30 seconds.Start up the engine without acting on theaccelerator pedal.Disconnect the diagnostic equipment.Test the vehicle by driving for severalkilometres then, with the engine warmed up, check that it is idlingcorrectly.

1056B82

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 1. Release and disconnect the electrical connections (1a) and (1b)from the injection/ignition system control unit.2. Undo the nuts (2a) and remove the injection/ignition controlunit (2b).2007339

1056B82

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal ( 3314861-5530B10battery - r+r ). Proceed with the removal 3315197-7040D14engine bay rear sidecover (one) lh or rh - r r (Right side). 1. Loosen the band (1a) and disconnect the oil vapour recirculationpipe (1b) from the corrugated hose.2. Loosen the bands (2a) and remove the hose between resonator andthrottle body (2b), complete with resonator (2c).2007340

1056B17

Lambda sensor on post-catalyzer-2

K18

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K18

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K18

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K18

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Engine coolant temperature sensor-sender unit

K36

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K36

K36 - Engine coolant temperature sensor-sender unit ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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K36

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K36

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K36

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K36

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K36

1088E10

1088E20

1088E11

Lambda sensor

K40

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K40

K40 - Lambda sensor ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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K40

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K40

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K40

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K40

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exhaust emission control system

1080B40

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp. Proceed with the removal 3315196-7040D12engine front side cover(one) lh or rh - r r (Right and leftsides). Proceed with the removal 3315198-7040D30engine bay front beamcover - r r . Proceed with the removal 3314147-1076A46heat shield for catalyticpreconverter r r . 1. Undo the upper nut securing the catalytic preconverter to theexhaust manifold.2007395

1080B60

1080B62

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.Position a hydraulic jack under the catalyticconverter.1. Undo the bolts fixing the catalytic converter to the exhaustpipe attached to the manifold.2. Tighten the bolts fixing the catalytic converter to the intermediateexhaust silencer.3. Remove the catalytic converter.4. Remove the seals.2007409

1080B92

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp. Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal ( 3314861-5530B10battery - r+r ). Proceed with the removal 3315196-7040D12engine front side cover(one) lh or rh - r r (Right and leftsides). Proceed with the removal 3315198-7040D30engine bay front beamcover - r r . 1. Disconnect the electrical connection for the left Lambda sensor.2007415

1080B93

1080B95

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp. Ensure that the ignition key is in OFFposition, then disconnect the negative terminal (-) from the battery( 3314861-5530B10battery - r+r ). 1. Disconnect the electrical connection for the rear Lambda sensorfor the catalytic converter.2007419

1080B38

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Place the vehicle on a ramp. Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal ( 3314861-5530B10battery - r+r ). Proceed with the removal 3315196-7040D12engine front side cover(one) lh or rh - r r (Right and leftsides). Proceed with the removal 3315198-7040D30engine bay front beamcover - r r . Proceed with the removal 3315302-7055B54under-engine guard -r r . Proceed with the removal 3314163-1080B92left upper lambda sensorr r . Proceed with the removal 3314317-1076A70heat shield for leftcatalytic preconverter r r . 1. Undo nut (1a) and remove collar (1b) connecting the exhaust pipesbetween preconverters and catalytic converters. 2. Undo nuts (2a) and remove the exhaust pipe between left preconverterand catalytic converter (2b), preconverter side. Remove the gasket.2008301

1080B39

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Place the vehicle on a ramp. Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal ( 3314861-5530B10battery - r+r ). Proceed with the removal 3315196-7040D12engine front side cover(one) lh or rh - r r (Right and leftsides). Proceed with the removal 3315197-7040D14engine bay rear sidecover (one) lh or rh - r r (Right side). Proceed with the removal 3315198-7040D30engine bay front beamcover - r r . 1. Loosen the band (1a) and disconnect the oil vapour recirculationpipe (1b) from the cylinder head.2. Loosen the bands (2a) and remove the hose from the flow meterto the air chamber (2b) complete with resonator (2c).2008306

1080B65

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Place the vehicle on a ramp. Proceed with the removal 3315302-7055B54under-engine guard -r r . 1. Undo the bolt (1a) and remove the collar (1b) connecting theexhaust pipes between preconverters and catalytic converter.2008349

1080B66

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Place the vehicle on a ramp.1. Open the cover of the electrical connection box.2. Remove the connections and disconnect the electrical connectionfor the left rear Lambda sensor for the catalytic converter.Release the electrical wiring for the leftrear Lambda sensor for the catalytic converter from the fastenings inthe engine bay.2008377

1080B97

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Place the vehicle on a ramp.1. Open the cover of the electrical connection box. 2. Remove the connections and disconnect the electrical connectionfor the right rear Lambda sensor for the catalytic converter. Release the electrical wiring for the rightrear Lambda sensor for the catalytic converter from the fastenings inthe engine bay. 2008380

Air temperature sensor

K42

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K42

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Rpm sensor

K46

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K46

K46 - Rpm sensor ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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K46

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K46

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K46

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K46

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K46

K47

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K47

Altitude sensor

K49

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K49

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Detonation sensor

K50

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K50

K50 - Detonation sensor ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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Knock sensor 2

accelerator pedal control

1068A12

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Remove the rubber accelerator pedal cover.

1068A14

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting211. Disconnect the end of the accelerator cable (1a) from the acceleratorpedal (1b).2. Remove the clip (2a), undo the bolts (2b) and remove the acceleratorpedal (2c).2007347

K58

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Fuel vapour recovery solenoid

L10

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L10

L10 - Fuel vapour recovery solenoid ( FRONT ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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L10

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L10

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L10

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L10

L10 - Fuel vapour recovery solenoid ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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evaporation control system

1080E11

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the lift.3314704-4450B11WHEEL (one) rear - R.R. (right) Undo the bolts and remove the rear partof the right rear wheel arch liner.1. Undo the bolts fixing the fuel filler pipe to the bodyshell.2007422

1080E20

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting213314703-4450B10Front WHEEL (one) - R.R. (right) 3315298-7055B39front additional wheel arch half (one), lh or rh,front element - r r (right) 1. Disconnect the fuel vapour inlet and outlet pipes from the activecharcoal filter.2. Undo the bolt (2a) and remove the active charcoal filter (2b).2007425

1080E24

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting213314048-1016A40ignition coil cover on cylinder head- r+r . 3314111-1048A48throttle heater sleeve - r r . 1. Disconnect the electrical connection from the fuel vapour cut-outsolenoid valve from the filter.2. Undo the bolts (2a), disconnect the pipes (2b) and remove thefuel vapour cut out solenoid valve from the filter (2c).2007426

1080E10

3314169Refer to op..1080E11multifunctional valver r

Variable geometry control solenoid

L15

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L15

L15 - Variable geometry control solenoid ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

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L15

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L15

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Overboost solenoid

L35

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L35

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control/safety devices

1064B34

<anchor>0</anchor>Removing<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 ). 3315302-7055B54under-engine guard - r r . 1. Disconnect the electrical connection from the supercharging pressuresolenoid valve.2. Undo the nut securing the supercharging pressure solenoid valve.3. Disconnect the pipes (3a) and remove the supercharging pressuresolenoid valve (3b).2007805

1064B42

1064B50

1064B52

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Proceed with the removal 3314409-1016A10sound-proofing cover- r + r . 1. Disconnect the pipe from the solenoid valve to the turbochargervane position actuator, solenoid valve side.2. Release the pipe from the solenoid valve to the turbochargervane position actuator from the fastenings.2008775

Engine management control unit

M10A

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M10A

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M10A

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M10A

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M10A

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M10B

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M10B

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M10B

获取访问所有汽车的接线图

M10B

获取访问所有汽车的接线图

M10B

获取访问所有汽车的接线图

M10B

获取访问所有汽车的接线图

M10C

获取访问所有汽车的接线图

M10C

获取访问所有汽车的接线图

M10E

获取访问所有汽车的接线图

M10E

获取访问所有汽车的接线图

M10E

获取访问所有汽车的接线图

M10F

M10B

获取访问所有汽车的接线图

Fuel injection main relay diode

M11A

获取访问所有汽车的接线图

M11B

获取访问所有汽车的接线图

M11

M11 - Fuel injection main relay diode ( ENGINE ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

获取访问所有汽车的接线图

M11A

获取访问所有汽车的接线图

M11B

获取访问所有汽车的接线图

M11

获取访问所有汽车的接线图

CODE control unit

5580E46

5580E50

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting211. Press in the direction of the arrow and lower the volumetricsensor unit (1a), releasing it from the inner retainers (1b) and(1c). 2071341

abs check/adjustment devices

N40

N40 - Fuel pump and sender unit ( REAR ) Alfa Romeo 166 2.0 TS da 04/01 a 02/02

5540B46

5540B48

injectors and lines

1060F10

1060F20

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Undo the bolts and move the fuel returnmanifold pipe away from the air chamber.1. Undo the connector for the pipe from the pressure pump to thefuel manifold, manifold side, using a suitable spanner2. Undo the connector for the pipe from the pressure pump to thefuel manifold, pump side, using a suitable spanner.3. Remove the pipe from the pressure pump to the fuel manifold.767Fit a new high pressure pipe fromthe pressure pump to the fuel manifold upon reassembly. 2008708

1060F30

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting213314362-1060F36lines to injectors - r r . 1. Disconnect the electrical connection from the fuel pressure sensor.2. Undo the connector for the pipe from the pressure pump to thefuel manifold, manifold side, using a suitable spanner3. Undo the connector for the pipe from the pressure pump to thefuel manifold, pump side, using a suitable spanner.4. Remove the pipe from the pressure pump to the fuel manifold.767Fit a new high pressure pipe fromthe pressure pump to the fuel manifold upon reassembly. 5. Undo the nuts (5a) and remove the single fuel manifold pipe (5b).2008710

1060F34

3314362Refer to op..1060F36lines to injectors -r r .

1060F36

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting211. Undo the nuts (1a) and move the fuel filter (1b) away from theair capacity body.2. Undo the nuts (2a) and remove the oil vapour separator (2b) awayfrom the air chamber.3. Undo the bolts (3a) and move the fuel return manifold pipe (3b)aside.4. Undo the connectors for the pipes from the fuel manifold to theinjectors, injector side, using a suitable spanner.5. Undo the connectors for the pipes from the fuel manifold to theinjectors, injector side, using a suitable spanner.6. Remove all the pipes from the fuel manifold to the injectors.767Fit new pipes from fuel manifoldto injectors upon reassembly.2008712

1060F50

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 1. Disconnect the electrical connection from the fuel temperaturesensor.2.Disconnect the following from thefuel return manifold pipe:the fuel return pipe for lubricating the injectors (2a),the fuel return pipe from the pressure pump (2b),the fuel return pipe to the tank (2c),the fuel return pipe from the filter (2d).2008714

1060F52

<anchor>0</anchor>Removing<icon><imageid>20</imageid></icon>1Refitting21Disconnect the pipe from the injectorsto the fuel recovery manifold, manifold side.Remove the springs on the injectors andremove the pipe from the injectors to the fuel recovery manifold.