Alfa Romeo2003–2008Technical specifications

166 2.4 JTD 20V: Technical specifications

Workshop data for the 2.4-litre diesel (engine code 841H.000). Covers engine, fluids, brakes, service, torques and air conditioning: the figures to check before a job or a parts order.

Common faults & fixes

Summary

Match the engine code (841H.000) to the vehicle before ordering parts or applying these figures.

Vehicle specifications

Overview

Make: Alfa Romeo
Model: 166
Years: 2003–2008
Fuel: Diesel
Engine code: 841H.000

Performance & efficiency

Power: 129 kW (175 hp)
Engine size: 2,387 cc
Cylinders: 5 · DOHC
Fuel system: Bosch

Fluids & capacities

Engine oil (with the filter): 5.0 litres

All 93 specifications below

Engine & identification

Vehicle identification

No. of cylinders Type	5/DOHC
Capacity cc	2387
Fuel system Make	Bosch
Fuel system Type	EDC 16C8

Injection system

Air metering Type	Mass
Fuel/injection pump assembly Make	Bosch
Pump type	Common rail
Fuel main pump delivery pressure bar	150-1350
Injector nozzle Make	Bosch

Injection sequence

The injection sequence for the Alfa Romeo 166 2.4 JTD 20V (2003–2008) is 1-2-4-5-3.

Injection sequence	1-2-4-5-3

Valve clearances

Valve clearances on the Alfa Romeo 166 2.4 JTD 20V (2003–2008) are hydraulic — they self-adjust, so no manual clearance figure applies.

Valve clearance - INLET mm	Hydraulic
Valve clearance - EXHAUST mm	Hydraulic

Engine oil & fluids

Engine oil

The Alfa Romeo 166 2.4 JTD 20V (2003–2008) takes 5.0 litres of engine oil with the filter.

See the reference table for the complete engine oil entries and their conditions.

Manual gearbox

The manual gearbox has a listed capacity of 2.9-3.1 litres. The specified oil is SAE 75W-85 semi-synthetic, with classification GL-4.

Coolant

The listed total cooling-system capacity is 9.1 litres.

Grades, filling conditions and capacities

Lubricants and capacities — complete reference
Engine oil options
Ambient temperature range	All temperatures
Engine oil grade SAE	5W-40 Synthetic
Engine oil classification OEM	Fiat 9.55535-M2
Engine oil classification API/ACEA	CF/B4
Ambient temperature range	-15°C➞
Engine oil grade SAE	10W-40 Synthetic
Engine oil classification API/ACEA	CF/B3
Engine with filter(s) litres	5.0
Other lubricants and capacities
Manual transmission oil grade SAE	75W-85 Semi-synthetic
Manual transmission oil classification	GL-4
Manual transmission litres	2.9-3.1
Cooling system - total capacity litres	9.1
Brake fluid Type	DOT 4
Power steering fluid Type	Dexron II
Power steering fluid litres	1.4

Brakes & wear limits

Brake disc thickness

Brake discs on the Alfa Romeo 166 2.4 JTD 20V (2003–2008) are replaced at a minimum thickness of 26 mm (ventilated) front and 9 mm rear.

Minimum disc thickness for replacement - ventilated Front	26 mm
Minimum disc thickness for replacement Rear	9 mm

Brake disc and drum dimensions

Disc runout Front	0,15 mm
Disc runout Rear	0,15 mm
Minimum pad thickness Front	1,5 mm
Minimum pad thickness Rear	1,5 mm

Service & electrical

Battery

The Alfa Romeo 166 2.4 JTD 20V (2003–2008) uses a 12 V, 100 Ah battery.

Battery V/RC(Ah)	12 (100)

Tuning and emissions

Idle speed rpm	850±20
Oil temperature °C	80
Idle speed - for smoke test rpm	810-890
Governed speed range - for smoke test rpm	4900-5100
Maximum time at governed speed secs	1,0
Test mode A/B	B
Probe type 1/2	1
Conditioning Accelerations/rpm	2-3
Smoke opacity - EU limit m-1 (%)	3,00 (73)

Starting and charging

Alternator output A/V/rpm	105/14/-

Service checks and adjustments

Radiator cap bar	0,98
Thermostat opens °C	78-82

Tightening torques

Cylinder head bolt torque

The cylinder head bolts on the Alfa Romeo 166 2.4 JTD 20V (2003–2008) are tightened in 4 stages: 65 Nm, then 90°, then 90°, then a final 90°.

Cylinder head
Renew bolts	Yes
Tighten	65 Nm
Tighten	90°
Tighten	90°
Tighten	90°

Other engine tightening torques
Cylinder head instructions	—
Main bearings Renew bolts/nuts	No
Main bearings Stage 1	25 Nm
Main bearings Stage 2	100°
Big end bearings Renew bolts/nuts	No
Big end bearings Stage 1	25 Nm
Big end bearings Stage 2	60°
Oil pump to cylinder block	10 Nm
Sump bolts	—
Sump drain bolt	21 Nm
Flywheel/driveplate	160±16 Nm
Clutch pressure plate	25±3 Nm
Crankshaft pulley/damper centre bolt	340±17 Nm
Camshaft sprocket/gear	120±12 Nm
Camshaft carrier/cap	16 Nm
Camshaft/rocker cover	25±2 Nm
Inlet manifold to cylinder head	25±2 Nm
Exhaust manifold to cylinder head	25±2 Nm
Water pump	25±2 Nm
Injector/clamp	30 Nm
Injector pipe unions	22±2 Nm
Fuel/injection pump sprocket/gear	50±5 Nm
Fuel/injection pump mounting	25±2 Nm
Glow plugs	—
Engine coolant temperature (ECT) sensor	20 Nm
Chassis tightening torques
Front hub	70 Nm+50°
Rear hub	320 Nm
Steering track rod end	45 Nm
Brake disc to hub Front	17 Nm
Brake caliper to carrier Front	27 Nm
Brake caliper/carrier to hub Front	160 Nm
Brake disc to hub Rear	12 Nm
Brake caliper to carrier Rear	27 Nm
Brake caliper/carrier to hub Rear	57 Nm
Road wheels	86±8 Nm

Air conditioning

No. of AC service connectors	2
Air conditioning restrictor type	Expansion valve
Compressor clutch/magnetic coupling	Yes
Compressor variable displacement solenoid	No
Air conditioning refrigerant Type	R134a
Air conditioning refrigerant quantity grams	500
Air conditioning oil group	PAG
Air conditioning oil Type	Dens Oil 8
Air conditioning oil quantity cm³	130
Air conditioning oil viscosity ISO	46

Frequently asked questions

What is the injection sequence of the Alfa Romeo 166 2.4 JTD 20V?

The injection sequence for the Alfa Romeo 166 2.4 JTD 20V (2003–2008) is 1-2-4-5-3.

How much oil does the Alfa Romeo 166 2.4 JTD 20V take?

The Alfa Romeo 166 2.4 JTD 20V (2003–2008) takes 5.0 litres of engine oil with the filter. See the reference table for the complete engine oil entries and their conditions.

What are the valve clearances for the Alfa Romeo 166 2.4 JTD 20V?

Valve clearances on the Alfa Romeo 166 2.4 JTD 20V (2003–2008) are hydraulic — they self-adjust, so no manual clearance figure applies.

What is the cylinder head torque for the Alfa Romeo 166 2.4 JTD 20V?

The cylinder head bolts on the Alfa Romeo 166 2.4 JTD 20V (2003–2008) are tightened in 4 stages: 65 Nm, then 90°, then 90°, then a final 90°.

What is the minimum brake disc thickness for the Alfa Romeo 166 2.4 JTD 20V?

Brake discs on the Alfa Romeo 166 2.4 JTD 20V (2003–2008) are replaced at a minimum thickness of 26 mm (ventilated) front and 9 mm rear.

What battery does the Alfa Romeo 166 2.4 JTD 20V use?

The Alfa Romeo 166 2.4 JTD 20V (2003–2008) uses a 12 V, 100 Ah battery.