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Alfa Romeo 159

1. fifth gear meshing sixth gear meshing DESCRIPTION Motion reaches the gearbox through the primary shaft and via the fixed driven gear is transferred to the driven gear fitted on the lower secondary shaft The synchroniser fifth and sixth gear transfers motion to the fixed transmission gear also integral with the differential crown The same synchroniser is operated in the opposite direction to mesh sixth gear Traccia Didattica Alfa 159 en ridotta 202 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A GEARBOX TRACCIA DIDATTICA ALFA 159 ae After Sales Training Reverse TT Re II po TT7 7 GY DESCRIPTION Motion reaches the gearbox via the primary shaft to the first gear fitted on the lower secondary shaft This gear is an idle gear because it transfers motion to the reverse gear fitted on the upper secondary shaft with which it meshes At the same time this passage reverses motion The reverse synchroniser makes the gear integral with the upper secondary shaft and transfers motion to the dif
2. ari 4 ERRO I 47 leg ee E 49 Pistons and CMA Ing OS ie fcc ater casio em toe bed iaia E a 50 b EU EE E EE E 51 Eee 51 TAPIA BE 59 RE gc EE TET UU UM 60 LELE eee Re T I A RA 60 ITU FA En De 63 E gl eege EE 64 SE elle Le er E 65 Continuous cam variable iming Syste DEEN 65 OGG Sy un EE 68 LUDE C ANOM SV E 70 BION UE EE 72 Le ui E E 73 ew ee E DEE TT SEENEN 93 Pd cU 110 Exhaust diagrami cold part dE 111 o Boe MED Nc E Eolo 02 EE 111 STA opara no EE 113 ACAO OES ES COC ON EEN 113 SSE Le AM e EE 114 SV SSN Sela e EE 114 e e E conio MR E m THE 114 Combustion control lambda EE EE 115 sinere des remain 116 Acceleration mixture enrichment Control NEEN santa ska estas assit isse ENNER 117 Accelerator TEE ERT EE 118 LEN de ONEA 119 Maximum engine speed control eebe eebe EE ppepaesagebaaai bibi riad RED A ar 120 gu foie ex COMTO ec 121 Climate attente 122 Cylinder positio ACKNOWIEC Mentre 122 Optimal injection me for ere Allee iisiceccsiivtsntinacincirshevivinndecasiedecensisedncdsancendiudnettaiauissasiednccnsielacinddeatdindd eisesnestavednadldutss nleuiedeiandieesiedens 123 neenon T I TM 125 ABS ies e B Keen tieio RN IE T T TT DOTT 126 geld on ee lic gic 6 un E EE 126 3 1 5 Engine maintenance special EE eege eege 128 2004 Fiat Auto S p A All righ
3. B 4 IN JCRANKNGENABLEFROMNCA Asin B 5 IN 9JJTRRKEYON mtconected B 6 LN 9 DjJSTAM STO d B 7 AJSTAH STO2 O B 8 OUT _ 60 to starter motor pee gu EELER o ooo a IN BRAKE SWITCH TNO 5 IN TRRCRANK 1 notconnected 6 IN TRRCRANK2 notconnected O c 8 OUT NA gt gt II O1 AGNI wg O1 OH Traccia Didattica Alfa 159 en ridotta doc 265 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM soi illa ba After Sales Training NTR pinout PN FUNCTION 8 pin connector p n AMP C 174955 E NC TEG inserted position output 12V TEG inserted CANB 0 O PAV pinout ERE 15 start stop symbol light Light ground Ignition cranking control protected power Positive signal AVV from ignition cranking to NBS Ignition cranking control protected power Positive signal AVV from ignition cranking to NBS 7 Negative signal for ignition cranking control ring LEDs Not connected Traccia Didattica Alfa 159 en ridotta doc 266 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 9 3 ON BOARD INSTRUMENTS Three versions of the panel are available gt gt gt HIGH MEDIUM BASIC
4. 31 PVE AS SV SIBI RE 312 EOLICO cc ETT 313 lege et ut 314 Ee GE el EE 317 Sei i 317 2004 Fiat Auto S p A All rights reserved Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training 1 BRIEFING 1 1 GENERAL TECHNICAL DATA 1 1 1 Presentation Alfa Romeo 159 is the first of a new generation of Alfa Romeo cars Stemming from the long consolidated experience of Alfa Romeo in the top of the range sports car and appealing coupe range the Alfa Romeo 159 project implements innovative engineering methods to maximise the skills of an international team and uncompromisingly combine performance and objectives until before deemed difficultly compatible maximum driving pleasure high performance distinctive style with top safety comfort and robustness This all led to the creation of a new bodyshell with unprecedented suspensions and a new generation of engines and transmissions The Alfa 159 underwent a very demanding reliability test cycle eighty five cars clocked a total of 4 250 million kilometres on all types of road and in all weather conditions for timely analysis and solution of all anomalies arising during development To increase driving pleasure and safety to absolute levels the Alfa 159 engineers developed a sophisticated four wheel drive system some versions only which enhances the car s already superlative dynamic performance and increases safety es
5. Voltage to pins A 42 and A 44 Traccia Didattica Alfa 159 en ridotta 160 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Idling speed control The ECU process the signals from the various sensors and adjusts the amount of injected fuel and gt controls the pressure regulator gt adapts injector injection times CONTROLLER Loaic OUTPUT PARAMETERS ELECTRICAL QUANTITY INPUT PARAMETERS ELECTRICAL QUANTITY Engine speed sensor Pump pressure regulator i m Control voltage between Frequency on pins A12 A27 EDC 16C39 pins A 49 and A 19 Engine coolant temperature l Injectors sensor The ECU controls the amount of gt Voltage to pins Resistance between pins A injected fuel according to the signals A 16 A 47 A 2 A 31 41 and A 58 from the sensors and the mapped A 1 A 46 A 17 A 33 values A 18 A 48 5 cylinder controls the pressure regulator Speedometer signal adapts injector injection times Signal from ECU ABS to pins the ECU takes battery voltage into B 61 and B 62 account within certain thresholds Battery voltage Power supply voltage by Fuel cut off SCH W d The ECU implements the following procedures when the accelerator pedal is released gt it stops supplying the injectors and partially resumes supply before reaching idling speed gt contro
6. iii 243 CRC RA 243 EE 244 CROCI ORRORI RISE IO 24 EB d FS Ty TE 24 9 1 0 Networks and SHANE aida ARR d 24 ONKONU AN E75 m PEEE S 24 E E QU TT T E 246 9 1 11 Mini F L Ore N C E architecture dagranm essen enn nnn n nnn nsns assu sassa asa a asas assa senses sss assa saga sisi sanas nass assa sas rnrn aa sna 249 91 12 DAO SUC AUC CC LS iaia ne 25 Silea 253 SITR EA RE EE KE MP 255 2004 Fiat Auto S p A All rights reserved Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A After Sales Training CONTENTS ALFA 159 TRAINING MATERIAL Rc NI P T E EE E ee E RE ege Eege e E 9 2 5 Code system programming and component management 9 2 6 Procedures Tor replacing componens urina 927 NTR Ee ee Ee lee 9 ON BOARD INSTRUMENTS Rial 9 3 1 HIGH and MEDIUM instrument panels ient tap tnu nha aa tea v a e X EUER REY ari ROSAS e EXITIUM TP HO M RTT ae dc ec eee ss ses dee eee AES 933 Notons on he Serice ee EE 04 COMPUTERISED SY d NEE v ee E X m cog n Ga Mo eoo alii 05 TYRE PRESSURE DETECTION SYSTEM alri SV ana CIO FREE OA CROLLI PEER
7. Frizion 9 2 2 Structure The system consists of the following parts gt TEG Entry and Go remote The TEG is a device that integrates the door and boot lock remote control and transponder for Code functions Up to eight enabled TEGs can be programmed gt NTR TEG reader node Task of the NTR node is to reach the transponder codes housed in the TEGs and to interface with the NBC The NTR is located on the instrument panel gt NBS steering lock node The NBS locks and releases the steering wheel whenever a valid TEG is inserted in the NTR It is fastened to the steering wheel column gt PAV ignition button The PAV is used to start the engine It is located on the dashboard near the NTR Traccia Didattica Alfa 159 en ridotta doc 256 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM SRO dr DUET After Sales Training 9 2 3 Operative procedures Accessing the vehicle The TEG is the only control device A radio frequency signal is transmitted whenever a TEG button is pressed The signal is picked up by the TEG reader NTR The NTR interprets the signal and sends commands out to the various vehicle access system devices The commands are sent to the various vehicle access functions door locking system alarm blinker ceiling lights TEG Command mapping The following table summarises the actions which occur after a TEG button is pressed Key Type of
8. 8 1 4 Angle and vehicle trim inspections The following procedure is used to check correctness of vehicle geometric trim angles Weigh the car the vehicle must be in Std 0 configuration i e with engine liquids at specified level and approximately 6 litres of fuel in the tank Measure and adjust tyre pressure adjust the pressure according to tyre type as shown in the following table Measure vehicle trim as shown on the next page measure the four distances from the ground A B C D and calculate the difference between B A front suspension and D C rear suspension The resulting values must be equal to that shown in the following table for the different vehicle versions Traccia Didattica Alfa 159 en ridotta 238 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Front suspension trim measuring points Rear suspension trim measuring points HEIGHT FROM THE GROUND with a tolerance of 5mm FRONT B A Std 0 Std A ooo rTc lt wu w _ lN l llE lll l lfoz o lLLEKE REAR D C Std 0 Std A 10 8 1 5 Geometrical trim adjustment Front suspension The front suspension wheel toe in can be adjusted by means of the nut on the steering linkage Wheel camber cannot be adjusted Traccia Didattica Alfa 159 en ridotta 239 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S
9. Oil Life is a software only function No specific sensor is used This strategy informs the driver that engine oil must be replaced The kilometrage threshold stored in the ECU is 50 000 kilometres This function can vary according to use and above all according to DPF regeneration procedures During regeneration post injections occur during piston downstroke In this way the injected fuel reaches the cylinder walls washing the liner and consequently diluting lubricant Oil dilution reduces its lubricating power according to the number of regenerations The ECU uses software counters to count the distance driven and the number of regenerations The starting threshold of new oil is set to 50 000 kilometres for distance and 100 for number of regenerations The oil change warning light will come on when the first of the two counters reaches zero Care is required when replacing or re flashing the ECU Oil must be replaced in such cases otherwise the new ECU counters starting from zero will not be able to provide the necessary indications for operating the warning light The counter parameters must be reset when the oil is changed 3 2 3 Electrical features of sensor THE FOLLOWING FEATURES ARE PROVIDED BY THE WAY OF EXAMPLE Tachometer sensor electrical features TTI o D x Traccia Didattica Alfa 159 en ridotta 174 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Tr
10. Spline support Main plate Rivet Friction lining support sheet Rivet Friction lining E E Some technical specifications are Nominal load 5750 N Minimum load 70 N Lift off 1 05 mm Drive torque 0 3 Nm VV NON Traccia Didattica Alfa 159 en ridotta 196 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training 4 5 CLUTCH RELEASE Clutch mechanism Pulse damper Clutch release coaxial hydraulic actuator Line between pump and actuator Clutch pump Reserve oil tank SAS PN CHARACTERISTICS The hydraulic clutch release system fits an actuator consisting of a annular cylinder fitted in the clutch bell coaxially with respect to the gearbox primary shaft and integrated with the thrust bearing The releasing action is performed directly on the thrust bearing spring without the interposed linkages of the traditional systems The application of this system maintains performance constant during the working life of the clutch and contributes to reduction noise and vibrations transmitted by the pedal CONSTRUCTION The two main components of the system are the clutch release pump and the hydraulic actuator cylinder for generating the oil flow needed to release the clutch and for actuating clutch release respectively Annular cylinder fitted on M32 transmission clutch bell Traccia Didattica Alfa 159 en ridotta 197 318 2004 Fiat Auto S p
11. 185 S e Og oe E EE 185 42 ATENO le 18 122 ee DA E nE E E eit E T E EO NER T EE T EEN A E TE 189 D Eeer E lt 189 CO ENORMI 189 4 3 2 SAT Self Adjusting Technology plate wear take up system cscccccececcessscsensuseeceseececeesessaaaaauaessseeeeescesessssaaaaaaeneasaseeeeesessesssaaaansnes 189 4 33 Driven eio 191 29 BE da iae RIJG eee 192 4A T Dua mass VN 19 E EE EE 194 4 gt CLiFEeHRELE SE Rail 197 A AA ETA SAM RTE liana e Ee te EE e Re ee e EE E an Een RT Ee e EE eee RTE Third and fourth gear RUE RR S oem Rea MEN ee DUE NIMM EM eee o A Cc M M E A T Vds e X s Piselli Besse n EIE TIT o To EE EE Traccia Didattica Alfa 159 en ridotta 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A CONTENTS ALFA 159 TRAINING MATERIAL After Sales Training Bee Te RR ner er eer nC eer cen tnt eect Tee ai 204 YY IIMS tree eae per te rss eles estes E TT 20 Manni 206 Gessate 206 EE Ee 20 AGI 20 NEI RR RR IE OE AE 208 TAPO PMI rai 208 6 BRAKING SYSTEM cca 210 OlFEXURES ladino 210 6 1 1 Braking Ree 210 Pea DO HE 210 Br
12. AT STACCO lenta COCO AOLO E e eT tree etree neen eer rere tert tr eer rer crete ert rete mT erate rer er a iE Ea terete err SO CAR POETA OE EZRA M o Ee E e 9 6 PARKING ASSISTANCE E 9 6 1 Notions for calculating distance from obestacles EEN CEI CZ IAA 9 6 9 EICCIONIC EE GO dela alice leone 9 6 4 Ulirasound Sensors iaia EAE AARE RERA Aa RESER soe CCL A 9 6 6 Switching ihe System on and e EE DG COV Eo E T EEA CRE ORRORE EE Eege 900 ECJ PIDOU lana SO Eege EEN Y ES Ee ee EE EE IO SOA 9 7 4 Front seat belt pretensioners EE 9 7 5 Fon SCal ee Ee e 9 7 6 Airbag system warning lights ii 9 7 7 Airbag System tailur warning Mg m 9 7 8 Passenger airbag deactivated warning light i STIRO 28 9 8 FRONT LIGHT CLUSTER XENON GAS DISCHARGE VERSION nenne nennen nnne nnns earn nnns nnn ses nri se nnns nnns nean nnns CERCO REI SM 9 8 3 Wiring diagram and optical cluster connector pinouUt is esee nennen nhanh nnne nha ihnen sins saa sn snis ss sa aan nr sena aa sinn nnns nna 9 8 4 Automatic headlight eeler oss ocuUs M PCL cR Noo OIA S p EL P CIO m CORI REA no sg esti eosin ets ence eee sees ese ecien hed 10 CLIMATECONTROLSYSTEM E 10 1 CLIMATE CONTROL SY
13. MODE MODE MODE TRIP TRIP up TRIP down and km One negative contrast alohanumeric LCD VVVVVVV Y Speedometer rev counter and auxiliary instruments Like the HIGH and MEDIUM panel versions Buzzer BASIC version The buzzer can provide signals of different intensity for the following functions Doors open while car is travelling Handbrake applied while car is travelling Speed limit exceeded Acoustic feedback for functions activated by means of buttons Acoustic feedback for stored seat and mirror positions Feedback for warnings alarms shown on display VVVWVWVWv Light sensor BASIC version The sensor positioned on the speedometer dial measures environmental light conditions and sends this information day and night to the body computer which compares this information with the taillight state and selects the appropriate lighting configuration inside the vehicle day night mode The instrument performs as follows after receiving the data gt In day mode the display and dials are fully lit and graphics are off gt In night mode the display graphics and dials can be set to eight levels The setting is transmitted to the components which consequently adjust their brightness climate control system display radio display Traccia Didattica Alfa 159 en ridotta doc 269 319 2004 Fiat Auto S p A Tutti i diritti sono riservati EE ALFA 159 TRAINING MATERIAL deo
14. Traccia Didattica Alfa 159 en ridotta doc 254 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM dii a ilaria After Sales Training Vehicle accessibility During logistic mode activation accessibility to the vehicle must always be guaranteed The following functions are deactivated gt Centralised locking system gt Anti theft protection dead lock alarm etc except for the Code system gt Remote controls TEG gt Electrical window winders it must be possible to operate the driver s window at least while travelling Entertainment All entertainment components are deactivated including gt Radio gt Navigator gt DSP Comfort The following functions are deactivated Power sockets cigar lighters Clock Heater climate control system Supplementary heater Power sunroof Heated seats VVVVVV Visibility The following functions are deactivated gt Ceiling lights Boot bonnet lights Windscreen rear window defroster Puddle lights Parking lights Fog lights Dipped beam headlights when car is not travelling Main beam headlights when car is not travelling VVVVVVV System All events generating CAN wake up at key off are deactivated except for those which are necessary to ensure driveability and safety such as for example gt The door locking unloading command door boot locking unlocking from the lock which forwarded the command is possible
15. 2 MED 7 6 1 Control voltage to pin A 18 The ECU controls the solenoid valve in alternating sequences Engine speed sensor to wash out the activated Injectors carbon filter Voltage to pins A 50 A 49 A 47 A 48 A 32 A 33 A 35 A 34 Frequency on pins A55 and A40 Pre cat lambda sensors Voltage signal on pins K 77 and K 79 Post cat lambda sensors Voltage signal on pins K 75 and K 53 Motorised throttle Voltage to pins A 15 and A 30 Maximum engine speed control The ECU according to the engine speed gt over 6800 rpm cuts off supply to the injectors the maximum limit of 7000 rom can be held for no longer than 5 seconds gt resumes injector control under 6600 rpm Traccia Didattica Alfa 159 en ridotta 120 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Engine speed sensor Injectors Voltage to pins Frequency on pins A55 MED 7 6 1 A 50 A 49 A 47 A 48 and A40 A 32 A 33 A 35 A 34 The ECU according to engine speed cuts off supply to Ignition coils solenoid valves and reduces Voltage disconnected from advance pins A 46 A 31 A 01 A 16 Motorised throttle Voltage to pins A 15 and A 30 Fuel pum
16. 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training ABS ASR ECU connection The interface between the engine control ECU and the ABS ASR ECU via the CAN line between the two ECUs The engine ECU if the wheels slip indicated by the ABS ASR ECU to reduce drive torque by gt reducing ignition advance gt reducing throttle opening angle gt reducing injection time INPUT PARAMETERS CONTROLLER ELECTRICAL QUANTITY OUTPUT PARAMETERS ELECTRICAL QUANTITY Motorised throttle Voltage to pins A 15 and A 30 LOGIC CAN line signal on pins K 85 and K 63 e MED 7 6 1 Brake node signal nl Ignition coils Voltage disconnect from The ECU receives the pins A 46 A 31 intervention request to limit A 01 A 16 torque by the ABS ECU and modifies the torque output by the Injectors engine Voltage to pins A 50 A 49 A 47 A 48 A 32 A 33 A 35 A 34 Variable timing management The ECU according to the following information engine temperature engine speed engine oil accelerator pedal position lambda sensor signals VV ON ON V Traccia Didattica Alfa 159 en ridotta 126 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training independently manages two variable timing systems continuously with timing angles in the range from 0 to 50
17. 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The connection to the engine ECU is CONNECTION TO ECU CONNECTOR DRAWING connector pin 1 to ECU pin 20 Pressure side A pn connector pin 2 to power wire TECHNICAL SPECIFICATIONS All data refer to a temperature of 23 C and control voltage of 14 V 0 02 V Pressure range from 0 4 to 12 MPa Return pressure 0 4 MPa Operating principle proportioning valve closed without current Working pressure 11 MPa at 600 rpm Maximum flow 100 I h 50 um fine mesh input filter LIFESPAN OF COMPONENT The specific tolerances of the component are designed to last for 10 years or 150 000 km REMOVAL REFITTING Make sure that the housing is intact and clean before fitting the valve Lubricate the o rings with clean non silicon based engine oil Insert the valve to the end of the collar The fasten the M6 aluminium screws tightening torque of 6 1 Nm Replace the o ring and the filter when refitting the valve ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS OF Solenoid valve ACTUATOR Working current 1 8 A COMMAND TYPE PWM signal maximum voltage 12V frequency 500 Hz The ECU must be powered to pick up the output signal An osciloscope or Examiner with SAM Examiner Smart MEASURING METHOD module is needed to view the signal considering its type Set Examiner as a voltmeter and acquire the signal for approxi
18. Fiat Auto S p A TECHNICAL DATA ALFA 159 TRAINING MATERIAL After Sales Training 2 14 2 Greases Recommended product specifications 1 9 19S 2 2 JTS 1 9 M jet 8V 1 1 9M jetl6V 19M jetl6V 2 4 24M jet20V 24M jet20V Front n Joint Tutela MRM Zero Tutela MRM Zero Tutela MRM Zero Tutela MRM Tutela MRM Zero differential side Zero jug Tutela STAR 500 Tutela STAR 500 Tutela STAR 500 Tutela STAR 500 Tutela STAR 500 Wheel hubs steering linkage various parts Lubrication and protection of underbody parts Lubrication of brake circuit components Iu cud 2 14 3 Lubricant capacity 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Engine oil scheduled replacement sump 5 4 5 4 4 6 4 6 6 4 and filter litres Gearbox front differential oil kg 2 3 2 3 2 3 2 3 2 8 2 14 4 Grease amounts 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V CV joint on wheel side g differential side g Traccia Didattica Alfa 159 en ridotta 37 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A TECHNICAL DATA TRAINING MATERIAL After Sales Training 2 15 VEHICLE FEATURES 2 15 1 Dimensions The following figure shows the main dimensions of the vehicle expressed in mm Thiel 2261 LEIET Z2Z 1 The values in brackets refer to versions fitting 215 55 R16 tyres 2 15 2 Performance st TS 2 2 JTS
19. O ring 0 Temperature sensor presi e sen ae Ee Traccia Didattica Alfa 159 en ridotta 103 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training POSITION The flow meter is arranged along with intake air conduit upstream of the throttle body and the intake plenum 1 Air mass meter 2 Throttle body ELECTRICAL SPECIFICATIONS Air flow characteristic Graphical Ual V Air mass flow kah Mon Traccia Didattica Alfa 159 en ridotta 104 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Temperature characteristic min Resistance Resistance kt 40 20 20 40 e a 100 12 140 Temperature C SENSOR FEATURES 14V power OUTPUT SIGNAL TYPE Refer to the air flow voltage characteristic and resistance to the temperature characteristic Temperature sensor Set multimeter to resistance mode ohmmeter MEASURING METHOD Ground sensor Arrange multimeter for measuring voltage with sensor powered by ECU Pre cat exhaust gas sensor FEATURES The linear wide band sensor with integrated heater works at A 0 65 in air The sensor must be used in connection with an ECU Two sensors with 6 pin electrical connectors are provided because the exhaust system is split Traccia Didattica Alfa 159 en ridotta 105 318 2004 Fiat Auto S p A All r
20. Specify the number required Note that the electronic key reader NTR was designed to store no more than eight electronic keys TEGs Orders for more than eight electronic keys TEGs summing up the newly ordered keys and those already in the customer s hands will be rejected Check the form that shows this situation when ordering new electronic keys TEGs Traccia Didattica Alfa 159 en ridotta doc 261 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM i i ic dora a rg After Sales Training Programming TEGs in the NTR memory After receiving the new electronic keys TEGs from Fiat Ricambi make sure you have all the customer s old electronic keys TEGs Connect the instrument to the car s diagnostic socket and proceed as follows Connect the instrument to the car s diagnostic socket Set the electronic key reader NTR to Programming mode Insert all the electronic keys TEGs in sequence in the electronic key reader NTR Shut down Programming mode All electronic keys TEGs not presented during this step will not be deleted and cannot be stored again at a later time 5 Check that the system is working properly before delivery to the customer by using all the electronic keys TEGs to start the engine and lock unlock the doors with the remote control E NOTE Only use spare parts to deal with functional anomalies Never exchange remote control electronics
21. air supply accelerator pedal engine cooling exhaust with catalytic converters controlled by four lambda sensors fuel vapour recirculation VVVVVV Traccia Didattica Alfa 159 en ridotta 111 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The JTS engine ECU manages the high pressure fuel pump by controlling a pressure regulator and the respective pressure sensor Also the throttle is electronically controlled by the ECU opening of the throttle is controlled according to a specific engine ECU logic called torque control in this way in addition to eliminating the mechanical connection between the accelerator pedal and the throttle the ECU can very accurately monitor the real amount of fuel needed in each instant of operation manage the power pressure most suitable to for each cycle and define the fuel injection start point to introduce the perfect amount of fuel into the combustion chamber in the best instant The ECU also controls the variable timing as described more in detail below Thanks to a specific sensor the ECU also detects drops of vacuum in the brake booster and intervenes by appropriately reducing the load to restore more efficient braking The main functional characteristics of the system are gt self learning system self adaptation Alfa Romeo Code Immobilizer recognition cold start up control combustion control lam
22. 1 9 ewirl Type a HDEV 1 1HF Low Pressure Fuel Purnp Fuel high pressure three cylinder pump Fuel high pressure injectors Connection to fuel rail Fuel pressure regulator valve Fuel pressure sensor High pressure pipe from pump to fuel rail Low pressure pipe from fuel rail to pump Tank with low pressure pump 9 Xo we mI e FEATURES The fuel injection system consists mainly of a fuel rail to which the injectors are connected With this system the fuel can be directly injected into the cylinders via high pressure injectors The intake air flow is freely controlled by the electronic throttle control A hot film air flow meter is used to measure air accurately The air fuel mixture is monitored directly by the universal lambda sensors placed in the exhaust gas flow before and after the catalytic converter They are guarantee that A is equal to 1 and that the engine is running on a lean mixture They are also responsible for precise control of catalytic converter regeneration Traccia Didattica Alfa 159 en ridotta 78 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Input output diagram Injectors Fuel pump A C compressor Engine coolant fan Cruise control 4 digital inputs Post cat lambda sensor A C gas pressure linear sensor Brake pedal switch Speedometer signal from CAN 10 Pre cat lambda sensor 11 Coolant temperature sensor 1
23. 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A GEARBOX TRACCIA DIDATTICA ALFA 159 After Sales Training ae ELA T e SE 5 2 6 Differential 5 2 7 Axle shafts ai Ze r2 T D w K Kai T Pie S Ja SNE Sv ALT IVA x V CH da wy V ALI te e E l la by tok he D RIP SZ A A E FUNCTION The axle shaft subassembly transmits the torque output by the engine to the drive wheels Obviously live axles are only needed to transmit motion to the drive wheels normally the front axle Similarly four wheel drives are also fitted with a rear live axle CONSTRUCTION The main components of the axle are the axle shafts an intermediate shaft where fitted CV joints which allow a certain degree of oscillation of the wheels with respect to the body while transmitting power and a balancing weight which dampers the oscillations induced by drive axle rotation CHARACTERISTICS The axle components and specifically the axle shafts are normally subjected to twisting or twisting and bending as well as sudden changes of force For this reason high mechanical strength steel is used for these parts such as XC45 for tulip version or 42CrMo4 for the drive axles to withstand the stress induced by operation What is more the entity of transmitted torque subjects the drive shafts to considerable angular distortion due to twisting force The
24. C 40 60 80 100 120 140 SENSOR FEATURES NTC thermistor sensor Variable resistance from a maximum of 45kOhm to 40 C 60 TPUT SIGNAL TYPE EES Ohm to 150 C MEASURING METHOD Set multimeter to resistance mode ohmmeter Air mass meter SENSOR FEATURES Double sensor consisting of NTC and hot film sensitive element OUTPUT SIGNAL TYPE See tables below Temperature sensor Set multimeter to resistance mode ohmmeter MEASURING METHOD Ground sensor Arrange multimeter for measuring voltage with sensor powered by ECU Traccia Didattica Alfa 159 en ridotta 177 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training CARATTERISTICA SENSORE CARATTERISTICA SENSORE TEMPERATURA PORTATA ARIA Resistenza Kf Temperatura C min nom max A0 35 40 39 260 43 760 30 20 770 22 960 25 310 m Ua Kg h V 8 12899 10 13647 io 7943 8 609 9 307 1 5271 o sm 5499 5892 19026 eo 2 4150 10 3 0384 440 1095 1156 1238 0 779 0 835 470 0 416 0 452 A T 20 C 41 C Vbati 14V 40 1V 0 285 precisione 3 80 oo91 0 102 om4 Fuel pressure sensor 15 a5 L Tensione In uscita V o f O Li AJ x da Lo LA O 509 1000 1500 Pressione combustibile ban SENSOR FEATURES Piezoelectric pressure sensor Variable voltage according to measured pressure Nominal specifications OU
25. COMMAND TYPE Control with PWM signal maximum voltage 12V carrier 360Hz MEASURING METHOD Oscilloscope or analogue tool Examiner with SMA 3 2 4 Injector Ri FARE sy ATE SIP Pi SON Nes I Thyp ass d n Thold Tboost ET ELECTRICAL SPECIFICATIONS OF Typical current levels ACTUATOR Average peak current bypass Ib 20A Peak current ripple bypass delta Ib 3A Average hold current Ih 2 13A Hold current ripple bypass delta Ih 4 Typical actuating times Energizing Time ET 2 160ms 2ms Boost time Tboost 82ms Peak time bypass Tbypass 80ms 350ms Peak hold current decay time Toffl 11ms Average hold time Thold ET Tboost Tbypass Toff1 Current decay time from hold Toff2 approximately 45ms COMMAND TYPE Maximum voltage 12V MEASURING METHOD Oscilloscope or analogue tool Examiner with SMA Traccia Didattica Alfa 159 en ridotta 180 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training VGT solenoid valve wo M 40 50 B To an Di 100 r Gen Dury CYCLE Ix Solenoid valve ELECTRICAL SPECIFICATIONS OF Working range 13 16V ACTUATOR Winding resistance 7 8 0 3 Ohm 20 C PWM carrier frequency 100 150 Hz COMMAND TYPE Solenoid valve PWM modulated square wave voltage MEASURING METHOD Oscilloscope or analogue tool Examiner with SMA Fuel pump sE ss Tse sz eee zz ee Traccia Didattica A
26. ECU ground connection 14 Bulb ground connection 9 8 4 Automatic headlight position corrector Due to the high brightness output by the bulb the vehicle is fitted with an automatic headlight trim corrector to prevent dazzling oncoming vehicle drivers when the trim changes The device works in the following conditions gt static for load distribution dynamic for acceleration and deceleration Traccia Didattica Alfa 159 en ridotta doc 293 319 2004 Fiat Auto S p A Tutti i diritti sono riservati EE ALFA 159 TRAINING MATERIAL deo SYSTEM After Sales Training The automatic corrector also improves driving comfort because the illuminated area is stabilised and the driver s eye does not need to constantly adapt to changes of lighting The device consists of gt astepper actuator for each headlight gt two load sensors connected to the front and rear suspensions on the right hand side Correction function Correction is made by means of the load sensor signal which connected to the suspensions provides an indication of vehicle load The ECU is activated at key on and resets the headlights to the exact position calculated according to vehicle load after moving them to end of stroke position and back The load sensor signals are regularly acquired and appropriate mediated to readjust the position of the headlight if necessary e g fuel consumption while travelling This readjustment is not immediate It is fi
27. FIAT AUTO SPA D 2 D 3 FIAT E ZFA F 1 F 2 1380 F 3 2280 G I 27 12 2004 J M J 1 AUTOVETTURA PER TRASPORTO DI PERSONE USO PROPRIO J 2 AF VEICOLO MULTIUSO K OEZFAO9ESTO3 E3 2001 116 0151 E32 i N 2 N 3 NA N 5 0 1 900 0 2 n P 2 051 00 P 3 GASOL Q 8 1 4 S 2 d 79 Er 3000 V 1 v 2 V 3 V 5 IMPOSTA V 7 114 0 DIBOLLO V 9 2002 80 CE B Ewe VIRTUALE Motor vehicles including vans up to 3 5 tons EURO1 EURO2 EURO3 EURO4 registered after 1 1 1993 registered after 1 1 1997 registered after 1 1 2001 registered after 1 1 2006 91 441 EEC 94 12 EEC 98 69 EC 98 69 EC B 91 542 EEC 96 1 EC 99 96 EC 98 77 EC 93 59 EEC 96 44 EC 99 102 EC 99 102 EC B 96 69 EC 2001 100 EC A 2001 1 EC B 2002 80 EC A 2002 80 EC B Traccia Didattica Alfa 159 en ridotta 41 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training 3 ENGINE 3 1 1 9 AND 2 2 LITRE DIRECT INJECTION PETROL ENGINES 3 1 1 Features The 1 9 and 2 2 direct injection petrol engines are the first of a new generation of Alfa Romeo four cylinder petrol engines created to replace the current 2 0 JTS petrol family The main features of these powerful sophisticated multivalve engines are their light weight both the cylinder head and the crankcase are made of aluminium and their performance specific powe
28. It has a three wire interface power ground and 125KHz modulated signal The 125KHz signal must be appropriately amplified to ensure correct operation of the system in all working conditions environmental range power voltage range perturbed field The typical operative range is one metre Location of Ferrite in initiator Ferrite core Waiidemaudng Magnelc held Inr 9 5 7 Control unit The microprocessor control unit manages RF transmission and reception Control software is present in the ECU The ECU is provided with A Bus and diagnostic K line interface It must be provided with an auto location system capable of provided tyre pressure indications immediately at key on The ECU must ensure at least the following functions 1 Querying each sensor and providing information to the user in 10 to 15 seconds identifying each wheel 2 Managing tyre changes without need to reprogram the ECU externally 3 Self learning of wheel sensor identification codes at end of line 9 5 8 Operating details The tyre pressure ECU CPP acquires information on the state of the four tyres via radio frequency A sensor is queried at key on by being energised by the respective initiator One initiator is provided for each of the four wheels The CPP communicates on the A Bus serial line with the NBC The NBC transmits the following signals on the B Can line Traccia Didattica Alfa 159 en ridotta doc 279 319 2004 Fiat Auto S p A
29. Red graphics MEDIUM or BASIC panel versions or white graphics HIGH panel versions gt Right hand drive or left hand drive versions present different orientation of indicators direction of rotation of dials and fastening point on tunnel Auxiliary instrument panel for left hand drive petrol versions Auxiliary instrument panel for left hand drive diesel versions Traccia Didattica Alfa 159 en ridotta doc 268 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training The auxiliary instrument panel comprises three indicators according to the version including Fuel gauge with reserve warning light Coolant temperature indicator with overheating warning light Engine oil temperature indicator with overheating warning lights petrol versions only Turbo charger pressure indicator diesel version only YYYY 9 3 2 BASIC instrument panels Features of the BASIC on board panel Two analogue dials speedometer and rev counter in instrument body Three analogue indicators in the auxiliary instrument panel 31 warning lights 1 spare warning light position diesel versions 29 warning lights 3 spare warning light positions petrol versions One buzzer One light sensor for automatically adjusting instrument brightness day night mode Interface with 7 external buttons fitted on steering wheel stalks and left hand panel
30. Robotised transmission pump activation The following wake up events must always be present CAN interface key on Hazard lights VVVVV Deactivation before delivery to customer The logistic mode function must obviously be deactivated before the vehicle is delivered to the customer The NBC receives the deactivation command from Examiner In addition to quitting low consumption mode it sends the logistic mode deactivation command to the CAN lines All the involved ECUs when the command is received will restore their full functionality and send a confirmation message to the NBC The logistic mode function once it is deactivated cannot be reactivated Traccia Didattica Alfa 159 en ridotta doc 255 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A After Sales Training SYSTEM ALFA 159 TRAINING MATERIAL 9 2 TRW SMART KEY SYSTEM The smart key is an electronic system that replaces the traditional ignition switch and mechanical key It is used to gt remotely control locking and unlocking of doors and boot gt release the steering gt start the engine 9 2 1 Functions Functions of the Smart Key system include Accessing the vehicle by RF radio frequency recognition of the remote control TEG Starting the engine by Code recognition Power distribution aboard the vehicle 15 INT A 50 via the steering wheel lock node NBS Releasing and locking the steering wheel VVVV
31. connector pin 3 to ECU pin 24 side A power CONNECTOR DRAWING Sensore fase 2 Sensore press carburante REMOVAL REFITTING The sensor is fitted by being pressed into its housing Lubricate the seal with mineral oil It is fastened with a screw POSITION The timing sensors are positioned on the right hand side of the camshafts A a ae Re 1 Camshaft timing sensors Traccia Didattica Alfa 159 en ridotta 95 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training ELECTRICAL SPECIFICATIONS SENSOR FEATURES 5V power from the ECU Variable voltage signal in time maximum value and frequency according to pulse waveform square wave when sensor meets phonic wheel teeth Two long teeth are followed by two short teeth OUTPUT SIGNAL TYPE The ECU must be powered to pick up the output signal Examiner with SAM Examiner Smart module is needed MEASURING METHOD to view the signal considering its type Set Examiner as a voltmeter and acquire the signal for approximately 5 seconds High pressure fuel sensor FUNCTION To measure the fuel pressure in the rail by sending a feedback signal to the injection ECU to control injection pressure and duration FEATURES This is piezoelectric pressure sensor consists of a mixed metal and plastic body The metal part comprises a diaphragm pressure gauge a plastic part
32. degrees controls the two proportioning solenoid valves to ensure careful timing management and better control over emissions and engine output torque OPERATING CONDITIONS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY voltage on pin A 41 LOGIC ELECTRICAL QUANTITY Variable timing solenoid valves Voltage to pins A 19 MED 7 6 1 exhaust and A 04 intake Ignition coils Voltage disconnected from Timing sensor 2 voltage on pin A 56 Air flow meter pins A 46 A 31 A 01 A 16 Injectors Voltage to pins A 50 A 49 A 47 A 48 A 32 A 33 A 35 A 34 The ECU manages the variable timing solenoid valves to ensure maximum engine performance while containing emissions Variable timing is continuous and the systems can be controlled independently Voltage on pin A 12 Engine speed sensor Frequency on pins A55 and A40 Pre cat lambda sensors Voltage signal on pins K 77 and K 79 1 4 Post cat lambda sensors Voltage signal on pins K 75 and K 53 Potentiometer signal on throttle Voltage to pins A 25 and A 10 _ Traccia Didattica Alfa 159 en ridotta 127 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training 3 1 5 Engine maintenance special tools Engine assembly adapter Pin for blocking balancing countershaft chain tensioner USE EQUIVALENT FIAT TOOL Bushing for fitting crankshaft gaske
33. stroke 242 mm gt Continuous backrest adjustment with two sided joint gt Headrest adjustable on the Z axis by approximately 40 mm gt Semi parallel standard seat height adjustment system on driver s and passenger s side Traccia Didattica Alfa 159 en ridotta 310 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A 210 DA 4 e 51 4 ALFA 159 TRAINING MATERIAL After Sales Training gt Optional tilt function for both front seats gt Side bag installed inside seat upholstery gt Adjustable lumbar support Rear seats The standard rear seat is split 40 60 and the cushion can be tipped The rear seat cushions have optimal design to prevent anti submarining The rear seat foam is comfortable thanks to variable lift this parameter measures the capacity of the padding to give under the weight of the body in different areas of the seat cushion backrest sides of cushion and backrest 60 40 split seat Storage compartment built into armrest REAR SEAT FEATURES Number of seats 3 40 60 split backrest Height adjustable headrests Padded central armrest Central armrest with built in storage compartment VVVVV Three point seat belt for middle passenger integrated in backrest when this is tipped Three point Isofix fasteners two on cushion and on one backrest Traccia Didattica Alfa 159 en ridotta 311 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S
34. the x coordinate shows the distance in millimetres between the thrust plate and the clutch cover the y coordinate shows the load of the spring in KN 6 910 17 KN BEE BEE LVI e E N ATT TUE AY Te LL LL ty ee LL IT ee des W s MV The diaphragm spring with the clutch engaged pushes the thrust plate onto the friction plate with a force equal to approximately 7 KN When the control is released the resistance of the spring must be overcome for the first millimetre The load decreases progressively as the thrust plate is distanced The diagram shows the force characteristic of releasing the device the x coordinate shows the shift of the thrust bearing the y coordinate shows the force in KN needed to release the clutch vu LLL LLL LLL LL LL LILLLLLLLLL il m MM Note that the clutch requires a linear force of approximately 13 kg to move the thrust bearing for the first 2 mm Driven friction plate LENS E y E a ef wm nay Ss d E SW Dd I n o ee L A pu 3 ELI Ki w OS M cke A m fi ei P A LU d k ta E ac 27S Bh o DI Bag F d h Li d PANI lF pre i lt at Zen ei Pee E fof K 1 A d Zo l ali SE BON E LA sa Ta F F Fk ans IV A if i Es T j AA y A d F d Fi Ce Traccia Didattica Alfa 159 en ridotta 195 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training Friction plate diagram
35. 1 B CCAN vES BCAN ves NO YES Radio receiver node BCAN NO 7 NO i YES BCAN YES i O YES NO YES O NO i O YES NO YES NO YES NO YES O YES NO S K line B CAN S Climate control node B CAN B CAN Passenger trim node B CAN S B CAN S Steering wheel node BCAN NO NO O O O O S O S S S S S O N N N N YE YE YE YE YE N YE YE YE YE YE YE YE N YE Traccia Didattica Alfa 159 en ridotta doc 253 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM i i ic dora a rg After Sales Training 9 1 13 Logistic mode function The special power mode called logistic mode is needed to reduce current draw caused by unnecessary loads while cars are stored during the time elapsing from the end of the assembly line to delivery to customers and therefore preserve the battery charge Logistic mode must ensure the possibility of accessing and driving the car without compromising safety within an acceptable range of reduced comfort The function is activated after release from the plant and must be deactivated by the dealer before delivery to the end customer The basic requirements of logistic mode implementation are gt Considerable reduction of on board electrical electronic component performance and consumption during storage to preserve the battery charge and increase its life cycle T
36. 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Top speed km h 11 8 4 Acceleration S 2004 Fiat Auto S p A All rights reserved 38 318 Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A TECHNICAL DATA ALFA 159 TRAINING MATERIAL After Sales Training 2 15 3 Capacities 49 STS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Fuel tank litres Fuel reserve litres Engine cooling circuit and HVAC litres litres eng ft _ Brake circuit kg circuit kg 2 15 4 Consumptions fee 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Uban 122 130 80 Bi 392 Extra urban 6 6 7 3 4 7 4 8 5 4 Combined DI 394 59 60 G j 2 15 5 Emissions 19JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V CO2 g km 221 156 All powerplants respect Euro 4 emission limits 2 15 6 Tyres and inflation pressures bars 1 9 JTS version nflation L nator pressure nflation dit nflation e nflation Ge 215 55 R15 225 50 R17 2 2 JTS version inflation pressure inflation pressure inflation pressure inflation pressure 225 50 R17 235 45 R18 1 9 M jet 8V version em E Sr Sr EE nflation pressure een pressure nflation pressure nflation pressure 205 55 R16 Traccia Didattica Alfa 159 en ridotta 39 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A TECHNICAL DATA TRAINING MATERIAL After Sales Training 1 9 M je
37. 90 of the maximum torque The double variable timing means that use of a two way module suction system is no longer necessary Code location on engines The engine identification codes are positioned vertically on the cylinder block on the flat surface of the oil filter housing Old code New code 2 2 XHR Z22XHR 11247400 939A5000 1247400 1 9 XHR Z19XHR 11247500 939A6000 1247500 Traccia Didattica Alfa 159 en ridotta 46 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training o D e D Ka D pum LI Be Ei i Es I lt c 09 o ia D lt K iL st ql 2a lt tc LU C Z Z lt tc ep ate lt x LL J o Ke O O O vX ons SE ATVG VE x D x o do op o amp otocse cooocos OX OX d O O O GI oC oz UO DC OG e O O O aono o o o Oo o o ccecce E Rod anchoring bracket gearbox side to gearbox Eng Eng Eng Eng Eng Eng 1 2 3 4 5 6 7 3 1 2 Engine components Traccia Didattica Alfa 159 en ridotta Engine mounts Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training FUNCTION The engine mounts fasten the powerplant to the body load bearing structure They are dimensioned to support the weight of the powerplant and the loads deriving from reaction torque transmitted by the engine They also damper vibrations transmitted by the engine to the body and improve handli
38. A ALFA 159 TRAINING MATERIAL CONTROLLER LOGIC ELECTRICAL QUANTITY Fuel pump enable EDC 16C39 Voltage to pin B 91 Regardless of engine speed the ECU gt powers the auxiliary fuel pump at key on gt cuts off auxiliary pump power if the engine is not cranked up within a few seconds After Sales Training OUTPUT PARAMETERS INPUT PARAMETERS ELECTRICAL QUANTITY Key on Voltage to pin B 28 Cylinder position check The ECU recognises the firing cylinder and controls the injection sequence to the necessary cylinder during each engine revolution CONTROLLER OUTPUT PARAMETERS INPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Engine speed sensor Frequency to pins A 27 and A Injectors Voltage to pins A 16 A 47 A 2 A 31 A 1 A 46 A 17 A 33 A 18 A 48 5 cylinder EDC 16C39 12 The ECU recognises the firing cylinder and controls the injection sequence to the necessary cylinder during each engine revolution Frequency to pins A 20 and A 50 Traccia Didattica Alfa 159 en ridotta 169 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Injection pressure closed cycle control The ECU according to engine load controls the pressure regulator to obtain optimal line pressure INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTI
39. A All rights reserved Fiat Auto S p A GEARBOX ALFA 159 TRAINING MATERIAL wee After Sales Training 5 M32 GEARBOX 5 1 FEATURES The M32 mechanical gearbox was designed to be installed in front wheel drivelines with transversal engine arrangement The code M32 means that the gearbox was designed to withstand a maximum torque transmission of 320 Nm It is fitted in 1 9 16v and 2 2 16v direct petrol injection engine versions and in 1 9 Multijet 8v and 16v direct diesel injection engine versions d d NI S gee oe sui Xe I T n ud AM n M HL MEA OL cd bla ras EE EXE LL TE al la Tad Ng d i Lt ap ULES SE H Feo d E i ell T cm Zen KK ka Lig VEU M ef e ni e ADI LI n i m da I ien EE Ke SN EE ran Special features are gt fixed transmission cascading arrangement mechanical gearbox with six transmission ratios plus reverse all synchronised gears including reverse helical teeth gears three shafts one input two secondary upper and lower integrated differential in gearbox dry weight 46 7 kg hydraulic clutch actuation designed for coupling with dual mass flywheel body split into three parts for easily servicing VVVVVV VV Traccia Didattica
40. A auxiliary instrument panel is inserted in the middle of the dashboard Four auxiliary instrument panels are available vyv YYYY VV V Petrol instrument panel HIGH panel version Petrol instrument panel MEDIUM panel version Diesel instrument panel HIGH panel version Diesel instrument panel MEDIUM panel version 1 HIGH and MEDIUM instrument panels Two analogue dials speedometer and rev counter in instrument body Three analogue indicators in the auxiliary instrument panel 15 warning lights 5 spare warning light positions diesel versions or 13 warning lights 7 spare warning light positions petrol versions One buzzer One light sensor for automatically adjusting instrument brightness day night mode Interface with 7 external buttons fitted on steering wheel stalks and left hand panel MODE MODE MODE TRIP TRIP up TRIP down and km One monochromatic reconfigurable matrix LCD with two colour red amber area Additional heater versions with automatic robotised transmission only 160 180 L 140 120 Outfit specific HIGH and MEDIUM panel variants Petrol and Diesel differences concern rev counter scale Left hand drive and right hand drive differences concern speedometer scale in kilometres for left hand drive versions and in miles for right hand drive versions Automatic robotised transmission and manual transmission differences concern presenc
41. Auto S p A BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training Hydraulic Brake Assist This function assists panic braking In the event of panic braking detected by measuring the brake pedal application speed on the basis of the oil pressure signal inside the electro hydraulic unit the system automatically and rapidly increases braking pressure This function increases deceleration in the event of panic braking and reduces the braking system response time The system is classified as a brake assist system BAS in accordance with international classifications HCU i SENSORE DI PRESSIONE VDC signals The VDC system signals operation by flashing the instrument panel warning light GHz DC 50 and by showing a message on the instrument panel display on models where fitted Warning light functions S Val x 140 160 180 200 x 120 2204 100 PNE E E 1 VDC warning light 2 EBD parking brake warning light 3 ABS warning light The ABS ECU runs system self diagnostics In the event of a failure it transmits the concerned function code to the NQS on the serial line to gt deactivate the entire system gt deactivate part of the system Traccia Didattica Alfa 159 en ridotta doc 223 319 2004 Fiat Auto S p A Tutti i diritti sono riservati BRAKING SYSTEM ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training Check 4s While travelling ASH off f
42. Auto S p A Tutti i diritti sono riservati Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A BRAKING SYSTEM ALFA 159 TRAINING MATERIAL SE After Sales Training 6 1 4 EBD function The EBD is integrated in the ABS for optimising brake distribution with respect to a mechanical brake corrector The system measures the slip of the front and rear wheels and adjusts the brake force to ensure that the slip of the rear wheels is always lower than that of the front wheels Based on the real grip with the ground the system can automatically control rear pressure increases due to changes in vehicle load road gradient and friction material efficiency 6 2 VDC SYSTEM The VSC EBC430NG system is available for all engine versions It consists of a 12 valve electro hydraulic unit and integrated pressure sensor which a steering angle sensor built into the steering wheel stalk and the longitudinal lateral and yaw accelerator sensor built into a unit fitted on the tunnel near the centre of gravity of the car The main functions of the system in addition to the ABS functions are Hill Holder HBA VDC ASR MSR VVVV WV Electro hydraulic control unit sch Electro hydraulic control unit 2 Solenoid valves 12 Traccia Didattica Alfa 159 en ridotta 216 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training er ia ee e e ee e
43. EE 34 CETT Goo LACO O a E A ii 34 2 10 2 FIGNTSUSPCISION SLA CONI ai 3 2 10 3 Rear SUSpension Std ee ee EE 3 LENS eebe 36 Traccia Didattica Alfa 159 en ridotta 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A CONTENTS ALFA 159 TRAINING MATERIAL After Sales Training OE SUC Cal EEE e E EEA AI 36 PNPESPApIIuseme dq oE 36 2121 Gharacie nalit FRA 36 MR EE E 36 214 FLUIDS AND TE CR KE 36 E Ee EE 36 VAL ELICI TC E 3 CALCIO made 3 AGI ala 3 PA oa Am cae RTE 38 SEENEN 38 ZE 38 O OR RIA 39 EE 39 ZI 39 2 15 6 Tyres and inflation pressures bars eee iiis eun n oret aar nk oak epa bike neni SEEN AN TR ai 39 2 16 SERVICE SCHEDULE entrent tnter tren tn rr rr rtr ens rrr e rr rr rrt rn rnnt p rns LEALI EAEan nnan 40 S ENGINE m C 42 3 1 1 9 AND 2 2 LITRE DIRECT INJECTION PETROL ENGINES 42 lt del Q 4 eiae armi ele Ee DNI TU T T ET E 43 eM d T E 43 Rer ei Ce EN e Roa TTE E T i mr 43 e Rer ere ub ite CIO MMC PER TET 44 EROS speciicatons Compared alcalina 45 Ee Haten elen le 46 Codec e ie erede aahpereuaueieraenemmaee 46 SEENEN
44. Engine ECU pins Connector A Connector pins 44 2 Ground 37 3 Temperature signal output 42 4 Air flow rate signal output Traccia Didattica Alfa 159 en ridotta 140 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training OPERATION The flow of air normally invests the sensor kept at constant temperature from A to B The temperature drop caused by the air on the thermo resistors NTC1 NTC2 causes a variation of resistance which is proportional to the amount of measured air and imbalances the bridge Two thermo resistors are used to determine the direction of the air flow reversed flows or pulses are possible in certain conditions of the use of the engine The ECU measures the temperature used to integrated the air flow output by the air mass meter on ECU pin 1 lo 0 A m gt dE t L AD ai li 1 Ml I Also if the flow of air goes from B to A backflow the engine ECU is informed and can implement the appropriate strategies Analogue air mass meter Digital air mass meter Ac E g l 2 SaN T I i D j dA De 4 P The HFM6 air mass meter has a four pin connector while the analogue meter has a five pin connector The extra wire D is used for the 5V voltage provided by the ECU and used to ensure that the air flow rate signal is independent from battery voltage variations The operating principle of the active part of the flow me
45. Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training Throttle closing control while stopping a su OR 3 12y mmm qu The injection ECU immediately closes the throttle to intake to limit shaking when the engine is stopped The throttle is in all other conditions CONTROLLER OUTPUT PARAMETERS INPUT PARAMETERS ELECTRICAL QUANTITY Locic ELECTRICAL QUANTITY Key switch Throttle closing valve n EDC 16C39 e Stop position m TT PWM bos pin Immediate throttle closing and position check via feedback PWM signal sent by the sensor Variable swirl actuator control To improve volumetric filling and emission control the ECU manages an electrical actuator that controls the angular position of the throttles on the intake manifold according to engine temperature engine speed and engine load Traccia Didattica Alfa 159 en ridotta 173 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Coolant temperature sensor Throttle open actuator Voltage between pins EDC 16C39 Voltage signal from pin A 41 and A 58 A 45 Engine speed sensor Throttle opening actuator on Frequency to pins A 27 and intake manifold A 12 Air flow meter Voltage to pin A 42 and A 44 Oil Life function
46. I I Front Cat DPF Pressure Drop Instrument panel The MIL and DPF warning lights are present on the instrument panel The MIL is fitted in all outfits the DPF can be replaced by a message on the display according to the versions The warning light where fitted is activated for approximately 20 seconds to indicate that the trap is full MIL and DPF warning light or message management is governed by the engine ECU DPF warning light message management The DPF warning lights and or message informs the driver than a certain drive cycle speed gt 40 km h for at least 15 consecutive minutes as shown in the Owner s Handbook is required for the regeneration system to work The DPF will continue to accumulate particulate if the spontaneous regeneration conditions are not reached and the warning light and or message will stay on The DPF warning light is managed according to the number of interrupted regenerations this threshold can be calibrated by the ECU and will inform the driver that spontaneous regeneration is either needed or not possible In the latter case forced regeneration according to the respective procedure at a workshop is required No performance limiting recovery mode is envisaged The error codes are not stored in the ECU memory MIL management The MIL will light up when the 250 threshold is reached to indicate the need to have the trap regenerated at a workshop by applying the forced regeneration procedure In
47. L2 L3 in brief L1 is the basic version L2 is the medium version and L3 is the most prestigious version This classification is only used is this training material to avoid mentioning commercial names which may change in time L1 outfit gt Seven airbags Manual climate control system 16 rims Tyre kit deflated wheel and compressor L2 outfit The following features are added to the L1 outfit Eight speaker sound system with CD player Foglights gt Trip computer gt Ski compartment rear armrest gt Leather steering wheel and gearlever knob gt Reconfigurable display instrument panel gt Flocked upholstery gt Double compartment central console one of which insulated gt Painted dome mirrors gt Shiny tailpipe L3 outfit gt Two zone automatic climate control system gt AQS rain sensor gt Rear electric windows with pinch force safety function gt Cruise control Electrochromic interior rear view mirror Sound system controls on steering wheel gt Alfatex upholstery Aluminium interior accents 1 2 5 Engine versions The Alfa 159 fit state of the art petrol and diesel engines Three new JTS engines with continuous dual variable valve timing inlet and exhaust are available All the engines have outstanding features and meet Euro 4 standards exploiting the direct petrol injection in full a particular combustion system known as JTS Jet Thrust Stoichiometric Traccia Didatt
48. Provider over the telephone If the services are enabled the service provider will call the user back to answer the question The answer may be provided over the telephone and completed by sending a text message containing the relevant information Information received in text messages when containing geographic coordinates and telephone number can be stored and used directly by the user using Connect to make a telephone call and or start navigating towards the destination SOS button B The following functions can be activated manually to automatically call the service provider medical help subscription needed road rescue subscription needed personal number emergency number settings VVVV WV Operation of the SOS button gt The Assistance screen appears on the Connect display with the Medical help function highlighted gt The user can program the system so that if the default selection by pressing a button on the front panel is not changed within 25 seconds the Medical help call is automatically forwarded to the service provider gt The user can select Road rescue in this case a Road rescue call will be forwarded to the service provider or quit the Assistance page and cancel the call gt lf the user is not subscribed the only functions that can be activated are the emergency call function call to a personal number and access to the settings menu NAV button C This repeats the
49. S p A SYSTEM See After Sales Training 9 6 10 ECU pinout B C 8 channel configuration Connector A 1 Key on 15 6 Not conneeted ______ 8 Grou 9 Notconmnected ______ Connector B Signa 7 10 12 Connector C H 5 Right inner rear sensor ground Right inner rear sensor signal Left inner rear sensor signal Right outer rear sensor signal Left outer rear sensor signal Right inner rear sensor power Left inner rear sensor ground Right outer rear sensor ground Left outer rear sensor ground Left inner rear sensor power Right outer rear sensor power Left outer rear sensor power c 0 OO P ON sch NM Traccia Didattica Alfa 159 en ridotta doc 284 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 9 6 11 Ultrasound sensor Sensor pinout Sensor power supply Buzzers The two buzzers one front and one rear inform the driver on the distance and indicate system failures The frequency and volume of the warnings are controlled by the ECU E CH rz ei Ee 4 noce e Car E ze 9 7 AIRBAGS 9 6 1 Overview The car is equipped with driver and passenger knee airbags The knee airbags integrate the front airbags and the seat belts They reduce risk of injuries to the occupants knees and even prevent cont
50. Tensione segnale Pressione 1800 Bar FUNCTION This sensor provides a feedback signal to the injection ECU to gt adjust pressure inside the fuel rail gt adjust injection time Accelerator pedal potentiometer LOCATION The accelerator pedal potentiometer consists of an armature fastened to the accelerator pedal FUNCTION It provides information to the engine ECU on the position of the accelerator pedal which is integral with the potentiometer itself OPERATION Mechanically the potentiometer consists of an armature inside which a spindle turns the spindle is integral with the accelerator pedal A helical spring ensures return to home position when the pedal is not pressed Two potentiometers are fitted inside the armature one main potentiometer and one backup Their resistance varies according to the angle of rotation of the spindle i e the angular position of the accelerator pedal with which they are integral The changes in resistance offered by the potentiometer is read by the ECU Two potentiometers are provided for safety reasons A coil spring on the shaft ensures the correct resistance to pressure of the pedal while a second spring ensure return when the pedal is released Traccia Didattica Alfa 159 en ridotta 145 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Engine ECU pins connector B Connector pins 46 1 Potent
51. Tutti i diritti sono riservati ELECTRICAL SYSTEM ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training ECU programmed not programmed ECU OK not OK Wheel indication with spare wheel management Tyre pressure advanced information axle imbalance rapid or slow loss of pressure Advanced tyre state indications axle imbalance rapid or slow loss of pressure TPMS on off Run flat tyre management indication of remaining distance VVVVVVV The four wheel pressure temperature information information on the spare wheel is optional must be available on the network within 10 sensors from key on After this start up phase the information above will be managed on a 15 second basis with regular on event messages The NQS acquires these signals and manages the respective indications The message is transmitted regularly via the A Bus from the CPP every 15 seconds A CPP anomaly signal is sent and displayed by the NQS if the body computer does not receive a message for one minute 9 5 9 Key on key off strategies If an anomaly is reported during key on ECU failure low pressure the information will be represented at the next key off key on cycle only if the anomaly occurs again Specifically in the case of run flat tyres the CPP ECU is capable of correctly managing residual distance run flat management If loss of pressure from one or more tyres occurs during key off the respective message will appear on NQS within 10
52. action Press once Unlock driver s door Unlock boot Eliminate dead lock Switch on ceiling lights Switch off door LED and blinker Disarm alarm Press twice Unlock all doors Hold pressed Open sunroof and windows Release Stop opening sunroof and windows Lock doors Lock boot Switch on door LED and blinker Arm alarm Apply dead lock Start blinking door LED and blinker Close sunroof and windows Stop closing sunroof and windows Unlock all button Press once Lock all button Press twice Hold pressed Release Press once Unlock boot Start blinker Start blinking door LED and blinker Unlock boot button Hold pressed Feature not present in NPA CCP versions Dead lock management The dead lock is applied only when all the doors and the boot are correctly closed Automatic re lock after unlocking doors The locks will be automatically locked again if the user does not take possession of the vehicle opening a boot or the boot turning the key on within 150 seconds from when the doors are unlocked The automatic locking function does not generate signals Traccia Didattica Alfa 159 en ridotta doc 257 319 2004 Fiat Auto S p A Tutti i diritti sono riservati EE ALFA 159 TRAINING MATERIAL deo SYSTEM After Sales Training Multiple command and or overlapping inhibition The NBC inhibits all door locking and unlocking commands for 2 seconds to prevent interference caused by conne
53. air instead of from the intake manifold walls The air and petrol load therefore has a higher density and is cooler this reduces the compression ratio which has been set to a high value 11 3 despite the use of Euro Super petrol with a relatively low octane rating of 95 The high compression ratio is useful to increase performance and increase engine energy efficiency Fuel consumption is reduced by up to 20 with respect to similar traditional injection spark ignition engines thanks to direct injection CO2 emissions are reduced on the road Consumption reduction is possible with direct fuel injection when the engine can switch from stratified partial load to homogenous full load Injection system requirements include extreme precisionofthe injected fuel quantity generation of the necessary injection pressure A definition of precise instant of ignition of the mixture according to the operating mode of the engine fuel introduction directly and accurately into the engine combustion chamber Traccia Didattica Alfa 159 en ridotta 77 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Injection system architecture 6 HP Fuel Feed Tube from Pump to Fuel Fail LE HD 1 0 50 ccirev 3 Cvlinder High Pressure Fuel Pump Quick connector to the vehicle fuel feed system I 2 High Pressure Vehicle Fuel Injectors Gei 206010 2 2 17 5 BO0 n 0
54. and under the steering wheel These modules protect the lower limbs and increase protection for the driver and front passenger especially by preventing forward slipping that can cause chest injuries Construction The knee airbag module consists of a metallic casing housing a gas generator and a nylon bag The container is fastened to a supporting plate and a safety anchoring that fastens it rigidly to the lower part of the dashboard External cover Bag Gas generator Generator support Support plate Safety plate Quom Ie Seat belts with pretensioner on buckle The same system of sensors that controls the airbags also activates the seat belt pretensioners The pretensioners recover belt slackness and hold the occupant against the vehicle from the first instants of the collision to reduce movements inside the passenger compartment Furthermore the pretensioner on the buckle allows to control hip movement limiting forward movements and loads on thighbones in the event of collisions The belts are also equipped with progressive load limited which decrease the force to two decreasing thresholds for releasing the belt This along with the protection offered by the airbags integrates the occupant s safety more gradually and efficacy The load limiter force levels considerably reduces the risk of fractures to shoulder bones and ribs also for the most delicate bones e g the elderly Four position height adjuster are fitted on the front seats t
55. at such high pressure An atmospheric pressure circulation is also present This is needed to dump the diesel used to operate the pilot valve and convey the leakage mentioned above The temperature of the fuel recirculated by the injector can be very hot 100 C therefore the recirculation system must be equipped with pipes suited to withstand such temperatures Injector structure CONSTRUCTION The injector can be split into two parts to better understanding how it works see figure above 1 actuator atomiser consisting of the nozzle and the pressure rod pin assembly 2 control solenoid valve consisting of the solenoid and the valve CHECK PORT The space inside the pilot valve immediately over the actuator is called the check port and is essential for injector operation It is permanently supplied by fuel via Z from German Zufluss inlet This volume is emptied through A from German Abfluss outlet whose opening is controlled by the solenoid valve The fuel contained in the check port exerts a modular intensity pressure which acts on the upper surface of the pressure rod whose area Is Ac The force on this area therefore depends on the pressure inside the check port Traccia Didattica Alfa 159 en ridotta 148 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training ATOMISER ACTUATOR The actuator atomiser consists of the nozzle and the pressure rod pin a
56. between electronic key TEG systems this may compromise future servicing of the car 9 2 6 Procedures for replacing components Replacing the electronic key reader NTR Ask the customer for all the electronic keys TEGs in their hands The customer must also be asked to demonstrate that the car is actually theirs by presenting the car s logbook and a valid form of identification Connect to Fiat Ricambi using the personal computer provided Enter the chassis number the model code and use a depannage order to request a new NTR by entering the part number to identify the version Specify the number required Proceed as follows after receiving the new NTR from Fiat Ricambi Check that the serial number printed on the label applied to the order coupon corresponds to that on the NTR Check that the chassis number printed on the label applied to the order coupon corresponds to care Install the NTR if all codes correspond Store all TEGs owned by the customer in the NTR All TEGs which are not included in the procedure will be eliminated from the NTR and cannot be stored again Check that the system is working properly before delivery to the customer by using all the TEGs to start the engine and lock unlock the doors with the remote control DREI Replacing the engine control ECU Install a new engine control ECU and insert a TEG in the NTR to start the self programming procedure Press the start stop button with the brake clutch pedal
57. called crash box the rear fits a very thick crossmember with collapsible open section Both crossmembers are made of high strength steel and are screws onto the floor pan for easier replacement A specific gantry boxed structure is fastened behind the rear seat backrest this is structural element of primary importance for obtaining torsional stiffness of the body The result is the excellent torsional rigidity of the bodyshell over 180 000 daNm rad given a torsional stiffness of 156 equal to approximately 100 000 daNm rad Gantry boxed structure Both sides of all bodyshell structural elements are galvanised Some panelling has thicker galvanised coatings to prevent rusting and ensure structural performance for the car s entire lifespan 1 2 8 Suspensions The suspensions let the car face all types of terrain by reducing roll and pitch of the chassis damping vertical stress and constantly maintaining the maximum grip of the wheels on the ground They must therefore ensure comfort for passengers driveability and road hold bodyshell movements are limited and pleasant Alfa Romeo puts the accent on handling i e prompt response to commands precision steering progression high stability and control in limit conditions The Alfa 159 suspensions where designed to become a new absolute reference in the balance between handling and comfort The front high quadrilateral suspension arrangement implements the best feat
58. connected Not connected Not connected 6 NAG NAP power ground 8 30 NAG NAP 9 BCANB PIN A FUNCTION O i _0r rrrrrrrrrrrr11 6 Notcomeded 8 Sidebagnegativesignal oS EE lb uou v dl 1 111 p Traccia Didattica Alfa 159 en ridotta 316 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A 510 DA 4 e 51 4 ALFA 159 TRAINING MATERIAL After Sales Training Passenger presence sensor SBR The SBR is installed under the cover of the passenger seat cushion Along with the airbag ECU NAB and the instrument panel node the sensor informs the driver and the passenger that the seat belts are not fastened by means of acoustic and visual reminders Sensore tachimetrico Interruttore fibbia cinture di sicurezza Sensore presenza passeggero SBR Seat operation Manually adjustable front seats replace pictures with those of the Alfa 159 To adjust in the longitudinal direction simply lift the lever A and move the seat To adjust in height operate lever B Knob C is used to adjust the seat tilt and knob D is used to adjust the lumbar setting The other possible settings are shown in the following table Tilting where fitted Traccia Didattica Alfa 159 en ridotta 317 318 2004 Fiat Auto S p A Tutti i diritti sono riservati 10 4 e st ALFA 159 TRAINING MATERIAL Fiat Aut
59. connected by a stiff rubber teflon bushing to a teflon coated uniball joint Thanks to this and the front bushing faster response time and excellent road hold is obtained also thanks to wheel toe in under lateral loads The riser is compatible with all wheel drive applications The double tube spring shock absorber assembly has been increased in size with respect to similar prior applications The double tube arrangement has been preferred to other convention solutions with the possibility of controlling the three damping areas in detail in compression and rebound This totally favours the handling comfort balance The configuration with 13 mm rod and 30 mm valve unit is fastened to the body by a generously sized split damper mount for excellent filtering performance also in the presence of high damping forces The camber arm in addition to adjusting static camber has generated a geometry ensuring high camber take up in shaking to constantly improve contact between the tyre and the ground and to ensure controlled wear of the wheels also in limit conditions Ec ki PT Ar ET DI e L fag E ry ea The entire suspension is connected to the vehicle via a high strength steel crossmember isolated from the body by four 90 mm bushings which increase isolation at high frequencies All points of attachment of the suspension are designed to obtain the best possible stiffness response promptness and filtering to reduce the n
60. designed to help and integrate the protection offered by the system Two robust coaxial tubes arranged at the front and one at the back covered by the front seat cushion restrain the occupant correctly in frontal collisions and minimise seat distortion in lateral collisions The front tube and PPE polypropylene block embedded in the foam of the cushion protect from the so called anti submarining effect that is prevent the occupant from slipping underneath the seatbelt A robust two sided hinge between the backrest and the bottom was designed to optimise restraining performance in low speed rear end collisions This feature in combination with appropriately lighter side panel areas gradually absorb the energy of high speed rear end collisions in a controlled fashion Rear seats The backrest frame has a tough tubular structure and is designed to withstand the forces of a frontal collision with occupants on the rear seat and or loads in the boot The front part of the cushion presents a raised reinforcement to prevent submarining also for rear seat passengers Two ISOFIX mountings for child safety seats are standard for all outfits on the side rear seats These anchoring devices have two peculiarities gt they incentive continuous and correct use the child safety seat providing two fasteners on which to clip and anchor the child safety seat gt they standardise the dimensions of attachments and their distance so that the child safet
61. difference between the two values The particulate accumulation process and respective increase of exhaust gas pressure inside the DPF depends directly on gt vehicle weight gt engine displacement and power gt engine emission profile Regeneration process The filter is regenerated by taking the exhaust gas at DPF input to gt 580 C with an O2 content of gt 5 The engine ECU controls the process by metering diesel up to 5 injections in the cycle per cylinder controlling air EGR supercharger pressure The generation pressure can last from 8 to 12 minutes according to the vehicle type and level of obstruction During this phase the specific calibration of the engine ensures that there is no disruption of output torque with respect to normal operation The driver will not be aware of the process and regeneration will be maintained active in all engine running conditions Traccia Didattica Alfa 159 en ridotta 155 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The process is explained in the following graph PILOT PRE e Pilot Main Injection Timing Injection Pressure EGR Boost Pressure Throttle Zep Ta ES Valve valve Si SS E EE Tem perature increase gt 600 C by HC addition sua M Oxidation reaction Pre Cat Temp sce pee w I vi i p
62. environmental friendly down to the chose of materials machining processes and recyclability It was built without harmful substances such as asbestos chromium cadmium and CFC which are replaced with Kevlar organic pigments aluminium zinc and water respectively What is more material used were chosen by applying a LCA Life Cycle Assessment process In line with what will become mandatory for all industrial processes in the future the method accounts for the global environmental impact of materials in addition to their engineering and industrial characteristics from extraction of raw materials to disposal after use including transformation machining packing transportation use and recycling Being reassured that the only materials which were harmless for the environment were used to make the new model and that emissions were reduced to the minimum Alfa Romeo focused on the recyclability of the various parts of the 159 when it reaches the end of its working life To obtain these important results the materials were carefully chosen from the beginning of the new Alfa 159 project for example by decreasing the number of polymers used and by favouring the use of more easily recyclable plastics 1 2 19 Production process The roof is laser spot welded to the bodyshell for a total of 2 8 metres of welding this is the first time that this solution has been adopted by Fiat Auto This ensures perfect coupling along the entire len gt
63. feed system components are carefully arranged to protect the possible areas concerned by a collision Furthermore the layout of the various systems followed in detail from the beginning is very protected and referenced to prevent criticalities Pedestrian protection The style of the front of the car was developed considering pedestrian protection Shapes are smooth and rounded No risky projections for pedestrians are present The wide surface of the bonnet minimises the risk of contact between the pedestrian s head and the stiff front pillars Inside the engine compartment the stiffest components are arranged at a suitable distance from the bonnet to prevent it from absorbing the energy derived from the impact with the pedestrian s head 1 2 11 Alarm system The electronic system consists of the following transmitter receiver ECU with siren volumetric sensors and anti lifting sensors The alarm is armed and disarmed by radiofrequency using electronic keys that send an encrypted variable code The electronic alarm monitors illicit attempt to open doors bonnet or boot peripheral protection operation of the ignition key cutting of the battery wires presence of moving bodies inside the passenger compartment volumetric protection and anomalous lifting slanting of the vehicle for versions markets where fitted Volumetric protection can be cut out CAUTION The engine immobilizer function is ensured by the Alfa Romeo Code system w
64. fitted in all versions Specifically a traditional filter is fitted in one zone versions while a two layer paper filter containing a chemical substance capable of withholding also finest dust and particulate is fitted in two and three zone versions 10 2 MANUAL CLIMATE CONTROL SYSTEM The manual climate control system is a one zone device The classical control panel that integrates the NCL ECU is shown in the figure below 10 2 1 Structure The air mixing 17 air distribution 18 and air recirculation 16 controls are transmitted by stepper motors controlled directly by the ECU see figure on page 3 and wiring diagram on page 5 The climate control fan speed is controlled by aclassic resistive splitter 20 fitted in the air manifold 10 2 2 Operation The manual climate control system can be used to adjust the temperature and air flows let into the passenger compartment using buttons and knobs The following parameters functions can be adjustment manually Temperature Air distribution five positions Fan speed Compressor enabling Recirculation Defrosting demisting VVVVV WV 10 3 SUPPLEMENTARY HEATER Diesel versions fit a supplementary heater for warming up the passenger compartment faster while the engine is warming up The device consists of a plate 9 split into two sections each of which integrates a PTC that heats up when powered The plate is positioned inside a specific compartment 5 in the body of the heater uni
65. function of the NAV button on the Connect front panel Convergence C1 The vehicle is setup to connect to the optional Convergence system Convergence C1 is an innovative electronic module for interfacing the computer with a Bluetooth cellular phone within the operating range of the system approximately 5 metres The interaction method of the system consists of the following devices gt Microphone in ceiling light Controls on steering wheel connected via CAN Monochromatic display on on board panel connected via CAN The system provides effective and intuitive access to the following functions Traccia Didattica Alfa 159 en ridotta doc 276 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM nop eni ra After Sales Training Hands free cellular phone use without needing to operate the telephone itself i e the telephone needs to be inside the car but not necessarily reachable Voice recognition call in Speaker dependent and Speaker independent modes Copying of personal numbers from telephone to on board module and reading on on board panel Display interaction for called numbers incoming calls and incoming text messages Access to normal telephone functions answer reject calls recall back number etc using buttons on the steering wheel YYYY WV 9 5 TYRE PRESSURE DETECTION SYSTEM 9 5 1 Overview The TPMS Tyre Pressure Monitoring System check
66. injections controlled before TDC according to engine speed and engine load AAA Construction The fuel feed system consists of a low pressure circuit and a high pressure circuit The low pressure circuit consists of gt auxiliary pump gt fuel filter gt fuel return manifold gt connection lines The high pressure circuit consists of gt fuel pressure pump common rail Traccia Didattica Alfa 159 en ridotta 129 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Fuel pump 1 2 SE Fa le Se i SE ibd 1 Electrical motor 2 Pump impeller 3 Terminal cover Function To take fuel from the tank and send it to the high pressure pump at a pressure of 3 5 bars to ensure correct operation of the high pressure pump Location Inside the fuel tank Features The fuel pump is integral with the level gauge in the tank and the fuel filter These components cannot be replaced individually Operation The pump consists of a permanent magnet electrical motor which directly controls the pump impeller This is a centrifuge not positive displacement pump The impeller transfers a certain kinetic energy to the diesel which in the stator is transformed into pressure Advantages The use of a centrifuge pump instead of a positive displacement pump offers the following advantages gt high performance also at low electrical motor po
67. into the tank Uncondensed vapours are sent back to the canister valve Traccia Didattica Alfa 159 en ridotta 83 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Fuel pump in tank 1 Fuel pump 2 Float level gauge arm 3 Wiring harness connector FEATURES The fuel pump is provided with a permanent magnet electrical motor which controls the pump impeller and a terminal support cover which contains the electrical and hydraulic connections A single stage peripheral flow pump is fitted providing high performance in low voltage and temperature conditions The advantages with respect to positive displacement pumps are light weight and compact dimensions Low pressure fuel line FUNCTION This line is found in direct injection petrol systems to connect the fuel tank to the high pressure pump and forms the low pressure fuel supply system 2004 Fiat Auto S p A All rights reserved Traccia Didattica Alfa 159 en ridotta 84 318 Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training FEATURES Working pressure up to 0 7 MPa Pipe system tightness up to working pressure System lifespan specific tolerances are valid for up to 10 years or 150 000 km WORKING CONDITIONS Storage temperature from 40 C to 70 C Component temperature from 30 C to 110 C maximum 115 C Dynamic resistance admissible vibration level 600
68. is always less than 9 of the engine Traccia Didattica Alfa 159 en ridotta 116 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Engine speed sensor Ignition coils Frequency on pins A55 MED 7 6 1 and A40 we Voltage disconnected from pins A 46 A 31 A 01 A 16 Voltage between pins The ECU implements the following A 43 and A 58 logics in the event of knocking Injectors A 44 and A 59 e adapts spark advance by delaying it Voltage to pins Timi e adapts injection times A 50 A 49 A 47 A 48 ge e resets all parameters when A 32 A 33 A 35 A 34 voltage on pin A 41 knock disappears voltage on pin A 56 z Acceleration mixture enrichment control The ECU in event of high acceleration demand modifies the injection time and position of the throttle RECOVERY PROCEDURE The ECU replaces the signal from the faulty air mass meter with the signal from the potentiometer integrated in the throttle actuator Traccia Didattica Alfa 159 en ridotta 117 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training INPUT PARAMETERS ELECTRICAL QUANTITY Engine speed sensor Frequency on pins A55 and A40 CONTROLLER OUTPUT PARAME
69. local operations using the manual selector knob by pressing the switch to close the sunroof without the safety protection The movement will be completed if service relay 2 switches from on to off two minutes after key off or when a door is opened while the sunroof is moving following a manual control If an automatic control is received at key off while a manual control is in progress the manual control is completed A new remote control must be sent to move the sunroof automatically after this Remote movements can be stopped by the user either by changing the position of the manual selector knob or by pressing the inhibit button Traccia Didattica Alfa 159 en ridotta 307 318 2004 Fiat Auto S p A Tutti i diritti sono riservati 210 DA 4 e st ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training The sunroof will ignore the remote control and reach the newly set position on the selector Pinch force safety function The pinch force safety function managed by the ECU protects occupants from movement controlled from inside the vehicle in compliance with Directive 2000 4 EC It is active during horizontal closing front edge and vertical closing rear edge and trips when an obstacle e g finger hand is encountered The possibility of pinching between the sides of the sunroof is prevents by adopting side guards which prevent access to dangerous areas Movement of the panel is automatically stopped when a
70. m s peak Canister bleeder valve OBJECTIVE The valve is used to bleed the flow from the activated carbon filter FEATURES It is provided with a fastening support and 2 pin integrated connector The connection to the engine ECU is CONNECTION TO ECU CONNECTOR DRAWING connector pin 1 to ECU pin 18 Elettrov side A Canister connector pin 2 to power wire 18 LS REMOVAL REFITTING When lubricants are used e g to connect pipes the utmost care must be devoted to prevent blocking the flow and being sucked into the internal parts of the valve An arrow on the seat shows the direction of flow Make sure that the valve is not subjected to mechanical stress during removal The valve cannot be reused if it is dropped or if visible damage is apparent Traccia Didattica Alfa 159 en ridotta 85 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training High pressure fuel circuit SYSTEM ACTUATORS gt High pressure fuel pump Injection piping High pressure injector Pressure regulator valve Fuel high and low pressure line Ignition coil module VV VV ON High pressure fuel pump OBJECTIVE The high pressure fuel pump increases input fuel pressure equal to 3 5 bars to 120 bars for supplying the rail This pressure reduces pressure fluctuations inside the rail TECHNICAL SPECIFICATIONS Three cylinder radial piston pump Displace
71. mechanical code programming date VVVVV Proceed as follows to replace and consequently order Code system components Loss of electronic key TEG gt Ask the customer for all the electronic keys TEGs in their hands The customer must also be asked to demonstrate that the car is actually theirs by presenting the car s log book and a valid form of identification gt Cancel all electronic key TEG codes from the NTR memory as follows 1 Connect Examiner to the car s diagnostic socket 2 Open the NTR programming menu and follow the instructions 3 Enter the electronic keys TEGs still owned by the customer in the electronic key TEG reader when prompted by the instrument 4 Shut the programming procedure down The electronic keys TEGs not presented during this step will not be deleted and cannot be stored again at a later time At the end of the procedure it is advisable to print out a table showing the identification codes which are still enabled lt no printer is available copy the codes from the screen into the specific Fiat Ricambi system form Transmit the codes to Fiat Ricambi to update the database only if the electronic key reader NTR already contains 8 electronic keys TEGs Requesting new electronic keys TEGs Connect to Fiat Ricambi using the personal computer provided Enter the chassis number the model code and use a depannage order to request a new electronic key TEG by entering the part number
72. of a failure to one of the circuits The system is also equipped with the following brake and handling assistance systems gt ABS wheel anti locking system EBD electronic brake distributor acting between the front and rear wheels ASR traction control system which combines the action of the brakes and the engine ECU MSR engine brake control governed by the engine ECU VDC stability electronic control HBA automatic braking pressure in the event of panic braking Hill Holder auxiliary system for holding the car stationary when starting uphill the brakes are released when the vehicle starts off VVVWVVWV 6 1 1 Braking system components Pedal board The pedal board has a plastic mount housing the brake and clutch pedals The clutch pedal is made of plastic The brake pedal made of steel is fitted with a device that makes the pedal board collapse in a collision This minimises intrusion in the passenger compartment and prevents lesions to the lower limbs Traccia Didattica Alfa 159 en ridotta 210 318 2004 Fiat Auto S p A Tutti i diritti sono riservati BRAKING SYSTEM ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training The accelerator pedal made of plastic is fitted by the side on a specific mount The drive by wire electronic system is in common for all engine versions The pedal brake ratio ratio between pedal stroke and brake cylinder piston is 3 5 This parameter ensures reduced brake
73. on whenever the value is either equal to or less than the following partial thresholds a 1800 1600 1400 1200 1000 800 600 400 200 100 50 km b 27 24 21 18 15 12 9 6 3 days The message will not be shown at key on until the next partial threshold is reached The message shown at key on must show the kilometres miles or real days before the programmed deadlines once one of the thresholds is exceeded Consequently this value must be equal to or less than the respective threshold value considered Panel display logic after all nine coupons No message must be appear in Automatic Service mode No setup menu item can be selected in On demand mode the function must not be active Counter resetting by service network Servicing personnel at each scheduled service deadline must gt Reset the kilometre or mile counter and the day counter to initial values 20 000 kilometres 12 000 miles and 365 days using the diagnostic instrument Data must remain readable and writable using the diagnostic instrument gt Store performed scheduled service data Trace of the last service coupon must remain through o coupon date o number of the coupon o total distance driven Data must remain readable and writable using the diagnostic instrument The coupon number must be decreased at each Service Info Reset starting from 9 decreasing from 9 to 0 Instrument panel configuration after replacement When replacing the on boar
74. oo CMG a2 X X X i91evMjet 150 CM6 2 X XxX X 1 9 16V M jet 150 AUT 6 X 24 20V Mjet 200 EE 2 4 20V M jet 200 AUT 42 zk 2 4 20V Mjet 200 Ice IL O X O c E Lu A DIESEL MULTIJET 3 0 Mjet AUT6 M4 X CM5 CME 5 6 gear mechanical transmission AUT Automatic transmission MTA Automated mechanical transmission Selespeed The versions available at time of release are shown in bold print 2004 Fiat Auto S p A All rights reserved 22 318 Traccia Didattica Alfa 159 en ridotta mmm ALFA 159 TRAINING MATERIAL 1 2 23 Product grid according to outfit level Contents EO SBR Seat Belt Reminder and alarm Pretensioners on front seat belt clasps Front seatbelt with progressive load limiter FPS inertia switch Isofix mountings on rear side seats and third central upper tether strap Anti intrusion bars on front and rear doors ABS EBD VDC with Hill Holder including ABS EBD ASR HBA ASR VDC cut out Automatic three zone climate control system temperature and air flow Visibility pack 2 rain sensor dusk sensor demister sensor odour sensor electrochromic mirror incompatible with manual climate control system Split rear seat Rear seat fitted armrest with storage compartment cup holder and ski compartment Mechanically tilting driver and passenger seat Front seat heater Alfatex upholstery Traccia Didattica Alfa 159 en ridot
75. p A BODYWORK ALFA 159 TRAINING MATERIAL Se After Sales Training 11 2 2 Front seat structure Anti whiplash system The front seat backrests are provided with an anti whiplash system which tilts in a rear end collision The headrest is moved towards the occupant s head to reduce bouncing of the head which can cause whiplash The system does not need to be operated because the backrest advances by effect of the energy of the collision itself It is held in normal position by a spring that automatically restores the original backrest position The mechanism therefore does not need to be adjusted nor restored after a rear end collision The figure below shows the two positions of the backrest in normal position and when the anti whiplash system is in action 1 Axis of backrest in normal position 2 Axis of backrest with anti whiplash spring in action Traccia Didattica Alfa 159 en ridotta 312 318 2004 Fiat Auto S p A Tutti i diritti sono riservati BODYWORK ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training 11 2 3 Electrically adjustable seats Electrically adjustable front seats are available on demand The driver s side seat is provided with three pre settings for storing the various configurations Longitudinal seat adjustment Seat tilt Backrest tilt Seat height adjustment oN a Traccia Didattica Alfa 159 en ridotta 313 318 2004 Fiat Auto S p A Tutti i diritti sono riserv
76. pressed The engine will be cranked until either the clutch brake pedal or the start stop button is released The operation is accepted for up to 10 seconds after which the procedure must be repeated Stopping the engine and extracting the TEG The engine will stop if the start stop button is pressed regardless of the position of the brake or clutch pedal when the engine is running In vehicles with automatic transmission the TEG is only unlocked if the gearlever is in Park position The NBS will not lock the steering when the TEG is extracted if the vehicle speed is faster than 4 km h or not valid at key off Emergency TEG extraction The TEG can be released and extracted in all conditions also while travelling by means of an emergency mechanical insert The TEG can be removed in an emergency by extracting the mechanical insert and inserting it in the specific hole on the reader 9 2 5 Code system programming and component management Code system spare parts management database Orders for all Code system components are managed by Fiat Ricambi s centralised database in common for all markets The production plant will transfer all the necessary data to the database when the vehicle is manufactured Fiat Ricambi will access the database to handle orders for components to be replaced in service The database contains a variety of information including vehicle chassis number secret code electronic key TEG codes emergency key
77. pump Camshaft timing phonic wheel SSR qoc FUNCTION To contain and correctly support the various timing parts suction and exhaust conduits spark plug houses and injector housings It determines the shape of the combustion chamber MATERIAL The cylinder head for 1 9 and 2 2 litre engines is an aluminium alloy casting FEATURES Plastic cylinder head cover Spark plug holes slanted towards the exhaust conduits by 3 mm Traccia Didattica Alfa 159 en ridotta 57 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Injectors positioned directly in the cylinder head spraying directly into the combustion chamber The injectors are pre assembled on an intermediate flange which houses the fuel rail Valves actuated by rollers equipped with hydraulic tappets Exhaust conduits directed towards the back of the engine Presence of twin continuous variable timing SERVICING OPERATIONS Cylinder head flattening is allowed to correct errors of planarity in the range from 0 05 and 0 15 mm Flattening is not necessary under this range and not allowed over the range replace the part Flattening must ensure a minimum depth of 12 75 mm measured in the points shown in the drawing the minimum depth of the combustion chamber volume EEN mE 1112 IL 1012 1113 ams p TIE az Depth measuring point Depth measuring point Depth measuring po
78. rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training Digital air mass meter 1 Air flow inlet proportional to total flow 2 Resistive sensitive element 3 Signal detection and amplification circuit 4 Interference shielding 5 Connector 6 Body The HFM6 air mass meter sensor exploits the same operating principles of the previous hot film air mass meters with a new path of the air flow onto the sensitive element HFM6 The evolution of air flow conduits in analogue air mass meters Traccia Didattica Alfa 159 en ridotta 139 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training HFM5 HFM5 C HFM5 CL One of the advantages of digital air mass meters with respect to analogue meters is that the sensitive element of the sensor is more protected from impurities in the air Sensitive element measuring point Measuring flow Main flow The measuring flow is taken from the main flow through a secondary bypass This conduit has a smaller section and is longer than the main conduit It houses the sensitive element The new bypass design lets pollutants in the main flow out towards the outlet by kinetic energy without entering the measuring conduit The measuring flow is designed so that the amount of air is proportional to that in the main conduit Air mass meter to ECU connection UM
79. second spring ensure return when the pedal is released OPERATION The position of the accelerator pedal is transformed into an electrical voltage signal and sent to the potentiometer ECU connected to the pedal The accelerator pedal position signal is processed along with the engine speed information to define throttle body position injection times and respective fuel pressure Traccia Didattica Alfa 159 en ridotta 76 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The sensor connections to the engine ECU are CONNECTION TO ECU CONNECTOR DRAWING connector pin 1 to ECU pin 83 o 61 60 59 83 82 81 side K i connector pin 2 to ECU pin 61 side K connector pin 3 to ECU pin 60 side K connector pin 4 to ECU pin 59 side K connector pin 5 to ECU pin 81 side K connector pin 6 to ECU pin 82 side K Potenziometro su pedale acceleratore Electrical specifications Double resistance sensor SENSOR FEATURES Power voltage 5 V Electrical voltage signal Variable resistance according to accelerator pedal position Resistance track 1 1 2 kOhm OUTPUT SIGNAL TYPE 1 5 kOhm pedal 5096 1 9 kOhm pedal 100 Fuel injection system FEATURES The direct injection system injects fuel directly inside the cylinder The main advantages are better fuel evaporation and increased engine volumetric yield because evaporation heat is subtracted from the suction
80. shown in the following figure Electrical system layout Fedi Sy Se son pik Se igorl pk Fe adii DX H m CPS __r _ crs CPD P a AR R Sere CAF Bnme s Ir eras E arme i B amp GUI GOL am 4 0 H SE Seasons MODE i CHA i H T Vu i HIDE eegene ll Ale naite Heke S My i EES Sere ara Tend Wotortvo dauutm e vb Le age I aldy HPL CS s sl E m T i NP ET el Lr COS rer iae py EE REA R CONTROL HEAD CILCPO MBA d RN Traccia Didattica Alfa 159 en ridotta 242 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM Ei After Sales Training 9 1 3 System electrical component classification The Mini F L Ore N C E components are classified according their implemented technology The table below shows the classes to which the various components belong JD TECHNOLOGICALCLASS EXAMPLES B Electrical power generators 1 Battery alternator C Distribution components Interconnection units wiring harnesses clock wire D Manual controls___ Stop switches reverse switches control panel Nodes ECUs Body computer airbag ECU te devices I Heaths o controls L___ Inductanees__ Compressor solenoid valve relay speakers _ Motors Window winders door locks fuel pump ege EE sg R Resstrs Heatedre
81. technical specifications Clutch cover Friction plate Flywheel Total Weight kg 3 75 0 95 12 90 17 6 Moment of inertia kom 0 0389 0 0055 0 154 4 4 1 Dual mass flywheel INT RAINS KI E ad 1 WI ue LASTS d Pirano KR T E ta A TOR UEM d CC Ki vu N ei S m T Wn i SE a ur tn OBJECTIVE The flywheel makes engine operation smooth by accumulating kinetic energy during the active stroke of the engine and letting it out during the three passive strokes this ensures smoother engine running because the engine power output to the driveline is stabilised by the flywheel that levels the engine power output CHARACTERISTICS The engine version fits a dual mass flywheel with two weights one integral with the crankshaft and the other integral with the gearbox primary shaft via the clutch plate A damping torsional flexible system consisting of a double spring system also arranged in parallel with different elastic stiffness is arranged between the two masses Another consequence of this type of flywheel is bending resonance variation which respect to a normal flywheel is under the engine running speed The diagram below shows the theoretical bending damping characteristic of the flywheel The x coordinate shows the working angle in degrees of the internal system relative angle between the two parts of the flywheel primary and secondary the y coordinate shows the transmitted torque in Newton metres Tr
82. the wiring diagram Traccia Didattica Alfa 159 en ridotta 301 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM BI en After Sales Training 10 5 7 Two three zone climate control system wiring diagram ACT 2 19 ACT 4 18 ACT 3 ACT 5 24 ACTA 23 12V 30 ali ACT 6 22 ACT 7 20 21 Traccia Didattica Alfa 159 en ridotta 302 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM di eda eine After Sales Training One zone ECU pinout Connector A Pin Signal description Colour Pin Signaldescription Colour 9 Notused le 16 Bt coil Recirculation White black 5 PTC2reay Rediyellow 18 Notused O 6 INT A Blower relay Redigrey 19 B2colMode TI Blue geen 7 Notused X 20 A2cilMoe LI Brownfred 8 Noued J 31 AtcoilMode Blackgreen 9 Notused 3 4 2 3 22 BftcolMoe IL Orange L 10 Notused_____ E Greenmauve Compressor Purple black A1 coil Mix Brown black A C Request B CAN Pink white A2 coil Mix Brown yellow B CAN Pink black B1 coil Mix Blue yellow Connector B Seo mme 0 Bediblack Red yellow Grey blue Traccia Didattica Alfa 159 en ridotta 303 318 2004 Fiat Auto S
83. this case when the start stop button is pressed the clutch or brake pedal is pressed and a valid TEG is inserted in the reader the NBS will activate loads key on and start the engine as described if the button is held pressed The start button must be released and pressed again to start the engine if the NBS is clear after key on Clutch and brake pedal validation The engine can be started if brake pedal is pressed also if the clutch pedal is not To prevent accidental ignition the clutch pedal will be ignored by the NBS if it is held pressed for longer than 5 minutes The clutch pedal must be released and pressed again Stopping the engine and extracting the key Pressing of the start stop button while the engine is running regardless of the state of the brake or clutch pedal is interpreted as the user s intention to stop the engine The NBS will switch off the 15 54 INT and INT A loads and will unlock the TEG from the TEG reader In vehicles with automatic transmission the TEG is only unlocked if the gearlever is in Park position The NBS will not lock the steering when the TEG is extracted if the vehicle speed is faster than 4 km h or not valid at key off Smart key system signals The Smart Key system controls various indicators on the instrument panel for the following functions gt Accessing vehicle and or alarm gt Steering lock unlock Starting and stopping the engine In particular Locking the doors Locki
84. time with valve opening lets more fresh ADVANCE air into the cylinder At high speeds the output air acquires a good inertia which allows delayed closing of SOSIA the valve and air flow also after BDC EXHAUST OPENING This expels burnt gas favoured by the higher pressure in the chamber and decreases ADVANCE the ejection work CLOSING DELAY This exploits all the kinetic energy deriving from combustion expansion of the mixture RECIPROCAL CROSSING MAY PROVIDE HIGH LOAD More input of fresh air due to vacuum caused by flow of burnt gases PARTIAL LOAD Recall of burnt gas into the chamber with a beneficial effect on emissions virtual displacement reduction LOW LOAD Decay in combustion quality with problems of regularity 3 1 4 Operating strategies Alfa Code recognition INPUT PARAMETERS OUTPUT PARAMETERS ELECTRICAL QUANTITY ELECTRICAL QUANTITY Key on Cranking enable relay activation Voltage on pin K 92 Signal from pin K 25 Engine ECU interfaces with Interface with Code ECU Code ECU for on serial line enabling cranking Signal from CAN line C Traccia Didattica Alfa 159 en ridotta 113 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Self learning The ECU implements self learning logic in the following conditions gt installation of a new injection ECU gt installation of a new throttle actuator gt
85. top of the injector magnet The IMA code of the injectors must be stored in the ECU using Examiner after replacing one or more injectors Variable geometry intake actuator VARIABLE SWIRL FEEDBACE SEGN LOCATION In the engine compartment connected to the intake manifold FUNCTION To control throttle operation and optimise swirl in the combustion chamber CONSTRUCTION The variable swirl system essentially consists of Traccia Didattica Alfa 159 en ridotta 149 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TR ini 59 TRAINING MATERIAL After Sales Training an electrical actuator controlling the angular position of the throttles on the intake manifold a double conduit intake manifold for each cylinder aset of throttles fitted on each of the two intake manifold for each cylinder ACTUATOR What is swirl It is the twisting motion of intake air or air fuel mixture in Otto cycle engines around the cylinder axis Swirl is obtained by appropriate shaping the intake conduits the valves and the combustion chamber It is exploited to optimise air mixing with fuel inside the combustion chamber to provide more efficient combustion and consequent reduction of polluting emissions CLOSED THROTTLE The throttles are closed when idling and at medium engine speeds The powerplant runs a two valve per cylinder engine with considerable benefits in terms of volumetric filling and torque a
86. used by the ECU to adjust the position of the VGT actuator and therefore supercharger pressure to optimise engine operation and to adjust injection time FEATURES This double sensor is used to read the air temperature via a NTC Negative Temperature Coefficient measuring element and the pressure inside the manifold via a piezoelectric measuring element The sensor is connected to ECU pins 28 53 13 and 40 via connector A pins 1 2 3 4 respectively Engine coolant temperature sensor LOCATION This sensor is fitted on the thermostat cup where the thermostat valve is fitted FUNCTION The sensor detects the engine coolant temperature FEATURES This NTC Negative Temperature Coefficient sensor sends the coolant temperature signal to the engine ECU The sensor is connected to ECU pins 41 and 58 via connector A HFM 6 digital air mass meter The advantages of the new air mass meter are 1 Better protection of the sensitive of the element from impurities in the air particles water oil vapours etc 2 Better measuring accuracy The differences between the HFM6 and previous air mass meters are Digital air temperature and flow rate signals Four wire electrical connection New bypass arrangement of air flow onto sensitive element Turret welded to air flow conduit Protection grid on air flow outlet to condense oil vapours ae Ns Traccia Didattica Alfa 159 en ridotta 138 318 2004 Fiat Auto S p A All
87. via a single conduit A particular feature of this pump is that it is lubricated and cooled at the same time by the fuel circulating inside it through specific gaps A low pressure regulating solenoid valve is fitted on the pump inlet to adjust delivery pressure and compress only the fuel needed to each the pressure mapped in the ECU The main features of the Radialjet pump are shown in the table on the following page Traccia Didattica Alfa 159 en ridotta 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Radialjet pump specifications Radialjet radial pumps Numberofpummps OO Numberofpumps Total displacement 0 697 cm rev 4 cylinders 0 794 cm rev 5 cylinders Volumetric efficiency gt 76 at 1600 bars 1000 pump rpm 40 C fuel Maximum working pressure 1600 bars Drawn power 1 6k W at 1600 bars 3450 rpm 4 cylinders 3 2 kW at 1600 bars 2800 rpm 5 cylinders Topspeed S See following paaa Fuel feed Fuel pressure 3 5 bars minimum flow rate equal to 160 litres hour Lubrication J Byfuel Cooing Low pressure regulator solenoid valve Characteristic line w Maximum delivery Q T Zero delivery A Detail A j amamni gt le EU Zero T n ara T Maximum delivery delivery FEATURES The pressure regulator is used to control the amount
88. 04 Fiat Auto S p A All rights reserved 32 318 Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A TECHNICAL DATA ALFA 159 TRAINING MATERIAL After Sales Training 2 8 FRONT SUSPENSIONS 2 8 1 Helical springs Basic and medium outfits Basic EE 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jetiGV 2 4 M jet 20V Wire diameter mm 13 6 0 05 13 6 0 05 13 9 0 05 13 9 0 05 No of active turns 5 83 Hand of helix Right Right Right Right Fi i po Free spring height Compressed spring 198 at 628 19 198 at 628 19 198 at650 20 198 at 650 20 Se height mm daN daN daN daN compressed spring 152 at 823 daN e SG height mm daN E Marking colour 1 brown 1 white 1 white High outfits High outfits 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Wire diameter mm 13 6 0 05 13 9 0 05 13 9 0 05 14 4 0 05 No of active turns 5 5 Maximum 152 at 823 152 at 854 daN 152 at Hand of helix Right Right Right Free spring height 35 355 355 35 35 mm Compressed spring 198 at 645 19 198 at 645 19 198 at 667 20 198 at 667 20 198 at 716 height mm daN daN daN daN 21 daN Maximum 152 152 152 152 compressed spring 192 height mm at 840 daN at 840 daN at 871 daN at 871 daN at 947 daN Marking colour 2 8 2 Shock absorbers o 19JTS 2 2 JTS 1 9M jet8V 1 9 M jet16V 2 4 M jet 20V Open rengti startoi 446 2 2 5 4462425 4462 25 446 2 2 5 446 2 2 5 dampin
89. 18 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training CLUTCH ALFA 159 TRAINING MATERIAL 4 WORN PLATE RELEASE The toothed plate 1 is released by the diaphragm spring 3 and can therefore slip onto the next gear tooth 7 It is now in a position to turn the gear at the next engagement 5 NEXT ENGAGEMENT The toothed plate 1 presses the tooth for a distance that corresponds to the height of the tooth This operation turns the gear 7 and at the same time the toothed sector 5 and therefore the thrust ramp 8 via the slanted section system At the end of engagement the ramp has shifted axially to the exact wear value to be taken up 4 3 3 Driven friction plate The friction plate is fitted with a buffer damping spring system The propeller shaft is connected to the transmission by means of a splined hub The flywheel is shown in the photo Traccia Didattica Alfa 159 en ridotta 191 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training 1 Buffer damping springs 2 Splinedhub 4 4 LUK FLYWHEEL CLUTCH CHARACTERISTICS The LUK flywheel clutch is fitted on 2 4 M jet 20V versions and presents the following features gt dry single plate clutch gt push release system this means that the clutch is released when the sleeve pushes the diaphragm spring reversing its concavity gt dual mass flywheel Some
90. 2 Timing sensors 13 Knock sensors 14 Fuel pressure sensor 15 Engine speed sensor 16 Accelerator pedal potentiometer 17 Air flow meter with built in temperature sensor 18 Battery in addition to permanent power the ECU receives key on signal and power after main relay 19 Brake pedal switch 20 Driven throttle body 21 CAN for communicating with Body Computer for the following signals engine speed engine coolant temperature coolant overheat warning light fuel gauge ABS ASR VDC and automatic transmission signals where fitted 22 Fiat CODE on CAN and redundant W line 23 Diagnostic socket 24 Fuel vapour recirculation solenoid valve 25 Ignition coils 26 Variable timing control valves 27 Injection warning lights amber MIL EOBD 28 Oil pressure switch 29 Engine speed signal from CAN 30 Fuel pressure regulator valve 1 2 3 4 5 6 T 8 9 Traccia Didattica Alfa 159 en ridotta 79 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Bosch MED 7 6 1 ECU FEATURES The electronic control unit governs the engine system It has two connections one for the wiring on vehicle side K one for the wiring on engine side A It is fastened with mounts inside the engine compartment Identification numbers 0 261 501 034 MED761A003 0 261 501 041 MED761A002 0 261 S01 042 MED761A007 E
91. 3 i AIRBAG SYSTEM FUSE 7 5 15 FUSE FOR NRC CPP radio setup 7 5 REAR WINDOW WIPER CURRENT SOCKET ON TUNNEL FUSE max 120W 15 30 FUSE FOR DIRECTION INDICATORS HAZARD LIGHTS NQS 10 RELAYS T T T s zi Traccia Didattica Alfa 159 en ridotta 247 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ALFA 159 TRAINING MATERIAL ELECTRICAL Fiat Auto S p A SYSTEM After Sales Training Engine compartment fusebox CVM CODE APPLICATION FUSES F 1 30 CPL2 CVB FUSE F 2 30 CLIMATE CONTROL SYSTEM FAN FUSE F 3 NBS FUSE F 4 NFR1 FUSE F 5 NFR2 FUSE ENGINE COOLING FAN LOW SPEED one two fan configurations HIGH SPEED MOTOR 1 two fan configurations FUSE ENGINE COOLING FAN HIGH SPEED one two fan configurations HIGH SPEED MOTOR 2 two fan configurations FUSE F 8 MTA PUMP FUSE F 9 HEADLIGHT WASHER FUSE F 10 HORN FUSE F 11 IGNITION SECONDARY VARIOUS SERVICES FUSE F 14 RH MAIN BEAM HEADLIGHT FUSE F 15 LH MAIN BEAM HEADLIGHT FUSE F 16 INJECTION SYSTEM INT1 FUSE F 17 INJECTION PRIMARY SERVICES FUSE F 18 30 NCM NCR or NCA NSC FUSE F 19 COMPRESSOR FUSE F 20 spare F 21 FUEL PUMP POWER FUSE F 22 INJECTION PRIMARY SERVICES FUSE PETROL F 22 INJECTION PRIMARY SERVICES FUSE JTD F 23 30 NIT NRR FUSE 15 15 54 NCA NSC or NCR FUSE FOG LIGHT FUSE F 7 2a 2 2 jm io o a Oo BIN RB M o o uluaulolo o o olo lo o N O1 Ni Al a uao RELAYS l RA
92. 45 5 Distance between cylinders 96 96 Crankcase height 221 221 Compression ratio 11 3 11 3 Piston compression height 28 28 Number of valves per cylinder 35 3 35 3 Exhaust valve diameter 30 3 30 3 Maximum valve lift suction exhaust 10 3 10 1 10 3 10 3 Variable timing stroke suction exhaust 50 50 50 50 Engine weight 150 151 Max output 160 185 Max rated power speed 6500 6500 Specific power 86 1 84 2 Area power 68 9 79 6 Average piston speed at Pmax 17 3 20 5 Maximum admitted rotating speed 7000 7000 Maximum torque 190 230 Maximum torque speed 4500 4500 Maximum PME 12 9 13 1 _ 333 ssa 3333 3333 bh gl lk fl mom EE m m m A gt lt I KA 3 HP litre HP dm rev min Z 3 A A E mmu 9 a 3 D oO D Traccia Didattica Alfa 159 en ridotta 45 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Engine performance These new engines with respect to their predecessors have more power and torque as shown in the following table B 1 8 L8501 9 2 0 JTS petrol L8502 2 Displacement CC 1747 1858 1970 2198 Maximum power HP 140 160 165 185 Maximum torque kgm 16 7 19 4 21 0 23 4 Specifically the presence of double continuous variable timing combined with the separate twin catalysing system exhaust provides excellent torque output at only 2000 rpm at which speed both engines provide
93. 51 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training FUNCTION The flywheel makes engine operation smooth by accumulating kinetic energy during the active stroke of the engine and letting it out during the three passive strokes this ensures smoother engine running because the engine power output to the driveline is stabilised by the flywheel FEATURES The engines dealt with here fit a dual mass flywheel one fastened to the crankshaft and the other connected to the primary gearbox shaft An elastic double stiffness damping system is arranged between these two rotating masses with springs of different elastic stiffness and a planetary gear set with sun and planetary gears Other advantage of this type of flywheel is the low vibrations of the crankshaft flywheel system at slow engine speeds engine cranking ADVANTAGES The adoption of this type of flywheel better filters the vibrations induced by the engine to the transmission and to the rest of the driveline improving driving comfort and reducing transmission of abnormal loads to the gearbox 1 Shoe 2 Planetary gear 3 Sun gear 4 Primary flywheel fastened to crankshaft 5 Tangentially arranged helical springs DMF DUAL MASS FLYWHEEL OPERATION The two masses are connected together by springs to provide a high reduction of vibrations induced by the engine to the transmission especially at slower engine speed wh
94. 5V 0 04U D 2V Upper Range for Signal Range Check SRC 0 MPa Pressure p 14 MPa Nominal specifications SENSOR FEATURES Power voltage 5 V Power current 12 mA Variable voltage according to measured pressure SES RE Linear characteristic from 0 5 V 0 MPa to 4 5 V 14 MPa The ECU must be powered to pick up the output signal Examiner with SAM Examiner Smart module is needed to view the signal considering its type Set Examiner as a voltmeter and acquire the signal for approximately 5 seconds EASURING METHOD Knock sensor FEATURES This is a directly fitted piezoelectric knock sensor with compact connector Two sensors are fitted one between cylinders 1 and 2 and the other between cylinders 3 and 4 The sensor detects vibrations caused by mechanical pressure in the combustion chambers Traccia Didattica Alfa 159 en ridotta 98 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The connections to the engine ECU are CONNECTION TO ECU CONNECTOR DRAWING Knock sensor 1 connector pin 1 to ECU pin 59 side A connector pin 2 to ECU pin 44 side A Knock sensor 2 connector pin 1 to ECU pin 43 side A connector pin 2 to ECU pin 58 side A REMOVAL REFITTING The sensor is fastened on the cylinder block with a screw ADDITIONAL INFORMATION The entire surface of the sensor crankcase must be in contact to ensure correct tra
95. A loads and will unlock the TEG from the NTR when the start stop button PAV is pressed for at least two seconds In vehicles with automatic transmission the TEG is only unlocked if the gearlever is in Park position The NBS will not lock the steering if the TEG is extracted from the NTR when loads are deactivated by pressing PAV and the vehicle speed is higher than 4 km h or not valid In this case the following warning message will appear on the NQS Steering will not be locked Timed key off After key on 15 the NBS will automatically deactivate the 15 INT and INT A loads if at least one of the following events occurs within 20 minutes Traccia Didattica Alfa 159 en ridotta doc 258 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM np eni ta After Sales Training ignition pressing PAV with brake clutch pedal pressed vehicle speed gt 10 km h vehicle speed error engine running state change to key off VVVVV This strategy is needed to prevent the following cases gt key off on while travelling vehicle towing with key on key on while engine is running vehicle towed and raised vehicle speed error dynamometer test with engine running or not Start stop button PAV management The PAV ignition button is located on the dashboard panel lt consists of a dual circuit button with double output signal Both signals are acquired by
96. Alfa 159 en ridotta 198 318 2004 Fiat Auto S p A Tutti i diritti sono riservati GEARBOX TRACCIA DIDATTICA ALFA 159 Fiat Auto S p A After Sales Training input shaft upper secondary shaft three shaft arrangement ensures better compactness with respect to two shaft solutions lower secondary shaft 5 1 1 Gearbox interfaces b T fei ie gmi RRE J space for dual mass flywheel and wear take up clutch driven shaft housing gearbox control wire selection control wire hydraulic clutch actuator reverse sensor connector Traccia Didattica Alfa 159 en ridotta 199 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A GEARBOX ALFA 159 TRAINING MATERIAL wee After Sales Training 5 1 2 Transmission ratios The transmission ratios defined for the various engine versions are 1 9 16v and 2 2 16v 1 9 M jet 8v and 16v 3rd gear ratio 1 571 1 302 3 545 3 545 5 2 GEARBOX STRUCTURE 26 2B Traccia Didattica Alfa 159 en ridotta 200 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A GEARBOX TRACCIA DIDATTICA ALFA 159 After Sales Training 1 input shaft 16 first and reverse gear 2 lower secondary shaft 17 first and second gear synchroniser 3 upper secondary shaft 18 second gear 4 first gear on primary shaft 19 fifth gear 5 second gear 20 fifth and sixth gear synchroniser 6 third and fifth gear 21 sixt
97. CU CONNECTOR ON ENGINE SIDE A PN IL PINFUNCTION 60pinconnector Inlet variable timing LS signal 7 in 6 1 1 1 0 1 2 15 16 8 22 Engine coolant temperature sensor signal Not connected Not connected 4 Fuel pressure sensor and timing sensor 1 and 2 power pin 3 Throttle actuator IP2 signal pin 5 1 24 25 26 27 28 30 32 33 34 35 40 41 Not connected 0000 0 O 42 Not connected Traccia Didattica Alfa 159 en ridotta 80 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training High pressure injector cylinder 2 pin 2 High pressure injector cylinder 1 pin 2 pin 1 Not connected Not connected Not connected Timing sensor signal 2 pin 2 ECU CONNECTOR ON VEHICLE SIDE K PIN PINFUNCTION 9pinconneetor 6 Primayloadpower S O 8 Petrol pump relay positive S O 9 High pressure injector cylinder 1 pin 1 Stop light signal NO 17 A C linear pressure sensor signal ta Traccia Didattica Alfa 159 en ridotta 81 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training 41 Not connected 44 Not connected 45 Not connected Planar sensor 2 post cat pin 1 Linear sensor 1 pre cat pin 2 Linear
98. E DOOS EE 211 EGEO RR MIA 212 E I 213 e Deler le COMMON Te ET 213 LAMINATO TIA IAA 21 EE EE MENT TOT Em 215 DNE E zPETS A T e Y 216 MARCI VE Meio cc 216 ge ele e ei e ET EE 216 CAR CREO 21 Steering angle sensor SAS and steering angle node NAS nnne nennen nnne enn nennen err n nnns sensere nnns 218 Yaw lateral acceleration Sensor MEE T 219 C229 slate qe 220 QR 0 T nu f 22 CIA 223 Ls 223 AE d ele lo Il Tt Le 223 02 0 ASR ana VOC Ee EE 224 L t VIN e ia ie aaacasa ieri iii 225 ee 225 EE PREZZI 22 20 226 PROC PRE REI 226 FA ACCTING COMMIT EE 22 ARR Beet RIA 22 EE Ee LE 228 o FE TURES Gelo 228 RE AIA 228 FronksUspension coMPonents elia 229 ARIE IO RR 234 Rear suspension Corno gt seeker eee nee eee eee ener at 234 8 1 3 Hear suspension yield fasteners E 236 8 1 4 Angle and vehicle trim inspections EEN 238 olo GORI 239 ele Ee Ee e EE 239 en e e EE 240 D ELECTRICAL SISTEM EE 241 S VOVER VIEW OF THE ELECGIRICALSYSTEM GG icti ERR EI aio O n LIMA Aia 241 9 11 Tne Mni ee 241 CNN Ee TCA Sy ON VOU nni aa ia 24 9 1 3 System electrical component classification
99. E OOOO Traccia Didattica Alfa 159 en ridotta 248 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM ee After Sales Training 9 1 11 Mini F L Ore N C E architecture diagram C CAN Fail ini m ES E CAN in RF O Kee LIN LIN Ka z Em E we pee E eiu back i sonar I EPI PA he NIT NRE NCV Rr Notes on functions of nodes ECUs fuseboxes and components Engine compartment fusebox CVM The CVM is a fusebox installed next to the battery It contains fuses and relays is interconnects the front wiring harness the engine pre wired harness and the radiator pre wired harness Battery fusebox The battery fusebox is located on the positive battery terminal and contains the general protection maxi fuses and the safety battery cut off relay The latter is connected to the FIS and cuts battery positive off from the wire from the alternator wire in the event of a collision to prevent fires Dashboard fusebox CPL The CPL is a fusebox installed on the dashboard on driver s side It contains fuses and relays and interconnects the front dashboard and rear wiring harnesses Furthermore it is connected to the body computer node with which it is supplied by means of a connector on the back The CPL NBC set is called dashboard node NPL Body computer node NBC The NBC is an electronic component connected to the vehicle s serial networks f
100. EM dii a ilaria After Sales Training Tyre pressure ECU CPP Opt The tyre pressure monitoring ECU is an electronic device with RF receiver capable of receiving the low tyre pressure signal from a transmitter arranged on the valve It is located under the dashboard on the right hand in left hand drive models and on the other side in right hand drive models Lateral yaw sensor node NYL Opt The NYL is an auxiliary node of the NFR used to implement the VDC Vehicle Dynamic Control function It transmits vehicle trim conditions when cornering to the NFR It is only present in vehicles with braking system equipped with VDC It interfaces with the vehicle via the C CAN It is located on the central tunnel between the two front seats FPS or FIS The FPS Fire Prevention System also called inertia switch cuts off the fuel pump and disconnects the positive battery terminal from the alternator in the event of a collision to prevent fires It is located under the front left seat near the tunnel 9 1 12 Diagnostic architecture The diagnostic architecture for ECUs nodes with and without CAN interface is summarised in the following table The nodes requiring proxy alignment if replaced are shown in bold print Volumetric alarms ECU ABUS No X NO Steering column sakont aas no NO _Antitheft siren ECU JL ABUS MO NO Rain sensor ECU ABUS NO NO HeadiptECU LL Ys NO lAigECU LI es NO Body Computer node
101. ERIAL 1 Engine speed sensor ELECTRICAL SPECIFICATIONS SENSOR FEATURES Electrical resistance equal to approximately 1 kOhm Variable alternating voltage maximum value and frequency proportional to flywheel speed Examiner with SAM Examiner Smart module is needed to view the signal considering its type Set Examiner as a voltmeter and acquire the signal for approximately 5 seconds The graph must show the following characteristics wave amplitude and frequency proportional to each other and to the flywheel speed signal changes when sensor picks up missing tooth OUTPUT SIGNAL TYPE MEASURING METHOD Camshaft timing sensor FUNCTION For the engine ECU to acknowledge which cylinder is at compression stroke FEATURES The Hall effect timing sensor consists of a body which integrates a coupling element and a 3 pin connector a magnet and a signal acquisition circuit Two sensors are fitted one on each camshaft Traccia Didattica Alfa 159 en ridotta 94 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The sensor connections to the engine ECU are CONNECTION TO ECU Timing sensor 1 connector pin 1 to ECU pin 7 side A ground connector pin 2 to ECU pin 41 side A connector pin 3 to ECU pin 24 side A power Timing sensor 2 connector pin 1 to ECU pin 7 side A ground connector pin 2 to ECU pin 56 side A
102. Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Alfa Romeo 159 Traccia Didattica Alfa 159 en ridotta 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL CHANGES UPDATES 2004 Fiat Auto S p A All rights reserved Circulation and reproduction also partial and with any means is forbidden No liability will be assumed for involuntary mistakes or omissions Contents may be constantly updated Fiat Auto S p A cannot be liable for consequences deriving from use of obsolete data This publication is for training use only Refer to the service manual and to service bulletins for the concerned vehicle model for complete up to date technical information for servicing purposes 2004 Fiat Auto S p A All rights reserved Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A CONTENTS ALFA 159 TRAINING MATERIAL After Sales Training CONTENTS ENEE 3 1 BRIEFING iii 9 ii TOENERAL TECHNICAL DA TA E 9 CROCI RR 9 VAIL FREE 9 LI lei rie 9 UL e le 10 The dimensions in brackets refer to versions fitting 215 55 R16 tyreS eene nennen nennen nnne nnne nnn nnne 10 kea D X P 10 SCA NET EE e ee 11 122 5 tee p T 11 DERE uncis MR uuu in 1 The transmissions available at time of release are s
103. Fiat Auto S p A Tutti i diritti sono riservati EE ALFA 159 TRAINING MATERIAL deo SYSTEM _ After Sales Training 5 Supplementary heater PTC housing diesel versions 6 Climate control system body 7 Heater 8 Heater piping 9 Supplementary heater PTC unit diesel versions 10 11 Climate control system wiring connectors with dashboard wiring harness 12 Evaporator 13 Expansion valve 14 Weather strips 15 Climate control fan 16 Recirculation actuator 17 Mixer actuator 18 Distribution actuator 19 Heater piping clips 20 Fan speed adjustment resistive splitter 21 Cover 22 Climate control ECU NCL 23 Actuator fastening screws 24 Relay unit for powering climate control fan and supplementary heater PTC diesel versions CVM Engine compartment fusebox NCL Climate control node NVM Engine control node PTC1 2 Supplementary heaters 10 4 1 One zone climate control system wiring diagram h AT AIC 12V 46 M3RIC 18 M2 DIST V BATT 30 SS A6 Al Ad ASAI2A13A24 A25A26A23 A21 A20A22A19 A17 A14 A18A15 A Traccia Didattica Alfa 159 en ridotta doc 298 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM SR A After Sales Training 10 5 TWO AND THREE ZONE AUTOMATIC CLIMATE CONTROL SYSTEM 10 5 1 Two zone system The automatic two zone climate control system can differ the distribution and temperature of the air let into the pas
104. ICAL QUANTITY LOGIC ELECTRICAL QUANTITY EGR solenoid valve Frequency to pins A12 A27 EDC 16C39 PWM signal from pin A 60 for fixed opening 1 Key off No voltage from 15 and On the basis of the following frequency to pins A12 A27 signals cut off input engine stopping Voltage on 15 and cold cranking resistance between pins A air mass meter deviation 41 and A 58 the ECU opens the EGR fixed at 1 Voltage to pins B 9 and B 31 Air mass meter deviation Voltage to pins A12 and A27 gt Glow plug control The relay is built into the glow plug ECU The injection ECU during cranking and post cranking phases times operation of the glow plug ECU according to engine temperature if T lt 0 degrees CONTROLLER OUTPUT PARAMETERS INPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Pre heater ECU Signal from pins B 72 Coolant temperature sensor Voltage between pins A 41 and A 58 B 93 and B 52 During the following phases Glow plugs gt cranking kennd gt post cranking Voltage from pins 1 2 3 4 5 for 5 cylinder of the pre the ECU times the operation of the heater ECU glow plug ECU according to engine temperature Traccia Didattica Alfa 159 en ridotta 166 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training m Traccia Didatti
105. K fio TE 35 Ga TT po 228038 37 REMOVAL REFITTING The sensor is part of the exhaust system and is fasten to the exhaust pipe over the catalyzer The connector with seal is connected to the ECU and protected from water The wire layout prevents possible stress due to contact Replace the sensor if it is accidentally dropped SPECIFICATIONS Exhaust gas temperature lt 930 C Temperature outside sensor lt 570 C Connector temperature lt 120 C Maximum exhaust gas pressure 2 5 bar ELECTRICAL SPECIFICATIONS The graph indicates the measuring current variations according to lambda values and indicates the present of rich or lean mixture to the ECU optimal lambda 1 Traccia Didattica Alfa 159 en ridotta 107 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A _ After Sales Training Ip meas I mA ii i hd E Kind i i NI EN el ted SENSOR FEATURES 12 14V power Variable voltage signal according to characteristics of the exhaust gas and ee a engine speed increases and decreases Signal peaks are interference The ECU must be powered to pick up the output signal Examiner with SAM Examiner Smart module is needed to view the signal considering RUE ME TED its type Set Examiner as a voltmeter and acquire the signal for approximately 30 seconds Post cat exhaust gas sensor FEATURES The planar oxygen sensor works at A 1 The sensor must be used in connecti
106. Ki A e Je af AN i Iw 1 iN H i2 4 i IM E dr Sliding conduit Camshaft drive chain Camshaft pulleys Guide conduit Oil nozzle Crankshaft pulley Tensioning conduit Chain tensioner 99 M ur oo Ie Traccia Didattica Alfa 159 en ridotta 61 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Countershaft drive chain Countershaft drive pulleys Guide conduits Crankshaft pulley Tensioner unit Tensioner Countershaft drive chain Coolant pump drive gear SIL Timing system Output marking gt on camshaft actuator pulley drive chain Input marking Zon camshaft actuator pulley drive chain Fourth cylinder cam position Marking on countershaft drive chain input side brass colour Marking on crankshaft pulley drive chain silver colour Marking on countershaft drive chain silver colour p Bro SS Timing is adjusted using the fourth cylinder TDC as reference The TDC points on the chain are marked by coloured links These must correspond to the markings on the drive gear teeth Traccia Didattica Alfa 159 en ridotta 62 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Important Timing cannot be checked during the references once the engine has been timed after the crankshaft has turned once TIMING INSPECTION with fourth cylinder at TDC The camshaft pulleys mus
107. MED 7 6 1 Euro 4 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training 5600 1000 2000 3000 4000 000 BOG 7006 7500 giri min MOTORE Benzina iniezione diretta Tempi 4 Cilindri 4 Valvole per cil 4 __ Prestuziuni di cel ibero loppraved performance RA Prestazioni minime pormtite minimyn guaranteed performance Specifications 2 2 litre engine Type 2 2 XHR Displacement 2198 cm Bore 86 mm Stroke 94 6 mm Suction valve diameter 35 1 mm Exhaust valve diameter 30 1 mm Maximum power speed 136 1 kW 6500 rpm Maximum torque speed 230 Nm 4500 rpm Compression ratio 11 3 1 Engine ECU Bosch MED 7 6 1 Pollution standard Euro 4 Traccia Didattica Alfa 159 en ridotta 44 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training CN KW 190 E LIO I NS EN an BN DO i HE OJ ep 10 40 i Hn TA didi c NN D BEE a 20 d SC em 5 IL e 0 LEO l DI LX ARG 3000 400 5000 B TODD OU piriznin WOTORE Banziro iniezione diretto Tanpi 4 Cilimerit4 Vnlvalg per cil 4 Prestazioni dl del Ibera oppraved parfommanza Prestazioni minime gorentite Inininun guoreteed performance Engine specifications compared 1 9 litres 2 2 litres Bore 86 86 Stroke 80 94 6 Number of cylinders 4 4 Displacement 1859 2198 Bore x stroke ratio 0 93 1 10 Connecting rod length 153 1
108. Rear window winder cut out with respective indicator LED Traccia Didattica Alfa 159 en ridotta 250 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM dii a ilaria After Sales Training Steering column stalk DEV The DEV integrates the electronics for controlling the windscreen rear window wiper and the external lights windscreen rear window wiper washer cruise control trip computer functions rain dusk sensor and light dimmer It is connected to the dashboard and front wiring harnesses and transmits controls to the NBC via the A BUS serial line Radio receiver node NRR The NRR BLAUPUNKT is connected to the B CAN and the dashboard wiring The connectors are used to interface with an external audio amplifier External audio amplifier DSP Opt The BOSE DSP Digital Sound Processor is an electronic component connected to the audio wiring harness The DSP receives the signal from the NRR audio output From the NRR it receives enabling for activation and is capable of outputting an acknowledgement signal to the NRR It is usually located in the boot Radio navigator RNV Opt The RNV pictogram navigator Magneti Marelli is an alternative to the NRR Computerised info node NIT The NIT Bosch is connected to the B CAN the I CAN and the dashboard wiring Connectors are provided with connection for external microphone and handset The NIT can interact with the Convergence
109. S CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Key on EDC 16C39 Cranking enable relay activation Voltage to pin B 28 Signal from pin B 72 interfaces with Interface with Code ECU on Code ECU for serial line enabling cranking Serial signal to pin B 25 Traccia Didattica Alfa 159 en ridotta 158 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Fuel temperature control The ECU controls the pressure regulator to reduce line pressure without changing the injection times if the fuel temperature reaches 80 C measured by the sensor in the recirculation manifold INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Fuel temperature sensor Pump pressure regulator Resistance between pins B Control voltage between pins A 49 10 and B 11 Ss and A 19 Fuel pressure sensor The ECU controls Voltage signal to pin A 43 the pressure regulator and limits torque if the Enaine speed sensor fuel temperature i exceeds 70 C Frequency on pins A12 A27 Engine coolant temperature control The ECU implements the following procedure when the engine coolant temperature exceeds 105 C gt injected fuel amount is reduced engine power is reduced gt cooling fans are operated gt coolant temperature warning light is switche
110. S p A SYSTEM dii a ilaria After Sales Training gt If another warning event occurs the new event will appear on the instrument panel and the warning cycle in progress will be interrupted the buzzer will be muted and the seat belts warning light will switch from blinking to steady Warning of the last event will resume Naturally the warning cycle will be interrupted if the seat belt is fastened during the new warning cycle gt The warning cycle will stop immediately at key off Operation after 90 seconds If the seat belt remains unfastened gt The buzzer is muted gt The warning light will stop blinking and light up steady The warning cycle will be run once only if the aforesaid conditions subsist this means that the warning cycle is not repeated after the 90 seconds also if the belt remains unfastened New warnings The warning cycle will only be repeated if the unfastened seat belt condition is detected again transition from fastened to unfastened in one of the said conditions Warning cycle cut out warning light buzzer The user can deactivate the warning cycle temporarily by means of the following procedure Within one minute from key on gt Fasten the driver and passenger seat belts The seat belt can be fastened before key on to make the procedure easier gt Keep seat belts fastened at the same time for at least 20 seconds with TEG inserted gt Unfasten at least one seat belt The warning cycle i
111. STEM OVERVIEW u ie 10 2 MANUAL CLIMATE CONTROL SYSTEM lla EIA VIa 103 SUPPLEMENTARY HEATER E OE REI IE 10 4 ONE ZONE CLIMATE CONTROL SGvGIEM i e 10 4 1 One zone climate Control System wiring diagram E 10 5 TWO AND THREE ZONE AUTOMATIC CLIMATE CONTROL 1059 1 TWO 2ZONG SVSIOIN EE 10 9 2 From EE RR T Traccia Didattica Alfa 159 en ridotta 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A CONTENTS ALFA 159 TRAINING MATERIAL After Sales Training 10 Sa Mee zone lai 298 aA rea TNS COI eege 298 103 5 Notes on sensor Opera Uol near 299 10 5 6 Two three zone climate control system 300 10 5 7 Two three zone climate control system wiring dagranm ENEE 30 One 20ne ECU biella 303 Two ere RR A A A 304 10 5 6 Head control rear connector DIDOUE ina E EAE EEEE E ESSEE E EET EEEE EENES 304 OE es Rare ate ie ee ete sano cae senna eae eee eee 305 RTE 305 Fi E ee elei 30 RESOCONTO 306 EE 306 Manual Control via pre selector E 307 lee ien ME 307 heil 307 Pinch force safety UR Lee NRI mmm 308 FRENI 308 EELER 308 CECA Pe EIA 309 ESTREMA A TI 309 IRA c 309 piel i r EE 309 Reds aaa 311 1 2 2 FTON Sea UU
112. SYSTEM After Sales Training Buttons BASIC version The following buttons are fitted on the left hand steering stalk gt MENU gt MENU gt MENU for the following functions setup menu dimming and night panel The trip meter button is located on the left hand panel Press to show and hide the trip meter Hold pressed to reset it Alphanumeric LCD BASIC version The visible area of the two line negative transflective BASIC on board panel is 61 millimetres wide and 28 millimetres high The top row consists of nine 14 segment characters for displaying gt Clock gt External temperature and first decimal in degrees centigrade gt Setup menu The second row bottom consists of gt Wrench symbol indicating service deadlines gt Six 7 segment characters with decimal point for odometer and trip meter and TOT symbol to identify type of odometer shown gt Snow symbol for indicating ice hazard gt Unit of measure for odometer distances Basic on board panel display single version for right hand and left hand drive Type of information which can be displayed on the BASIC on board panel 9 3 3 Notions on the Service function Scheduled service information The Service message followed by the number of kilometres or miles according to the unit of measure programmed in the setup menu or days before the deadline will appear on the display as the service schedule deadline approaches autom
113. Sales Training Oil sump Dimension 1 1 75 2 75 mm Dimension 2 0 5 1 5 mm Oil baffle Oil suction pipe Oil level sensor oro RS FUNCTION To contain lubrication oil and cool it by effect of air while the vehicle is travelling MATERIAL The oil sump is made of aluminium alloy with evident advantages in terms of weight reduction and heat exchange features FEATURES A baffle is riveted to the oil sump for integrating the oil suction pipe The baffle avoids excess splashing of the oil while the vehicle is travelling and prevents no load priming of the pump It reduces noise and prevent mixing of residues from the bottom of the sump MAINTENANCE Residues of sealant grease and dirt must be removed from the coupling surfaces of the oil sump before refitting the oil sump Remove sealant residues with a plastic chisel The oil sump must be sealed with silicon sealant grey as follows Apply a bead of silicon sealant width 1 75 2 75 mm dimension 1 on the surface of the oil sump at a distance of 0 5 1 5 mm dimension 2 from the internal edge of each coupling surface Apply a bead of sealant width 1 75 2 75 mm on the oil suction pipe union NOTE The silicon sealant may get into the lubrication circuit and from there into the oil pump if it is not applied correctly on the oil suction pipe union Fit the oil sump within 10 minutes from application of sealant The dipstick guide pipe is designed to be used to drain the e
114. Seat belt reminder First warning cycle warning light The seat belt warning light comes on to indicate that a seat belt driver front passenger rear passengers has not been fastened as follows steady light at key on if the seat belt is not fastened steady light if seat belt is unfastened after key on unless blinking conditions subsist see below off if the seat belt was fastened before key on off if the seat belt is fastened during key on always off at key off VN NK NN NOTE The steady light indication cannot be switched off Warning cycle warning light and buzzer The warning cycle is activated for 90 seconds if with seat belt unfastened at key on at least of the following events occurs gt over 30 seconds have elapsed and vehicle speed is higher than 4 km h gt vehicle speed higher than 25 km h distance exceeding 500 m During the warning cycle the warning light will blink frequency 2Hz D C 5096 in combination with a buzzer tone Operation during the 90 second cycle gt The warning cycle will stop immediately the warning light will go out and the buzzer will be muted if the seat belt is fastened The system will set up for the next warning gt The cycle will continue for the entire 90 seconds if one of the three events which caused the warning cycle come less Traccia Didattica Alfa 159 en ridotta doc 288 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto
115. T Cosme oa L md 5 i LI da dl lida E 3 085 5 47335 5 asa DER 12324 The working voltage is 5 volts The measuring range is from 50 C to 150 C The duty cycle is from to 10 al 90 AIR FLOW RATE SIGNAL HFM5 Tensione di uscita V 0 Portata aria kg h Traccia Didattica Alfa 159 en ridotta 142 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training In analogue air mass meters the air flow rate signal has the pattern shown in the graph In digital air mass meters the signal sent to the engine ECU is equal to 5 volts and has variable frequency from 1 4 kHz to 12 kHz HFM6 Air flow rate Output frequency The frequency of the signal output by the meter increases along with the input air flow rate this consequently decrease the period A graphic voltmeter Examiner is needed to measure and test the signal amplitude 5 volts To measure the frequency simply use a multimeter selected to measure frequency and connect the probes to one of the air mass meter ground pins and to the air flow signal pin Motorised throttle FUNCTION To limit engine shaking while stopping For this function an electronically controlled throttle is fitted before the air plenum OPERATION The motorised throttle at rest is open When it is controlled by the engine ECU it closes and shuts off air flow to the engine ENGINE OFF the throttle
116. TERS LOGIC ELECTRICAL QUANTITY MED 7 6 1 Voltage to pins The ECU according to the A 50 A 49 A 47 A 48 acceleration request implements A 32 A 33 A 35 A 34 signal torque control strategies and according to emission containment and engine performance Motorised throttle Controls the throttle adapts injection time Voltage to pins A 15 and controls variable timing A 30 Variable timing solenoid valves Voltage on pin A 12 Voltage to pins A 19 exhaust and A 04 suction Potentiometer signal on throttle Voltage to pins A 25 and A 10 Accelerator pedal fuel cut off ECU functions include gt idling acknowledgement gt rpm number over a certain threshold It stops fuel injection according to engine speed engine temperature vehicle speed Dynamic decrease of engine speed is checked before reaching idling conditions Fuel injection is partially reactivated according to a logic for smoothly taking the engine speed to idling ratio Normal functions are reactivated when idling speed is reached Traccia Didattica Alfa 159 en ridotta 118 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Brake pedal switch Pressure regulator Voltage on pin K 14 MED 7 6 1 Clutch pedal switch Co
117. TPUT SIGNAL TYPE Fuel feed 5V Working range 0 1800 bars Linear characteristic 500mV 0 bar 4500mV 1500 bar MEASURING METHOD With sensor powered by ECU use multimeter set to read voltage Traccia Didattica Alfa 159 en ridotta 178 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Accelerator pedal potentiometer SENSOR FEATURES Double resistance sensor Variable resistance according to angle Nominal values Mechanical Idling position P 0 Working range P1 0 70 OUTPUT SIGNAL TYPE Mechanical stop range P2 0 88 Electrical Power voltage 5V 0 3V Potentiometer cursor terminal resistor 1 Kohm 0 4 Kohm Resistance track 1 1 2 Kohm 0 4 Kohm Resistance track 2 1 7 Kohm 0 8 Kohm MEASURING METHOD Multimeter set to ohmmeter mode Electrical features of actuators Pressure regulator Regolatore di pressione Posizione spillo 0 05 SE Corsa spillo 0 0 24 mm E 0 03 pem frequenza di 0 02 LU AUT i U pilotaggio N i IT iM ji mit 200 Hz o 0 01 500 Hz SS 1700 Hz d U 0 0 01 0 02 0 03 0 04 0 05 tempo s Traccia Didattica Alfa 159 en ridotta 179 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Solenoid valve Resistance 2 07 2 53 Q 20 C ELECTRICAL SPECIFICATIONS OF ACTUATOR i Maximum current 2 5A
118. TY LOGIC ELECTRICAL QUANTITY Engine speed sensor Pump pressure regulator y Control voltage between pins V Frequency to pins A 27 and A 12 EDC 16C39 A9 and A 19 Coolant temperature sensor Voltage between pins A 41 and A 58 The ECU controls the regulator to obtain optimal line pressure according to engine load determined Resistance between pins B 10 by processing the signals from and B 11 various sensors Fuel pressure sensor Voltage to pin A 43 VGT variable geometry turbine control The ECU processes the signal from the booster sensor and determines the amount of fuel to be injected according to the various engine operating speeds specifically the ECU injection time signal adjusts turbine geometry to optimise performance in all working conditions Traccia Didattica Alfa 159 en ridotta 170 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training OUTPUT PARAMETERS CONTROLLER LOGIC ELECTRICAL QUANTITY Injectors Voltage to pins A 16 A 47 A 2 A 31 Se A 1 A 46 A 17 A 33 A 18 A 48 5 cylinder The ECU processes the signal from the booster sensor and determines the amount of fuel to be injected according to the various engine operating speeds specifically the gt Control voltage between ECU pins A 49 and A 19 INPUT PARAMETERS ELECTRICAL QUANTITY Overpres
119. Traccia Didattica Alfa 159 en ridotta 91 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Ignition coil line FEATURES The ignition system features a unique single spark box for all four cylinder spark plug coils Ignition is electrically controlled The spark instant and time is determined for each spark plug in the cylinder Direct injection tends to create a more concentrated mixture in the middle of the chamber For this reason and thanks to the four valve per cylinder geometry having a second spark plug in the peripheral area of the chamber would not be advantageous The connections to the engine ECU are CONNECTION TO ECU CONNECTOR DRAWING engine ground pin 1 for coil ignition power pin 2 to rail connector pin 3 to ECU pin 16 side A connector pin 4 to ECU pin 1 side A connector pin 5 to ECU pin 31 side A connector pin 6 to ECU pin 46 side A ASSEMBLY The ignition module is fastened with 4 screws to the head cover REMOVAL A specific tool is needed ELECTRICAL SPECIFICATIONS Nominal current 7A Nominal voltage 14V Coil resistance 1 30hm COMMAND TYPE Signal from spark box ELECTRICAL SPECIFICATIONS OF ACTUATOR Traccia Didattica Alfa 159 en ridotta 92 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Sensors Engine speed sensor Cam
120. With additive The additive technology is patented by PSA under the name FAP Filtre A Particules The additive is a catalyser liquid which is used to burn the particulate in the trap at lower temperatures 500 C Advantages Lower regeneration temperature Shorter regeneration time Disadvantages More complex architecture Traccia Didattica Alfa 159 en ridotta 154 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Need to replace the trap and top up additive every 120 thousand kilometres Without additive FA has developed a proprietor technology employing multiple injections to sufficiently increase gas temperature to 600 C and burn the particulate Advantages More simple architecture More reliability due to lower thermal gradients Lower maintenance costs Disadvantages Higher regeneration temperature More oil dilution Operation When exhaust gas enters the DPF trap the internal channel in the element closes and the gas crosses section A accumulating in the filtering element After this the particulate accumulates and a substrate starts forming in section B dividing the gas passage from the filtering element The accumulation of particulate obstructs the passage of exhaust gas section C to raise the pressure detected by the respective differential pressure sensor by reading the DPF input and output pressure and measuring the exact absolute
121. a flow of coolant and on the other by a flow of engine oil LOCATION The heat exchanger is fastened to the cylinder block on flywheel side on the upper part Traccia Didattica Alfa 159 en ridotta 69 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Lubrication system Oil pump 1 Pressure regulator valve 2 Stator 3 Rotor FUNCTION The oil pump circulates the flow needed for forced lubrication of the various engine parts LOCATION The oil pump is built into the timing chain box FEATURES It is operated by the crankcase by damping torsional vibrations The pressure regulating valve can be accessed from the outside and opens a range of pressures from 4 to 6 bars The two main lubrication channels are supplied by the channels in the cylinder block casting These two main channels supply the entire engine lubrication system the bearings cylinder head balancing shaft and chains The oil pump is built into the timing chain gear assembly The pump gears one internal and one external are fitted on cams Displacement is variable according to engine speed Pump service opening cover TDC piston signal for timing Oil pressure regulating valve Stator Rotor Oil pump drive gear So I Traccia Didattica Alfa 159 en ridotta 70 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After
122. accia Didattica Alfa 159 en ridotta 192 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A Terque Nm eT Angle of travel A two stage torque fluctuation damping curve can be expected from this type of flywheel for effective targeted reduction of vibrations and transmission roughness 1 Primary flywheel 2 Primary flywheel cover 3 Friction plate 4 Gear 5 Secondary flywheel 6 Spring pack 7 Lubricant 9 Rivet 10 Balancing element 11 Diaphragm spring 12 Needle roller bearing 13 Friction ring Traccia Didattica Alfa 159 en ridotta 193 318 2004 Fiat Auto S p A All rights reserved CLUTCH ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training 14 Spring pack support 15 Primary flywheel cover 16 Primary flywheel cover 17 Flange 4 4 2 Clutch assembly In this clutch model the cover assembly also comprises the diaphragm spring No automatic driven plate wear take up system is provided The assembly consists of Clutch cover Pressure plate Diaphragm spring Taper plate spring PU IW e Traccia Didattica Alfa 159 en ridotta 194 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training The clutch cover is made of mixed compact spheroid graphite The diaphragm spring is tempered and hardened The diagram underneath shows the performance of the diaphragm spring
123. act with the surface of the dashboard They contribute to reaching the highest safety standards The driver s knee airbag is standards the passenger s is optional 9 7 2 Airbag system diagram SCHEMA DI DELIBERA IMPIANTO AIRBAG 932 4 Um Traccia Didattica Alfa 159 en ridotta doc 285 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM i i ic dora a rg After Sales Training Supplementary Early Crash Sensor ECS The supplementary Early Crash Sensor ECS located near the bonnet lock helps the ECU to anticipate airbag deployment with respect to a traditional system and avoids the risk of minor injuries caused by airbag deployment by inflating the airbags before the occupant starts advancing towards the steering wheel or dashboard It also decreases sensitivity in the case of collisions under the body for which airbag deployment is not necessary because they do not cause risks to occupants Manual airbag deactivation switch The switch located on the right hand side of the dashboard left hand side on right hand drive models can be used to deactivate the passenger s airbag to safely install a back facing child seat A LED will light up on the instrument panel when the airbag is deactivated Deactivation is only possible when the car is stationary 9 7 3 Knee airbag modules Features Two airbag modules are fitted in the lower part of the dashboard in front of the passenger s knees
124. adjustment interface Three air mixing actuators left front right front rear Three air distribution actuators left front right front rear One air recirculation actuator VV VV Traccia Didattica Alfa 159 en ridotta doc 299 319 2004 Fiat Auto S p A Tutti i diritti sono riservati EE ALFA 159 TRAINING MATERIAL deo SYSTEM After Sales Training gt gt gt gt gt One climate control system fan electronic speed regulator One temperature sensor downstream of the evaporator One internal temperature sensor integrated in the NCL One external temperature sensor locate din the left external mirror This sensor does not belong to the climate control system but contributes to its operation by means of a signal transmitted via NQS and B CAN One sun sensor located on the dashboard panel gt The system may be fitted with an optional AQS sensor located near the external air intake vent and a fog sensor located near the rain sensor V An optional supplementary heater may be fitted aboard two three zone systems in diesel versions This unit consists of a PTC resistor unit located downstream of the heater radiator Operation These functions are controlled by seven electrical actuators 18 19 20 21 22 23 24 consisting of stepper motors each integrated in an electronic control unit Each actuator is independent from the others and is a data acquisition unit The NCL communicates with the control units via a seria
125. aining SENSOR FEATURES OUTPUT SIGNAL TYPE MEASURING METHOD Electrical resistance equal to approximately 1 kOhm Variable alternating voltage maximum value and frequency proportional to flywheel speed An oscilloscope or Examiner with SMA Examiner Smart module is needed to view the signal considering its type Set Examiner as a voltmeter and acquire the signal for approximately 2 5 seconds The graph must show the following characteristics wave amplitude and frequency proportional to each other and to the flywheel speed signal modified when sensor reads the missing tooth every 58 signal peaks Timing sensor electrical features 1 ground 2 signal 3 power SENSOR FEATURES OUTPUT SIGNAL TYPE MEASURING METHOD Hall effect sensor 5V power from ECU Variable voltage signal in time according to pulse square wave when sensor meets tooth on pulley output signal 0 lt Vout lt 4 5 V Given the features of the sensor the ECU must be powered to pick up the output signal An oscilloscope or Examiner with signal acquisition module is needed to view the signal Timing sensor electrical features TT MEN WII E MAMMA il 3 67 s 3 80 s 3 92 s 4 06 s 4 19 4 32 Traccia Didattica Alfa 159 en ridotta 175 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training SENSOR ECU test circuit RL Ab
126. al mirror Boot node NVB The NVB is an electronic component connected to the B CAN and to the rear wiring harness It manages the electrical functions of the rear doors particularly when these are equipped with electrical window winders Passenger control ECU CCP The CCP is a component connected to the respective front door It manages the electrical window winder power and signal Control panel on driver s door PCP The PCP module integrates the controls on driver s door and is connected to the NPG via the front door wire on driver s side The PCP receives dimmed power for lighting the ideograms and houses the following controls External mirror movement folding Front window winders Rear window winders Rear window winder cut out with respective indicator LED YYYY Traccia Didattica Alfa 159 en ridotta doc 251 319 2004 Fiat Auto S p A Tutti i diritti sono riservati EE ALFA 159 TRAINING MATERIAL deo SYSTEM After Sales Training Window winder controls on passenger s side front door and rear doors CAP The CAP modules are connected to the NPP and to the NVB via wiring harnesses on the passenger s side front door and rear doors to control the respective window winder motor The receive power for lighting the ideograms Parking sensor node NSP Opt The NSP is an electronic component connected to the B CAN and to the rear and front wiring harnesses It is a driving assistance tool that informs of the presence
127. an ECU The throttle body includes an actuator a throttle valve and a valve position sensor potentiometer integrated in a single unit The actuator is a direct current dual stage motor The working life of the throttle body is 15 years with a minimum kilometrage of 250 000 km The connections to the engine ECU are Traccia Didattica Alfa 159 en ridotta 74 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training CONNECTION TO ECU CONNECTOR DRAWING 6 pins two rows connector pin 1 to ECU pin 30 side A DC electrical motor ground connector pin 2 to ECU pin 9 side A actuator ground connector pin 3 to ECU pin 24 side A sensor power connector pin 4 to ECU pin 15 side A DC motor power connector pin 5 to ECU pin 25 side A IP2 signal from actuator to throttle connector pin 6 to ECU pin 10 side A IP1 signal from actuator to throttle Attuetore Farfalla CONNECTION ROUTE The maximum slant of the wiring route with respect to the direction of the pins must not exceed 45 The wires fastened to the intake plenum must be shorter than 100 mm NLP Failure position UEA Home position OEA Maximum opening position Traccia Didattica Alfa 159 en ridotta 75 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training OPERATING PRINCIPLE The air flow is controlled by t
128. and Convergence are described in detail below The map radio navigator with and without telephone derive from Connect Nav and have the same navigation and audio features They differ for the absence of computerised services and for the absence of the integrated telephone and hands free kit the latter for RN _ 9 4 1 Connect NAV Connect Nav provides information such as for example local traffic weather services and timetables coordinated with the GPS The device includes gt radio module CD ROM drive GPS module dual band GSM telephone module self standing map navigation module TFT 6 5 colour display external Blaupunkt CD changer management if present voice recognition integrated module WAP protocol management software MP3 file software interface with controls on steering wheel three button panel on ceiling light NAV Connect SOS VV VV VV VV VV WV Traccia Didattica Alfa 159 en ridotta doc 273 319 2004 Fiat Auto S p A Tutti i diritti sono riservati EE ALFA 159 TRAINING MATERIAL deo SYSTEM After Sales Training Radio module General features music audio power 4 x 35W five band graphic equaliser easy to manage menu for adjusting radio settings and external interfaces CD changer remote control on steering wheel possibility of interfacing with external Blaupunkt 10 disc CD changer volume control according to speed possibility of operating some controls using the voice recogni
129. and a 3 pin connector one for power one for signal to ECU and one for ground The sensor connections to the engine ECU are Traccia Didattica Alfa 159 en ridotta 96 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training CONNECTION TO ECU CONNECTOR DRAWING connector pin 1 to ECU pin 7 side A ground connector pin 2 to ECU pin 8 side A connector pin 3 to ECU pin 24 side A power Sensore press carburante REMOVAL REFITTING The sensor is part of the injection rail and is fastened onto the rail It is fastened by turning the hexagonal metallic part ADDITIONAL INFORMATION The recommended assembly position is with the sensor hexagon facing downwards at a 0 to 90 slant with respect to the vertical line and minimum space between the sensor and the rail WORKING DATA gt Pressure range from0 to 14 MPa gt Response time 2 0 ms POSITION The pressure sensor is positioned on the front side of the engine on the right on the intake plenum by the side of the pressure regulator valve 1 Fuel pressure sensor Traccia Didattica Alfa 159 en ridotta 97 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training ELECTRICAL SPECIFICATIONS Output Voltage Una Upper Range for Signal Range Check SRC 0960 4 8 D 90U 4 5V Values for U 5 V n brackets 0 10Us 0
130. are was devoted to passive safety in layout the electrical steering column lock has been moved away from the front of the column away from the knee area and a controlled energy absorption collapsing system has been adopted for the steering column This along with the steering wheel airbags knee bags and the seatbelts ensured achievement of five star performance in EUNCAP crash tests 7 1 1 Hydraulic system Steering linkages Steering box Brake oil reservoir Cooling serpentine DO II Traccia Didattica Alfa 159 en ridotta doc 225 319 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A STEERING ALFA 159 TRAINING MATERIAL ees After Sales Training The hydraulic circuit fits a hydraulic pump operated by the utility belt The pump takes in oil from the reservoir near the pump The pump delivery reaches the steering box that houses the rotating distributor Oil discharged from the steering box is sent to the reservoir after crossing the serpentine on the radiator which is invested by the flow of air and cools the oil 7 1 2 Steering system components Power steering pump location Power steering pump The following features are standard for all versions gt aluminium pump displacement according to engine speed capable of ensuring 10 7 l min at 99 bars low engine speed reduced to 8 l min at higher engine speed to contain consumption gt piping shape length and damping devices optimised to minimi
131. arge version The need to improve the performance of current halogen lamp systems in terms of light energy output spectrum distribution and bulb life led to the development of gas discharge headlights and respective devices for operating on the vehicle The advantages deriving from the development of this technology are essentially three gt higher light efficiency for decreasing electrical power draw gt high light flow reduces the dimensions of the light flow particularly height and more freedom in front end design gt the life span is in average double that of a halogen bulb The gas discharge headlight technology has led to the development of a number of devices which briefly include Traccia Didattica Alfa 159 en ridotta doc 291 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM i i ic dora a rg _ After Sales Training xenon bulb headlight reflecting surface controlling electronic ballast automatic beam height correction VV WV wv Each light cluster integrates the components needed for operating the discharge bulb bulb reactor ECU and control motor It also comprises traditional components side lights direction indicators dipped beam headlight The cluster appears as follows Spot main beam headlight Concealed side light Main beam dipped beam headlight Direction indicators Pep c NOTE The spot main beam headlight is used alone to fla
132. arning generated by the system 9 6 1 Notions for calculating distance from obstacles The ECU generates a sequence of ultrasound pulses which are reflected by the obstacle through sensors built into the bumpers The reflected pulses are captured by the sensors which amplify and convert them into a digital signal emm Traccia Didattica Alfa 159 en ridotta doc 281 319 2004 Fiat Auto S p A Tutti i diritti sono riservati EE ALFA 159 TRAINING MATERIAL deo SYSTEM After Sales Training The ECU compares these signals with those previously transmitted and is capable of measuring the delay and consequent distance from the obstacle 9 6 2 Structure The parking assistance system consists of the following components gt One ECU located underneath the rear seat gt Eight ultrasound sensors four in the front grill and four on the rear panel gt Two dedicated buzzers one in the back of the passenger compartment and one in the front of the dashboard 9 6 3 Electronic control unit The ECU controls the following functions gt Activate the sensors gt Process the signals received from the sensors gt Check functionality of sensors gt Operate buzzer gt Manage diagnostics and test functions The ECU is equipped with a diagnostic B CAN interface 9 6 4 Ultrasound sensors The sensor is an ultrasound transducer for smart transmitting and receiving ultrasound pulse packets Both the pulse frequency and vol
133. arwindow cigarlights heaters 9 1 4 Ground points Front Battery ground Front Front Radiator Front Engine Pre Wiring Engine Pre Wiring Engine Pre Wiring Dashboard Rear Rear Front Dashboard Rear Climate Control Pre Wiring Rear Rear Traccia Didattica Alfa 159 en ridotta 243 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM ee After Sales Training 9 1 5 Electronic components The following table shows the most complete configuration on design level Some nodes or ECUs may not be installed for the moment in this model co o J Sesso SSCS E csa AmmetsrenEQU ooo E ost AwiayismmenECU E DSP__ BOSE hifi audio ampie NBC NOV FPassenesdoormode assenger s door node o ege m m m Smart Key TEG reader node NVO Z NAS __ Steering angle sensor node ABS VD cog in TI desio SOS E OPP__ Tyre pressure monitoring system ECU op E GPD Ruhteadig EQU S E GPS Let headight EGU w discharge headighiy E NCA Automatic transmission node op E NCR Robotised transmission node op T NF G P C A H N m li m m m TI Sunroof ECU opt NFR Braking system node VDC NFR_ Braking system node ABS and ABS VDC opt Lateral Yaw sensor node opt with VDC Traccia Didattica Alfa 159 en rid
134. as according to the engine Voltage to pins A 42 and A load and the accelerator pedal i i 44 Frequency to pins A12 A27 potentiometer signal Accelerator pedal sensor Voltage to pins B 9 and B 31 Traccia Didattica Alfa 159 en ridotta 164 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Air control cut off The EGR valve is opened by 1 in the following cases for this strategy OPERATING CONDITIONS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Cold start EGR solenoid valve Resistance between pins PWM signal from pin A 60 for A 41 and A 58 EDUC Io fixed opening 196 Prolonged idling Frequency to pins A12 A27 On the basis of the following signals engine temperature TS engine idling time SANG clutch operations during air flow i Voltage to pins A 42 and A 44 and on pin B79 reading changes large amounts of injected fuel the ECU opens the EGR fixed at D Voltage to pins A12 and A27 i Air control cut off The EGR valve is opened by 1 in the following cases for this strategy Traccia Didattica Alfa 159 en ridotta 165 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL OPERATING CONDITIONS CONTROLLER OUTPUT PARAMETERS ELECTR
135. ati BODYWORK ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training Electrical seat diagrams Wiring diagram of driver s seat Forward teckward motor Cscionup down Tilt updown Backrest forward backward Sc ci E electro pneunatic lunbar forward backward Ctshion heater Seat heater nodule OR ODULAR NIE MCPMDDU ARE e ae Back heater d r S I Z Heating wire ES EE alssie Lebabile z 0 35 B CAN A N C 0 35 B CAN GND SEGNALE 35 0 ul Traccia Didattica Alfa 159 en ridotta 314 318 2004 Fiat Auto S p A Tutti i diritti sono riservati BODYWORK ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training Wiring diagram of passenger s seat Forward backward motor Cuscion K Tilt up down Backrest forward backward LES c SBR Pretensionatore forward backward up down Buckle switch Cushion heater Seat heater module LE En Heating wire _ NEED R CONNETTORE CONNETTORE VA MCP MODULARE MCP MODULARE NTC sensor 1 CONNETTORE 12 VIE m Z 2 _ Heating wire Te n 2 3 d S S z e E s 3 Seat heating switch Traccia Didattica Alfa 159 en ridotta 315 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A 10 DA Alife 51 4 ALFA 159 TRAINING MATERIAL SE After Sales Training Front seat interface pinout DRIVER S SIDE FUNCTION PIN Heater power Heater control light 2 Not
136. atically automatic Service function at key on after the initial check procedure The service schedule information may also be displayed by the user by selecting a specific setup menu item In this case the information can be seen regardless of the deadlines The service schedule includes nine service coupons gt The initial kilometrage programmed by the on board instrument panel must be equal to 20 000 km or 12 000 miles The initial setting of 20 000 kilometres must be appropriately converted into miles by the on board panel to ensure acknowledgement of thresholds at which the information will be shown on the display as defined in the next paragraph The initial days must be equal to a 365 one year and must be set automatically by the on board panel when the total odometer reading is equal to 201 kilometres 125 miles On board display logic in automatic Service mode Thefirst message must be shown once only at key on whenever one of the following conditions occur Traccia Didattica Alfa 159 en ridotta doc 270 319 2004 Fiat Auto S p A Tutti i diritti sono riservati E ALFA 159 TRAINING MATERIAL o SYSTEM After Sales Training a the kilometres or miles according to the programmed unit before the programmed deadline are either equal to or less than the threshold 2000 kilometres or 1240 miles b there are thirty or fewer days before the deadline gt The message must be shown once only at key
137. attica Alfa 159 en ridotta 309 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A After Sales Training 210 BD 4 e st ALFA 159 TRAINING MATERIAL gt A modern lumbar support system is provided The system is specifically dimensioned to more completely adapt to the occupant s back and support it in a relaxing way by being very wide and functional gt The driver s seat can be adjusted in height and has a vertical stroke of approximately 50 millimetres The seat s height can be adjusted with the knob Operation is very light and easy Longitudinal sliding guides are provided They are fitted at a 4 5 slant which pulls the seat slightly upwards as it moves forward The driving position can be optimised for a very wide range of drivers by adjusting the height of the seat and the axial position of the steering wheel The backrest slant adjustment is continuous and regulate by means of a knob located in the area of the backrest facing the inside of the passenger compartment The lumber support can be adjusted in some versions on both the driver s and the passenger s seat using a knob on the outer side of the seat which controls a mechanism that varies the push in the lumbar area of the backrest The front seat foam is comfortable thanks to variable lift this parameter measures the capacity of the padding to give under the weight of the body FRONT SEAT FEATURES gt Distance between guides 446 mm
138. bda sensors knock control acceleration mixture enrichment control accelerator pedal fuel cut off fuel vapour recovery maximum engine speed control fuel temperature control climate control system connection cylinder position acknowledgment optimal injection time for each cylinder ignition advance regulation idling soeed management also according to battery voltage fan control ABS ASR ECU connection fuel system diagnostics variable timing management VVVVVVVV VV VV VV VV VV wv Continuous variable timing management The variable timing system of 1 9 and 2 2 JTS engines unlike the previous versions with on off variable timing on intake only is continuous and applied to both intake and exhaust It has a 50 degree adjustment range The controls on intake and exhaust side are completely independent The following table illustrates the effects of variable timing on engine operation by the way of example Settings are the result of a compromise between opening advance and closure delay to optimise consumption performance and emissions There is no clear application principle reference is made to the experience of motor engineers at the test bench Traccia Didattica Alfa 159 en ridotta 112 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training The main reasons for adjustments are explained below INTAKE OPENING The exhaust gas inertia combined at the same
139. c tool is needed to remove the injector When refitting replace the teflon ring the guide plate and the o ring Calibrate the teflon ring with a specific tool Injector removal tools A 0 986 616 100 B 0 986 616 101 Slant the tool to remove the injector along the installation axis of the valve Traccia Didattica Alfa 159 en ridotta 88 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Teflon ring calibration tool combustion chamber seal Two tools are needed to remove the combustion chamber seal 1 from the injector stem 2 A 0 986 616 098 B 0 986 616 099 Tool A holds the seal 1 tool B is used to position it 2 after fitting To refit the seal 1 Position tool A on injector 4 Pull the new seal 1 up combining tool A on the valve body stem Do not use lubricant CAS To calibrate the seal push tool B on the chamfered side turn it by half a turn on one LC side and then back to the starting point Pressure regulator valve FUNCTION The pressure regulator valve controls the fuel pressure inside the rail according to the ECU mapping independently from the amount of injected fuel and from the pulses caused by the high pressure pump Excess flow if sent back to the high pressure pump suction FEATURES Electronic pressure control valve with compact 2 pin connector Traccia Didattica Alfa 159 en ridotta 89 318
140. ca Alfa 159 en ridotta 167 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Intake control according to climate control system The ECU controls the A C compressor as follows by gt switching the compressor on off when the respective button is pressed gt switching the compressor off temporarily approximately 6 seconds during sudden acceleration or when maximum engine power is required CONTROLLER INPUT PARAMETERS ELECTRICAL QUANTITY OUTPUT PARAMETERS LOGIC ELECTRICAL QUANTITY Engine speed sensor Frequency to pins A12 A27 EDC 16C39 Compressor cranking enable The ECU controls the A C compressor as l follows by Voltage to pin B 29 Accelerator pedal sensor P gt switching the compressor on off Voltage to pins when the respective button is B 9 and B 31 pressed gt switching the compressor off temporarily approximately 6 Coolant temperature sensor seconds during sudden Voltage between pins acceleration or when maximum A 41 and A 58 engine power is required Fuel pump control Regardless of engine speed the ECU gt powers the auxiliary fuel pump at key on cuts off auxiliary pump power if the engine is not cranked up within a few seconds Traccia Didattica Alfa 159 en ridotta 168 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p
141. ccelerates the gas speed Higher entrance speed into the turbine cause higher peripheral speeds of the turbine and therefore of the centrifuge compressor 1 Turbine 4 Rotating ring 2 Vanes 5 Passage section 3 Pneumatic actuator Traccia Didattica Alfa 159 en ridotta 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Exhaust gas recirculation system EGR solenoid valve injection ECU heat exchanger exhaust manifold throttle body Sie FUNCTION The EGR system aspirates a variable part from 5 to 15 of the exhaust gas in certain conditions of operation This lowers the maximum combustion temperature to under 1800 C when NOx is formed in lean mixture conditions The EGR solenoid valve controlled by the ECU lets some exhaust gas from the exhaust manifold back into intake A heat exchanger partially cools the exhaust gas and additionally lowers the temperature in the combustion chamber OPERATION The engine ECU controls the EGR solenoid valve with a PWM signal when the coolant temperature is gt 20 C and the engine speed is in the range from 800 and 3000 rpm The changes in the duty cycle of the signal moves the actuator to control the burnt gas flow from the exhaust manifold to the intake manifold The result is two fold A less air is let into the engine the firing temperature is lowered due to the presence of inert gas consequently reducing the forma
142. ce 23m nmm PC A 12 34586 7B BID TN e W Ce cm e ee e er e e e e e e e e mm e e e e e i3 14 15 16 17 18 18 20 21 22 23 24 25 E fia 6 Kdignosiclne S 8 Rightfronesensornegaive S 9 Rightrearsensorposiive i8 a ie n 6 2 2 VDC wiring diagram T 2 n E H Marta m D e n s a ni o ww ww E gd did e a j i 5 H a Ll mm we i 3 33 dii sila G re O 5 sia Sensor an pelo _ IN YLE MAS C DES A cPL F i i i A m i oi ri TACO 1 CHA an e ER Ani di Poal an Pew 3 unc SENSORI z Traccia Didattica Alfa 159 en ridotta 217 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training Steering angle sensor SAS and steering angle node NAS The steering angle sensor detects the angular degrees and the rotation speed of the steering wheel The signals are made available on the C CAN line steering angle sensor node Versions equipped with ESP are provided with a steering angle node NAS which also fits the sensor This is fitted on the steering stalk clock spring C CAN L from NYL NSC C CAN L to NCM NCA NCR C CAN H from NYL NSC C CAN H to NCM NCA NCR INT from F 42 CPL 7 5 Ground DEA e Operation The sensor measures the following quantities with its internal electrical device gt st
143. cific device located in the igniter A voltage elevator circuit transfers the appropriate amplified overvoltage to the bulb and causes the discharge between the electrodes Arc take over During this phase that lasts for a few seconds the bulb is super powered to cause the rapid evaporation of metallic halides contained in the bulb and ensure that running brightness is reached rapidly In these conditions the bulb flashes with light whose intensity is double the normal value for approximately 100 microseconds Traccia Didattica Alfa 159 en ridotta doc 292 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM dii a ilaria After Sales Training gt Warm up The ballast adjusts brightness for approximately two minutes detecting the physical state of the bulb and its impedance closed loop gt Steady state The light beam is continuously controlled in a closed loop also during steady state conditions 9 8 2 Rear headlight view Headlight power 14 pin connector Headlight horizontal axis adjustment screw Headlight vertical axis adjustment screw ECU mi ad 9 8 3 Wiring diagram and optical cluster connector pinout Headlight power 14 pin connector PINOUT 1 Dipped beam headlight control 2 Main beam headlight control 3 Side light control 4 Direction indicator control 9 ECU key on power 10 Speedometer signal to master only 11 K diagnostic line 12 Serial line 13
144. concerning single wires with some improvements The maximum transmission speed is kbit s which results from electromagnetic compatibility requirements and clock synchronisation The LIN nodes do not use system configuration data except for master node denomination Nodes can be added to the LIN without requiring changes on hardware and software level in the other slave nodes A LIN can typically contain less than 12 nodes although this limitation is not binding due to the limited number of identifiers 64 and the Traccia Didattica Alfa 159 en ridotta 245 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM SA RIS After Sales Training relative slow transmission speed The main factors that make the LIN a cost effective solution are clock synchronisation the simplicity of UART communication and the one wire configuration UART Pronounced you art stands for Universal Asynchronous Receiver Transmitter The UART is a computer component that governs asynchronous serial communications UARTs are found in all computers for managing serial ports and in some internal modems Serial asynchronous transmission Asynchronous transmission is to used transmit data without forcing the transmitter to send a clock signal to the receiver On the contrary these two entities must establish the synchronisation parameters beforehand Furthermore special bits are added to each word for synchronisin
145. conditions of use 1 2 9 Active safety The Alfa Romeo 159 is equipped with some of the most sophisticated electronic and mechanical assistance systems gt ABS wheel anti locking system EBD electronic brake distributor between the front and rear wheels VDC vehicle stability electronic control ASR traction control system combining the action of brakes and engine ECU MSR engine brake control governed by the engine ECU HBA with VDC automatic braking pressure in the event of panic braking Hill holder with VDC auxiliary system for holding the car stationary when starting uphill the brakes are released when the car starts off VVVVVV The servo hydraulic braking system consists of two independent crossed circuits Each circuit works on a front wheel and the diagonally opposite rear wheel to ensure braking and stability also in the event of a failure to one of the circuits The Alfa Romeo 159 fits a pedal board with plastic mount housing the brake and clutch pedals The clutch pedal is made of plastic The brake pedal made of steel is fitted with a device that makes the pedal board collapse in a collision This minimises intrusion in the passenger compartment and prevents injuries to the lower limbs 1 2 10 Passive safety The striving for excellence in performance has led to the introduction of state of the art passive safety design construction and content solutions Fiat Auto and suppliers were called upon to take part in a f
146. conduit from the oil separator consequently preventing the access of oil into the sump 1 Blow by valve Traccia Didattica Alfa 159 en ridotta 72 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Air intake system 3 1 Intake plenum Canister bleeder valve Brake booster vacuum port Blow by valve Electronic throttle Supporting bracket fastening m ul FUNCTION The plenum contains the air that is taken in by the cylinders and conduits that convey the air evenly to the various cylinders MATERIAL The intake plenum is made of composite material with three layers of nylon filled with 30 glass fibres and friction welded FEATURES It distributes intake air to each cylinder The air flows from the throttle body inside the plenum and is distributed evenly through the single conduits and then into the cylinder volume The plenum volume and shape must stabilise the pulses created by intermittent suction of the various cylinders Air course length 255 mm Air course diameter 48 45 mm Capacity 3 55 dm Plenum weight 1900 g Complete module weight 3100 g Range of operation from 30 C to 120 C ASSEMBLY CONDITIONS The following elements must be taken into consideration when fitting the module INTAKE PLENUM SUPPORTING BRACKET The plenum is fastened to the bracket by a bolt AIR CONDUIT The plenum is joined to the injection conduit by means of 4 sle
147. cting the 30 battery power from accidentally locking the doors Key on The steering wheel is released by the NBS when a TEG stored in the NTR TEG reader is inserted 15 power is activated as described in detail below Steering wheel lock management The steering wheel is unlocked when a valid TEG is inserted in the reader Insertion is recognised by a switch in the node called TEG IN validity of the TEG is established by reading the transponder according to the Code operating logic A warning message is sent to the NQS to inform the user if the steering cannot be unlocked invalid unrecognised TEG The steering is locked when the TEG is extracted from the reader The TEG can only be extracted at key off except for using the emergency TEG procedure described in the specific paragraph below There are no recovery strategies for the steering lock As a consequence the device cannot be released and the engine cannot be started in the event of a fault to the system 15 signal activation To switch from key off to key on gt insert a valid TEG in the TEG reader or gt press the PAV button if the TEG is already inserted in the reader both insertion of the TEG and pressure of the PAV will wake the CAN up At this point the NBS will ask the NBC for permission to give 15 and after checking validity of the code via the NTR will unlock the steering and send a power enable to the electrical system The NBS provides 15 54 INT and INT A w
148. d on Traccia Didattica Alfa 159 en ridotta 159 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Engine coolant temperature Pressure regulator sensor Resistance between pins A 41 Control voltage between pins A and A 58 SE 49 and A 19 The ECU controls the pressure regulator Cooling fans fans and warning light if the coolant temperature exceeds 105 C nm Voltage to pins B 69 and B 90 Injected fuel amount control According to the signals from the sensors and the mapped values the ECU gt controls the pressure regulator gt adapts the pilot injection times for all engine speed ranges gt adapts the main injection time INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Accelerator pedal sensor Pump pressure regulator Voltage signal to pins Control voltage between B 31 and B 9 GEN pins A 49 and A 19 Engine speed Sensor According to the signals from the Injectors sensors and the mapped values Frequency on pins A12 the ECU e controls the pressure ME LU A 16 A 47 A 2 A 31 regulator A 1 A 46 A 17 A 33 e varies injection time by Air flow meter controlling four different A o ERR pilot and main injections
149. d panel service network personnel must Restore the total odometer reading kilometres miles gt Read the number of coupons done and store the value in the new instrument panel Read the kilometre mile and day counters before the next scheduled service deadline and program the values on the new on board panel Stored data must be maintained by the on board panel if the battery is disconnected N B Use the Fiat part number shown on the label if the failure is such to prevent reading of the damaged unit The parameters read from the panel to be replaced and stored in the new instrument panel are Odometer Distance in kilometres since the last coupon Service coupon number Service day counter information VV WV wv Traccia Didattica Alfa 159 en ridotta doc 271 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM A HE NUS Ls After Sales Training Main instrument panel pinout 8 LH EH a p eS ee eni i A A Ii UI e JI illelll II 6 E 2 T O i 18 BLACK connector ES DIN FUNCTION 1 INT from F 37 Analogue signal on LH stalk Mode 6 Analogue signal on RH stalk Trip up down NQS ground 8 Not connected Le Not connected Injection EOBD warning light negative signal from NCM Not connected Dimmed positive for button panel LEDs EHB warning light electrohydraulic brake NPB failure warning light Safety bu
150. d stylish appeal Spoilers Front Rear dams Tailpipes Sports trim springs Dome bars VV VV VV These features contribute to enhancing the most characterising aspects of the car the expression of a technological strong and decisive image The interior focus is on technology gt Rocker panel with and without lights gt Wood or technological material steering wheel and gearlever knob gt Leather gearlever boot and handbrake gt Sporty pedal board Leisure These accessories enhance comfort and versatility of the Alfa 159 gt Roof bars maximum capacity 50 kilograms for all transportation needs gt Tow hitch maximum load on ball of 50 kilograms for particular transportation needs The tow hitch capacity is shown in the Owner s Handbook The ECU fully integrates the car s sophisticated electrical system and body computer gt Ski holder snowboard holders surf holder bicycle holder storage box for all snow and sea sports gt Protective nets for withholding objects in the passenger compartment and boot and for conveniently transporting small objects gt Boot protection removable and washable for objects that could soil and or damage the carpet gt Bag kit designed by Centro Stile in line with the brand message gt DVD player for entertaining rear seat passengers gt Mini refrigerator Comfort To gratify the need for well being and for enjoying the appealing interiors Lineaccessori offers g
151. d therefore preserve the battery charge Logistic mode is activated by the factory only and ensures that the car can be accessed and driven safety although riding comfort is decreased within an acceptable range Logistic mode must be deactivated before the car is delivered to the end customer SMART KEY TRW The smart key is an electronic device that replaces the traditional ignition switch and mechanical key It is used to gt remotely control locking and unlocking of doors and boot gt releasing the steering Starting the engine Instrument panel MARELLI VDO The instrument panel features indicators for the new implemented functions including for example graphic obstacle indicator display TEG indications and special warning lights On board computer BOSCH The NIT may implement an optional system called Convergence Convergence is an electronic module for interfacing the computer with a Bluetooth cellular phone within the operating range of the system approximately 5 metres TPMS Tyre Pressure Monitoring System TRW The TPMS Tyre Pressure Monitoring System checks tyre inflation pressure and informs the driver if the pressure or temperature of one or more tyres is out of range Tyre state information is shown to the driver by means of visual signals on the panel Acoustic warnings are associated to the panel signals for the most critical cases e g badly deflated tyre Parking Assistance VALEO The Parking Assistance sys
152. dow above the rear axle another clear stylistic expression of strength robustness and dynamism and embraces the passenger compartment thanks to the stylistic device of the classic Alfa Romeo elbow The front pillar is set further back to make the line look sleeker underlining the presence of the powerful engine and making the passenger compartment look more compact improving visibility on bends Traccia Didattica Alfa 159 en ridotta 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training In other words sleek but solid dynamic but robust only outstanding stylistic balance can combine such different characteristics For example the muscular wing which next to the generous wheels marks the widest point of the car unequivocally conveys the ideal of a car that is firmly anchored to the ground In spite of its capacious size the rear end with its beautifully balanced form blends perfectly with the front setting off its unique personality and has a horizontal design underlined by a chromed double exhaust tailpipe on the more powerful versions And it is topped off by a small spoiler which combines styling and practicality right above the logo which is positioned where it is immediately visible and the elongated lights divided by the slit of the boot which include cylindrical shapes derived from the styling of we the front headlights And f
153. e Driver s door node NPG The NPG is connected to the B CAN and to the respective front door wiring It manages the electrical functions of the respective door the external mirror on driver s side and the rear ceiling light It is connected to the door control panel PCP As the NPA the NPG also makes the external temperature signal available to the network Passenger s door node NPP The NPP is connected to the B CAN and to the respective front door wiring It manages the electrical functions of the respective door the rear ceiling light and the external mirror It is connected to the door control panel PCS and houses a connector for directly connecting the wiring provided with the respective external mirror Boot node NVB The NVB is an electronic component connected to the B CAN and to the rear wiring harness It manages the electrical functions of the rear doors particularly when these are equipped with electrical window winders Passenger control ECU CCP The CCP is a component connected to the respective front door It manages the electrical window winder power and signal Control panel on driver s door PCP The PCP module integrates the controls on driver s door and is connected to the NPG via the front door wire on driver s side The PCP receives dimmed power for lighting the ideograms and houses the following controls gt External mirror movement folding gt Front window winders gt Rear window winders gt
154. e fuel injections and by the high pressure pump operation At the same time it must be stiff enough to rapidly respond to pressure variations during engine operation Traccia Didattica Alfa 159 en ridotta 86 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL Low pressure tube fitting Pressure regulator valve High pressure tube fitting Pressure sensor High pressure injectors os Dr REMOVAL REFITTING Two versions of the injection rail are available code AA for 1 9 litre engines and code BC for 2 2 litre engines The injectors are fixed with o rings only The assembly is directly mounted on the head A specific tool is needed to fit the clamps on the sleeves Simply press the injectors in their housings to assemble the rail Then fit the fastening screws at the same time with the correct tightening torque High pressure injectors FEATURES These electromagnetic high pressure injectors with compact 2 pin connector are connected directly to the fuel rail and spray directly into the combustion chamber The instant of opening of the injectors and the amount of injected fuel are managed by the electrical control signal of the injectors The injectors are fastened in their housings with devices to prevent loosing into the fuel rail This ensures correct positioning of the injectors on the head Replace the clamps after removal with the injector maintenance to ensure pe
155. e gearbox is supported by two taper roller bearings 7 Upper secondary shaft i SE P d HI z C SN EA EX d 2 ZE TA I IZ ERE Ae E h d CHARACTERISTICS The upper secondary shaft supports the third 3 fourth 4 and reverse R gears This gears are all idly mounted on roller bearings Two synchronisers are present one triple cone for making the third or fourth gear integral with the shaft and one single cone for reverse The shaft is provided with a gear for transferring motion to the differential crown wheel The shaft is supported by two taper roller bearings 7 Lower secondary shaft Traccia Didattica Alfa 159 en ridotta 204 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A After Sales Training TRACCIA DIDATTICA ALFA 159 2 1 R f h E s n 5 eee TIT l d 6 ei zl FS EN ENNA p Hr HE MSN 3 N i 4 CERIS REIGN SR Alioni SECH ZN AR AL L E P NE ESNS SN i i E _ pee a N o x 1 LN EE SEN a FUP EV HT SE i PET N Li NS x Wwe Me Rl NRE 5 NSSY Be AD TI NS The first 1 second 2 fifth 5 and sixth 6 gears are fitted on the shaft The first gear is also used for reverse R The shaft is supported by two taper roller bearings 7 5 2 4 Synchronisers An exploded view of the third and fourth gear synchroniser is shown in the figure Th
156. e of additional heater on display Speedometer HIGH MEDIUM and BASIC versions The system calculates the real vehicle speed on the basis of values provided by sensors on the drive wheels and according to the real circumference of the wheels provided by the on board computer The electronic architecture implements a microprocessor The speedometer dial is operated by a stepper motor The scale is appropriate for left hand and right hand drive versions with a clockwise angle of 270 The instrument panel slightly increases the real speed for safety reasons without exceeding the maximum tolerance allowed in countries where the car is marketed The speed value ranges are uniform The real speed value is provided also in the event of failures to one or both drive wheel sensors The indicator will point to home range in the event of a failure to the vehicle speed sensor The maximum full scale value is 260 km h for kilometre panels and 160 mph for mile panels Traccia Didattica Alfa 159 en ridotta doc 267 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM SA After Sales Training Rev counter HIGH MEDIUM and BASIC versions The electronic architecture implements a microprocessor The gauge is operated by a stepper motor ensuring precision continuity and reading across the entire scale within the operating range The scale presents a clockwise indication angle of 270 The diesel a
157. e selected Panel buzzer volume Panel button volume Door lock while travelling Separate driver s door release Separate boot release Auto close Dusk sensor sensibility VV V VV VV Connect For configuring some device operating parameters gt Brightness Contrast Display light Connect power off mode The device is used to show and possibly configure trip parameters The following functions are available gt General trip data display Trip B data display Speed current speed limit and alarm Setup trip parameter units of measure Info vehicle personal organiser General trip reset Trip B reset VV VV VV Ceiling light computerised buttons The first button simply repeats the functions of the NAV button on the front of the Connect unit The other two are used to access the Infomobility Targa services as shown below Traccia Didattica Alfa 159 en ridotta doc 275 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM dii After Sales Training 9 4 2 CONNECT button A A variety of external driving assistance services e g traffic information information on shops and stores etc can be accessed by subscribing to the service Press the CONNECT button to open a menu for selecting showing previously stored Infomobility messages If the services are currently active press CONNECT again to start information request to the TargaSys Service
158. ed assisted assisted Brake booster Tandem 9 9 Tandem 9 9 Tandem 9 9 Tandem 9 9 Tandem 9 9 cylinder diameter Anti locking system TRW EBC430 TRW EBC430 TRW EBC430 TRW EBC430 TRW EBC430 Traccia Didattica Alfa 159 en ridotta 31 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A TECHNICAL DATA TRAINING MATERIAL After Sales Training 2 6 2 Front brakes 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Disc type Ventilated Ventilated Ventilated Ventilated Ventilated Disc diameter mm le mm after refacing mm Minimum admitted thickness Calliper piston 42 amp pistons 2 6 3 Rear brakes 1 9 UTS 2 2 JTS 1 9 M jet 8V 1 9 M jetiGV 2 4 M jet 20V Disc type Not ventilated Not ventilated Not ventilated Not ventilated Ventilated Disc diameter mm Nominal thickness mm Caen 10 35 10 35 10 35 10 35 10 35 after refacing mm Bini LP thickness diameter mm 2 7 STEERING 1 9 JTS 2 2 22J78 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Tvpe ka a Hydraulic power Hydraulic power Hydraulic power yp P P assisted assisted assisted assisted assisted Curb to curb steering 144 144 circle m Wall to wall steering EN circle m Number of turns of an steering wheel total steering al EES mm turn Steering wheel wheel mn angle ratio Rackstroke 163 Force on steering cp wheel when stationary Nm Rack diameter mm 20
159. ed to pick up the output signal Examiner with SAM Examiner Smart module is needed to view the signal considering its type Set to resistance mode ohmmeter MEASURING METHOD Oil pressure on off sensor 1 Oil pressure indicator switch 2 Engine speed sensor FEATURES The oil pressure indicator on off sensor is fitted on the crankcase on the left of the oil filter and is connected to the engine ECU CONNECTION TO ECU CONNECTOR DRAWING 2g connector pin 1 to ECU pin 28 side A 0 5 H Traccia Didattica Alfa 159 en ridotta 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Oil level and temperature sensor FEATURES The sensor monitors lubricant oil level and temperature inside the oil sump fitted underneath the engine block This sensor is not connected to the engine ECU it interfaces with the instrument panel node NQS instead The diagram connection is SPLICE CONNECTION A CONNECTOR DRAWING Sensore livello connector pin 1 to splice pin 8 temper OLIO connector pin 2 to splice pin 3 connector pin 3 to splice pin 4 connector pin 4 to splice pin 5 POSITION The minimum oil level sensor connection is positioned on the front side of the engine on the bottom right d 1 Oil level and temperature sensor fitting 5 E z A Kap J Air mass meter FEATURES The air mass meter essentiall
160. een the sides of the sunroof is prevented by adopting side guards which block access to dangerous areas 1 2 16 Sound system The available sound systems are Standard system eight speakers four 165 mm 40 W mid woofers and four 30 W tweeters positioned in the sides front and rear doors and on the dashboard BOSE Hi Fi sound system nine speakers plus two amplifiers arranged in different locations according to version saloon and SportWagon a sub woofer with six channel power amplifier is positioned in the boot bass box with amplifier is positioned in the boot of the SportWagon version while a 10 woofer is positioned on the rear window shelf of the saloon version The speakers four 165 mm 45 W mid woofers four 40 mm 40 W tweeters and a 80 mm 25 W speaker are designed for the best sound conditions inside the car All speakers are water resistant Sound sources are gt Radio or Radio Navigator gt CD player MP3 player and CD changer 1 2 17 Navigator The Alfa 159 continuous Alfa s best tradition in terms of complete full computerised contents Various levels are available to suit all needs gt Traditional telephone setup Bluetooth telephone connection Convergence Map radio navigator RN Map radio navigator with integrated free hands telephone RNT Connect Nav radio navigator and telephone with information and rescue services VV ON ON The map radio navigator with and without telephone derives f
161. eering column angular position gt steering column rotation speed This information is processed directly by the sensor and made available to the brake node via the C CAN The sensor range is from 720 to 720 angular with a resolution of 0 7 angular Resetting with respect to the steering wheel position is indispensable for sensor operation Proceed as follows Turn the key off or extract it Turn the key on and start the engine Turn the steering wheel also with the vehicle stationary by half a turn leftwards Turn the steering wheel also with the vehicle stationary by half a turn rightwards Drive straight wheels straight for at least 100 metres faster than 8 km h until the warning light goes out vVVVV The sensor has self diagnostics functions and can check plausibility of processed data This information is processed directly by the sensor and made available to the brake node via the C CAN Calibration with respect to the steering wheel position is indispensable for sensor operation This calibration process is performed with the diagnostic tool The sensor has self diagnostics functions and can check plausibility of processed data Traccia Didattica Alfa 159 en ridotta 218 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A BRAKING SYSTEM ALFA 159 TRAINING MATERIAL Li After Sales Training Yaw lateral acceleration sensor The yaw lateral acceleration sensor detects t
162. eld supercharger off for a time calculated according to start up conditions The engine must not reach maximum value The calculated time can be very short to the extent that the parameter cannot be visualised with the diagnostic tool CLUTCH PEDAL PRESSED A fixed value supercharger off is set when the clutch pedal is pressed VERY LOW ENGINE SPEED In this condition the presence of the turbo charger generates oscillations in the intake air column This causes turbo charger noise SUDDEN CHANGES FROM HIGH TO LOW ENGINE SPEED In this condition the presence of the turbo charger generates oscillations in the intake air column This causes turbo charger noise Note the setting to 30 and then straight back to 75 before being activated again SUDDEN CHANGES FROM HIGH LOAD TO LOW LOAD In this condition the presence of the turbo charger generates oscillations in the intake air column This causes turbo charger noise Fan control The ECU according to coolant temperature and coolant pressure in the climate control system operates the fans at first and second speed CONTROLLER OUTPUT PARAMETERS LOGIC ELECTRICAL QUANTITY Relay 1 2 speed EDC 16C39 Voltage to pins INPUT PARAMETERS ELECTRICAL QUANTITY Coolant temperature sensor Voltage between pins A 41 and A 58 B 90 1st speed B 69 2nd speed Fan control first and second speed Traccia Didattica Alfa 159 en ridotta 172 318 2004
163. en chassis and body sidemembers must be added to the ten fasteners to the body This allows a better control of front end collapsing during crashes by ensuring the cooperation of the suspension frame Traccia Didattica Alfa 159 en ridotta 231 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Front suspension yield fasteners TO rene Em ie i e gra win 4 Special flanged six lobe head screw for fastening shock absorber fork to lower swing arm Special flanged six lobe head calibrated screw with cylindrical conical end for fastening of upper swing arm to body Flange hexagonal lock nut for fastening rear stabiliser bar u bolt to engine frame third fastening rear bushing lower swing arm to engine frame external vehicle side Flanged six lobe head screw with cylindrical conical end for front fastening of lower swing arm front bushing to engine frame Flanged six lobe head screw with cylindrical conical end for rear fastening of lower swing arm front bushing to engine frame internal vehicle side Traccia Didattica Alfa 159 en ridotta 232 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL Traccia Didattica Alfa 159 en ridotta 233 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sa
164. en the vibrations are higher This increases driving comfort especially at low engine speed The features of the flywheel include Y Variable damping Serial spring arrangement in guide shoe compartment Mechanical protection to prevent spring packing Combination of two damping principles Shoe friction on primary flywheel Damping proportional to speed on planetary gears No additional damping element is required by the system Lubricated for life with grease Neutral performance during cranking and stopping of the engine VV WW WWW ON With respect to a traditional driveline this flywheel reduces oscillation of engine speed transmission taking the resonance amplitude causing possible vibrations and roughness in transmission at sufficiently low engine speed to prevent interference with the speed range usually employed for driving Traccia Didattica Alfa 159 en ridotta 52 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Transmission diagram of a traditional one mass flywheel 8 d zs zs E g EB d S3 s ES enn S CE Thine The diagram engine flywheel clutch transmission shows the oscillation in time of the engine output speed and the transmission input speed Transmission diagram with Sachs dual mass flywheel gt ob 3 CR 2 8 E g E ES Tempo 3 HE uim OPERATION DIAGRAM The motion transmission course is sh
165. ening support assembly screw and 2 pin integrated connector The connection to the engine ECU is CONNECTION TO ECU CONNECTOR DRAWING Camshaft variable timing valve suction side Variatore Variatore u difase difase OUTLET INLET connector pin 1 to ECU connector A pin 4 connector pin 2 to power wire Camshaft variable timing valve exhaust side connector pin 1 to ECU connector A pin 19 connector pin 2 to power wire 0 75 NS 0 75 MN D in I od o Traccia Didattica Alfa 159 en ridotta 67 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Hydraulic features PT Working using engine oil Flow gt 3 8 l min Working pressure 10 bars Filters integrated on valves fine mesh 300 um Electrical characteristics Frequency signal in range from 200 to 250 Hz Cooling system FUNCTION To cool the various parts of the engine warm the air for the climate control system and cool engine oil FEATURES This is a total flow bypass cooling system in other words the coolant can be entirely recirculated by the pump suction if it is too cold at engine outlet The coolant pump is built into the engine block on timing side and is driven by the balancing shaft drive chain An o ring is arranged between the cylinder block and the coolant pump Both engine versions fit a heat exchanger for the engine oil Th
166. ensure comfort for passengers driveability and road holding limited and comfortable body movements to overcome critical situations and difficult obstacles possible causes of accidents active safety Promptness of the car s response is also very important in terms of handling along with steering precision and progression high stability and control in limit conditions The front high quadrilateral arrangement implements the best features of the 156 where it has already shown its worth The many improvements concern the longitudinal filtering and damping capacity which increases lateral stiffness and camber take up to ensure better grip of the tyre to the ground in limit conditions Reduced static camber and higher riser hub stiffness allow a more effective tyre wear The rear multilink arrangement is an entirely new design Also in this case longitudinal filtering and damping are ensured by a hydraulic bushing and transversal leaf architecture specifically designed to provide superior comfort The extreme lateral stiffness and the high camber take up ensure the best handling Control is ensured by four two tube shock absorbers with coaxial spring It is generously dimensioned to ensure optimal damping in all vibration filtering and noise conditions 8 1 1 Front suspension The high quadrilateral architecture ensures high dynamic performance excellent steering feel and steering accuracy The steering knuckle riser connection is retracted and
167. ent in the deactivated key table VV VV wv O O O O Traccia Didattica Alfa 159 en ridotta doc 263 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM Goes _ After Sales Training Wiring diagram C2 B2 B6 AS B7 Legend Component Location destination CBA Battery fusebox On battery Engine compartment next to battery Boot on left hand side Dashboard left hand side combined with NBC Dashboard central area SELESPEED Pin 1 To Selespeed NCA cranking enable G001 Ground Engine compartment front left hand side G022 Ground Dashboard right hand side AISIN pin 5 To Aisin NCA cranking enable Traccia Didattica Alfa 159 en ridotta doc 264 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM dii a ilaria After Sales Training NBS pinout Pn X X A3L4 FUNCTON amp A 1 OUT J NT2tCPL J A 2 BUS J BCANA O O 3 BUS BCANB 4 GROUND O A 5 IN CLUTCH SWITCH NO A 6 IN TEGPRESENT J 7 IN j NPEENABLE notcomectd 1 A 8 OUT _ 30PROTECTED2FORPAVPOWER PINS B 1 OUT JJ JNTItoCVM y O B 2 OUT 30PROTECTED1FORPAVPOWER PIN3 B 3 OUT CVBT21 frontseatheate
168. ents and a comfortable armrest that incorporates a large insulated storage compartment 2004 Fiat Auto S p A All rights reserved 10 318 Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The interior achieves a perfect balance between elegance and sportiness an equation that Alfa Romeo translates into refined colour combinations quality fabrics precious fine grain leather and luxurious materials like the aluminium mouldings The range includes three specification levels each featuring specific natural interior upholstery The sophisticated technology with which the facia was made guarantees a refined opaque effect and a surface that is soft to the touch The customer will appreciate the wraparound finely modelled seats which are made with carefully selected materials paying great attention to the details __ The passenger compartment has fourteen storage compartments the 156 had eleven to fully meet the customer s needs A great deal of emphasis was placed on improving the quality of air in the passenger compartment by choosing low emission materials The odour level of the Alfa 159 was analysed a team of experts were asked to smell the car while is was being developed to ensure a constantly excellence olfactory perception 1 2 4 Outfits and characteristics The main contents of the various outfits are illustrated below The outfits are called L1
169. er side FUNCTION To increase cylinder filling by providing more air mass given equivalent volume available in the combustion chamber This is obtained by compressing the air to a pressure higher than atmospheric pressure before it reaches the combustion chamber CONSTRUCTION The variable geometry turbo charger essentially consists of the following parts gt a turbine driven by exhaust gas appropriately deviated by the mobile distributor vanes gt acentrifuge compressor integral with the turbine that takes air from the intake manifold and accelerates it by impressing a certain kinetic energy that in the scroll is transformed into pressure energy gt aset of mobile vanes that form the turbine distributor gt apneumatic actuator that controls the angular position of the distributor vanes VGT operation The exhaust gas kinetic energy progressively increases along with the engine speed This would increase turbine speed and therefore that of the compressor given equivalent distributor passage proving more supercharging The vane control actuator intervenes in these conditions controlled by the ECU that detects increase of supercharger pressure over the allowed limit to increase the exhaust gas passage than therefore slow them down At slower speeds the gas has a low kinetic energy which is not sufficient to ensure optimal supercharging pressure In these conditions the pallet actuator reduces the exhaust gas passage section and a
170. erance free does not need adjustments exact recovery of plate wear robust system with simple mechanical parts unaffected by vibrations and shocks no particular precautions are needed for transportation no variations to flywheel attachments are needed free choice of type of membrane spring and driven plate progression VV NON Y The device consists of Y compression spring Stop positioning rings shim traction spring for shim traction spring for positioning rings VV VV V Traccia Didattica Alfa 159 en ridotta 185 318 2004 Fiat Auto S p A All rights reserved CLUTCH ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training Traccia Didattica Alfa 159 en ridotta 186 318 Registro Molla di trazione per registro Molla di trazione per anelli posizionatori uL m EX Molla di compressione Fermo Anelli posizionatori Fermo Molla per attivazione anelli A Between flywheel and mechanism B Between membrane spring and thrust plate C Between membrane spring and clutch box Thrust plate wear and movement 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training Wear detection gt Positioning rings compressed by the membrane spring gt Adjuster detects lining wear OPERATING PRINCIPLE Traccia Didattica Alfa 159 en ridotta 187 318 2004 Fiat Auto S p A All ri
171. erator potentiometer The ECU implements idling Voltage to pins A 15 signal strategies with accelerator pedal and A 30 Voltage on pins K 60 and K released electrical loads on and 92 according to engine temperature p Injectors Voltage to pins A 50 A 49 A 47 A 48 A 32 A 33 A 35 A 34 Brake pedal switch Voltage on pin K 14 Clutch pedal switch Voltage on pin K 32 Fan control The ECU operates the fan according to the coolant temperature gt temperature when first fan speed is switched on 97 C gt temperature when second fan speed is switched on 102 C The ECU runs the fan at first speed when the A C system is on If the coolant temperature signal is absent the ECU implements recovery mode by running the fan at second speed until the error is removed The throttle is opened before starting the fans to prevent drops of engine speed INPUT PARAMETERS CONTROLLER ELECTRICAL QUANTITY LOGIC Engine temperature sensor MED 7 6 1 Voltage signal on pin A 22 According to engine temperature Potentiometer signal on DEE Fan first speed relay hrottl throttle gt controls the first fan speed Voltage to pins A 25 and A 10 controls the second fan Voltage from pin K 89 speed gt increases idling speed OUTPUT PARAMETERS Motorised throttle Voltage to pins A 15 and A 30 Fan second speed relay Voltage from pins K 70 Traccia Didattica Alfa 159 en ridotta 125 318
172. ersions check smotness exhaust desalversons fe f fe pr EE EL Check evaporation system wet Gen Check engine control system operation via diagnostic Pas socket e rese a 5 ee ee GE SE a Replace spark plugs petrol versions LL Ltr Replacing fuel filter diesel versions ILL Ltr f Replace air cleaner filter petrol versions LL J _rrT_r_r rr_ _r__r_r_r MI Replace engine oli and of fiter pero versions t t Replace engine oil a oil filter Ge seio LLL ax Replacepollenfiller LI de l Or every three years if the car is used in the following particularly demanding conditions cold hot climates 2004 Fiat Auto S p A All rights reserved 40 318 Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A TECHNICAL DATA ALFA 159 TRAINING MATERIAL After Sales Training city use long standing with engine idling Or every five years regardless of kilometrage and conditions of use of the car The engine oil and oil filter must be replaced according to their actual decay as shown by the instrument panel warning light message Note The technical data contained in this publication may be subject to change and updated Refer to the Technical Service manual for more detailed up to date information Appendix Euro 4 compliant log book note the Euro 4 reference on line V 9 SS i e rona eL D 1
173. evel 92 Not fitted in versions with automatic transmission Connector A engine pre wired harness 3 QJNotcomeded S 4 QJFuelpresueregulatronral e 00000000000 6 Swirlsolenoid valve ground 8 Fuel pressure sensor S y O 9 Notconmnected S Traccia Didattica Alfa 159 en ridotta 135 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL 33 34 35 Diagnostic feedback swirl 38 Not connected 39 Driven throttle ground Pressure signal from air pressure temperature sensor Engine coolant temperature sensor 45 46 47 48 49 50 51 52 53 Temperature signal from air pressure temperature sensor 60 EGR solenoid valve Engine speed sensor FUNCTION The sensor provides an electrical signal to the engine ECU used to compute the speed and angular position of the engine LOCATION The sensor is fitted on the crankcase facing the phonic wheel on the crankshaft maximum magnetic flow 2 minimum magnetic flow Traccia Didattica Alfa 159 en ridotta 136 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training OPERATION The switch from empty to full due to the presence or absence of a tooth determines variations in magnetic flow capable of generating induced alternating voltage which is used
174. eves and 8 terminals COUPLING ELEMENT The additional plenum injection conduit fastening is obtained by means of a coupling element fastened with a screw and bolt Traccia Didattica Alfa 159 en ridotta 73 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Additional component fastening Coupling element Oil indicator tube housing Water pipe housing Brake booster vacuum port puc OIL LEVEL GAUGE PIPE HOUSING The oil gauge pipe is fastened to the plenum by a screw WATER PIPE HOUSING The water pipe is fastened to the plenum by a screw BRAKE BOOSTER VACUUM PORT The brake booster pipe is fastened to the plenum by a pipe clamp A specific tool is needed for fastening THROTTLE BODY The throttle body is fastened to the plenum bracket by bolts Fasten the four bolts in alternating pattern The air pipe is fastened to the body by means of a clamp BLOW BY VALVE The blow by valve welded to the plenum The valve consists of a body a spring and a diaphragm The valve assembly can be disassembled CANISTER BLEEDER VALVE The canister bleeder valve is clipped onto the plenum The valve fastening support is fastened to the plenum by means of two screws Electronic accelerator throttle FEATURES The ETC Electronic Throttle Control system is designed for spark ignition engines It consists of a throttle body a potentiometer on the accelerator pedal and
175. evice locks the steering column with a specific Rencol clutch bushing that allows rotation at torque comprised in the range from 100 to 240 Nm to prevent damage to mechanical parts of the steering system in the event of attempt to steal the car The steering column has a controlled energy absorption collapsing device with an axial stroke of 45 mm in addition to the adjustment stroke The high handling comfort objective is expressed on steering column design by its high structural stiffness by using a metal structure that does not penalise weight Similarly a new intermediate shaft design has been adopted with a high decoupling torsional damper capable of filtering the vibrations from the steering box without compromising handling accuracy and preventing the feeling of lightness in the middle 7 1 5 Yield point fastening FUNCTION Flanged six lobe head screw and cylindrical conical end for fastening the steering box to the engine frame quantity 2 Traccia Didattica Alfa 159 en ridotta 227 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A ALFA 159 TRA 59 INING MATERIAL After Sales Training 8 SUSPENSIONS 8 1 FEATURES The suspensions ensure that the car can tackle all roads without transmitting roughness from the wheels to the passenger compartment reducing rolling and pitching of the body damping vertical oscillations and ensuring maximum grip of wheel to the terrain The system must
176. f the roof and particularly the possibility of larger resistant sections laser welding is applied to one side pf the the other side can be boxed for superior performance OUTER ROOF SIDE The laser welding technology Agilaser Comau patent is used on Alfa 159 also for the doors which benefit from the same advantages providing flatter more homogenous panels Eed j F ua a T at Saat thy das The roof laser welding cabin 2004 Fiat Auto S p A All rights reserved 20 318 Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Wide use of medium frequency weld guns was made for the Alfa 159 as the best European competitor to use better performing material and thicker sheets This is also the first time this technology is applied in Fiat Auto A highly automatic body in white line has been created for the Alfa 159 127 robots entirely automatically apply 81 of the total weld spots thus ensuring constant quality in time Two optoelectronic stations for measuring 84 critical points on the entire production have been set up along with a measuring station that checks 490 key points at random every day 1 2 20 Aerodynamics The Alfa 159 has a Cx coefficient of 0 325 1 2 21 Anti corrosion and cosmetic warranty The anti corrosion warranty of Alfa 159 meets the standard now consolidated for all Fiat models gt cosmetic corrosion three year war
177. ferential 5 2 2 Gears MATERIAL AND TECHNOLOGY The gears are subjected to variable loads in time with fatigue characteristics For these reasons nickel chromium alloy steel is used to provide high mechanical resistance After machining the gears are deburred and rectified They are then subjected to thermal treatment for improving fatigue strength and wear hardening and tempering CHARACTERISTICS All gears have helical teeth The adoption of helical teeth gears allows higher torque transmission with respect to axial teeth gears of the same size Furthermore helical teeth gears provide smoother and quieter operation Another major feature of the gears in this gearbox is the high coverage factor of the teeth in other terms several teeth are constantly meshed more than one tooth with advantages in terms of transmission smoothness 5 2 3 Shafts Primary shaft Traccia Didattica Alfa 159 en ridotta 203 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A After Sales Training GEARBOX ALFA 159 TRAINING MATERIAL CHARACTERISTICS All the gearbox input shaft gears have integral teeth particularly the first 1 and second 2 gears physically part of the shaft thanks to mechanical machining while the third and fifth 3 5 gears the fourth 4 gear and the sixth 6 gear are fitted onto a spline in the shaft with appropriate interference The primary shaft of th
178. fusebox This component is wired to the front wiring harness and connected to the CBA CODE COMPONENT In A PTC1 SUPPLEMENTARY HEATER FUSE JTD versions PTC2 SUPPLEMENTARY HEATER FUSE JTD versions PTC3 SUPPLEMENTARY HEATER FUSE JTD versions Dashboard fusebox CPL The dashboard fusebox is located under the dashboard on the left hand side CODE APPLICATION In A NENNEN FUSES RH DIPPED BEAM HEADLIGHT FUSE 15 LH DIPPED BEAM HEADLIGHT HEADLIGHT TRIM CORRECTOR FUSE 15 INT A COIL RELAY CPL CVM NBC 7 5 30 NPG NPP NTR FUSE 15 NVB 1 POWER FUSE 20 20 15 FUSE FOR PCT REVERSING LIGHTS CRUISE CONTROL CLA NC AQS SENSOR 5 WATER IN FUEL FILTER SENSOR C R CONTROL LEVEL LIGHTING i 30 NVB FUSE NPA alternative to NPG NPP NVB 20 15 FUSE FOR CLA NA THIRD BRAKE LIGHT NQS CPS CPD 10 15 30 FUSE FOR NCL EOBD DIAGNOSTIC SOCKET CAV PAC REAR CEILING LIGHT CSA 4 EEMS CPP NRR NCV C1 C3 CELL PHONE SETUP REAR WINDOW HEATER FUSE 30 WINDSCREEN REAR WINDOW WASHER NOZZLE DEFROSTER HEATER WINDSCREEN RELAY COIL EXTERNAL MIRROR DEFROSTER WITH NPA ONLY i 15 FUSE FOR NFR NAS NYL 7 5 WINDSCREEN WIPER WASHER FUSE 30 CIGAR LIGHTER BOOT CURRENT SOCKET max 120W 20 CTA 2 FUSE 20 CTA 1 FUSE 20 NPG POWER FUSE 20 NPP POWER FUSE 20 p 4g 15 FUSE FOR NVO NIT NSP CTA CAV PAC PCS FRONT SEAT CONTROL LIGHTS 5 WINDSCREEN SERVICES CELL PHONE SETUP CEM NCV C1 C
179. g mm 318 5 2 5 318 5 2 5 318 5 2 5 318 5 2 5 318 5 2 5 Closed length locked mm Stroke mm 2 8 3 Stabiliser 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V 22 22 Bar diameter mm Traccia Didattica Alfa 159 en ridotta 33 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A TECHNICAL DATA TRAINING MATERIAL ner After Sales Training 2 9 REAR SUSPENSIONS 2 9 1 Helical springs 19JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Weien od 11 32 0 05 11 32 0 05 11 32 0 05 11 32 0 05 11 32 0 05 No of active turns Hand of helix Right Right Right Right Right 205 at 460 205 at 460 205 at 460 205 at 460 14 205 at 460 spring height mm 14 daN 14 daN 14 daN daN 14 daN Warin 150 at 612 150 at 612 150 at 612 150 at 612 150 at 622 compressed spring height mm gan daN daN daN daN Marking colour 2 9 2 Shock absorbers 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Type Type __ Open length start of n m 435 2 5 435 2 5 435 2 5 435 25 435 2 5 Closed ps locked 308 2 5 308 2 5 308 2 5 308 2 5 308 2 5 Stroke mm 17 127 2 9 3 Roll bar 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Bar diameter mm 21 2 10 TRIM AND CHARACTERISTIC ANGLES Tyre pressure for inspections and adjustments bars Tyres Fronts S Bear 2 10 1 Trim Std A conditions Front suspension
180. g the transmission and reception units 9 1 10 Fuses By the way of example the following tables show the list of fuses and relays fitted in the electrical system Boot fusebox CODE COMPONENT In A ES HOUSING FOR FUSE CONNECTED TO T21 avaiable J ES HOUSING FOR FUSE CONNECTED TO s3 SETUF SO F8 HOUSING FOR FUSE CONNECTED TO 30 SETUP Tm RELAY HOUSING AVAILABLE T_T Battery fusebox CBA The battery fusebox is a power distribution unit positioned on the battery positive terminal It contains power fuses and integrates the automatic battery cut off device in series with the battery terminal capable of cutting off power to the ignition recharging engine wire when the FIS is working The CBA is connected to the front wiring harness to the CVM engine pre wired harness and to the battery positive for the ignition recharging circuit The CBA is provided with a connection terminal for powering the fuses connected to the wiring harness The fusebox is connected to the terminal The fusebox pinout is shown on the following page CODE COMPONENT AUTOMATIC BATTERY CUT OFF CVM FUSE CPL 1 FUSE CVB CPL 2 FUSE F 3 PRE HEATER ECU FUSE a T i Be Ft ES T Y Traccia Didattica Alfa 159 en ridotta 246 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM ee After Sales Training CFO fusebox optional
181. ghts reserved Fiat Auto S p A CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training During wear the thrust plate and the recovery mechanism shift towards the flywheel 1 A gap is formed under the compression spring corresponding exactly to the lining wear 2 The adjuster slides and detects the wear 3 When the clutch is released 4 the lower positioning ring slides and closes the gap under the compression spring detected by the adjuster 5 When the clutch is engaged the wear is taken up and the membrane spring returns to its original position 6 VV ON ON Y Traccia Didattica Alfa 159 en ridotta 188 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training 4 2 2 Driven friction plate The bending pre damped driven plate on the Sachs flywheel clutch is fitted with buffer damping springs The benefits of this component are Y reduces hub wear gt lower angular and radial imbalance between engine and transmission better neutral decoupling with use of low stroke pre damper regardless of load variations reduced radial forces caused by crankshaft and transmission offset 4 3 VALEO CLUTCH 4 3 1 Clutch assembly CHARACTERISTICS Pull type single dry disk clutch with hydraulic control and internal coaxial actuator External diameter 240 mm spring load 640 daN Used with 1 9 M jet 8V and 1 9 M jet 16V turbo diesel e
182. gnostic procedures Foreword This function is used to run diagnostic procedures on system parts The NTR must be capable of identifying and storing the following faults gt Transponder o faulty missing or wrong secret code o cancelled deactivated o unknown not stored Transponder antenna o faulty battery connection open circuit short circuit to ground or to battery The following parameters data can be read using Examiner Code system state clear whenever a TEG is inserted programmed at end of line whenever a TEG is inserted spare part whenever a TEG is inserted Number of programmed TEGs the following data is available for each TEG inserted in the NTR gt TEGID gt position in the table gt whether the transponder is valid gt whether the TEG is stored gt whether the secret code is valid Other functions include Querying number and ID of last TEG used Querying reading of all enabled keys Querying number of enabled and deactivated keys Manual key storing procedures by means of later acquisitions quality of the transponder must be checked after each acquisition Acknowledging presence of a transponder in the antenna and establishing whether it is valid or not Querying the current system state to establish whether the last TEG used is enabled and recognised the immobiliser is clear the ID of the last TEG used is present in the enabled key table the ID of the last TEG used is pres
183. h gear 7 fourth gear 22 lower shaft adjustment ring 8 sixth gear 23 shifting linkage 9 primary shaft ring 24 CSC 10 reverse gear 25 reverse sensor 11 reverse gear synchroniser 26 differential crown wheel 12 third gear 27 differential box 13 third and fourth gear synchroniser 28 satellite gears 14 fourth gear 29 planetary gears 15 upper shaft adjustment ring 30 differential adjustment rings In the gearbox each transmission ratio is obtained by means of a constantly meshed gear pair one of which is idly mounted on the respective shaft Reverse is an exception to this and is obtained by means of a three gear set to reverse the direction of motion The primary shaft receives motion directly from the crankshaft When a gear is selected the torque is transferred to the secondary shaft and from there to the fixed transmission connected to the differential via the selected ratio gear pair 5 2 1 Meshing diagram First and second gear SS SS h ST SS UU M UL 22 n first gear meshing Second gear meshing DESCRIPTION In first gear motion reaches the gearbox through the primary shaft and v
184. he car off comfortably The following two situations illustrated how useful the system is The HH is automatically activated when the brake pedal is press in the following cases gt vehicle speed equal to zero gt gradient exceeding 4 596 and clutch pedal pressed In the instant the brake pedal is released the HH keeps the brake system pressurised for one second to let the driver s foot move from the brake to the accelerator pedal without the car backing off and without needing to use the handbrake After pressing the accelerator the HH will keep the car stopped for another 15 seconds or until the engine torque is sufficient to start the car off The time from 1 to 15 seconds is the maximum time that the ECU can vary i e reduce if the sequence of movements brake pedal acceleration sufficient torque is rapid enough On the other hand if the driver does not press the accelerator at least one second after releasing the brake pedal or the necessary engine torque is not reached within 15 seconds the HH will progressively reduce pressure to the hydraulic circuit The HH is deactivated in poor grip conditions This is because in extreme conditions e g if parked on an icy hill the HH would lock the wheels and the car would slip backwards A slip acknowledgement test by monitoring ABS or ASR activation or wheel locking straight before HH activation is implemented to recognise such extreme conditions During the test the ECU def
185. he longitudinal vehicle axis rotations yaw as well as lateral acceleration and inclination up down The connection to the ABS ECU is achieved on the C CAN Functional features of the sensor are Minimum voltage 8 2V Power voltage Maximum voltage 16V Nominal value 12V Minimum value 40 C Working temperature Maximum value 85 C Nominal value 70mA Measuring range 100 s Resolution 0 3 s Measuring range 1 8 g Power from F 42 CPL 7 5 C CAN H to NAS NSC DDOD C CAN L to NAS NSC 6 5 4 C CAN H from NBC C CAN H from NBC Ground Location the sensor is located in the car s centre of gravity under the central console Traccia Didattica Alfa 159 en ridotta 219 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training 6 2 3 Hill Holder PARKING UPHILL 1 2 HH off downhill with reverse engaged 2 3 HH on uphill with first gear engaged PARKING UPHILL 1 2 HH on uphill with reverse engaged 2 3 HH off downhill with first gear engaged The Hill Holder HH system is not a safety feature nor part of the vehicle parking system It is a comfort feature controlled by the ABS software The HH helps the driver when starting off uphill The HH automatically provides the braking torque needed to hold the vehicle until the clutch is fully released and the engine torque is sufficient to start t
186. he position of the throttle valve inside the cylindrical conduit The valve is controlled by an actuator that works in a range from UEA lowest electrical stop point to OEA highest electrical stop point The actuator is a dual stage mechanism controlled by a direct current motor The valve returns to the lowest of the mechanical positions NLP controlled by double spring system in the event of a failure INSTALLATION PREFERENCES The throttle body should be installed with the valve axis horizontal and by slanting the conduit gt 15 with respect to the horizontal line to eliminate possible accumulations of water ELECTRICAL FEATURES All technical data refer to an ambient temperature of 23 C 5 C and ECU nominal voltage of 13 5 V 0 5 V DC MOTOR ACTUATOR resistance 1 50 0 30 no load current lt 0 8 A no load speed 4500 rpm closing current typical 9 5 A maximum constant current at 100 C 2 5 A nominal current engine idling lt 1 5A maximum admitted generator current lt 10 0A POTENTIOMETER potentiometer voltage power 5V 0 2V resistance 1 25 KO 30 IP1 IP2 parallel connection typical cursor current 10 uA Accelerator pedal potentiometer FEATURES The sensor consists of a body fastened to the accelerator pedal inside which a shaft connected to the two potentiometers one main potentiometer and one safety potentiometer are axially arranged A coil spring on the shaft ensures the correct resistance to pressure while a
187. he pressure regulator adapts injector injection times Traccia Didattica Alfa 159 en ridotta 163 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Accelerator pedal sensor Pump pressure regulator Control voltage between pins Voltage to pins B 9 and B 31 n EDC 16C39 Roane Engine speed sensor According to the signals from the Injectors sensors and the mapped values Voltage to pins A 16 A 47 A Frequency to pins A12 A27 MESS 2 A 31 A 1 A 46 A 17 A e controls the pressure 33 A 18 A 48 5 cylinder regulator e adapts the main injection Air flow meter time Voltage to pins A 42 and A 44 A Exhaust gas recirculation EGR control Implementing EURO 4 anti pollution standard the ECU limits the amount of fresh intake air and partially takes in exhaust gas according to the engine load and the accelerator pedal potentiometer signal specifically the ECU INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Coolant temperature sensor EGR solenoid valve EDC 16C39 Resistance between pins A PWM signal to pin A 60 The ECU limits the amount of fresh 41 and A 58 Air flow meter intake air and partially takes in Engine speed sensor exhaust g
188. heel for effective targeted reduction of vibrations and transmission roughness The figure below compares the performance of a traditional flywheel and a Sachs DMF 350 coppia Nm iorgue med DNA Planetario C 2 i angolo angle 1 Conventional flywheel 2 Sachs planetary flywheel Traccia Didattica Alfa 159 en ridotta 55 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The configuration with planetary in home position without torque transmission The following figures compare the performance of a traditional dual mass flywheel and that of a Sachs dual mass flywheel when the engine is cranked Note the considerable reduction of oscillation of the gearbox shaft of the Sachs DMF Traccia Didattica Alfa 159 en ridotta 56 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training gin atero cambio Min ei e Bai Rs ES Paes ps 2 506 k JURE HERR o 2 56 75 600 625 650 6 75 Tae 90 67 276 200 929 950 87S 1000 1025 1050 10 75 1166 1129 1156 D V A paragonabile D V A Sachs The diagrams on the top show the gearbox shaft speed in rpm the diagrams underneath show the gearbox shaft acceleration vibrations Specific cam profiles Cylinder head Variable timing Variable timing solenoid valves Timing sensor Fuel high pressure
189. hen it is enabled by the NBC NOTE On versions with automatic transmission the NBS will also ask the NTR to lock the TEG if the gearlever is in a position other than Park If the code is not recognised the NBS will not be enabled by the NBC and the steering will not be unlocked When the TEG is inserted in the reader the NBS will ask the instrument panel NQS to show a message illustrating the ignition procedure The message will appear for 10 seconds when the TEG is inserted The message will disappear as soon as an attempt is made to ignite the engine or extract the TEG from the NTR A message will appear on the instrument panel if a problem that prevents the NBS from activating the 15 occurs PAV button light The start stop button light is governed by the NBS according to state of the B CAN as follows gt at key on the button is always lit gt at key off the button is lit until the B CAN is active The button LED is switched off when the system goes to sleep TEG reader light The TEG slot lights up when a TEG is inserted according to the following logic gt Key on the slot light will go out when the TEG is locked in the reader TEG unlocked slot light on TEG locked slot light off gt Key off the slot is lit according to B CAN state The slot light is on when the B CAN is active and goes out when the B CAN goes to sleep 15 deactivation or engine off With key on the NBS will deactivate the 15 54 INT and INT
190. hich is activated automatically when the key is removed from the switch The operation of the electronic alarm is adapted at the plant to the standards in force in the various countries The approval number of the transmitter is marked on the component for respecting the law in the matter of radio frequency devices in countries where this is required The code marking may also be written on the transmitter and or receiver according to the version market 2004 Fiat Auto S p A All rights reserved 16 318 Traccia Didattica Alfa 159 en ridotta ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training 1 2 12 Tyres and wheels A new family of tyres have been developed for the Alfa 159 to account for technological innovations and to achieve the best balance between handling and comfort Ten new specifications and four sizes have been developed to form a 16 17 and 18 range The guidelines followed in tyre development include handling and braking excellent road hold also in rainy conditions good level comfort The compounds benefit from the most recent research in the sector and offer extraordinary performance on dry and especially on wet roads These features in combination with the suspension design mean that the later are mainly responsible for filtering noise and vibrations with considerable advantages on the tyres which provide higher grip and present considerably less wear than the 156 Each tyre
191. hown in bold onmt sene enne nnn nn nana ran nnn nnns nsns nsns aaa aan 1 EUN vL NT 1 I SPO ISO EE 13 A EIU Ecc Q n rr 14 AN DF anii Ri c 14 AIR ara 16 Lo VS NO rach hs a ote le 1 iz 18 PIO SR EIA 18 Io ir 19 ZIO SS E 19 CIANO IR RE 19 Pico CI 20 L219 Froducton ee 20 CVA inn 21 12 21 Anti corrosion and cosmetic WAIN irlanda 21 RERE E E E EE 2 1 223 Product grid according to OUUM icone 23 Ba E E P E GOI ee 24 2 TECHNICAL DATA cd dida hei 27 ZIENcNE E 27 ZIE 2 Ze EIA pia 2 VIII I 2 ANI 28 2 1 5 Characteristic CUIVES OF DECIO iaia ian 28 GENICO lana api ani 30 PAS ele m 30 ZICLUTCHA ceE cEE 30 tii 30 29 DIFFERENTIAL abile 31 POBRA E EE 31 ARE LC ERO E IEEE 31 E eege 3 E EE 3 Z gt IFERINO Us 32 ZO DISONTOUSPENSIONS cei ria 33 WII j E een eee 33 202 Sae EELER 33 ARIE AAA 33 ZIREARSUSRPENSION 34 EEN ee 34 SEET ee 34 20 34 2 10 TRIMAND CHARACTERISTIC ANGLES
192. ia the fixed driven gear is transmitted to the first ratio driven gear idly mounted on the lower secondary shaft Operation of the respective synchroniser first and second gear makes the gear integral with the secondary shaft and the fixed transmission gear to the differential Shifting the synchroniser in the opposite direction the second ratio driven gear is made integral with the secondary shaft Second gear ratio is obtained in this way Traccia Didattica Alfa 159 en ridotta 201 318 2004 Fiat Auto S p A Tutti i diritti sono riservati GEARBOX ALFA 159 TRAINING MATERIAL After Sales Training Fiat Auto S p A Third and fourth gear third gear meshing fourth gear meshing DESCRIPTION Motion reaches the gearbox through the primary shaft and via the fixed driven gear is transferred to the driven gear fitted on the upper secondary shaft The synchroniser third and fourth gear transfers motion to the fixed transmission gear also integral with the differential crown like the one on the lower shaft Fourth gear is meshed by shifting the synchroniser in the opposite direction Fifth and sixth gear
193. ic Hydraulic tappets Suction mm tappets tappets tappets Cold valve clearance Hydraulic Hydraulic Hydraulic Exhaust mm tappets tappets 0 3540 05 tappets Hydraulic tappets Suction 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet 16V 2 4 M jet 20V OpesBTDC 2 3 Of 1010 32 Traccia Didattica Alfa 159 en ridotta 27 318 2004 Fiat Auto S p A All rights reserved TECHNICAL DATA TRAINING MATERIAL Fiat Auto S p A After Sales Training Exhaust RE oo 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet 16V 2 4 M jet 20V Opens BBDC 4 2 9 9 Closes ATDC 4 2 1 4 Injection ignition 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet 16V 2 4 M jet 20V Injection Bosch MED Bosch MED Bosch Bosch Type 76 1 76 1 EDC16c39 Bosch EDC 16c39 EDC16c39 Injection order 1 3 4 2 1 3 4 2 1 3 4 2 1 2 4 5 3 Ignition 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Coils ZS K 4x1 module ZS K 4x1 module Z3 Number of coils Sparkplugs Lc qu a gd _ i 9 Glow plug pre Cartier 51 299 l l Bosch Bosch 250 203 001 250 203 001 Bosch 250 202 036 Beru AO 100 276 Beru AO 100 276 010 010 1 3 4 2 1 3 4 2 1 3 4 2 1 2 4 5 3 2 1 5 Characteristic curves of the engine 1 9 JTS engine Maximum torque 190 Nm 4500 rpm Maximum power 118 KW 6500 rpm 2004 Fiat Auto S p A All rights reserved 28 318 Traccia Didatt
194. ic is also provided with a recovery function The system stops working correctly when errors are detected This could cause dangerous dazzling of oncoming vehicles The light beam is therefore positioned down to prevent dazzling in all cases but to ensure sufficiently lighting to safely reach a garage 9 8 8 Resetting When replacing a system component headlight sensor etc a self learning procedure must be run using a diagnostic tool for automatically resetting the system The system must acknowledge the correctly aligned headlight position zero position from where to control the various settings Traccia Didattica Alfa 159 en ridotta doc 295 319 2004 Fiat Auto S p A Tutti i diritti sono riservati EE ALFA 159 TRAINING MATERIAL deo SYSTEM After Sales Training 10 CLIMATE CONTROL SYSTEM The vehicle may be equipped with one of three types of climate control system configurations gt One zone manual gt Two zone automatic gt Three zone automatic 10 1 CLIMATE CONTROL SYSTEM OVERVIEW The climate control system implements a variable displacement Zexel Valeo compressor and a block expansion valve The effective capacity of regulating gas quantities in the evaporator achieved by these two elements has eliminated the need to use a frost sensor The system contains 550 40 grams of R134 gas 150 cm 15 30 cm of ZXL100PG oil is used A pollen filter accessible through the flap 2 shown in the figure on page 3 is
195. ica Alfa 159 en ridotta 2 2 JTS engine Maximum torque 230 Nm 4500 rpm Maximum power 136 KW 6500 rpm SPS s fer iniezione dicmtin laid Erop peta 1 9 Multijet 8V 120 HP engine Maximum torque 280 Nm 2000 rpm Maximum power 88 KW 4000 rpm J Bu d amp Power hi E m Torque Mimi 1 9 Multijet 16V 150 HP engine Maximum torque 315 Nm 2000 rpm Maximum power 110 KW 4000 rpm Traccia Didattica Alfa 159 en ridotta 29 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training TECHNICAL DATA TRAINING MATERIAL 2 4 Multijet 20V 200 HP engine Target Hrm Maximum torque 410 Nm 2000 rpm Maximum power 147 KW 4000 rpm z E ch ai jb ce i k E 3 d Ai B la zT A LT ei F a n 1l KL ig T d P Engi speed pan 2 1 6 Engine cooling 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet 16V 2 4 M jet 20V Calibration C 2 2 TRANSMISSION TS 9 22JIS 1 9Mjet8V 19Mjet16v 2 4M jet20V Traction Front Front Front Front Transversal Front Transversal Transversal Transversal Transversal 2 3 CLUTCH Lo 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet 16V 2 4 M jet 20V Dry single plate Dry single plate Dry single plate Dry single plate Dry single plate Thermostat Operation Push type Push type Push type Push type Hydraulic with Hydraulic with Hydraulic with Hydraulic with Hydraulic with internal coaxial interna
196. ica Alfa 159 en ridotta 11 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Alfa Romeo has always been on the leading edge in the field of diesel engines All engines are with Multijet technology turbo charging is entrusted to a variable geometry turbo and intercooler The 1 9 M jet exploits a specific turbine developed by Alfa Romeo while the 2 4 M jet has a new cylinder head and new fracture split steel connecting rods The three engines all meet Euro 4 requirements and incorporate a standard particulate trap DPF which considerably reduces the particulate contained in exhaust gas Alfa 159 engines are 1 8 16V 130 HP 96 kW 1 9 16V JTS 160 HP 118 kW 2 2 16V JTS 185 HP 136 kW 1 9 M jet 8V 120 HP 88 kW 1 9 M jet 150 HP 110 kW 2 4 M jet 200 HP 147 kW 3 0 V6 M jet 250 HP 185 kW VVVVVV V The engine versions available at time of release are shown in bold print 1 2 6 Transmission The Alfa 159 fits the following transmissions to best exploit the engine features M32 six manual gears for 1 9 2 2 JTS 1 9 8 16V M jet F40 six manual gears for 2 4 Multijet 200 HP M32 six speed Selespeed for 1 9 JTS AISIN AF40 six speed automatic for 2 4 M jet 3 0 V6 M jet and 3 2 V6 VV VM The transmissions available at time of release are shown in bold print 1 2 7 Bodyshell The new Alfa 159 bodyshell developed specifically for the Premium platfor
197. ights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training The connections to the engine ECU are CONNECTION TO ECU Linear sensor 1 connector pin 1 to ECU pin 56 side K connector pin 2 to ECU pin 55 side K connector pin 3 to ECU pin 73 side K pin 4 power from ECU connector pin 5 to ECU pin 78 side K connector pin 6 to ECU pin 77 side K Traccia Didattica Alfa 159 en ridotta DRAWING A B C D Sonda Lambda planare 1 a valle catalizzatore Sonda Lambda lineare 1 a monte catalizzatore Sonda Lambda planare 2 a valle catalizzatore Sonda Lambda lineare 2 a m onte catalizzatore L S LS L L S sg 55 a 25 ad 52 580050 57 79 54 L i D vol uw in i in in wu 3 Hima of o un n o Oli olal oiolol a 2 2lc a lalala oao ry g O fa Oo fs 106 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Linear sensor 2 connector pin 1 to ECU pin 58 side K connector pin 2 to ECU pin 57 side K Sonda Lambda planare 1 a valle catalizzatore Sonda Lambda lineare 1 a monte catalizzatore Sonda Lambda planare 2 a valle catalizzatore Sonda Lambda lineare 2 a m onte catalizzatore OQ cma connector pin 3 to ECU pin 51 side K pin 4 power from ECU connector pin 5 to ECU pin 80 side connector pin 6 to ECU pin 79 side I lii K
198. iming sensor 22 Coolant temperature sensor 23 Oil pressure sensor 24 Oil level sensor 25 Glow plugs 26 Glow plug ECU 27 Variable geometry turbine 28 Turbo actuator 29 Turbo control solenoid valve 30 Pre catalyser 31 Pre cat output temperature sensor 32 Catalyser 33 DPF particulate trap 34 DPF input temperature sensor 35 DPF differential pressure sensor 36 Pedal board 37 Engine ECU 38 Swirl actuator St OO One a s Traccia Didattica Alfa 159 en ridotta 132 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Auxiliary fuel pump Air pressure and temperature signal Swirl mechanism Timing sensor VGT solenoid valve Engine speed sensor A C compressor Speedometer EGR solenoid valve Battery Tachometer Alfa Code Cooling fan Diagnostic socket Glow plug pre heater ECU Pressure regulator Accelerator pedal with built in potentiometer Injectors Brake clutch pedal switch Glow plugs Differential pressure sensor Throttle solenoid valve Thermocouples Glow plug pre heater warning light Fuel pressure sensor Injection warning light Air mass meter Coolant overheat warning light Coolant temperature sensor Water in fuel warning light Cruise control Oil warning light RA DI RISI Dooooooooooooooooooo Q 000000000000000000000 ooooooooooooo0Q0 00000000000000 geo C
199. inally the new model offers a choice of 14 different colours 1 2 2 Dimensions EIE hb Faia 1555 loral 4d The dimensions in brackets refer to versions fitting 215 55 R16 tyres The 159 is bigger than the 156 Sa Length mm Width mm Height mm Wheelbase mm 159 4661 1828 1422 2701 1 2 3 Interiors The interior of the Alfa Romeo 159 also represents an evolved expression of the sportiness and elegance embodied by Alfa It was defined around the driving position focusing attention on the driver excellent ratios for the distances between pedals seat steering wheel and gearlever give the driver a sense of total control over the car which produces the enjoyable driving so typical of Alfa Romeo The facia and wraparound centre console incorporate all the driving instruments and are turned ergonomically towards the driver The soeedometer rev counter and other instruments all strictly analogue are circular with clear refined extremely legible graphics The anti glare lip accentuates the boat shape of the main instruments confirming a feature peculiar to Alfa Romeo design that is based on a deep rooted attention to volumes and mature treatment of surfaces To underline the functional continuity between the facia and the console the designers aimed to achieve stylistic continuity between them the console which is raised as if stretching towards the facia has a sporty gearlever with short precise movem
200. ines which wheel is the most stabile using the ABS parameters and then releases the brake pressure from this wheel maintaining the other three wheels braked Traccia Didattica Alfa 159 en ridotta 220 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training If the speed sensor of the wheel that is other than zero it means that the vehicle is moving despite the other wheels being locked This indicates poor grip The HH is therefore deactivated by releasing the pressure in the entire brake circuit If unbraked wheel does not keep still it means that the situation is stable and therefore the HH keeps on working The slipping test last for approximately 150 msec Fundamental features gt Automatic operation at zero speed and vehicle gradient gt 4 596 gt NOS warning light management gt Pressure holding time equal to 1 15 sec gt Automatic deactivation following acceleration clutch release or maximum timeout Necessary signals and sensors reverse engaged from C CAN clutch state from C CAN accelerator pedal state from C CAN brake pedal state direct engine torque from C CAN engine speed from C CAN longitudinal or slant sensor from C CAN brake pressure sensor built into VDC ECU VVVVVV VV Transmission Handbrake switgh Body Transmission Win Clutch switch p Accelerator NCM gt Engi
201. ing 15 activation gt 15 present confirmation signal also on B CAN gt Gearlever in park neutral automatic transmission versions gt Ignition enabled by NBC Code checked The starter motor will be turned 50 until the either the clutch brake pedal or the start stop button is released or for a maximum time of 10 seconds If ignition is correct the NBS will check the engine speed signal on the network and will mechanically lock the TEG in the TEG reader If the TEG lock is not successful the engine can be started but the NBS will not switch loads off key off when the TEG is extracted from the reader The PAV must be pressed to obtain key off For versions with automatic robotised gearbox the gearlever must be in park neutral position to start the engine The procedure must be repeated if it fails with the gearlever in the correct position Traccia Didattica Alfa 159 en ridotta doc 259 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training NOTE The vehicle cannot be moved using the starter motor with the gear engaged if the engine does not start because either the clutch or brake pedal must always be pressed From ignition to key off If no operation is performed within 20 minutes after inserting the TEG in the reader that is after 15 key on the NBS automatically deactivates the 15 INT and INT A loads key off In
202. ing system have four active sensors and four channels with integrated electronic brake distributor EBD Electro hydraulic control unit The system interfaces with gt NCM for controlling drive torque via the C CAN line gt instrument panel for controlling the warning lights via serial line Traccia Didattica Alfa 159 en ridotta 213 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A BRAKING SYSTEM ALFA 159 TRAINING MATERIAL es After Sales Training ECU PINOUT Right rear sensor positive Not TUN INPUT SIGNALS wheel speed sensors direct line brake pedal three stage switch direct line engine ECU on C CAN line throttle angle position on C CAN line instrument panel warning lights state on dedicated serial line VV VV WV WM OUTPUT SIGNALS brake pressure modulator ignition advance reduction on C CAN line engine power management on C CAN line injection time management on C CAN line engine power management on C CAN line VSO signal vehicle speed VVVVVV The ECU gt acquires data from the sensors gt Stores control parameters defined in the vehicle setup gt stores software Traccia Didattica Alfa 159 en ridotta 214 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training processes acquired data controls the braking process detects braking sys
203. int Depth measuring point pepe After flattening the cylinder head measure that the minimum depth of 12 75 mm is obtained in measuring points 1 2 3 4 Traccia Didattica Alfa 159 en ridotta 58 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Timing Cylinder head Fuel high pressure rail Spark plug Camshaft and pulley Head cover Ignition coil module SER FUNCTION The timing components open and close the suction and exhaust valves to provide the engine s timing diagram DESCRIPTION These engines are characterised by the new timing system consisting of a roller rocker arm system clearance is recovered hydraulically which considerably reduces loss due to friction and continuous variable timing on the suction line and the exhaust line obtained by means of compartments The variable timing constantly adjusts the timing angles on both lines suction and exhaust to maximise performance by providing the appropriate timing for all engine speeds and to reduce consumption and emissions at partial loads Continuous suction and exhaust valve variable timing acts on the exhaust valve to extend expansion by converting more heat into work and provide internal EGR functions by avoiding the leakage of the last exhaust gas which is rich in unburnt components and on the suction valve to improve cylinder mixture filling at the various speeds The cam pr
204. iometer positive 2 45 2 Potentiometer positive 1 9 3 Potentiometer signal 1 30 4 Potentiometer negative 1 8 5 Potentiometer negative 2 31 6 Potentiometer signal 2 Bosch CP1H high pressure pump INTRODUCTION The pumping effect of the Radialjet common rail fuel supply pump is obtained by three pistons in a radial arrangement with respect to the pump shaft The angular distance between two pumping elements is 120 FUNCTION The pump is turned by the engine at a speed equal to 2 3 4v and 25 43 2v of that of the engine via a timing belt Timing and injection are controlled by the ECU in injection systems of this kind The pump only maintains the fuel permanently in the rail at the required pressure REQUIREMENTS The pump must receive low pressure fuel at leas 3 5 relative bars and minimum flow rate is 160 litres hour for correct operation This is provided by a low pressure electrical pump High pressure pump operation Piston movement is determined by the rotation of a triangular cam integral with the pump shaft This cam determines the movement in sequence of the three pistons by shifting a mechanical interface tappets between the cam and the foot of the piston The contact between the cam and each tappet is ensured by a spring Each pumping unit is equipped with a plate suction valve and a ball delivery valve All three flows from the pumping elements are internally joined to the pump and convey the fuel to the common rail
205. irstly virtual and then experimental test plan at the Orbassano Safety Centre that can be summed up in the following figures 150 crash tests 100 HYGE sled crash simulations 200 tests on components and subsystems 10 new performance specifications and test procedures 8 specific passive safety structure co designer suppliers 3 of whom exclusively involved in designing and making safety devices Occupant protection system The occupant protection system consists of the following parts which are standard for all outfits A Multistage frontal protection system consists of ECU dual stage driver and passenger front airbag driver and passenger knee airbag front seatbelts with pretensioner and load limiter in winder safety sensor on front tunnel additional peripheral crash sensor on headlight crossbeam front seatbelt fastening reminder front seat occupant presence sensor and manual passenger airbag deactivation switch A chest and hip lateral protection system consisting of two side airbags in front seats two window bags in roof sidemembers Three point seatbelts for all three rear seats In other words the components inside the passenger compartment are all designed to ensure maximum protection for occupants 2004 Fiat Auto S p A All rights reserved 14 318 Traccia Didattica Alfa 159 en ridotta ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training Front seats The front seat structure was
206. is is a triple cone synchroniser exploited to optimise continuity and progression of torque transfer between shafts Third and fourth gear synchroniser one of the three cones contain a carbon friction ring 1 2 The first and second gear synchroniser have a friction ring on all three cones 3 he fifth and sixth synchronisers have a single cone the first two cones are missing 2004 Fiat Auto S p A Tutti i diritti sono riservati 205 318 Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A GEARBOX ALFA 159 TRAINING MATERIAL ees After Sales Training TRIPLE CONE SYNCHRONISER The first and second gear synchronisers consist of three tapered clutches hence the triple cone The purpose is to share the load caused by synchronising the speed of the gear and that of the shaft on three friction surfaces instead of only one Gear shifting is easier in this way SINGLE CONE SYNCHRONISER A single cone sync is used for the fifth and sixth gear and for reverse given the lower torque multiplication of the gearbox 5 2 5 Mounts Gear shifting system gear engagement lever gear selection lever The shifting system consists of a linkage connected to the lever in the passenger compartment via Bowden wires The linkages has two movements the vertical stroke is used to select the synchroniser the rotary movement is used to operate the respective synchroniser fork Traccia Didattica Alfa 159 en ridotta 206 318
207. is is positioned outside the engine block and is positioned on the oil filter side The coolant may penetrate inside the lubrication circuit if an o ring or the drive shaft gasket is not tight MAINTENANCE The cooling circuit must be emptied through the drain holes on the radiator and pump before removing the coolant pump Before removing the pump the coolant chain gear must be blocked with respect to the timing chain cover using a specific tool The balancing shaft chain and the timing chain housing do not need to be removed Cooling circuit components Traccia Didattica Alfa 159 en ridotta 68 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL Thermostat housing Thermostat Thermostat cover Pipe O ring pipe Coolant pump O ring pump Pump draining nut Coolant temperature sensor Ge EE The thermostat unit is connected to the crankcase with screws The temperature sensor is fastened to the unit with a threaded connection Oil water heat exchanger p D IL iy E zi Engine oil thermostat Oil filter adapter housing Engine oil cooler Oil filter housing pU Ie FUNCTION Effective oil cooling is needed to maintain the chemical physical and viscous properties of oil This function is ensured by a water oil heat exchanger MATERIAL The heat exchanger consists of a pack of aluminium plates crossed on one side by
208. isms are anchored to the required point or position The sunroof is equipped with a manual blind and handle to shield from the sun The blind is folded away with the sunroof inside the roof panel When closing the sunroof the blind will partially project to make the handle accessible The sunroof is operated by means of the opening closing pre selector on the front central ceiling light 11 1 3 Operating logic The operating logic is described below The electrical motor is controlled by an ECU Traccia Didattica Alfa 159 en ridotta 306 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A BODYWORK ALFA 159 TRAINING MATERIAL Li After Sales Training Manual control via pre selector key off t lt 2 min doors closed The sunroof can be moved to one of the programmed positions by turning the selector knob in the following cases gt at key on gt during the first two minutes after key off or until one of the doors is opened Remote control Opening closing from remote control at key off the CTA receives the signal for operating the sunroof from the body computer Notes The pinch force safety protection function is active for the entire stroke except for the last 4 mm during closing operations horizontal and or vertical Specifically the pinch force safety function is always active during operations controlled by the remote control The inhibit position can be selected for
209. ke pad surface 77 cm Ventilated disk diameter x thickness 292x22 mm TRW CII floating aluminium brake callipers piston diameter 38 mm The calliper includes the parking brake Pad surface 38 cm NOTES NOTE Aluminium monolith radial anchoring callipers are used for the first time Monolith means that the calliper is made from a single aluminium part instead of consisting of two casing screwed together The callipers are radially anchored to the riser instead of axially as traditional callipers These technical solutions were chosen to increase the calliper stiffness at equal weight and therefore to provide better performance especially for sporty use The large brake pad requires the use of four cylinders two on each side for evenly distributing the braking pressure on the disk Traccia Didattica Alfa 159 en ridotta 212 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training The TRW callipers are made of single part while the Teves callipers are made of two parts joined by two screws IMPORTANT NEVER DISASSEMBLE THE TEVES CALLIPERS AND OR LOOSEN THE SCREWS JOINING THE PARTS This operation can only be performed at the plant using specific gauges Disassembly and reassemble of the two parts of the calliper will cause misalignments which may severely compromise braking safety 6 1 2 ABS The TRW EBC430 New Generation ABS anti lock
210. l SS po 00000000000 OG poooooooooooooqQq pooooooo0o0o00000000000Qq g00000000000000000006 16 1 1530 29 7 28 50 Connector K engine utilities wire vehicle side PIN FUNCTION Injection primary utility power from B001 F17 Ground Not connected Ground Injection primary utility power from B001 F22 Ground Variable geometry turbine solenoid valve signal 8 Accelerator pedal potentiometer 2 9 Accelerator pedal potentiometer 1 Fuel temperature sensor Traccia Didattica Alfa 159 en ridotta 133 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Compressor relay control negative signal T5 31 Accelerator pedal potentiometer 2 Post particulate trap DPF temperature sensor signal Post particulate trap DPF temperature sensor 34 Pre particulate trap DPF temperature sensor signal 35 Pre particulate trap DPF temperature sensor 49 Not connected 60 LNotoonmected O 066 Notconnected 68 69 Traccia Didattica Alfa 159 en ridotta 134 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Water in fuel filter sensor signal 78 SET Cruise Control 79 Clutch pedal contact signal 82 83 84 85 89 Not connected _ _ _ _ 90 Engine cooling fan first l
211. l bus LIN to pin 8 and are connected in series The signal of the temperature sensor downstream of the evaporator is used by the ECU for calculating the temperature of the air to be let into the passenger compartment and is not a frost sensor It also contributes to the vehicle speed signal and the engine speed IMPORTANT The actuators cannot be switched because each once is equipped with dedicated software for their specific function For replacements order the new spare part by quoting the correct spare part number gt The system will adapt automatically after disconnecting and reconnecting power or replacing parts No alignment or resetting is therefore needed gt A proxy alignment procedure must be run to replace the NCL 10 5 5 Notes on sensor operation AQS Air Quality Sensor The AGS is used to detect the presence of pollutants in the air let into the passenger compartment This sensor generates a PWM signal with 12V amplitude whose duty cycle may vary in the range from 20 to 60 respectively in the absence or presence of pollutants and is used by the NCL to close the recirculation flap It is connected to pin 19 of the NCL Fog Sensor The fog sensor detects the fogging up of the windscreen and makes the NCL automatically select defrost air distribution The fog sensor provides a PWM signal with 12V amplitude whose duty cycle is established according to the degree of humidity inside the windscreen It is connected to pin 20 of
212. l coaxial internal coaxial internal coaxial internal coaxial actuator actuator actuator actuator actuator Driven plate outer diameter mm inner diameter 155 155 160 160 155 mm Plate spring load Tri mim Im Im Supplier Sachs Valeo 2 4 GEARBOX OOS 22J7 19Miet8v Type Gears heicateeh eelst nelicaltee 2004 Fiat Auto S p A All rights reserved 30 318 Traccia Didattica Alfa 159 en ridotta TECHNICAL DATA ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training 1 9 Multijet16V 2 4 Multijet 20V SE automatic Aisin AF40 6 Synchronisers I II III IV V VI R I II III IV V VI R Gears helicalteeth IT helicalteeth helicalteeth 1st gear ratio 3 818 3 769 4 148 3rd gear ratio 1 302 1 321 1 556 5th gear ratio 0 744 0 755 0 859 eth gear ratio 0 614 Reverse gear ratio 2 5 DIFFERENTIAL sg 1 9 JTS 2 2 JTS 1 9 M jet 8V Reduction a torque 4176 4176 3 650 Wheel ratio 15 944 15 944 13 936 Wheel ratio Il 9 826 9 826 7 877 Wheel ratio III 6 560 6 560 4 752 Wheel ratio IV 4 786 4 786 3 500 Wheel ratio V 3 938 3 938 2 716 Wheel ratio VI 3 596 3 596 2 241 Wheel ratio R 14 804 14 804 12 939 3 545 13 361 7 231 4 682 2 6 BRAKES 2 6 1 Braking system Ie 1 9 UTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Type Hydraulic power Hydraulic power Hydraulic power Hydraulic power Hydraulic power assisted assisted assist
213. les Training 8 1 2 Rear suspensions The multilink suspension architecture handles wheel motion in a controlled fashion to achieve better and higher level performance In this case the three link solution with transversal leaf has specialised the performance of the various components for longitudinal forces to obtain better lateral roughness filtering faster response stability and hold in limit conditions Rear suspension components Direction of travel longitudinal arm with bushing spring shock absorber assembly wheel riser camber arm crossmember transversal leaf oO IM Traccia Didattica Alfa 159 en ridotta 234 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The high strength steel longitudinal arm guides the riser during shaking and ensures longitudinal movement at the same time Equipped with a 80 mm diameter hydraulic bushing it ensure soft retraction with optimal damping of rebounds The filtering bushing is fastened by a three fastening bracket to the body This has increased the vertical fastening position embedding it in the body This provides better stiffness and better shaking wheelbase variations with additional benefits for overcoming obstacles The aluminium riser in addition to being equipped with a high stiffness hub also carries connection bushings for the camber arm and for the longitudinal arm The latter is
214. lfa 159 en ridotta 181 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training ELECTRICAL SPECIFICATIONS See graph above OF ACTUATOR Operative voltage from 6 16V Working pressure 150 350 kPa 1 5 3 5 bar COMMAND TYPE Battery voltage via relay controlled by ECU MEASURING METHOD Multimeter Glow plug pre heater ECU 30 EDC Engine ECU GCU Glow plug ECU 30 terminal Battery positive connection Ubat for powering glow plugs G1 G2 G3 G4 G5 Glow plug connection output terminal 86 terminal Power from EDC 31 terminal Ground ST terminal Start input to control from EDC K terminal Start input to control from EDC DI terminal Output for direct diagnostic to EDC Traccia Didattica Alfa 159 en ridotta 182 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Ton rele lt 10mS Toff rele lt 10ms PROVA CANDELETTE PRERISCALDO OK TIPO DI RILIEVO VALORI LETTI VALORI OR har aa ae 30 36 42 48 24 Traccia Didattica Alfa 159 en ridotta 183 318 2004 Fiat Auto S p A All rights reserved ELECTRICAL SPECIFICATIONS OF ACTUATOR COMMAND TYPE MEASURING METHOD Traccia Didattica Alfa 159 en ridotta ALFA 159 TRAINING MATERIAL Normal power voltage Drawn power Maximum working voltage Admitted voltage variations during normal operation Glow pl
215. ls the fuel pressure regulator on the rail Traccia Didattica Alfa 159 en ridotta 161 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Engine speed sensor Rail pressure regulator Frequency on pins A27 A12 EDC 16C39 Control voltage between pins A 4 A 34 Accelerator pedal sensor Voltage to pins B 9 and B 31 ALFA 159 TRAINING MATERIAL Injectors The ECU implements the following Voltage to pins A 16 A 47 procedures when the accelerator A 2 A 81 A 1 A 46 A 17 Aere A 33 A 18 A 48 5 cylinder l gt itcuts off injection power J ___ ___ _ l l2 it partially re powers the injectors 00 before reaching idling speed Coolant temperature sensor b itcontrols the fuel pressure Resistance between pins A 41 regulator Signal from ECU ABS to pins B 61 and B 62 Cylinder balance control up to 3500 rpm The ECU according to the signals received from the signals controls torque to 3500 rpm and varies the amount of fuel injected into the injectors injection time INPUT PARAMETERS OUTPUT PARAMETERS ELECTRICAL QUANTITY Engine speed sensor EDC 16039 Voltage to pins A 16 A 47 A Frequency to pins A12 A27 2 A 31 A 1 A 46 A 17 A 33 A 18 A 48 5 cylinder Speedometer signal The ECU cont
216. ltered in time to avoid undesired corrections e g potholes rough roads etc This correction is also performed when the lights are off so that the beam is correctly positioned the instant the headlights come on Load sensors The load sensors are fastened to the vehicle chassis An appropriately shaped lever follows the movement of the suspension The sensor is powered by the headlight ECU and provides a linear output signal which is proportional to the position of the suspension with respect to the body Connector Control lever Lever camber Sensor output signal voltage lt OD 9 8 5 Adjustment actuator A stepper actuator inside the light cluster makes the adjustment It consists of a electrical stepper motor and a worm screw reducer which transforms the rotary movement into linear motion of a pin hinged via a ball joint to the reflecting surface 1 Stepper motor Traccia Didattica Alfa 159 en ridotta doc 294 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM dii a ilaria After Sales Training 9 8 6 Self diagnostics The electronic system is provided with a self diagnostic function which constantly monitors functionality The ECU continuously self diagnoses system operation Specifically it detects and stores failures The failure stored in the ECU can be analysed using Examiner or other diagnostic tools 9 8 7 Recovery The self diagnostic management log
217. m in collaboration with GM presents radical architectural innovations with respect to the previous 156 chassis The bodyshell has various longitudinal boxed elements that are reciprocally connected by transversal elements completed by the dashboard and floor panels The floor pan boxed elements seamlessly integrate the body elements and form a perfectly integrated structure The energy of a front or rear end collision is mainly absorbed by the two load lines formed by the front struts the chassis the engine mount system the rear struts the sidemembers under the floor and the sidemembers The continuity between these parts for the entire length of the car ensures gradual progressive distortion Furthermore the connection between struts and suspension engine chassis contributes to the optimal distribution of the load front towards distortable obstacles The high strength material and differentiated thickness of the appropriately dimensioned front and rear sidemembers support the force developed by the front and rear crossmembers in low speed collisions without being damaged At the same time they entirely absorb the energy of high speed collisions without distorting the passenger compartment 2004 Fiat Auto S p A All rights reserved 12 318 Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The front fits a boxed crossmember with controlled distortion collapsible mounts
218. mal dimensions minimum length minimum diameter Capacity of reaching high torque values Low weight due to small dimensions and use of alternative materials Simple assembly single central bolt and fastening pin VVVV System operation Control valve exhaust side Control valve suction side Variable timing exhaust side Variable timing suction side Reversible oil duct Oil return duct Oil delivery duct mid iai RS OPERATION The hydraulic variable timing system is shown in the figure Duct 7 supplies the 4 3 distributor hydraulic solenoid valves four ports three positions each of which is connected to its own rotating actuator variable timing via two ducts The variable timing compartments between the rotor fixed to camshaft and the stator fixed to pulley can be filled with oil or emptied The rotor is turned by the filling and emptying of the conduits The rotor can turn with respect to the stator in either direction Traccia Didattica Alfa 159 en ridotta 66 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Variable timing exploded view Stator Block system Screws Pulley Rotor Adapter Plate Return spring Cover SN NO Variable timing control valves FEATURES The proportioning hydraulic valve is part of the variable timing hydraulic system Actuation is electromagnetic with return spring It is provided with a fast
219. mall ends are connected by a bronze bearing and a gudgeon pin held in plate by two snap rings The 2 2 engine connecting rods are 145 5 mm long the 1 9 engine connecting rods are 153 mm long MAINTENANCE Since connecting rod caps are fracture split each cap couples perfectly with its connecting rod When refitting connecting rod caps make sure that each cap is coupled with its connecting rod to prevent damage due to imperfect surface coupling Crankshaft 1 Crankshaft 2 Phonic wheel 3 Phonic wheel fastening screws FUNCTION The crankshaft transmits motion to the flywheel and therefore to the driveline by effect of the drive torque resulting from the thrust of the gasses It drives the other turning parts of the engine and the various accessories MATERIAL The crankshafts of both engine versions are made of cast iron FEATURES The crankshaft is supported by five main bearings supported by the crankcase main bearings and eight counterweights The steel phonic wheel is fitted on the eighth counterweight with three screws Along with the speed sensor the phonic wheel generates the crankshaft speed signal and determines top dead centre The crankshaft ends on one side with a flange for fastening to the flywheel and with an engine pulley on the other end The crankshafts of the two engine versions 1 9 and 2 2 are different Flywheel The Sachs flywheel is of the damped dual mass type Traccia Didattica Alfa 159 en ridotta
220. mately 5 seconds Traccia Didattica Alfa 159 en ridotta 90 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Fuel high and low pressure line SI co po High pressure connection Fuel pump fastening element Fuel pump fastening shelf High pressure fuel rail fastening element Low pressure fuel rail fastening element Mount fastening bracket Mount fastening holes FEATURES The line joins the low pressure fuel line fuel pressure up to 0 6 MPa to the high pressure line fuel pressure 10 MPa to the fuel injection rail ASSEMBLY VVVVVVV Position elements 1 2 and 3 at the same time high pressure pump connection and shelf Fit connector 2 to the high pressure pump Fit high pressure connections 1 and 4 by hand on both ends Fasten connection 1 to the pump at the necessary torque Fasten connection 4 to the rail at the necessary torque Fit connection 5 to the low pressure line at the necessary torque Position the shelf on mounts 6 and 7 Fasten onto mounts 6 and 7 and onto the shelf 3 REMOVAL gt Loosen connections 1 3 4 5 6 7 gt Move the T fasteners from the mounts 6 and 7 gt Release connector 2 from the high pressure pump ADDITIONAL INFORMATION The high pressure pump connection screw is coated with wax to provide the right torque during assembly Repeat the procedure when refitting 1 Wax coated screw
221. ment 0 5 cm rev Pressure range 2 12 MPa 0 4 MPa at start up Speed range 40 3500 rpm LIFESPAN OF COMPONENT The specific tolerances of the component are designed to last for 10 years or 150 000 km WORKING CONDITIONS Fuel temperature during normal use maximum 80 C not in use 100 C maximum temperature of 130 C can be held for 30 minutes Fuel vapours must not penetrate inside inlet area Two filters main filter on supply line with 5 um fine mesh and filter on connection with 30 um fine mesh Admissible dynamic load lt 600 m s REMOVAL REFITTING The pump is fitted on the head axially with respect to the camshaft with an Oldham clutch It is essential to lubricate the o ring with engine oil clean no silicon The Oldham clutch is joined without applying force Union with the head is obtained by applying a force not exceeding 200 N ADDITIONAL INDICATIONS The pressure of the screws on the head must not exceed 360 N mm 2 The Oldham clutch and the bearing required continuous lubrication during operation Replace the o ring after each removal Handle the pump with care Injection piping FUNCTION To ensure supply of fuel in direct injection petrol systems FEATURES Four fuel injectors a pressure regulating valve and the pressure sensor are fitted on the fuel rail The rail is also fitted with a high pressure and a low pressure connector The rail must be adequately flexible to damper pressure oscillations generated by th
222. moved outwards This improves vehicle stability when braking see figure below The careful geometry and wheelhouse volume design has been exploited to obtained better steering angles with wider tyres to considerably improve the curb to curb steering circle Traccia Didattica Alfa 159 en ridotta 228 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training Front suspension components 2 DIRECTION OF TRAVEL wheel hub upper swing arm sliding bushing mount spring shock absorber assembly front bushing stabiliser bar connecting rod stabiliser bar chassis 10 lower swing arm 11 rear bushing 12 wheel riser 13 guard 0 09 Le at Traccia Didattica Alfa 159 en ridotta 229 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The connection points between the wheel riser and the levers are coated to exploit the available space inside the 16 rims to the maximum with considerable benefits on lateral stiffness The adoption of a very stiff hub has additionally improved this stiffness Coaxial shock absorber spring unit with double tube shock absorber has increased size and now fits a 15 mm rod and 32 mm valve unit The oversized dimensions have increased the shock absorbing filtering capacity by also reducing the hysteresis levels The unit is connected to the b
223. n obstacle obstructing the movement of the panel is detected The panel may stall for no longer than 20 30 milliseconds to prevent an unpleasant pinching feeling and the movement is reversed to return to the programmed position gt The function is active for the entire horizontal stroke if the sunroof is opened by more than 4 millimetres and trips if an obstacle is encountered on the front side of the glass panel Motion is reversed for 100 millimetre from the point of encounter The function is active for the entire vertical stroke if open for more than 4 millimetres from the edge of the weather strip and trips if an obstacle is encountered on the rear end of the glass panel Motion is reversed to reach max tilting position The inversion load is lt 100 N as requested by Directive 2000 4 EC in both cases 11 1 4 Emergency operation 1 Volumetric sensor support 2 Control electric motor 3 Operating key In the event of an emergency or servicing without power the front motor can be operated manually to open close the front glass panel as follows gt gt gt Remove front central ceiling light Insert an emergency key in the motor Turn the key to close or open the panel turn accordingly 11 1 5 Initialisation procedure VVVVVVV VV Turn key on Note Wait for three seconds after key on to replace a geared motor Turn key off an wait for three seconds Turn the key on again and proceed as follows Turn the k
224. nance free The belt is pulled by an automatic tensioner The power steering pump is controlled by a second narrower belt MAINTENANCE The belt tensioner must be loaded against the pressure of the spring with a specific tool This releases tension from the belt which can therefore be removed The power steering drive belt must be removed using the specific tool SR E l f KOT AN ke W 2 ON d HJ S E nt u mr 1 Utility belt tensioner 1 Course of the belt with A C compressor 2 Height of belt with A C compressor and second power steering pump belt Traccia Didattica Alfa 159 en ridotta 64 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Balancing countershafts FUNCTION The engine is equipped with two balancing countershafts to improving riding comfort in terms of noise and vibrations These eliminate the reciprocating forces typical of four cylinder in line engines that the crankshaft counterweights cannot balance MATERIAL The rotating countershafts are made of cast iron FEATURES The two countershafts with cast iron balancing counterweights ensure high performance in terms of noise and vibration containment They are located inside the crankcase and controlled by the countershaft chain The countershaft gear teeth are provided with damper rings which additionally reduce the noise from the chain The coolant pum
225. nce measured by the central sensors remains unchanged The signal on the other hand is interrupted after three seconds if this situation occurs for side sensors to avoid warnings when for example manoeuvring along a wall parallel to the car No rear obstacles are detected if a trailer is fitted 9 6 6 Switching the system on and off A self diagnostic test is run on all peripherals when the ECU is switched on at key on The system is ready for use in less than 0 5 seconds The distance measuring system only runs when the system is active Only the ECU microcontroller runs when the system is not working The system is beeps at increasing frequency when the system is active in the presence of obstacles The system is switched off when the speed exceeds 18 km h or when the on off button A is pressed Traccia Didattica Alfa 159 en ridotta doc 282 319 2004 Fiat Auto S p A Tutti i diritti sono riservati E ALFA 159 TRAINING MATERIAL e SYSTEM After Sales Training Ko a A B lleg E E n e rea RO e a pris a z fr tua LLLA A pa aca za SE 3 SI Sa en ve ai ai t em lid UR 9 6 7 Coverage area The system covers the rear middle and side areas of the car Obstacles in the rear middle area are detected at a distance of approximately 1 40 m maximum value Obstacles in the rear side area are detected at a distance of approximately 0 6 m Obstacles in the front middle area eight sensor systems only are detected a
226. nd petrol version rev counters differ for the maximum scale 6000 rpm for diesel and 8000 rpm for petrol and for the start of the red sector 4500 rpm for diesel and 6800 rpm for petrol Buzzer The buzzer can provide signals of different intensity for the following functions gt Doors open while car is travelling Handbrake applied while car is travelling Parking sensors Speed limit exceeded Acoustic feedback for functions activated by means of buttons Acoustic feedback for stored seat and mirror positions Reverse and automatic robotised transmission safety position Driver s door open with TEG inserted Feedback for warnings alarms shown on display VVVVVVVV Light sensor HIGH and MEDIUM versions The sensor positioned on the speedometer dial measures environmental light conditions and sends this information day and night to the body computer which compares this information with the taillight state and selects the appropriate lighting configuration inside the vehicle day night mode Auxiliary instrument panel HIGH MEDIUM and BASIC versions The central instrument panel presents three analogue instruments managed by an integrated electronic ECU The instruments are directly controlled by the main instrument panel via a LIN Central instrument dashboard configurations and variants The following variants are available gt Petrol with engine oil temperature indicator or diesel with turbo charger pressure indicator gt
227. ne speed p Engine torque S Pedale reng e 18 171 X Anu t i h Frizione ANE d inn on SC i t 4 pressione fornita TA i valore di coppia meto vicina a TZ B a padala Tano rilascia z trizione rilasciata Faggiumo T1 la pressione comincia a scendere 20 02 Sec TZ coppia necessaria allo spunto b pedale freno premana d frizione preis Traccia Didattica Alfa 159 en ridotta doc 221 319 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A BRAKING SYSTEM ALFA 159 TRAINING MATERIAL ub After Sales Training 6 2 4 ASR TCS MSR ORDINARY DIFFERENTIAL ASR TCS ASR This function controls vehicle traction It works on the braking system by applying the brakes to the wheel that is slipping to transfer the torque to the other wheel of the axle and on the engine by reducing engine torque MSR This function controls the engine brake during cut off On particularly slippery ground the engine brake could cause the drive wheels to slip at cut off with severe consequences on control and stability This condition is even more dangerous for four wheel drive vehicles where the rear wheels could be locked when the accelerator pedal is released In such conditions the system increases engine torque to reduce engine brake and prevent wheel locking Traccia Didattica Alfa 159 en ridotta doc 222 319 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat
228. ng comfort TYPE Centre of gravity balanced engine mount system with two pads and two reaction rods 5 and 7 in the figures above which act as linkages The mounts are aligned along an axis passing through the centre of gravity of the engine which eliminates reaction moments on the mounts CONSTRUCTION Each support is provided with a vibrations damping rubber and metal pad 1 Engine rodengine side 2 Engine rod gearbox side Traccia Didattica Alfa 159 en ridotta 48 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training Cylinder block Oil filler housing Crankshaft shaft speed sensor Oil pressure switch Knock sensors Cylinder block Bottom plate 1 2 3 4 o 6 FUNCTION In addition to containing the cylinder liners the cylinder block supports the mobile parts of the engine pistons connecting rods crankshaft camshaft etc the inserted fixed elements cylinder head oil sump timing box and the auxiliary organs alternator starter motor climate control compressor etc MATERIAL Made entirely of aluminium alloy in two parts the cylinder block itself and the bottom plate FEATURES Dry inserted liners Integrated balancing countershafts Ventilation lubrication and cooling conduits built into crankcase Integrated oil filter housing Main caps fully integrated in bottom plate to stiffen the crankshaft journal sy
229. ng the boot Applying the dead lock Unlocking the doors Unlocking the boot Arming the alarm system Disarming the alarm system Electrical steering lock failure No TEG recognition Start stop button failure Steering not locked Smart Key reader failure TEG in reader when driver s door is opened after key off TEG inserted VVVWVWVWVWVWVWVWVWVWWw Emergency extraction The TEG can be released in all conditions also while travelling by means of an emergency mechanical insert This operation will be detected by the NBS which will send a signal to the instrument panel for indicating the steering will not be locked 9 2 4 Overview of fundamental operations Key on The steering is released by the NBS when a valid TEG is inserted in the TEG reader 15 is consequently activated H no operation is performed within 20 minutes after inserting the TEG in the reader the NBS automatically deactivates the 15 INT and INT A loads key off In this case when the start stop button is pressed the clutch or brake pedal is pressed and a valid TEG is inserted in the reader the NBS will activate loads key on and start the engine if the button is held pressed Traccia Didattica Alfa 159 en ridotta doc 260 319 2004 Fiat Auto S p A Tutti i diritti sono riservati E ALFA 159 TRAINING MATERIAL do SYSTEM After Sales Training Cranking The engine is cranked 50 when the clutch or brake pedal is pressed and the start stop button is
230. ngine oil for replacement Traccia Didattica Alfa 159 en ridotta 71 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Oil filter A QR x E Py FOSS Jill Wise k 2T d Ji N 1 Opt Wwe 1 Oil filter housing 2 Oil filter cover 3 Filtering cartridge LOCATION The oil filter housing is made in the cylinder block casting FEATURES The oil filter consists of a paper cartridge The screw on filter cartridge contains the bypass filter MAINTENANCE Use the specific tool to remove the oil filter cover Change the engine oil regularly as shown in the Owner s Handbook Blow by system FUNCTION To collect the oil vapours developed in the crankcase and cylinder head to prevent dispersion outside the engine to condense them and send them back to the sump FEATURES Vapour emissions are controlled by an oil separator which collects the vapours from the crankcase and the tappet cover The condensed vapours return to the sump through a pipe The uncondensed vapours are conveyed by a pipe to the suction air sleeve BLOW BY VALVE A regulating valve is arranged on the vapour conveying pipe In normal conditions the valve spring presses a membrane keeping it open and letting oil vapours from the oil separator through When the vacuum inside the pipe exceeds its calibration the spring moves the membrane and closes the
231. ngines 4 3 2 SAT Self Adjusting Technology plate wear take up system CHARACTERISTICS The Valeo clutch has a mechanical friction plate wear take up device called SAT which exploits the rotation between two rings on adjacent slanted planes The components of this system are shown in the following section Traccia Didattica Alfa 159 en ridotta 189 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training Toothed plate Clutch cover Diaphragm spring Pressure plate Ratchet wheel and slanted sector Worm screw Toothed ring Thrust ramp with slanted sector Se ee EE SYSTEM OPERATION OVERVIEW FU L LLL ferri ra L d k mimi tac Se egene CA J EE i P A ESI la db Vir I I f i T Pr ML Di KM RA T T F4 1 s ES K i Ed 1 ee d H i 4 FA F4 LI T BC V AlI ANT L MEL i EI Ff Py EI r1 i 1 i al AUS f A A prt n el GH 6 F aem E F J if J i de iS QD TIU I 2 NEW PLATE RELEASE The toothed plate 1 rests on the stop built into the cover 2 In this position it is still in contact with the previous tooth 3 WORN PLATE ENGAGEMENT The toothed plate 1 presses the gear tooth 7 whose value corresponds to the friction plate wear Traccia Didattica Alfa 159 en ridotta 190 3
232. no riservati Fiat Auto S p A 10 DA Alife 51 4 ALFA 159 TRAINING MATERIAL ee After Sales Training The sunroof consists of the following parts gt A frame consisting of two aluminium guides in which the mechanisms and the two crosspieces slide front crosspiece made of plastic and rear crosspiece make of metal and joined to side guides A right and left system of mechanisms inserted in aluminium guides for moving the glass panel operated by an electrical motor via a metallic spiral wire A manually moveable sun blind with handle and slots for letting air through A tempered glass panel 4 millimetre thick low energy lt 17 and light gt 35 transmission A direct current motor and geared reducer a magnetic wheel fitted on drive shaft one or more Hall effect sensors and a 6 pin interface connected to the vehicle wiring harness An electronic control unit A knob for selecting the various opening and closing positions with additional cut out position VV VVV WV Electrical motor Racks Emergency screw Electrical connector Sa 11 1 2 Operation of the sunroof The sunroof is moved along the sliding guides on the frame by an electrical motor which can be controlled manually by means of the selector knob or remotely where fitted via a control sent by the body computer to the ECU The motor moves the flexible drive racks housed in the specific housings in the frame onto which the sunroof supporting tilting mechan
233. nob all to the left anticlockwise Press the knob and hold pressed until the sunroof is mechanically locked clearly visible Release the knob Within 5 seconds press the selector again and hold it pressed The sunroof will start an automatic cycle after a few seconds Hold the selector pressed Release the selector when the sunroof initialisation ends The sunroof will be in the 0 position Turn the selector knob and take the sunroof to the required position Traccia Didattica Alfa 159 en ridotta 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A After Sales Training 510 DA 4 e 51 4 ALFA 159 TRAINING MATERIAL M089L r E EH Hi Elle cosol con 11 2 SEATS 11 2 1 Features of the seats Front seats The front part of the front seats is optimised to prevent anti submarining i e to prevent the occupant s body from slipping forward underneath the seatbelts in the event of a violent front collision This considerably contributes to limiting injuries for the abdomen and thighs by reducing forward acceleration of the body The main features of the front seats are gt The seats are provided with an efficient spring system in the ischiococcygeal area made of thin plastic coated steel wires anchored with springs to the external frame to favour vibrational comfort and particularly to dampen vibrations induced by road roughness e g tram lines etc Traccia Did
234. node Convergence node NCV Opt The NCV is a device connected to the B CAN capable of interacting with the NIT via a Bluetooth cell phone It interfaces with the controls on the rearview mirror and with the free hands microphone on the front central ceiling light Front door node NPA The NPA is connected to the B CAN and to the respective front door wiring It manages the electrical functions of the front doors the electrical heated mirrors the puddle lights and the rear ceiling lights The NPA is present when the rear doors are not fitted with electrical window winders and it manages the electrical functions of both rear doors The NPA also makes the external temperature reading acquired by the sensor built into the mirror available Driver s door node NPG The NPG is connected to the B CAN and to the respective front door wiring It manages the electrical functions of the respective door the external mirror on driver s side and the rear ceiling light It is connected to the door control panel PCP As the NPA the NPG also makes the external temperature signal available to the network Passenger s door node NPP The NPP is connected to the B CAN and to the respective front door wiring It manages the electrical functions of the respective door the rear ceiling light and the external mirror It is connected to the door control panel PCS and houses a connector for directly connecting the wiring provided with the respective extern
235. non symmetric position of the differential with respect to the middle line of the vehicle which would require the use of drive shafts of different length if the transmitted torque is very high This is why an Traccia Didattica Alfa 159 en ridotta 207 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A GEARBOX ALFA 159 TRAINING MATERIAL ee After Sales Training intermediate drive shaft is fitted to allow the use of two drive shafts of the same length and obtain smoother transmitted torque Specifically the tulip has a twisting stiffness of in the range of 500 600 Nm while the drive shaft is in the range of 170 180 Nm variable values according to engine version Axle shaft structure un n lur umm L E ILA JI IN Gui ini gemit d ASSEMBLED ASSEMBLATO CV joint stop ring collar boot collar axle shaft collar boot collar spare part kit tripod stop ring tulip CASH ITONMIOM gt D While travelling the axle constantly oscillates with respect to the gearbox due to road roughness thanks to the presence of suspension linkages interposed between the wheel hub and the body Two CV joints the tripod joint Slides axially are fitted to allow the axle to adapt to the wheel oscillations These allow transmission of motion between the shafts whose axles are not coinciding this occurs between the wheel hub axis and the axle shaft T
236. nsmission of the signal POSITION The knock sensors are positioned on the front side of the engine underneath the intake plenum 1 Knock sensors ELECTRICAL SPECIFICATIONS SENSOR FEATURES Piezoelectric knock sensor OUTPUT SIGNAL TYPE Electrical pulse signal 2004 Fiat Auto S p A All rights reserved Traccia Didattica Alfa 159 en ridotta 99 318 Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Temperature sensor FEATURES Sensor for measuring engine coolant temperature with 2 pins working range from 40 C to 130 C fitted in crankcase The connection to the engine ECU is CONNECTION TO ECU CONNECTOR connector pin 1 to ECU pin 7 side A ground connector pin 2 to ECU pin 22 side A 22 I ur e A pin 7 massa ur e Sensore temp acqua motore REMOVAL REFITTING The tightening torque must be in the range from 18 to 25 Nm POSITION The sensor is positioned on the cooling circuit thermostat housing 1 Temperature sensor 2 Coolant circuit thermostat housing Traccia Didattica Alfa 159 en ridotta 100 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training SENSOR FEATURES NTC thermistor sensor Variable resistance from a maximum of 45kOhm to OUTPUT SIGNAL TYPE 40 C 60 Ohm to 150 C The ECU must be power
237. ntrol voltage on pin A 20 Voltage on pin K 32 Injectors Engine speed sensor Voltage to pins Frequency on pins A55 A 50 A 49 A 47 A 48 and A40 A 32 A 33 A 35 A 34 The ECU processes the signals received from the various sensors and determines the fuel Signal from ECU ABS to cut off strategy by controlling pins B 61 and B 62 Motorised throttle Voltage to pins A 15 and A 30 e controlling the pressure regulator Engine temperature e controlling injectors sensor e advance Voltage signal on pin A Accelerator potentiometer signal Voltage on pins K 60 and gt K 82 Fuel vapour recovery The polluting fuel vapours are collected in an activated carbon canister and are sent to the intake manifold to be burnt The occurs by means of a solenoid valve controlled by the ECU which alternates open stages canister wash out and closed stages fuel factor learning stage When opened the solenoid valve opening duty cycle is controlled by the ECU to eliminate fuel vapours without changing engine carburetion Traccia Didattica Alfa 159 en ridotta 119 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training O moe ALFA 159 TRAINING MATERIAL INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Engine temperature Fuel vapour intake sensor solenoid valve Voltage signal on pin A 22
238. o S p A After Sales Training Heating press the button at key on only A LED in the button will light up to indicate that the system is working The button is replaced with a four position knob in electrically adjustable seats Front backrest folding to form a table Electrically adjustable front seats Adjustment is possible at key on or for one minute after key off or extraction of the key or for three minutes after opening the doors gt gt gt gt Longitudinal adjustment A Height adjustment turn the knob A anticlockwise to lift the rear end of the cushion turn clockwise to lift the front end Backrest slant control B Heater C Storing driver s seat positions Three different positions of the driver s seat and external rearview mirrors can be stored and recalled Press one of the buttons 1 2 3 for three seconds until a confirmation tone is heard to store the current seat and mirror position A new position will be stored if the same button is held pressed again The preset seat positions do not comprise lumber adjustment and heating The car speed must be less than 10 km h to recall a preset position Pressing of any button while a preset position is being recalled will stop the function anti panic mode Traccia Didattica Alfa 159 en ridotta 318 318 2004 Fiat Auto S p A Tutti i diritti sono riservati
239. o ensure maximum comfort and optimal safety Traccia Didattica Alfa 159 en ridotta doc 206 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM dii a ilaria After Sales Training 9 7 4 Front seat belt pretensioners Features The pretensioners fitted on the front seat belt buckles are pyrotechnic devices electrically activated by a signal from the ECU The same logic that controls the airbags also activates the seat belt pretensioners The pretensioners recover belt slackness and hold the occupant against the backrest from the first instants of the collision to reduce movements inside the passenger compartment The belts are also equipped with two threshold progressive load limiters to decrease the force transmitter to the occupant s chest the load limiter force levels considerably reduces the risk of fractures to shoulder bones and ribs also for the most delicate bones e g the elderly The pretensioner mechanism is shown in the following figure 1 Gas generator 2 Piston 3 Cylinder 4 Metallic wire Operation When a sufficiently high deceleration is detected by the system accelerometers the electronic sensor in the ECU sends a signal to fire the pyrotechnic charges of the gas generators The combustion of the propellant develops a chemical reaction and forms inert gas whose pressure generates a force that pushes a piston The piston is connected to the metallic wire which
240. o ensure that the car can always be safely driven also during storage An activation and deactivation procedure which is cost effective in terms of time requirements and operations No revolution in basic architecture of the car where the system Is applied is needed VV V The nodes involved in the logistic mode function are Activation at the factory Logistic mode is activated at the factory at the end of the line The NBC is the ECU set up to receive the service When the NBC receives the activation signal it switches to low consumption mode deactivates some loads and sends the logistic mode command to the CAN B CAN C CAN and LIN All concerned ECUs and nodes will implement their own low consumption strategy During logistic mode activation the ECUs may be requested not to read some signals and or not to actuate certain actuators In these cases the diagnostic procedures referred to these components must not store false errors The ECUs must therefore deactivate the diagnostic procedures which would not be efficient while logistic mode is up All network wake up events at key off will be deactivated except for those concerning driveability and safety The following wake up events must always be present gt CAN interface gt key on gt hazard Performance after activation Vehicle performance is split into the following macro areas Vehicle accessibility Entertainment Comfort Visibility System VVVVV
241. o offer customisation options without compromising the global coherence of the model Despite its large size capacious boot and roomy passenger compartment the 159 with characterised by appealing lines and a sporty elegant style Lineaccessori protects the cars image and enhances these aspects without neglecting comfort versatility and well being on board n 2004 Fiat Auto S p A All rights reserved 24 318 Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The cars features express the driver s lifestyle personality and image The accessories proposed for the 159 complement the Cars original fittings and offer options for customising the car adapting it to appearance and functional needs arising when the car is purchased and later in use The accessory grid is split into thematic areas to help customers identify the most suitable accessories needed more promptly Sportiness Sportiness is one of Alfa Romeo s strongest values It is a highly emotional area and a wide range of customisation options are offered Exterior proposals include gt Alloy rims and tyres responding to the severest quality and safety criteria while accentuating the car s dynamic design Designed to perfectly integrate the suspensions and enhance the excellent road holding features of the 159 Possible sizes 17 18 and 19 Front and rear bumpers characterised by excellent finish an
242. odium cooled exhaust valves to reach high volumetric yield The maximum suction valve lift is 10 3 mm for both engine versions The roof shaped combustion chamber has four valves per cylinder with valve valves with respect to a 86 mm bore 35 3 mm suction and 30 3 mm exhaust for easy air flow to favour engine performance Attention in designed focused greatly on the piston height to contain the total height of the engine despite the 94 6 mm stroke to provide a compression height of only 28 mm this result is excellent considering the high area power reached Drive chains FEATURES One chain drives the camshaft and another drives the balancing countershafts and the coolant pump Two maintenance free hydraulic tensioners ensure that the chains are correctly pulled The timing chains cross two Ip Traccia Didattica Alfa 159 en ridotta 60 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training centrally fitted conduits and guides fastened on the tensioner side of the timing box A sliding conduit guides the chain between the camshaft pulleys The oil nozzle in the middle ensures correct lubrication Specific chain lubrication is allowed by the oil returning from the head MAINTENANCE The chains last for the entire life of the engine and must not be opened Camshaft drive chain A ees 4 nl a rs i AJ A au P Ki dn L j ti h W 4 m in SL em MN
243. ody by a generously dimensioned split mount with a high noise filtering capacity solutions The main feature is the specialised bushings connected the arm to the chassis The lower bushing is extremely stiff and withstands most lateral and longitudinal loads by opposing extremely low distortion with benefits on loss of camber when cornering The double sized hydraulic rear bushing is only responsible for providing the suspension with an excellent longitudinal filtering capacity Lower swing arm rear bushing Traccia Didattica Alfa 159 en ridotta 230 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL The lower aluminium arm has a pair of sliding bushings This solution is preferred because it offers better performance in terms of steering progression The dry friction bushings have been chosen to ensure the best robustness and reliability The anchoring points to the body have vertical reinforcements and are designed to ensure maximum structural rigidity with benefits on noise filtering capacity The anti lift level of the front suspension has been reduced to benefit performance when overcoming obstacles The anti dive level is kept high to minimise diving of the car s nose when braking The suspension is fastened to the body via a closed geometry frame with lateral stiffness levels of higher order with respect to crossmember solutions A strut betwe
244. of fuel let into the pump OPERATION Flow into the pump is maximum when the solenoid is de energised i e the regulator is fully open and is a simply passage for the fuel conveyed from the submerged electrical pump at a pressure of 3 5 bars and flow rate of 160 l h The ECU powers the regulator in PWM to limit the flow rate and let in only the amount of fuel to be compressed and sent to the rail The graph clearly shows that the flow rate decreases when the control current increases The safety function is no longer present This function is preformed by the regulator on the rail Traccia Didattica Alfa 159 en ridotta 147 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Injectors i 2 E 3 e E 5 D 6 N a IN 8 9 i 1 10 nt H 11 E i 12 Jr 13 f 1a 14 Sip 1 spring 11 calibrated shim 2 electromagnet 12 reference dowel 3 anchor 13 atomiser 4 ring 14 nozzle 5 valve 15 electrical connector 6 ball pintle 16 fitting 7 pressure rod 17 Z 8 body 18 Vc control port 9 spring 19 A 10 nut FEATURES The solenoid valve is supplied at high pressure only The fuel flow in the injector is split into two parts one two supply the atomiser and the other to the pressure control rod Both parts of the flow lubricate the moving parts of the injector thanks to the considerably leakage in the injection system that works
245. of obstacles in front of and behind the car The NSP is connected to the front rear bumper sensors and trailer ECU A button and respective LED is provided to cut out the front sensors The NSP is arranged in the boot on the right hand side Steering angle sensor node NAS Opt The NAS is an electrical component provided with the steering wheel stalk unit It is connected to the C CAN and to the dashboard wiring and transmits the steering wheel angle to the NFR for the VDC function Antitheft siren ECU CSA The TRW CSA is connected to the front wiring harness to the NBC and communicates with the A bus serial line It is located under the front left wheel harness Clock wire CVS The CVS is an interconnection component supplied with the steering column stalk unit It ensures the connection between the dashboard wire the steering wheel controls NVO and the airbag module on driver s side Ignition button PAV The PAV directly connects to the NBS from which is receives protected power and the command to light up the ideograms on the button It is located on the dashboard next to the NTR Steering lock node NBS The NBS interfaces directly with the ignition button PAV and the NTR and NBC via the B CAN It manages the steering lock release and power distribution to various on board services It emulates the functions of the traditional key switch to all effects It is fastened by means of a metallic collar to the steering column TEG reade
246. ofile which determines the valve opening and closing method has been revised to provide the performance required by Alfa Romeo The maximum power is reached at 6500 rpm thanks to the use of wider profiles while allowing to run without problems at 7000 rpm which the maximum engine speed allowed by the electronic limiter Traccia Didattica Alfa 159 en ridotta 59 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Camshaft Valve Valve stem cap Spring Hydraulic tappets Roller rocker arm Continuous variable timing Camshaft Timing sensor phonic wheel Se SONS MATERIAL The camshafts are made of cast iron Cams are tempered and hardened The surface treatment increases surface hardness of the cams and increases resistance to wear FEATURES The camshaft is driven by a chain whose main advantage with respect to a belt system is that it does not need to be replaced for the entire life of the engine There are two suction valves and two exhaust valves for each cylinder The spark plugs are positioned vertically between the two valves The hydraulic tappets used in these engines automatically cancel valve backlash while the engine is running this reduces the need for interventions on the engine and engine noise The high area power the specific power released on the piston of the engine 80 HP dm for the 2 2 litre called for the adoption of s
247. oise in the passenger compartment 1 steel crossmember 2 bushing Traccia Didattica Alfa 159 en ridotta 235 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL 1 chassis fastening to body 2 longitudinal arm fastening to body 8 1 3 Rear suspension yield fasteners FUNCTION Special flanged six lobe head screw with cylindrical conical end for fastening of longitudinal arm bracket to body 1 Special flanged six lobe head screw with cylindrical conical end for fastening of crossmember to body 2 Special flanged six lobe screw for fastening longitudinal arm to bracket 1 Special flanged six lobe screw for fastening leaf to crossmember 2 Special screw for front fastening of longitudinal arm to wheel riser 5 Special hexagonal head screw and flat offset pre fitted washer for rear fastening of longitudinal arm to wheel riser 7 Special flanged hexagonal nut for fastening camber rod to crossmember 3 an Special flanged hexagonal lock nut for fastening camber rod to wheel riser 4 Traccia Didattica Alfa 159 en ridotta 236 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL Traccia Didattica Alfa 159 en ridotta 237 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training
248. on with an ECU Two sensors with 4 pin connectors are provided because the exhaust system is split 2004 Fiat Auto S p A All rights reserved Traccia Didattica Alfa 159 en ridotta 108 318 Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The connections to the engine ECU are CONNECTION TO ECU DRAWING Planar sensor 1 Sonda Lambda planare 1 a valle catalizzatore Sonda Lambda lineare 1 a monte catalizzatore Sonda Lambda planare 2 a valle catalizzatore K Sonda Lambda lineare 2 a m onte catalizzatore connector pin 2 to ECU pin 74 side K L S LS L S bi ag 52 538058 57 connector pin 3 to ECU pin 50 side K pin 4 power from ECU connector pin 1 to ECU pin 75 side DONE Planar sensor 2 connector pin 1 to ECU pin 58 side ome pin 2 to ECU pin 52 side me pin 3 to ECU pin 94 side oon 4 power from ECU REMOVAL REFITTING The sensor is part of the exhaust system and is fasten to the exhaust pipe under the catalyzer The connector with seal is connected to the ECU and protected from water The wire layout prevents possible stress due to contact SPECIFICATIONS gt Exhaust gas temperature lt 930 C gt Temperature outside sensor lt 570 C gt Connector temperature lt 120 C ELECTRICAL SPECIFICATIONS Variable voltage signal according to characteristics of OUTPUT SIGNAL TYPE exhaust gas The ECU must be powered to pick up the output signal Examiner wi
249. oof panels The sunroof consists of a tempered glass sliding element electrically operated by an electrical motor and adjustable by means of a nine position selector knob three spoiler positions and six foldaway positions in addition to the closed position A weather strip in line with the profile of the roof is arranged along the edges of the sliding roof The sliding roof is also equipped with a manually operated rigid blind for shielding from the sun The knob is located on the ceiling light between the two ultrasound sensors It controls the operation of the electrical motor via an ECU Movement is obtained by means of two fixed racks onto which the sunroof carriage guides are anchored A safety function is activate when the sunroof is closing sliding or tilting movements to prevent the risk of crushing for passengers and objects caused by the moving panel Drain channels are present on the front and rear sides of the frame These drain water through pipes provided with one way valves to prevent water from leaking through the weather strips if the sunroof is not perfectly closed or badly aligned 11 1 1 Sunroof components Tempered glass Weather strip Sun blind Drain pipe Drain channel Tilting mechanism Mechanism guide Motor Potentiometer 10 Flexible racks 11 Supporting tilting mechanism 12 Mechanism guard ee eS aN Traccia Didattica Alfa 159 en ridotta 305 318 2004 Fiat Auto S p A Tutti i diritti so
250. opped by applying the brakes and steering carefully The valves are specific For this reason Fiat approved sealants only must be used to repair the tyres use of other fluids may prevent normal system operation Particular precautions are needed to fit and remove tyres and or rims Tyres and or rims must be replaced by specialised personnel only to prevent damage and incorrect fitting of the sensors 9 5 4 TPMS deactivation The system can be deactivated by Examiner The unit can be deactivated if the user decides to change the type of tyres using tyres without a sensor e g snow tyres in the winter In this case it is advisable to program the TPMS as if it were not transmitting rather than having failure messages appear on the NQS The NQS must consider the TPMS as deactivated Traccia Didattica Alfa 159 en ridotta doc 278 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM ee After Sales Training 9 5 5 Tyre pressure monitoring system The sensor is fitted on the wheel rim according to the various configurations pressed steel or die cast alloy The sensor is capable of measuring pressure and temperature via specific transducers and to transmit to the ECU via RF 433 92 MHz for the European market 315 MHz for other markets Communication with the energiser is performed at 125kHz 9 5 6 Initiator The initiator is a ferrite based antenna located near the wheelhouse
251. or managing the basis Mini F L Ore N C E architecture functions It hosts the gateway between the B CAN and the C CAN The NBC also interconnects the dashboard front and rear wiring harnesses It is connected to the dashboard fusebox with which it is supplied via a connector arranged on the front An EOBD connector is arranged on the front part for connecting the diagnostic tool Instrument panel node NQS The NGS is an electronic component connected to the B CAN and the dashboard wiring Three versions of the panel are available HIGH MEDIUM and BASIC Auxiliary instrument ECU CST The CST is arranged in the middle of the dashboard and includes the fuel level gauge the engine temperature gauge and the engine oil temperature gauge It interfaces with the NQS via a LIN serial line Traccia Didattica Alfa 159 en ridotta 249 318 2004 Fiat Auto S p A Tutti i diritti sono riservati na ALFA 159 TRAINING MATERIAL E SYSTEM After Sales Training Steering column stalk DEV The DEV integrates the electronics for controlling the windscreen rear window wiper and the external lights windscreen rear window wiper washer cruise control trip computer functions rain dusk sensor and light dimmer It is connected to the dashboard and front wiring harnesses and transmits controls to the NBC via the A BUS serial line Radio receiver node NRR The NRR BLAUPUNKT is connected to the B CAN and the dashboard wiring The connectors are used to in
252. otta 244 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM Ei After Sales Training 9 1 6 User control modules The user control modules are components which comprise devices for acquiring controls from the user or from sensors The modules are listed with the other controls in the following table CODE ID Description GAP Window winder contol onreardoes SSS D CEM Hazard lights switch D CLA Brakelightscontrol o Pos Cowosboadk o PR Giutch mounted sali D PAY anion button D PGP Contr panel on divers door DD o Per Control pansiontumei DD D PAG Central front celing ight DD D ccp Control ECU on passengersside SSS 9 1 7 Fuse and relay box Cop i Description SSCS 9 1 8 Networks and serial lines NAME DESCRIPTION 9 1 9 The LIN concept Features LIN Local Interconnect Network is a serial one line protocol implementing SCI UART byte word common interface LIN access is governed by a master node no management of arbitrage or slave node collision is required Worst case waiting times for signal transmission are therefore ensured A particular characteristic of the LIN system is the synchronisation mechanism which allows clock resetting via slave nodes without the use of quartz or ceramic resonator The specifications of the driver and the line receiver comply with ISO 9141
253. own below 2004 Fiat Auto S p A All rights reserved Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training 1 Primary flywheel 2 Secondary flywheel 3 Ring gear The crankshaft transmits motion to the primary flywheel The guide shoes receive motion from the primary flywheel and transfer it to the springs The spring system damps the torque variations The shoe spring system transmits motion to the ring gear which in turn transmits it to the secondary flywheel The planetary gear set consists of a gear carrier primary flywheel a planetary ring gear and eight satellite gears This gear set is submerged in grease and the satellite gears have rotation inertia It therefore acts a second damping element The guide shoes are provided with anti packing caps This means that in the presence of sudden torque variations the springs are distorted until the shoes pack to prevent excessive spring distortion The primary flywheel arrangement of the planetary gear and the radial and axial bearings is shown in the figure a Traccia Didattica Alfa 159 en ridotta 54 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL 1 Planetary gear 2 Axial bearing 3 Radial bearing DMF TWO STAGE CHARACTERISTIC A two stage torque fluctuation damping curve can be expected from this type of flyw
254. p A ALFA 159 TRAINING MATERIAL After Sales Training Rear suspension 1 camber adjustment screw 2 toe in adjustment screw Both the wheel toe in and camber can be adjusted on the rear multilink suspension The two screws shown in the figure can be operated independently to adjust both angles Traccia Didattica Alfa 159 en ridotta 240 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM Ei After Sales Training 9 ELECTRICAL SYSTEM 9 1 OVERVIEW OF THE ELECTRICAL SYSTEM 9 1 1 The Mini F L Ore N C E architecture The electrical system implements the now well known Mini F L Ore N C E architecture which has been in use for some time on other Fiat Group models The innovations that characterise this model and application are illustrated below Innovations changes and implementations LIN Bus The LIN Local Interconnect Network is a serial line used for exchanging information between systems which do not require particularly fast data transmission speeds The LIN protocol allows the use of relative simple hardware and low costs The LIN is used for communications between the NCL and the climate control actuators and between the NQS and the central instrument unit Logistic mode Purpose of the power mode called logistic mode is to reduce unnecessary load current draw while vehicles are stored during the time elapsing from end of production to deliver to end customers an
255. p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM GE After Sales Training Two three zone ECU pinout Front control head connector pinout NCL Pin Signal JL Wirecolour Pin Wire colour 1 Ground Gnd Notused 2 30 battery voltage Vbatt Red green 15 A C Compressor A C Request Purple black 3 30 for Lin Bus V batt Lin Bus i eee SEA CHDNRE 5 Ground Agnd Blackgreen 18 Notused pene Md Blue yellow ld Quality Sensor AQS PWM Brown black Signal PTC 1 relay Grey brown Fog sensor PWM signal Brown yellow Lin Bus Green 21 Not used 9 PTC2relay Blue white LH sun sensor driver B CAN Pink white 23 Notused B CAN Pink black RH sun sensor passenger Evaporator sensor White green Fan speed regulator feedback Grey blue Signal 10 5 8 Head control rear connector pinout Bian Wirecolou 30 for Lin Bus Vbatt Lin Bus Ground Gnd Traccia Didattica Alfa 159 en ridotta 304 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A 510 DA 4 e st ALFA 159 TRAINING MATERIAL After Sales Training 11 BODYWORK 11 1 SUNROOF The sunroof is a mobile glass panel which tilts vertically and slides away horizontally The glazing lets external light into the passenger compartment when closed offering an outside view The full span on the glazing can be opened The mobile panel slides in a specific seat between r
256. p control The ECU gt powers the fuel pump at key on for 5 seconds with engine speed gt 25 rpm gt cuts off power to pump at key off with engine speed 25 rpm OPERATING CONDITIONS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY Locic ELECTRICAL QUANTITY Engine speed sensor Pump relay Frequency on pins A55 and A40 MED 7 6 1 Voltage control to pin K 08 The ECU starts controlling the pump when an engine speed of BATT 30 voltage 25 rpm is reached Traccia Didattica Alfa 159 en ridotta 121 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Climate control system connection The compressor draws engine power when the climate control system is started When idling the ECU adapts the air flow to the new power request with the advantage for ensuring optimal drivability The ECU cuts out the compressor gt over 6500 rpm gt over a certain engine coolant temperature threshold 117 C gt when cranking OPERATING CONDITIONS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY ELECTRICAL QUANTITY Engine speed sensor Motorised throttle MED 7 6 1 Frequency on pins A55 Voltage to pins A 15 and A 30 The ECU controls the climate and A40 HVAC on request signal control compressor as follows Compressor relay switching the compressor button is pressed switching the compressor off temporarily a
257. p is part of this chain driving system The countershafts run at double speed in the opposite direction These ensure regular and smooth engine rotation VES I ANA do id i rox fes Ilio VC d o Lo B 7 4 Countershaft gear Countershaft retainer bearing Countershaft Countershaft bearing prep Continuous cam variable timing system Variable timing control valve Variable timing system Traccia Didattica Alfa 159 en ridotta 65 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training FUNCTION The electro hydraulic variable timing replaces the standard camshaft control system It controls and varies the timing diagram according to the engine conditions to increase the power peak at high speed and decrease HC NOx emissions and fuel consumption at the same time FEATURES These engine fit two variable timing systems one on each camshaft They are capable of varying the cam angle during engine operation according to conditions of use The variable timing on suction side provides continuous variation of camshaft slant by even 30 The variable timing on exhaust side allows a rotation of 25 The engine ECU determines the position of the cam through the sensors arranged on the camshaft and the crankshaft and sets the position of the control valve fitted on the head which controls the oil flow into the variable timing system ADVANTAGES Opti
258. pecially in poor grip conditions Alfa Romeo has always meant continuous research and innovation combined with a glorious racing tradition based on the work and professional pride of thousands of individuals technicians factory workers managers who have worked in the factories in the offices and on the race tracks in the course of time These are the roots of the incomparable personality that makes an Alfa Romeo stand out among all the other cars on road 1 2 The car 1 2 1 Style Designed by Giorgetto Giugiaro in collaboration with the Alfa Romeo Styling Centre the new car has a number of distinctive features that highlight its strong personality and make it immediately recognisable in the best Alfa tradition Starting from the front which is strong and dynamic dominated by the Alfa Romeo family feeling of the characteristic cloverleaf sporting the large shield The line of the entire car springs from here combining a light stylistic aggressiveness with strikingly elegant forms an impression that is underlined by the light clusters which are delightful design features The trapezoid shape of the front accentuates the car s sensation of solidity highlighted by the way the passenger compartment rests on a powerful shoulder This runs all EC Ww along the waistline of the car broadening considerably when it reaches the rear pillar E This pillar has a double stylistic function it links to the curve of the rear win
259. pedal stroke and better exploitation of the brake booster characteristics in addition to providing optimal braking progression Detail of the collapsible pedal board Hinge fastening screw When the load on the pedal exceeds 130 N the brake pedal is released from the fastening screw and turns on the hinge Brake booster 1 tandem vacuum brake booster 2 brake cylinder Traccia Didattica Alfa 159 en ridotta 211 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training A TRW large diameter 9 9 tandem brake booster with 1 aluminium cylinder and 36 stroke is fitted This ensures a good pedal stroke reserve and low force on the pedal also in extreme conditions of overheating Brake actuators The braking systems are differentiated as follows to account for the differences in weight and installed power of the various engine versions ENGINE VERSION BRAKES FEATURES Ventilated disk diameter x thickness 305x28 mm Front Teves FNS floating cast iron brake callipers piston diameter 60 mm Brake pad surface 58 cm Full disk diameter x thickness 278x12 mm Rear TRW CII floating aluminium brake callipers piston diameter 38 mm The calliper includes the parking brake Pad surface 38 cm Ventilated disk diameter x thickness 330x28 mm Brembo M4 42 brake callipers Fixed aluminium monolith calliper four pistons diameter 42 mm bra
260. pproximately 6 seconds during sudden Voltage signal on pin A acceleration when maximum 22 engine power is required or when the engine is overheating Engine temperature sensor Cylinder position acknowledgment The ECU acknowledges which cylinder is firing at each engine revolution it controls the injection and ignition sequence of the cylinder in a sequential and timed fashion Traccia Didattica Alfa 159 en ridotta 122 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS i ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Engine speed sensor Frequency Po A55 and MED 7 6 1 Injectors e THE ECU CONTROLS THE Voltage to pins INJECTORS AND COILS INA n A 50 A 49 A 47 A 48 SEQUENTIAL TIMED FASHION A 32 A 33 A 35 A 34 ACCORDING TO FIRING ORDER Timing sensor 1 Ignition coils Voltage disconnected from voltage on pin A 41 sine A 46 A 31 A 01 A 16 Timing sensor 2 voltage on pin A 56 Optimal injection time for each cylinder When idling and up to 1200 rpm the charge is stratified with lambda of 1 3 1 4 Idling injection start angle is approximately 45 The mixture is homogenous and lambda is 1 when no idling The injection starting angle varies from 310 to 370 to ensure homogenous mixture VV ON ON T
261. pressed to start the engine Check that the engine is running properly Replacing the electrical steering lock NBS Install a new NBS and insert a TEG in the NTR to start the self programming procedure Remove the TEG from the NTR after 10 seconds and wait for the mechanical steering lock to be applied after approximately 5 seconds Check that the steering wheel is locked Replacing the body computer NBC Install a new body computer and insert a TEG in the NTR to start the code alignment procedure Press the start stop button with the brake clutch pedal pressed to start the engine Check that the electrical system is running properly Replacing lock barrels and or emergency mechanical key Connect to Fiat Ricambi using the personal computer provided Enter the chassis number the model code and use a depannage order to request a new electronic key and barrel kit by entering the part number according to vehicle type and outfit NOTE One only barrel cannot be ordered by providing the mechanical code only IMPORTANT The mechanical code of the emergency key and the electronic code of the electronic key TEG are matched when the vehicle is programmed for the first time at the end of the line and must not be separated for any reason Traccia Didattica Alfa 159 en ridotta doc 262 319 2004 Fiat Auto S p A Tutti i diritti sono riservati E ALFA 159 TRAINING MATERIAL da SYSTEM After Sales Training 9 2 7 NTR dia
262. r node NTR The NTR Entry and Go remote control reader manages the door locking Code and RF functions The Entry and Go remote control TEG is inserted in the NTR It is located on the dashboard next to the PAV It provides the TEG in and TEG blocked signals to the NBS which powers it Brake lights control CLA The CLA is the typical two contact NO NC brake light switch on the brake pedal It controls the brake lights and provides pedal status to the ECU that require it Clutch pedal switch IFR The IFR is a two contact switch NO NC on the clutch pedal It is similar to the CLA brake light It provides the status to the NCM and NBS Control panel on tunnel PCT The PCT is located on the central part of the tunnel behind the gearlever It connected to the front wiring harness The PCT has buttons for the following controls gt ASR VDC deactivation gt Door lock unlock gt Hazard lights switch Left control board left PCS The PCS is a panel for controlling the external lights and headlight trim corrector It connected to the dashboard harness It is located on the dashboard to the left of the steering column on left hand drive cars The PCS houses the following controls Taillights parking lights Headlights correct up down Fog lights Rear fog lights VV WV wv Traccia Didattica Alfa 159 en ridotta doc 252 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYST
263. r out in excess of 60kW I output torque higher than 100Nm I The main features of the new engines are gt four cylinder in line arrangement gt twin overhead camshaft and 16 valve timing gt direct petrol injection continuous twin variable timing on suction and exhaust side aluminium alloy engine block cylinder head oil sump and timing cover gt dry insert cylinder liners in engine block hydraulic tappets twochain driven countershafts in engine block internal water pump gt oil filter built into engine block chain driven timing light weight electronic accelerator and motorised throttle body pencil coil ignition system with spark plug connectors integrated in a single module gt low consumption and emissions Euro 4 compliant gt four lambda sensors gt Type 4 2 in 1 exhaust manifold Traccia Didattica Alfa 159 en ridotta 42 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training Engine suction side Engine exhaust side Specifications 1 9 litre engine Type Displacement Bore Stroke Suction valve diameter Exhaust valve diameter Maximum power speed Maximum torque speed Compression ratio Engine ECU Pollution standard Traccia Didattica Alfa 159 en ridotta 43 318 1 9 XHR 1859 cm 86 mm 80 mm 35 1 mm 30 1 mm 117 9 kW 6500 rpm 190 1 Nm 4500 rpm 11 3 1 Bosch
264. raccia Didattica Alfa 159 en ridotta 123 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training INPUT PARAMETERS ELECTRICAL QUANTITY Engine speed sensor CONTROLLER OUTPUT PARAMETERS LOGIC ELECTRICAL QUANTITY Injectors Voltage to pins Frequency on pins A55 and A4O MED 7 6 1 A 50 A 49 A 47 A 48 A 32 A 33 A 35 A 34 a Ignition coils Timing sensor 1 Voltage disconnect from pins A 46 A 31 A 01 A 16 voltage on pin A 41 Timing sensor 2 voltage on pin A 56 u The ECU controls the injectors in a stratified or stoichiometric way according to the engine Voltage on pin A 12 temperature throttle position Engine temperature sensor engine speed and piston position Potentiometer signal on throttle Voltage to pins A 25 and A 10 The ECU acknowledges idling when the accelerator pedal is released The ECU controls idling speed according to the utilities which are running and the brake clutch pedal signals It controls the position of the driven throttle and the injection time Traccia Didattica Alfa 159 en ridotta 124 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training OUTPUT PARAMETERS ELECTRICAL QUANTITY CONTROLLER ELECTRICAL QUANTITY LOGIC Frequency on pins A55 and A40 MED 7 6 1 Motorised throttle Accel
265. rance by most insurance agencies Cradle safety seat and additional mirror for children Breakdown kit Snow chains Anti theft bolts Fire extinguisher VV VV ON 2004 Fiat Auto S p A All rights reserved 26 318 Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A TECHNICAL DATA ALFA 159 TRAINING MATERIAL After Sales Training 2 TECHNICAL DATA 2 1 ENGINE 2 1 1 Engine type __ f9JT8 22JTS 1 9Mjet8V 1 9Mjet 6V 2 4M jet20V_ 939A3000 Front Transversal No ofcylindrs 4 4 Cylinder i l In line In line In line In line In line arrangement per cylinder Timing 2ACT 2ACT 1ACT 2ACT 2ACT Fuel L Petrol Petrol Diesel Deeg Diesel ___ JTS Multijet 2 1 2 Engine specifications Poo 1 9 ITS 2 2 JTS 1 9 M jet 8V 1 9 M jet 16V 2 4 M jet 20V Bore m _ 8 amp 486 82 8 88 _ Stroke mm 80 94 6 90 4 90 4 90 4 cm 11 3 0 15 1 11 3 0 15 1 18 0 45 1 17 5 0 45 1 17 0 45 1 Maximum power HP EEC Maximum power kW EEC 8 110 147 Maximum output 6500 6500 4000 4000 4000 speed rate rpm 118 136 8 Maximum torque Nm 190 230 280 315 1 410 6 EEC Maximum torque kgm Ja SI n ratio 4500 4500 2000 2000 2000 Idling ratio rpm 800 50 800 50 850 20 850 20 850 20 2 1 3 Timing angles Valve clearance E 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet 16V 2 4 M jet 20V Cold valve clearance Hydraulic Hydraulic 0 30 0 05 Hydraul
266. ranty gt perforating rust eight year warranty Specific actions were required to reach these results throughout all model development stages from design and production The most advanced innovative reliability methods FMEA Robust Design were implemented The basic level of protection has been defined in parallel to project and process criteria the Alfa 159 body is totally made of double galvanised steel on both sides Particularly all structural body elements are entirely galvanised The safety structures suspension mounts seat belt reinforcements etc are made of galvanised steel with a thick zinc coating 20 um instead of the usual standard 8 um The mobile parts panelling and respective frames and fixed external panels of the body including door frames which are visible when the doors are open are entirely made of double sided galvanised steel All the anti corrosion measures adopted for the Alfa 159 were subjected to laboratory tests and passed for life on vehicle tests conducted on specific test grounds which reproduce the severe conditions expected by northern European markets The fully galvanised external bodyshell along with the additional protection provided by the paintwork means than the three year target can be reached without problems of cosmetic corrosion The protective package galvanised steel and cataphoresis on all structures ensures eight years of vehicle life without penetrating rust in severe northern E
267. remains open ENGINE RUNNING the throttle remains open during normal operation of the engine ENGINE STOPPING while stopping the engine the ECU powers the motorised throttle with a PWM signal and closes it SPECIAL THROTTLE MANAGEMENT STRATEGIES In addition to preventing shaking when the engine is stopped the throttle is used for the DPF regeneration strategies During this function the throttle is controlled using a PWM signal for constant opening control and manage the temperatures needed to regenerate the trap Engine ECU pins Connector A Connector pins Pin 1 39 Pin 2 12V Pin 4 52 Pin 6 59 Traccia Didattica Alfa 159 en ridotta 143 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Fuel pressure sensor SENSORE DI PRESSIONE a 1 ground 2 output signal 3 power Engine ECU pins connector A Connector pins Pin 8 1 Pin 43 2 Pin 28 3 LOCATION The sensor is fastened directly onto the end of the fuel rail as shown in the figure OPERATION The piezoresistive sensor output increases in a linear fashion as the voltage signal pressure increases The internal bridge of the sensor and the linear response curve are shown in the voltage and pressure graph below T Traccia Didattica Alfa 159 en ridotta 144 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL
268. removal refitting of engine speed sensor or phonic wheel for misfire acknowledgment The throttle learning settings are maintained also when the battery is disconnected The misfire acknowledgement phonic wheel settings on the other hand are lost System self adaptation The ECU is provided with a self adaptive function which acknowledges changes in the engine due to settling in time and ageing of components and the engine itself There are two adaptation functions for two intervention plans minimum and user Cold start up control Mixture is naturally leaner during cold starts due to low fuel evaporation at low temperatures and higher engine oil viscosity The engine ECU acknowledges this condition and corrects the injection time according to gt coolant temperature gt intake air temperature gt battery voltage engine speed Spark advance is controlled according to the engine speed and engine coolant temperature only While cranking the ECU controls a first simultaneous injection for all injectors full group injection and after starts normal sequential timed operation after acknowledging the cylinder stroke When the engine is warm the ECU governs the throttle to control the amount of air needed to keep the engine running The engine speed is decreased as the engine temperature increases to obtain nominal values when the engine is warm Traccia Didattica Alfa 159 en ridotta 114 318 2004 Fiat Auto S p A All rights
269. reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training INPUT PARAMETERS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Engine temperature sensor Pressure regulator Voltage signal on pin A 22 MED 7 6 1 gt Conto is epee Engine speed sensor Injectors According to the signals from Frequency on pins A55 and the sensors and the mapped gt controls the pressure 49 A 47 A 48 A 32 A regulator on the rail 33 A 35 A 34 gt adjusts the injection and ignition time Ignition coils Voltage Voltage to pins A 27 and A 11 disconnected from pins A 46 A 31 A 01 A 16 Combustion control lambda sensors In EOBD systems the lambda sensors are arranged before and after the catalyser system The pre cat sensors control the first loop strength closed loop The post cat sensors are used to diagnose the catalyser and fine tune the first loop parameters In this perspective the second loop adaptation is used to recover production dispersions and slow deviations of the pre cat sensors caused by ageing and poisoning This is called the second loop control closed loop Traccia Didattica Alfa 159 en ridotta 115 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training INPUT PARAMETERS CONTROLLER ELECTRICAL QUANTITY LOGIC Engine speed sen
270. rfect tightness 1 Fuelrail 2 Injector clamps 3 Injectors Traccia Didattica Alfa 159 en ridotta 87 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training The connections to the engine ECU of each injector are CONNECTION TO ECU CONNECTOR DRAWING High pressure injector cylinder 1 connector pin 1 to ECU pin 50 side A pole connector pin 2 to ECU pin 49 side A pole High pressure injector cylinder 2 connector pin 1 to ECU pin 47 side A pole connector pin 2 to ECU pin 48 side A pole 2 1 High pressure injector cylinder 3 connector pin 1 to ECU pin 32 side A pole connector pin 2 to ECU pin 33 side A pole High pressure injector cylinder 4 connector pin 1 to ECU pin 35 side A pole connector pin 2 to ECU pin 34 side A pole inj cil 1 Inj cil 2 Inj cil 3 Inj cia E LR i ig on 1 5 MB 1 5 MN 15RG TECHNICAL SPECIFICATIONS Working pressure 50 43 af 48 32 33 i5 dd At start up 0 4 MPa Reference 10 MPa 25 kPa Maximum admitted 14 MPa Maximum temperature of injector nozzle 170 C Tightness and flow are ensure by the system up to 1 milligrams of impurity for the entire life of the product REMOVAL REFITTING The injector is fitted on the fuel rail The combustion chamber o ring must not be lubricated A maximum force of 200 N can be applied to fasten the injector to the head A specifi
271. ripod joint The tripod joint is a CV joint characterised by the possibility of transmitting motion between non coinciding axles This allows a certain axial movement of the two shafts connected by the joint The joint essentially consists of two elements each of which is integral with one of the connected axles the first element is called a tulip due to its shape The tulip is made of pressed XC45 steel and contains a tripod formed by three plates arranged at an angle of 120 which slide inside the housings on the tulip The tripod presents a spline for connecting the second axle Lubricant gears is needed for correct operation of the joint see technical specifications the joint is contained in a plastic boot to prevent dispersion of grease during operation Traccia Didattica Alfa 159 en ridotta 208 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A After Sales Training GEARBOX TRACCIA DIDATTICA ALFA 159 Protective boot Traccia Didattica Alfa 159 en ridotta 209 318 2004 Fiat Auto S p A Tutti i diritti sono riservati BRAKING SYSTEM ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training 6 BRAKING SYSTEM 6 1 FEATURES The servo hydraulic braking system consists of two independent crossed circuits 1 and 2 in the figure above Each circuit works on a front wheel and the diagonally opposite rear wheel to ensure braking and stability also in the event
272. rols torque regularity up Signal from ECU ABS to pins to idling speed according to the B 61 and B 62 signals from sensors and I adapts the amount of fuel injected by dine Gniecien ms Frequency to pins A 20 and A 50 Traccia Didattica Alfa 159 en ridotta 162 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Anti sawing control The ECU processes the signals from the various sensors and corrects the amount of fuel to be injected to improve handling and reduce jerking by adapting the injector operating time CONTROLLER INPUT PARAMETERS OUTPUT PARAMETERS LOGIC Brake pedal switches Pump pressure regulator Voltage to pin B 17 EDC 16C39 Control voltage between pins A 49 and A 19 Clutch pedal switches Voltage to pin B 79 Injectors Voltage to pins A 16 A 47 A 2 A 31 A 1 A 46 A 17 A 33 A 18 A 48 5 cylinder Engine speed sensor E T Frequency to pins A12 A27 i Ge E DAS SN gt the various sensors and adjusts the amount of injected fuel and Speedometer signal gt controlling the pressure regulator B 61 and B 62 gt adapts injector injection times and A 58 Exhaust smokiness control during acceleration i signals received by the accelerator potentiometer air flow meter and rpm sensor specifically the ECU controls t
273. rom button 1 EBD failure ABS failure ASR failure HH failure ESP failure Low brake oil or handbrake applied ASR ESP working HH working System state EBD ABS ASR ESP HH OFF for the first 500 ms EBD ABS ASR ESP HH ON EBD ABS HH ESP 2 ON ASR OFF EBD ABS ASR ESP HH OFF EBD ON ABS ASR ESP OFF HH ON OFF EBD ABS ON ASR ESP OFF HH ON OFF 3 EBD ABS ASR ESP ON HH OFF EBD ABS ASR ON ESP OFF HH ON OFF EBD ABS ASR ESP HH ON EBD ABS ASR ESP HH ON EBD ABS ESP HH ON 6 2 8 ASR and VDC deactivation ASR LED on button ON OFF ON ON ON ON OFF OFF OFF OFF OFF EBD warning light on NQS ON OFF OFF ON OFF OFF OFF OFF ON OFF OFF ABS warning light on NQS ON OFF OFF ON ON OFF OFF OFF OFF OFF OFF ESP warning light on NQS ON OFF OFF ON ON ON OFF ON OFF Blink 4Hz DC 50 OFF HH warning light on NQS ON OFF OFF ON ON ON OFF ON ON OFF OFF OFF ON As shown in the figure above the ASR where fitted can be deactivated by pressing the button on the central tunnel NOTE the EBD handbrake warning light will light up independently from ASR deactivation when the handbrake is applied The figure above shows the possibility of deactivating the VDC in addition to the ASR which is deactivated at the same time This operation is possibly by holding the ASR off button pressed for at least 1 5 seconds In
274. rom Connect Nav and has the same navigation and audio features The two devices differ for the absence of computerised services and for the absence of the integrated telephone and hands free kit the latter for RN Convergence is an innovative electronic module for interfacing the computer with a Bluetooth cellular phone within the operating range of the system approximately 5 metres The interaction method of the system consists of the following devices Microphone in ceiling light Controls on steering wheel connected via CAN Monochromatic display on on board panel connected via CAN The system provides effective and intuitive access to the following functions Hands free cellular phone use without needing to operate the telephone itself i e the telephone needs to be inside he car but not necessarily in the user s hands Voice recognition call in Speaker dependent and Speaker independent modes Copying of personal numbers from telephone to on board module and reading from on board panel Display interaction for called numbers incoming calls and incoming text messages Access to normal telephone functions answer reject calls recall back number etc using buttons on the steering wheel YYYY WV Traccia Didattica Alfa 159 en ridotta 19 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training 1 2 18 Materials used The Alfa 159 is
275. s activated automatically again at the next key on The warning cycle can be deactivated permanently only by Technical Assistance The deactivation procedure is run from the on board panel using the diagnostic tool Examiner NOTE No one can deactivate the instrument panel warning light which will always remain on steady light when the seat belt is unfastened 9 7 10 Clock contact pinout SIGNAL Horn button negative signal Notconnected o Not connected B CAN B Traccia Didattica Alfa 159 en ridotta doc 289 319 2004 Fiat Auto S p A Tutti i diritti sono riservati SYSTEM ALFA 159 TRAINING MATERIAL ELECTRICAL Fiat Auto S p A After Sales Training Airbag 1st level Airbag 1st level ECU pinout PN GINA E Front colton senor gear 6 Notconnected ooo 8 BOANBlie ooo 9 Passenger airbag deactivation key SSS o 22 Passenger knee airbag H S 28 Driver knee airbag 0000oooo 8 Driver knee saiten Traccia Didattica Alfa 159 en ridotta doc 290 319 2004 Fiat Auto S p A Tutti i diritti sono riservati E ALFA 159 TRAINING MATERIAL Ao SYSTEM After Sales Training B Rear connector rear wiring harness black SIGNAL PIN 6 Driver side airbag O OCO OoOO 8 Passenger side air O OC 9 Notconnected S 14 Driver belt pretensioner 19 Driver seat belt reminder switch signal 9 8 FRONT LIGHT CLUSTER xenon gas disch
276. s tyre inflation pressure and informs the driver if the pressure or temperature of one or more tyres is out of range Tyre state information is shown to the driver by means of visual signals on the panel Acoustic warnings are associated to the panel signals for the most critical cases e g badly deflated tyre The anomalies concerning one or more tyres detected by the system are gt deflated tyre gt very deflated or punctured tyre gt excessively inflated tyre 9 5 2 Structure The tyres pressure monitoring system consists of gt One HF management and reception unit CPP located under the dashboard gt Four HF pressure sensors located inside the tyre on wheel rims gt Four LF low frequency initiators antennas located in each wheelhouse The system also uses the on board panel to provide acoustic and visual information to the user gt One indicating icon combined with the display indicating Tyre pressure in the event of deflated or excessively inflated tyre s Low tyre pressure in the event of punctures or very deflated tyres and acoustic warning buzzer Tyre pressure monitoring function not available in the event of system failures with acoustic warning buzzer Each warning is associated with an indication of the wheel that caused the anomaly front left rear left etc as shown in the diagram below The system structure is shown in the following figure Traccia Didattica Alfa 159 en ridotta doc 277 319 2004 Fia
277. sand km e The driver is informed of the need to change the oil and given a 1000 km notice The quality parameter must be reset after changing the oil This is only possible at dealer workshops Force regeneration at dealer workshop The DPF must be regenerated by a dealer workshop by means of the forced regeneration procedure when obstruction exceeds 250 MIL on This procedure must be run that the workshop by trained personnel in a controlled fashion because it must not be interrupted once started to prevent damage to the internal parts of the filter it causes a considerable generation of heat and possible emission of smoke which could concern the customer who may stop the regeneration procedure before it is completed Examiner is needed for forced regeneration Traccia Didattica Alfa 159 en ridotta 157 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL ld E Rigenerazione forzata con EXAMINER Avvia motore Invia comando Start procedura e attendi inizio Th20 gt 80 C Rigenerazione Tramite lo strumento EXAMINER possibile attivare la procedura di Il regime motore rigenerazione per a 3500 Rom pulire ij filtro DPF Elettroventole ON per circa 5 minuti Risultato Rigenerazione Bosch EDC 16C39 ECU logic Alfa Code recognition The ECU interfaces with the body computer at key on to implement the Fiat Code function and enable cranking INPUT PARAMETER
278. se vibrations and hydraulic noise gt oil air heat exchangers on all versions 7 1 3 Steering box This rack and pinion constant ratio system is dimensioned for ensuring a maximum assistance thrust of 10 85 KN The technical features are in common for all versions gt ratio 70 mm turn gt maximum stroke 163 mm gt assistance curve is controlled to maximum high speed steering accuracy and parking manoeuvres with an average force of 4 Nm gt maximum steering speed exceeding 700 degrees sec before starting to cut off assistance The box anchoring mounts to the lower chassis are dimensioned to snap in a crash and maximise energy absorbed by the bogy Traccia Didattica Alfa 159 en ridotta 226 318 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A STEERING ALFA 159 TRAINING MATERIAL e After Sales Training 7 1 4 Steering column With telescopic sleeves the column ensures gt vertical rotation with a stroke of 2 gt axial adjustment with 45 mm total stroke The fastening lever under the upper sleeve in the specific compartment under the lower upholstery complies with the most recent EUNCAP safety indications The standard electrical steering column lock is housed in the lower steering sleeve near the anchoring bracket to the dashboard crossmember In this way it is away from the knee area according to current EUNCAP requirements In compliance with current European standards the d
279. seconds at the following key on as shown in the finalised tyre pressure monitoring system ECU specifications Wiring diagram Cani LI pr Pe C5 Fentreline plancia SCALA 33 Ex E Togl uesza US fana Cn ceed oe 4 mn T Nassa vano motore ari DX AnLa na TPE ruoka anl SR B3EEZE S095 beget lee iam E i Pisi kiri Ea e C Si L SETA Dieses Arkanne TPS rosis ant DX WEB E dra iilii osare R homm BM gnam a i Centralina pressione pneunmntic ZCPP kitana TRS ruota post SE einh eg Paali ira Mi I Sen Mesae 2 Anienna TPHS ruota poai Os 280 319 Traccia Didattica Alfa 159 en ridotta doc 2004 Fiat Auto S p A Tutti i diritti sono riservati E ALFA 159 TRAINING MATERIAL da SYSTEM After Sales Training Tyre pressure ECU E x E x Bi BE E ka m 4 n Li j L i u U LF Ground LF Ground LF Ground Il I TI TT I TT IT m 9 6 PARKING ASSISTANCE The parking assistance system provides information on distance between obstacles in front of and behind the car while parking The system helps the driver by identifying obstacles outside the driver s view The driver is informed on the presence and distance of the car from the obstacle by means of acoustic signals whose frequency depends on the distance and on the display by means of visual indications The driver can avoid collisions by integrating direct visual information with the acoustic w
280. senger compartment two different levels for the driver rear seat and the front seat passenger The system is managed by an ECU that monitors the temperature outside the passenger compartment and either warms or cools the air to reach the required level of comfort The climate control system automatically adjusts the following parameter functions Air temperature at air vents on driver passenger side Fan speed continuous variation Air distribution on driver passenger side Compression operation Recirculation Defrosting demisting of windscreen and rear window VVWVWVWVWV The automatic two zone climate control panel integrates the ECU and is shown in the following figure 10 5 2 Front two three zone controls 10 5 3 Three zone system Overview The automatic three zone system offers the possibility of adjusting the air distribution and temperature in different ways for the driver front passenger and rear seats From a structural point of view it differs from the two zone system due to a different climate control unit and for the presence of a supplementary ECU with respective controls for adjusting air mixing and distribution for the rear seats The front ECU is the same as that of the two zone version 10 5 4 Rear three zone controls Construction In particular the system consists of the following parts see figure on page 9 and wiring diagram on page 11 gt NCL climate control node forming the governing unit Rear seat
281. sensor 1 pre cat pin 1 Linear sensor 2 pre cat pin 2 Linear sensor 2 pre cat pin 1 60 Acceleratorpedalpoteniometersignal oS 64 C CAN H 66 Notconnected ____ 68 LS command for M I warning ligh tto NQS 69 Not connected o Linear sensor 1 pre cat pin 3 Planar sensor 1 post cat pin 2 Planar sensor 1 post cat pin 1 Linear sensor 1 pre cat pin 6 Linear sensor 1 pre cat pin 5 Linear sensor 2 pre cat pin 6 80 Linear sensor 2 pre cat pin 5 86 CCAN gt gt gt 89 LSrelay negative to CVM for engine cooling fan low speed o 90 Notconnected 0000000000 Planar sensor 2 post cat pin 3 Traccia Didattica Alfa 159 en ridotta 82 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Low pressure fuel circuit A low pressure pump with parallel mechanical pressure regulator is fitted inside the fuel tank The tank supplies the high pressure pump via a pipe Delivery pressure of the low pressure pump is 3 5 bars Fuel tank 3 1 1 Fuel tank 2 Pump housing 3 Petrol vapour floating valves 4 Overflow proof fuel filler FEATURES The pump supplies the lower pressure fuel circuit and two floating valves are fitted in the fuel tank These send fuel vapours to the separator where they condense and drip back
282. sh the headlights when the headlights are off and in combination with the xenon bulb when switching from dipped to main beam An appropriately shaped metallic shield is lowered to switch the xenon bulb from dipped beam to main beam The following bulbs are present Xenon D1S bulb for dipped beam main beam headlights gt W5W all glass blue bulb for side lights 12V 5W gt PY21W all glass silver bulb for direction indicators 12V 21W gt H1 halogen bulb for spot main beam headlights 12V 55W The left cluster is the master The sensors for controlling vehicle trim are connected to this cluster The right cluster is the slave and is connected to the master via a specific serial line 9 8 1 Xenon bulb Construction and operation Construction The xenon bulb consists of a ampoule containing to electrodes arranged at a distance of a few millimetres and filled with low pressure xenon gas Light emission is sparks an arc between the two electrodes which is maintained during the operation of the bulb This process is similar to that of neon lights for residential purposes Unlike neon lights however it is not possible to wait for a few minutes for the process to stabilise The light cluster is equipped with an ECU that ensures warm up time equivalent to that of a traditional headlight Operation The operation of a xenon bulb consists of four phases lgnition During this phase the ballast generates a voltage capable of sparking a spe
283. shaft timing sensor High pressure fuel sensor Knock sensor Temperature sensor Oil pressure on off sensor Oil level and temperature sensor Air mass meter Linear lambda sensor post cat Planar lambda sensor pre cat Engine speed sensor FUNCTION The sensor sends an electrical signal to the engine ECU used to compute the speed and angular position of the engine FEATURES The sensor consists of a body and metallic coil and a 2 pin connector OPERATION The switch from empty to full due to the presence or absence of a tooth on the phonic wheel determines variations in magnetic flow capable of generating induced alternating voltage which is used to count the teeth on a ring or phonic wheel The frequency of the voltage sent to the ECU varies according to the angular speed of the crankshaft The sensor connections to the engine ECU are CONNECTION TO ECU CONNECTOR DRAWING connector pin 1 to ECU pin 55 side A connector pin 2 to ECU pin 40 side A 3 A0 a un REMOVAL REFITTING Fit the sensor by pressing it in the housing and fasten with a screw Replace the sensor if it is accidentally dropped POSITION The crankcase sensor is positioned on the front side of the engine in the bottom right it faces the phonic wheel positioned on the crankshaft Traccia Didattica Alfa 159 en ridotta 93 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MAT
284. sor Frequency on pins A55 and A40 Pre cat lambda sensors The ECU controls the amount of Voltage signal on pins K injected fuel according to the ni 77 and K 79 signals from the sensors and the mapped values and Injectors Voltage to pins A 50 A 49 A 47 A 48 A 32 A 33 A 35 A 34 Post cat lambda sensors e controls the pressure regulator Ignition coils Voltage disconnected from Voltage signal on pins K 75 and K 53 e adapts injector injection times e adapts spark advance pins A 46 A 31 A 01 A 16 Air flow meter Voltage on pin A 12 bg Knock control The ECU can delay ignition selectively on the cylinder where this is required according to the combination of values received by the knock and timing sensors and gt reduces ignition advance in 3 steps to a maximum of 9 updates the threshold to account for background noise and engine ageing The ECU during acceleration uses a higher threshold to increase engine noise When knock disappears the ECU will increase ignition advance in 0 75 steps to total recovery The ECU self adaptive function Stores the continuously repeated advance reductions gt updates mapping to the various conditions in which the engine operated RECOVERY PROCEDURE A variable spark delay is implemented according to the engine speed and temperature in the event of failure to the timing sensor or knock sensor The maximum ignition delay
285. ssembly The nozzle is supplied with pressurised fuel when the pressure rod pin assembly is raised The latter is lifted by the imbalance of counterpoised forces on the assembly Three forces act on the pressure rod pin system Elastic force Fe in the direction of closure due to the spring on the pin This force ensures tightness of the nozzle when the line pressure drops to zero and avoids dripping of fuel into the cylinder Force Fc also in the direction of closure due to the pressure of the fuel in the check port This pressure acts on the upper area of the pressure rod Force Fa in the direction of opening is due to the pressure of the fuel in the feeding port and acts on the circular crown area delimited on the outside by the sliding diameter of the pin in the nozzle and the seal diameter of the tapered seat The balance of the pressure rod pin assembly depends on the balance of these three forces The pressure in the feeding port and in the check port are identical and equal to the line pressure provided by the rail when the injector is not energised In these conditions Fc F gt F IMA injector classification Injectors are inspected and the characteristics in various conditions of pressure flow rate are tested Any injectors which are not up to standards are eliminated The injectors that pass the tests are classified with a 9 character alphanumeric code called IMA code see arrow in figure above The code is laser engraved on the
286. stem MAINTENANCE The cylinder block and bottom plate must be replaced at the same time The liner inserts in the cylinder block cannot be replaced Traccia Didattica Alfa 159 en ridotta 49 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The figure below shows one of the four oil sprayers on the pistons Refer to the technical servicing manuals for tightening torques of screws fastening the bottom plate to the cylinder block Pistons and connecting rods Upper gas ring Secondary gas ring First oil scraper Second oil scraper Pin Piston Snap ring Bronze bearing Connecting rod 0 Half bronze bearing 1 Connecting rod cap fastening screws ATO eS MATERIAL The pistons are made of aluminium alloy casings The connecting rods are made of high resistance cast iron Traccia Didattica Alfa 159 en ridotta 50 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training FEATURES The pistons of both engine versions have indents for valves and a dish for the combustion chamber on the roof The lower part is cooled by a jet of oil The 2 2 litre engine piston has a seat on the skirt for avoiding interference with the sprayer nozzle The connecting rod caps are fracture split and joined by pressure with screws along with 1 mm thick half bronze bearings Pistons and connecting rod s
287. sure sensor Voltage to pins A 13 and A 40 1 Pressure regulator controls the pressure regulator adapts injection time controls VGT valve operation Control from pin 7 Turbo pressure solenoid valve VGT Supercharger cut off According to this strategy the supercharger control in certain engine running conditions is inhibited by setting the allowed supercharger percentage to a preset value OPERATING CONDITIONS CONTROLLER OUTPUT PARAMETERS ELECTRICAL QUANTITY LOGIC ELECTRICAL QUANTITY Cold start Turbo die ST valve Resistance between pins A PWM signal from pin A 60 for 41 and A 58 fixed opening 1 Prolonged idling F to pins A12 A27 ell TE temperature stabilised idling time Shifting operation of the clutch during air Voltage to pins A 42 and A flow readings and large amounts 44 and on pin B79 of injected fuel opens the EGR fixed t01 Voltage to pins A12 and A27 Traccia Didattica Alfa 159 en ridotta 171 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training According to this strategy the supercharger control in certain engine running conditions is inhibited by setting the allowed supercharger percentage to a preset value RECOVERY AND FAILURE CONTROL SYSTEM In recovery conditions can be set to 30 40 75 supercharger off COLD START In this condition a fixed value is h
288. t The driver s leg room 37 millimetres more than the 156 has been increased for more comfortable driving positions The rear leg room has also been increased The front 13 7 millimetres and rear 32 5 millimetres door heights have been increased to improve access The boot capacity has been increased with respect to the 156 to increase versatility dm3 500 450 400 350 300 250 200 150 m BERLINA Ed 1 2 14 Climate control system Three types of climate control systems are available according to the outfit gt Manual gt Two zone automatic gt Three zone automatic The automatic climate control system allow different temperature and air distribution in two or three different areas of the passenger compartment 2004 Fiat Auto S p A All rights reserved 18 318 Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training 1 2 15 Sunroof The Alfa 159 sunroof is a traditional mobile glass panel which pushes out slides horizontally and retracts The mobile panel slides in a specific seat between roof panels The safety function managed by the ECU protects occupants from movements controlled from inside the vehicle in compliance with Directive 2000 4 EC It is active during horizontal closing front edge and vertical closing rear edge and trips when an obstacle e g finger hand is encountered The possibility of being pinched betw
289. t A handy compartment for sunglasses instead of the driver s side handle Four different mat combinations all elegant and specifically designed to match the interiors A Bluetooth system for using the customer s own cell phone in maximum safety and comfort Clothes hook behind front head restraint useful for business gala dinners and leisure Rear window sun blinds for extra comfort A handy elegant PC desk to be positioned on the rear armrest VV VV ON Traccia Didattica Alfa 159 en ridotta 25 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training gt A Car Care Kit for cleaning interiors and exteriors Safety Lineaccessori offers useful elements for the safety of the car and occupants alike gt Traditional alarm implementing pin to pin technology that integrates the car s electronic control unit Easy to install the system uses the car s remote control Functions include volumetric and perimeter protection Can be integrated with anti lifting kit gt Satellite alarm this alarm system is extremely compact and reports to all attempt to steal the car the central desk and all attempts to break into the car that cause alarms to the user State of the art technology is exploited for simple installation and interfacing with on board signals offering unquestionable advantages in terms of safety and comfort Offers 80 saving on theft and fire insu
290. t timing side USE EQUIVALENT FIAT TOOL Adapter for measuring engine oil pressure USE EQUIVALENT FIAT TOOL Adapter for removing and installing valve springs USE EQUIVALENT FIAT TOOL Oil filter wrench FOR ON VEHICLE FITTING REMOVAL ONLY Tool for loosening utility belt tensioner Support for blocking torsional vibration damper Bushing for installing crankshaft gasket transmission side USE EQUIVALENT FIAT TOOL Support for fastening coolant pump drive pulley TO REMOVE COOLANT PUMP WITHOUT DISCONNECTING TIMING CHAIN Traccia Didattica Alfa 159 en ridotta 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training 3 2 1 9 2 4 MJET DPF ENGINE 3 2 1 Fuel feed rail Common rail 1 9 16v 150cv 2 4 20v 200cv Fuel tank Submerged pump assembly Fuel filler tube Inertia switch Filter Water in fuel sensor High pressure pump High pressure lines Common rail 10 Injectors 11 Return line from injectors 12 Return line from rail 13 Fuel return manifold 14 Pump pressure regulator 15 Rail pressure regulator 16 Fuel pressure sensor ud dn ERE DN Features High injection pressure up to 1600 bar Modulated injection pressure from 150 to 1600 bar in all engine conditions Fuel supply up to 100 mm3 stroke at engine speed in the range from 100 to 6000 rpm Accurate injection control in terms of both advance and duration One or more pilot
291. t 16V version Front low load Rear low load Front full load Rear full load inflation pressure inflation pressure inflation pressure inflation pressure guess nie 03 t I 205 55 R17 2 6 235 45 R18 2 6 2 4 M jet 20V version Front low load Rear low load Front full load Rear full load inflation pressure inflation pressure inflation pressure nation pressure 205 55 R16 RR O 205 55 R17 215 55 R15 225 50 R17 27 2 7 235 45 R18 2 8 2 6 2 16 SERVICE SCHEDULE Description Thousands of kilometres VS Mal kal e e Leal ll e I required Check lighting system operation headlights direction SELL indicators hazard lights boot passenger compartment instrument panel warning lights etc Check windscreen wiper washer operation adjust sa RH HE nozzles Check conditions and wear of front disk brake pads and operation of pad wear indicator Check rear disk brake pad conditions and wear II Inspect conditions of exterior bodywork underbody protection flexible and stiff piping exhaust fuel feed brakes rubber parts boots sleeves bushings etc Check conditions and cleanness of bonnet and oi AAA Check and top up liquids if required engine coolant lede brakes windscreen washer battery etc Inspect conditions of accessory drive belt s Check handbrake stroke and adjust if necessary Check tappet clearance and adjust if necessary 1 9 M OEE jet 8V Check emissions in exhaust dies v
292. t Auto S p A All rights reserved Fiat Auto S p A TECHNICAL DATA TRAINING MATERIAL After Sales Training 2 11 ALTERNATOR 2 11 1 Characteristic data o 19JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Code type Voltage V Nominal current A 70 120 70 Supplier S 2 12 STARTER MOTOR 2 12 1 Characteristic data l 2 4 M jet 20V TT on 22575 enn 1omjenov DAMIEN Manufacturer Mitsubishi Mitsubishi Bosch Bosch Bosch M000T35471 V Nominal power em e I side Number of excitation poles 2 13 BATTERY 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jet16V 2 4 M jet 20V Voltage V Capacity An 60 60 Intensity A 2 14 FLUIDS AND LUBRICANTS 6 460 X 2 14 1 Oils and fluids Recommended product specifications o 1 9 JTS 2 2 JTS 1 9 M jet 8V 1 9 M jett6v 2 4 M jet 20V Engine oil i 3 Selenia Star Selenia Star Selenia WR Selenia WR Selenia WR Gearbox Tutela Car Tutela Car front Tutela Car Matryx Tutela Car Matryx Tutela Car Matryx Matrvx Matrvx differential oil y y Brake liquid Tutela Top 4 Tutela Top 4 Tutela Top 4 Tutela Top 4 Tutela Top 4 a e Tutela GI E Tutela GI E Tutela GI E Tutela GI E Tutela GI E Radiator fluid Paraflu Up 50 Paraflu Up 50 Paraflu Up 50 Paraflu Up 50 Paraflu Up 50 2004 Fiat Auto S p A All rights reserved 36 318 Traccia Didattica Alfa 159 en ridotta
293. t Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM SA After Sales Training TX3 TX4 Posteriore Posteriore SX DX Legend NQS Instrument panel node NBC Body Computer node A BUS Serial line carrying data from CPP to NBC B CAN Serial line carrying data from NBC to NQS TXn Transmitter sensor inside wheel rim CPP Tyre pressure ECU K LINE Serial line for ECU and system programming and diagnostics 9 5 3 Operation The system monitors the pressure of the four tyres fitted and not that of the spare wheel in vehicles equipped with a space saver spare The monitoring system will not work when a spare wheel is fitted until a normal size wheel equipped with pressure sensor is fitted back On the other hand in vehicles equipped with a normal size spare wheel the system monitors the pressure of the four tyres fitted and not that of the spare wheel while this is stowed in the boot When the spare is fitted the system will be cut out for a few minutes to give time for the sensor inside the wheel to be recognised by the system The conditions of the four fitted tyres will be monitored by the system Similarly if one or more wheels without sensor are fitted the system will not be available and the respective message will appear on the display until the four wheels with sensors are fitted again The TPMS cannot indicate sudden loss of tyre pressure e g caused by puncturing In this case the car must be st
294. t a distance of approximately 0 9 m maximum value Obstacles in the front side area are detected at a distance of approximately 0 6 m 9 6 8 Diagnostics The ECU runs an auto diagnostic test on system and sensors at key on The sensors are continuously monitored while the system is running The failure of also only one sensor will inhibit the operation of the entire system in this case the system will automatically cut out and send a failure message Faults and errors are immediately reported on the on board panel Rear sensor deactivation with trailer The rear sensors must be deactivated in the presence of a trailer Connect connector A pin 5 to ground in this case 9 6 9 Component characteristics Parking sensor ECU CPA The ECU is an electronic component connected to the rear wiring harness that provides assistance to the driver by performing the following functions receiving from the CAN and directly from the respective button the activation deactivation signals controlling the operating LED controlling the sensors processing the signals received from the sensors checking the functionality of sensors operating the buzzers managing diagnostics and test functions VVVVVVV The ECU is provided with a protection device against voltage surges and short circuits EN fi IR 153 h Traccia Didattica Alfa 159 en ridotta doc 283 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto
295. t and is invested by the air let in from the outside 10 3 1 Operation The PTCs are powered by two relays in the unit 24 and are controlled directly by the NCL ECU when gt The engine temperature is cooler than 65 C Traccia Didattica Alfa 159 en ridotta doc 296 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL SYSTEM ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training gt The outside temperature is cooler than 20 C Two and three zone versions only when the temperature set by the user is higher than that inside the passenger compartment The two sections are operate according to battery voltage as follows gt no section is operated if the battery voltage is under 12 2 V gt one section is operated if the battery voltage is included in the range from 12 2 V to 12 6 V gt both sections are operated if the battery voltage is over 12 6 V 10 4 ONE ZONE CLIMATE CONTROL SYSTEM if E TL ELI FT T ymi i a 1 mot T i r i5 ui Hn i Ke D s x iF H LE E Abu H H e TA 1 pr d VK t Row dC eg er 1 e V Lr LE ar T us ZE alis d is dr j i D y ry MAT i o A Acar 34 4 A d SATTA ht kl VW i A a LF I 4 i Wu Y Li L One zone climate control system legend Air intake unit Pollen filter Upper distribution unit D ESI Ie Pollen filter compartment flap Traccia Didattica Alfa 159 en ridotta doc 297 319 2004
296. t be positioned with a specific tool The markings on the torsional vibration damper and the timing box must be aligned in this position Camshaft tensioners LOCATION The two hydraulic chain tensioners are arranged gt inthe head crankshaft drive chain gt timing box countershaft drive chain MAINTENANCE Remove the concerned tensioner before starting any job on the chain Crankshaft drive chain tensioner turn the piston by 90 press back and lock in this position with the specific tool Camshaft drive chain tensioner remove the tensioner Before installing the camshaft drive chain tensioner the internal piston must be pressed against the spring and locked against the last tooth of the piston by turning it rightwards The lock is automatically released when the engine is cranked Important Disrespect of these precautions can cause excessive chain tensioning which could damage the tensioning conduits and the chain WI DS Ei i 5 a GE ING JK NN AY o A o Hak d Camshaft chain tensioner Countershaft chain tensioner locked with specific tool Chain tensioner O ring Seal Internal piston with spring Thrust piston Roo ee Traccia Didattica Alfa 159 en ridotta 63 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Utility drive belt FEATURES The alternator and A C compressor drive belt is mainte
297. t low speeds In this condition the air column has a considerable swirl exploited to optimise mixing with fuel and considerably improve combustion efficiency Traccia Didattica Alfa 159 en ridotta 150 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training OPEN THROTTLE At full load the engine needs more air flow The throttles are opened and the powerplant works as a normal four valve per cylinder engine At high speed the very high speed may create over swirl the overlapping of flows generated by the swirl may worsen or even cancel the advantages of swirl The column of air introduced by the second conduit the one with the throttles has an opposite swirl with respect to that of the primary conduct In this way an opposite air flow is let to the chamber to slow down the swirl in the combustion chamber This phenomenon is shown in below Effects of throttle opening at high speeds SWIRL OPPOSITE SWIRL GARRETT VGT 17 turbo charger engine ECU VGT solenoid valve vacuum reservoir mobile impeller actuator turbo charger alli al cot Traccia Didattica Alfa 159 en ridotta 151 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training LOCATION In the engine compartment connected to the exhaust manifold turbine side and to the intake manifold turbo charg
298. t will go out after the four second diagnostic procedure Otherwise it will stay on The warning light will stay on or light up while the vehicle is running when gt the ECU detects an airbag system failure gt the ECU detects a collision and the system is deployed gt an failure in the warning light connection circuit occurs The warning light will stay on until the operative conditions of the system are restored i e the concerned component is replaced and the ECU is reset using Examiner following a collision that deployed only the pretensioners or side airbags If the collision deployed the front airbag modules the warning light will remain on permanently The ECU cannot be reset it must be replaced The warning light will come on fixed if during the ECU s life internal errors that cannot be reset using Examiner occur 9 7 8 Passenger airbag deactivated warning light With TEG inserted the passenger airbag deactivated warning light amber will light up for approximately four seconds initial self diagnostic procedure and then blink for the next four seconds If the ECU detects a warning light failure it will store the failure code switch the failure warning light on and deactivate the passenger side airbag Proceed with Examiner as for the failure warning light to restore system operation NOTE The TEG MUST NOT BE INSERTED IN THE TEG READER to deactivate the passenger airbag module this would store an error in the ECU 9 7 9
299. ta 23 318 Fiat Auto S p A After Sales Training VI nN ioioiooioooiooo o JN N r oO CD LO S O Standard in 5 Standard in 5 Standard in 5 and 6 cylinder and 6 cylinder and 6 cylinder versions versions versions S O S O S O Standard in 5 Standard in 5 Standard in 5 and 6 cylinder and 6 cylinder and 6 cylinder versions versions versions s o 0o 0O o 0o o S 8 gt o 0 fF 8 o o o sf e o o 0 J Lele o 0o 0O O O O o 0 Oo o 0o oOo O S 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL Axial and height adjustable collapsible steering column Tow hitch setup CD charger Bi xenon headlights main beam and dipped beam Cold climate pack specific engine oil and oversized electrical system O cojojojojloilo ioOo oo ojojoi looovoloolilooilooocovpijo o jo jo o Product grid legend O Optional S Standard Not available NOTE The contents shows in the product grid are subjected to change according to commercial strategies 1 2 24 Lineaccessori La Lineaccessori accessory grid expressly developed for Alfa 159 completes the original fittings by enhancing and consolidating some specific particularities of the car and its personality The specifically stylistic elements were designed by Centro Stile Alfa Romeo and developed at the same time as the car t
300. tage are generated in the transducer The output pulses are reflected by obstacles The transducer thus receives an echo that is amplified and converted into a digital signal sent to the ECU via the same line used to request transmission Each sensor can also be operated as a receiver only to triangulate the two sensors This technique allows better reception of smaller obstacles in situations characterised by critical reflections The sensors all have the same electrical and mechanical properties The maximum detection distance of each sensor can be adapted by software according to its position on the bumper 9 6 5 Buzzers The front buzzer informs the driver on the distance from the obstacle located in front of the vehicle by means of beeps Similarly the rear buzzer whose tone is different from that of the front buzzer informs the driver on the distance from an obstacle behind the car The beeps inform the driver that the car is approaching an obstacle The warning tone consists of beeps whose duration is constant 75 ms The pauses between beeps is directly proportional to the distance from the obstacle beeps in rapid sequence indicate the presence of a very close object An continuous signal indicates that the distance is less than 30 centimetres The closest approaching obstacle is signalled if there are several obstacles The beeps cease immediately if the distance from the obstacle increases The sound cycle remains constant if the dista
301. talyser performance the exhaust plenum is not exposed to the current of air hitting the vehicle being positioned so that the engine shields it from the wind instead x gt wi e Pre cat lambda sensor Post cat lambda sensor Pre cat lambda sensor Post cat lambda sensor Heat shield Nut Gg E Traccia Didattica Alfa 159 en ridotta 110 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Exhaust diagram cold part MOTORE 1 9 1 Flexible coupling 2 Central muffler 3 Rear muffler The 1 9 litre version has a single rear muffler configuration with one tailpipe end 1 Flexible coupling 2 Central muffler 3 Rear mufflers The 2 2 litre version has a rear double rear muffler configuration with one tailpipe 3 1 3 Bosch MED 7 6 1 ECU operating logic The 1 9 and 2 2 JTS engines are characterised by a fuel feed system with high pressure direction injection pump The electronic control system governs and controls all engine parameters optimising performance and consumption by providing real time response in various operating modes The system is managed by a single Bosch Motronic MED7 6 1 driven throttle ECU that controls sequential and timed ignition and injection The ECU controls the actuators on the basis of the signals received from numerous sensors and governs the following systems gt fuel system high pressure fuel pump
302. tem component failures transmits and receives data via the diagnostic socket interfaces with the engine ECU transmits and receives data via the C CAN line VVVVVV 6 1 3 ABS wiring diagram 3 2 H 2 v 1 elettronica pompa E 4 elettrovalvalvole LX Sr elettronica N e NBC terzo stop NCM NCA n Ca a 2 N H a n 9 2 3 E 1 5 Y z a u N e e cvm 1 2 1 2 1 2 1 2 G005 A a wo CPL 2 es 2 x 2 i 8 EH i x r35 m T rz s 8 s s a NBS 5 d D d D AI EI o CBA mo wn vw Ses ele Ant sx Ant dx Post sx Post dx NBC SENSORI E ST 5 ful H cavi twistati NCM Vb 40 spire metro Speed sensor The wheel speed sensors are active and like the passive sensor fitted in earlier ABS versions detect the wheel speed The fundamental characteristic of the active sensors is in that the signal is processed directly by the sensor instead of sending a sinusoidal wave to the ABS ECU The main advantages include capacity of reading speed signals close to zero passive sensors cannot read speed slower than 2 75 km h less sensitive to external electromagnetic interference caused by electromagnetic fields in cities and in high tech high industrial concentration areas Thanks to the possibility of detecting very low speeds active sensors increase the accuracy of on board navigation Systems Vilow 2004 Fiat
303. tem provides information on distance between obstacles in front of and behind the car while parking It consists of four rear sensors and four front sensors The driver is informed on the presence and distance of the car from the obstacle by means of acoustic signals whose frequency depends on the distance and on the display by means of visual indications Knee airbag TRW This is a dual stage airbag with ECS sensor Two airbags for protecting the knees on driver and passenger side have been added to the classical configuration The front seat belt pretensioners are electrical pyrotechnical and fastened to buckle Bi xenon headlights Automotive Lighting The car also fits xenon dipped beam headlights The innovation consists of a ballast system integrated in the bulb The trim regulation system and the operating principle is used on other models of the make Traccia Didattica Alfa 159 en ridotta 241 318 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM ee After Sales Training Three zone automatic climate control system Delphi In addition to the manual one zone and automatic two zone climate control systems the car may be fitted with a three zone climate control system The three zone climate control system is used to adjust and differentiate the temperature and air distribution settings for the front seats and the rear seat 9 1 2 Electrical system layout The vehicle component layout is
304. ter is based on the application of a double resistance bridge also called a Wheatstone bridge consisting of Ra Rb Rc and Rx The double bridge plus heating resistor R1 is made on the support hot film by applying epitaxial technology Traccia Didattica Alfa 159 en ridotta 141 318 2004 Fiat Auto S p A All rights reserved ALFA 159 TRAINING MATERIAL Fiat Auto S p A After Sales Training The Wheatstone bridge in addition to being used to measure resistance is specifically employed as a measuring circuit for resistive sensors A thermo resistor whose values are known is employed instead of an unknown resistance Rx The resistance of the thermo resistor varies with the temperature and causes imbalance of the bridge There is therefore a proportional link between voltage imbalance unknown resistance and temperature The first resistive bridge P1 with a thermo resistor controls and stabilises the heater temperature R1 of the sensor hot film heating The second resistive bridge P2 with two thermo resistors exposed to the air flow detects and converts the voltage air flow variation also defining the direction of flow TEMPERATURE SIGNAL HFMS Resistenza ki jn D Temperatura C The temperature is measured by a NTC in analogue air mass flow meters The characteristic is shown above The measurement of a digital air mass meter is a constant frequency duty cycle modified PWM signal HFM6 C
305. ter range in normal working conditions Traccia Didattica Alfa 159 en ridotta doc 274 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A SYSTEM np eni ta After Sales Training Dead reckoning This method determines vehicle position by integrating the vehicle direction speed and direction signals provided by sensors fitted aboard the vehicle It is used to ensure positioning if no GPS signals are picked up tunnels covered places etc Map matching This method compares the vehicle s course and the topographic characteristics of the terrain The actual position of the vehicle is pinpointed in this way and connected to the roads The navigation module receives positioning advancement and direction change data from the on vehicle sensors These data are gathered and processed by a specific algorithm which also considering the current position of the GPS satellites calculates the estimate position of the car car positioning Setup The device is used to operate on the Connect and vehicle setup Variations selected by the user are proposed on the on board panel The menu offers three main function groups gt Language amp Date amp Temperature for selecting type format and unit of measure of the information shown gt Vehicle for configuring the functions of same on board devices if the specific outfit does not include the feature the corresponding menu item cannot b
306. terface with an external audio amplifier External audio amplifier DSP Opt The BOSE DSP Digital Sound Processor is an electronic component connected to the audio wiring harness The DSP receives the signal from the NRR audio output From the NRR it receives enabling for activation and is capable of outputting an acknowledgement signal to the NRR It is usually located in the boot Radio navigator RNV Opt The RNV pictogram navigator Magneti Marelli is an alternative to the NRR Computerised info node NIT The NIT Bosch is connected to the B CAN the I CAN and the dashboard wiring Connectors are provided with connection for external microphone and handset The NIT can interact with the Convergence node Convergence node NCV Opt The NCV is a device connected to the B CAN capable of interacting with the NIT via a Bluetooth cell phone It interfaces with the controls on the rearview mirror and with the free hands microphone on the front central ceiling light Front door node NPA The NPA is connected to the B CAN and to the respective front door wiring It manages the electrical functions of the front doors the electrical heated mirrors the puddle lights and the rear ceiling lights The NPA is present when the rear doors are not fitted with electrical window winders and it manages the electrical functions of both rear doors The NPA also makes the external temperature reading acquired by the sensor built into the mirror availabl
307. th SAM Examiner Smart module is needed MEASURING METHOD to view the signal considering its type Set Examiner as a voltmeter and acquire the signal for approximately 5 seconds Traccia Didattica Alfa 159 en ridotta 109 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TR ini 59 TRAINING MATERIAL After Sales Training Exhaust system FEATURES The engine has a 4 in 2 in 1 exhaust system with two three way CCC Close Coupled Converter catalysers built into one The catalysing elements are relatively close to the engine This means that Euro 4 specifications on the emission of pollutants can be reached without adopting particular systems such as secondary air or electrical heating Double injection lasting for approximately 50 seconds is exploited to significantly reduce emissions thanks to the possibility of injecting petrol directly into the chamber Double injection is exploited to make the charge richer near the spark plug so that the better fuel ignition quality will provide a longer ignition delay This have two advantages firstly gases are hotter and therefore the catalyser warms up faster secondly due to the gases being hotter during expansion and exhaust a significant fraction of the unburnt hydrocarbons is converted before reaching the catalyser The content of these components is approximately 5 times lower than that of a traditional engine To decrease heating time and improve ca
308. the NBS The user s intension is determined by the transition of one of the two signals PAV ignition button The system will behave as follows in the event of start stop button failure Start stop button failure always off In the event of discrepancy between two signals the NBS simply needs to acknowledge pressing of the button by means of one of the two PAV signals to start stop the engine In this case an error which can be read in diagnostic mode will be stored Acknowledgement is only possible with the CAN active in the event of a failure PAV signal The network is woken up simply by opening a door of the vehicle Start stop button failure always on To prevent undesired start ups the signal will be ignored if one or both the NBS inputs detect PAV pressure for 30 consecutive seconds until state change is detected In both cases steering is blocked when TEG is extracted and a warning message is sent to the instrument panel From ignition to drive The engine is started by pressing the start stop button when the clutch or brake pedal is pressed versions with mechanical transmission or when the brake pedal is pressed versions with automatic robotised transmission The loads will be switched off key off if the start stop button is pressed and the brake or clutch pedal is not pressed The NBS checks the following conditions before driving the starter motor when the start command is acknowledged Y Clutch brake pedal pressed dur
309. the NCL Sun sensor The sun sensor is only used by the NCL to correct the air temperature let into the passenger compartment considering the degree of thermal radiation due to the presence or absence of sun The device consists of two photodiodes arranged behind a screen which allows the crossing of particular light radiations The sensor generates a linear analogue signal 0 5VDC proportional to the detected radiation Traccia Didattica Alfa 159 en ridotta doc 300 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 10 11 12 13 Climate control system wiring connectors with dashboard wiring harness 14 Evaporator 15 Expansion valve 16 Weather strips 17 Climate control fan 18 Rear mixer actuator 19 Left front mixer actuator 20 Right front mixer actuator 21 Recirculation actuator 22 Rear distribution actuator 23 Left front distribution actuator 24 Right front distribution actuator 25 Heater piping seals 26 Fan speed electronic regulator 27 Evaporator temperature sensor 30 Kohm 20 C 28 Cover 29 Climate control ECU NCL 30 Rear climate control system ECU 31 Mixing controls two zone system 32 Actuator fastening screws 33 Supplementary heater PTC power diesel and fan power one zone system relays 34 Sun sensor NOTE The AQS and fog sensor are not shown in the technical drawing or
310. this case error code P1206 will be stored in memory and slight limitation of performance will be implemented by the recovery system In these conditions the system manages normal regenerations according to conditions After exceeding the 250 threshold and reaching 300 of particulate accumulation code P2002 is stored in the memory to indicate that the particulate trap exhaust system and engine are at risk Performance is dramatically limited to prevent damage to the system In such conditions the only option is to attempt to generated the trap by means of the forced regeneration procedure The possibility of regenerating during vehicle use is factually eliminated Regeneration process flow The system will work on two permanent working stages gt Accumulation gt Regeneration Traccia Didattica Alfa 159 en ridotta 156 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL Regeneration Spontaneous regeneration occurs when Vehicle speed gt 40km h for at least 15 minutes Particulate mass charge lt 200 Regeneration is managed fully autonomously by the engine ECU according to gt regeneration needs gt enabling conditions Oil The use of delayed oil injections to regenerate the trap decreases the oil level in the sump The oil replacement frequency therefore differs from that show on the service schedule and becomes flexible 15 thousand 50 thou
311. this case in addition to the message on the display the VDC warning is also switched on see note above This does not indicate a failure The VDC will remain off until the key is extracted and the vehicle is fully stopped The VDC and the ASR is reactivated at the next key on Traccia Didattica Alfa 159 en ridotta doc 224 319 2004 Fiat Auto S p A Tutti i diritti sono riservati Fiat Auto S p A STEERING ALFA 159 TRAINING MATERIAL sula After Sales Training 7 STEERING 7 1 FEATURES The steering is designed to ensure the best sporty driving performance optimal handling and low effort when parking These objectives in combination with high handling comfort has led to the creation of a steering with the following general technical features gt Steering wheel turns 2 33 total for all versions Steering ratio 13 0 steering wheel turns wheel turns gt Force on steering wheel 4 Nm when stationary Steering circle 11 1 m curb to curb Steering circle 11 6 m wall to wall The steering ratio is lower than that of the 156 to ensure truly precise and direct steering despite the longer wheelbase 103 mm Handling comfort is improved by perfecting soundproofing of the power steering system and adopting a new steering wheel and column design characterised by a high structural stiffness Furthermore a new high decoupling vibration damper is installed on the intermediate steering shaft Special c
312. tion module VV VV ON VV CD ROM drive Connect is equipped with a CD ROM drive and are therefore capable of reading playing and managing gt normal audio CDs gt CD ROMs containing MP3 files gt official Magneti Marelli CD ROMs containing updated copies of management software and map database needed for navigation GSM module Connect is equipped with a dual band telephone module and a small SIM card the SIM card can be inserted by the user It also fits an external microphone for hands free kit and voice recognition system and is ready for connecting a telephone handset Security Connect remains automatically locked if there is no CAN connection In this case enter the master code to authenticate the body computer and start operation Available language The test strings menu items and navigation voice messages are available in the following languages gt French English German Italian Spanish Dutch European Portuguese VV VV V V A specific CD setup CD must be inserted whenever the voice recognition language is changed Navigation Connect can be used for vehicle localisation and route guidance services The vehicle is positioned by gt GPS satellite positioning Deadreckoning gt Map matching GPS positioning Positioning is based on the reception of GPS signals At least three satellites must be received by the antenna located on the roof of the car GPS positioning is precise within a 20 me
313. tion of NOx The ECU can calculate the amount of air recirculated to compare the theoretical intake mass for the various engine running conditions value stored in mapping and the real intake mass that crosses the air mass meter and is therefore measured DPF particulate trap The DPF Diesel Particulate Filter is a particulate abatement system fitted aboard Fiat Group diesel engines Traccia Didattica Alfa 159 en ridotta 153 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A After Sales Training ALFA 159 TRAINING MATERIAL n Throttle Valve i Flow Meter U Valve Temp rature Sensor LI Catalyzed Soot Filter CSF J Muffler m 3 Ke The DPF system consists of gt DPF gt sensor and actuators gt specific engine ECU strategies The trap is an accumulation system that must be regularly regenerated cleaned by burning the particles of particulate in the filter whose quantity is calculated by the ECU by applying an algorithm The ECU uses multiple injection to increase the exhaust gas temperature to 600 C and burn the particulate The DPF abates emissions of particulate to 90 during NEDC test cycle from 0 025 g km to 0 001 g km in compliance with Euro 4 limits The trap is an accumulation system that must be regularly regenerated cleaned by burning the particulate in the filter There are essentially two regeneration technologies
314. to count the teeth on the phonic wheel The frequency and amplitude of the voltage sent to the ECU varies according to the angular speed of the crankshaft The sensor is connected to ECU pins 27 and 21 via the shielded wire to connector A INSTALLATION REQUIREMENTS The distance between end of sensor and phonic wheel must be in the range from 0 8 to 1 5 mm for the signals to be correct Cam angle timing sensor LOCATION The sensor is located on the cylinder head facing the camshaft drive pulley A tooth on the pulley is used by the timing sensor to acknowledge the engine timing position FUNCTION For the engine ECU to acknowledge which cylinder is at compression stroke The sensor is connected to ECU pins 11 50 and 20 via the shielded wire to connector A Intake air pressure and temperature signal 4 3 2 1 o Masse GROUND gt Z NIC NIC o J Drucksensor 3 EN PRESSURE SENSOR o 4 Ug Druck DUTPUT SIGNAL ground NTC air temperature signal 5V power supercharger pressure signal N gp Traccia Didattica Alfa 159 en ridotta 137 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training LOCATION The intake air temperature and pressure sensor is fitted on the intake manifold FUNCTION The sensor provides information on air temperature and pressure in the intake manifold to the engine ECU This information is
315. trim measurement 2004 Fiat Auto S p A All rights reserved 34 318 Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A TECHNICAL DATA ALFA 159 TRAINING MATERIAL After Sales Training Rear suspension trim measurement Standard A vehicle in running order with full tank and tyres inflated at specified pressure A B mm D C mm 1 9 16V basic 205 55 R16 tyres 1 9 16V medium 215 55 R16 tyres 2 2 16V medium 215 55 R16 tyres 1 9 M jet 8V basic 205 55 R16 tyres 1 9 M jet 8V medium 215 55 R16 tyres _1 9 M jet 8V high 215 55R16tyres 1151 Ir D 1 9 M jet 16V basic 205 55 R16 tyres 1 9 M jet 16V medium 215 55 R16 tyres 2 4 Multijet 20V medium 225 50 R17 tyres 2 4 Multijet 20V automatic high 225 50 R17 tyres 113 4 NOTE The Basic Medium and High outfits are those previous referred to as L1 L2 and L3 outfits in the briefing 2 10 2 Front suspension Std A conditions Characteristic angles 2 10 3 Rear suspension Std A conditions Characteristic angles i TS 22JTS 1 9M jet8V 1 9M jeti6V 2 4M jet20V Caster 49 17 18 49 17 18 49 11 18 49 11 18 4 12 18 3 2 0 4 3 2 0 4 3 2 0 4 Standard A vehicle in running order with full tank and tyres inflated at specified pressure Torsional stiffness of the body is equal to 180000 daNm rad Traccia Didattica Alfa 159 en ridotta 2004 Fia
316. ts knees and hard parts which could cause injury to lower limbs in a frontal collision Furthermore this risk is additionally reduced by the presence of a knee bag The area underneath the steering column typically the most dangerous for knees is protected by an energy absorber arranged between the column and the upholstery The retractable steering column angular adjustment lever and the absence of an ignition switch block the vehicle is fitted with a standard electrical steering lock and the start button is located on the dashboard additionally reduce the possible areas of contact with the driver s knees in a collision Door panels The arrangement of the functional elements of the panel i e the armrest and the upper part are designed to ensure correct interaction with occupant s body in the event of a side collision The upper part is smooth and soft while the necessary projection of the armrest is made harmless by collapsing at a load level well under that which may cause internal injury Interior upholstery Interior upholstery is characterised by soft materials with cover also the necessarily stiff parts such as front seatbelt height adjuster Fireproof material is used fire propagation speed slower than 100 mm min to limit risks in the event of a fire Fire protection The entire car from the bodyshell to the various components was designed in accordance with the Alfa most recent strictest fire protection standards The fuel
317. ts reserved Traccia Didattica Alfa 159 en ridotta Fiat Auto S p A CONTENTS ALFA 159 TRAINING MATERIAL After Sales Training 3 2 1 9 2 4 MJET DPF ENGINE 3 2 1 Fuel feed rail common rail EE ee e eren E ERA E EE 3 2 2 Bosch EDC 16C39 electronic ee EEN 131 le DER EE 136 EREECHEN eebe ee 197 Intake air pressure and temperature sign 137 Engine coolant temperature EE 138 PIENO GONA Ar Mass EE 138 eicel elki a Lo 100 EE 143 Fuelpicssure e E 144 Accelerator pedal elen 145 Bieren CP1A Noh pressures PUMP EE 146 High pressure PUMP OPSTAO EE 146 pss elei eui pump Rz o sce ez iie n GE 147 Low pressure regulator solenoid Valle 147 Pecorino 148 nee e Lada i 148 IMA let eier S SMMC e re E 149 Variable geometry intake ee E 149 CARRETE YVYGT I7 UDO CHANGED EN 151 Exhaust gas recirculation system EE 153 Sietzen lee Re lee TE 158 PNA OS CO GN 158 3 2 3 EE leat res OF SS lla 174 Tachometer sensor electrical features ei 174 Timing sensorelechnical RE 175 Timing sensor electrical osare 175 Een Een Ee E 176 Coolant temperature sensor electrical features 177 lg nu E 177 EE RE ee 178 Accelerator Pedal poteNliomMelel Lisi lalla alain 179 Electrical features of actuators EE 179 QUAE I 216 6 PI OS M 180 CIE Ee ER 181 BI i E ee eee een en 181 Giow plug pre heater EGU E 182 O or
318. type was tested to measure road hold response aquaplaning performance racing performance on the Pirelli track at Vizzola Ticino braking distance on dry and wet roads rolling resistance noise filtering capacity and wear resistance The rims created for the Alfa 159 are shown below 18 RIMS 17 RIMS Traccia Didattica Alfa 159 en ridotta 17 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training 1 2 13 Roominess The Alfa 159 is bigger than the 156 and consequently roomier PERCENTILE COMPARISON Front Rear 99 hmax 1 93 m 82 5 hmax 1 83 m 97 5 nmax 1 83 m 70 nmax 1 80 m This term is used in the automotive sector to indicate the dimensions of dummies used to measure the roominess of cars For roominess tests the dummies are adjusted according to percentile values fractions of 100 which represent the percentages of population which fall into certain ranges of measurements Specific studies conducted by the USA Health Department indicate that ninety five people out of one hundred are shorter than 1 85 metres Therefore 95 percentile is used to indicate a maximum height of 1 85 metres Similarly 50 percentile indicates a height of 1 75 metres 50 of the population and 10 percentile a height of 1 65 metres In the case of the 159 front percentile of 99 indicates that 1 93 metre tall occupants can comfortably sit in a front sea
319. u Al 2 k PARTICULARITIES The sensor is provided in electronic circuitry for squaring the Hall effect sensor signal The connection to the ECU must be maintained to power the sensor correctly The output signal pattern is that of a square wave Supercharger sensor features B C tn an Output Voltage Un in V 0 20 250 Absolute Pressure pas in kPa Double sensor consisting of NTC temperature sensor and piezoelectric pressure sensor SENSOR FEATURES Temperature sensor variable resistance from to Pressure sensor variable voltage from to OUTPUT SIGNAL TYPE Temperature sensor Set multimeter to resistance mode ohmmeter MEASURING METHOD Pressure sensor The ECU must remain powered for correct measurement Set multimeter to voltmeter mode Traccia Didattica Alfa 159 en ridotta 176 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Coolant temperature sensor electrical features Q tg d 2 4 i ds 1 d_ lg ia d_J Ss E E LI ELELELLELLEELILEL ELSS ss e umm PI em E O Nuus mun tini tt Et SS SE SE GS Sen PS Fees IS DS ES E E ET ER M a E e E ES SS SSS SS SS SSS SSS aS lt W mm eteri E I SE WEEN cc ETH EE SE i EE EE ES Gi MH P E te RE E E e IEEE IRE GERMEN e E Er UH SSES E E E E
320. ug power off Nominal current on terminal 30 Maximum direct current on terminal 30 Nominal current on G1 G5 terminals Maximum direct current on Gi1 G5 terminals Total voltage drop between terminal 30 and G1 G5 Relay energising voltage Relay release voltage t ON contacts closed t OFF contact open Relay coil current Nominal current on relay NO contact Voltage control from ECU Multimeter ammeter clamp 184 318 Fiat Auto S p A After Sales Training 12 volt 10W 24 volt for 1 minute 23 C 6 16 volt gt 16 volt 48A 275A for 1 second 8A x 5 55A x 5 for 1 seconds lt 200m volt 10A lt 7 5 Volt 23 C lt 5 5 Volt 23 C lt 10ms lt 10ms lt 500 mA 12V 23 C 48A 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training 4 CLUTCH MADE BY SACHS 4 2 CLUTCH ASSEMBLY CHARACTERISTICS Pull type single dry plate clutch with hydraulic control and internal coaxial actuator External diameter 228 mm spring load 600 daN Used with 1 9 16V and 2 2 16V direct injection engines 4 2 XTEND plate wear take up device OBJECTIVE The automatic clutch plate wear take up device keeps the idle clutch engagement release stroke constant during vehicle use CHARACTERISTICS The automatic wear take up device called XTend has the following distinctive characteristics tol
321. ures of the 156 which has already shown its worth The many improvements concern the longitudinal filtering and damping capacity which increases lateral stiffness and camber take up to ensure better grip of the tyre to the ground in limit conditions Reduced static camber and higher riser hub stiffness provide a more effective tyre wear A multilink architecture was chosen for the rear suspension Also in this case longitudinal filtering and damping are ensured by a hydraulic bushing and transversal leaf architecture specifically designed to provide superior comfort The extreme lateral stiffness and the high camber take up ensure the best handling Control is ensured by four two tube shock absorbers with coaxial spring Traccia Didattica Alfa 159 en ridotta 13 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The handling comfort objectives of the Alfa 159 set a new superior reference by providing the dynamic performance and passive safety of a smaller lighter model like the Alfa 156 the current reference for the segment combined with the typical comfort performance of a higher range model This result was obtained in the course of a three year fine tuning process The tests conducted on various terrain and tracks around the world were exploited to refine all suspension components and implement the changes needed to obtain the required performance regardless of
322. uropean climates and meets the European standard for safety points ten years without structural weakening The Alfa 159 is a low environment impact car for the reasons above and for its innovative painting process A new painting plant has been designed and made using the most recent technological innovations available on the market as concerns the adoption of application systems and the choice of products Traccia Didattica Alfa 159 en ridotta 21 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The innovation concerns the introduction of water enamel and the use of PUR 2K transparent resin instead of traditional products for all colours This solution in addition to reducing emission of organic compounds into the atmosphere improves the final appearance better application and better brightness initially and in time conferring to the finishing paint as well as better resistance to chemical and mechanical environmental aggressions including to micro scratching caused by car wash rollers 1 2 22 Range The complete Alfa 159 range is shown in the following table DISPLACEMENT POWER HP TRANSMIS TRACTION pf ug LL SION 0 CMS H8 19 eMe 2 DATATA 19 90 MTAG 42 LL X X _ 22 85 em m2 ___i x x 32 265 M Jes XX 32000265 AUG Jes LL X LX 2GTA 40 X MTA0 Io TI GTA 1 98V M jet n
323. via a rotation pin pulls the buckle downwards NOTE After deploying the pretensioners the belts remain blocked and must be replaced 9 7 5 Front seat belt reminder sensors When the seat belts are not worn the risk of injury for occupants is higher than that of seat belt wearers also in very less severe crashes Specific signals from the seat belt reminder sensors in the front seat belt buckles and from a pressure sensor embedded in the seat cushion foam are used by the ECU to deploy the airbags but not the pretensioners if a passenger is sitting in the seat The pretensioners are not deployed in this case which would only determine additional cost for repairing the vehicle 9 7 6 Airbag system warning lights 1 Airbag system failure warning light on instrument panel 2 Passenger airbag deactivate warning light on front ceiling light 3 Seat belt reminder warning light on front ceiling light Traccia Didattica Alfa 159 en ridotta doc 287 319 2004 Fiat Auto S p A Tutti i diritti sono riservati EE ALFA 159 TRAINING MATERIAL do SYSTEM After Sales Training 9 7 7 Airbag system failure warning light With TEG inserted the airbag system failure warning light red will light up for approximately four seconds initial self diagnostic procedure and then goes out The corresponding failure code is stored if the ECU detects a failure If no failures are detected at key on and no failure events are stored the warning ligh
324. wer and low fluid temperatures gt light weight smaller size Fuel filter Traccia Didattica Alfa 159 en ridotta 130 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training 1 metal filtering element cartridge 2 water in fuel filter sensor 3 bleeder 4 from fuel pump to high pressure pump 5 to high pressure pump FUNCTION To filter the fuel before it is sent to the high pressure pump LOCATION The fuel filter is fitted on the firewall in the engine compartment FEATURES The metal grafted cartridge fuel filter consists of a pack of paper disks with a filtering surface of 5300 cm and 4 5um filtering capacity COMPONENTS The fuel filter is provided with the following components in addition to the filtering cartridge gt water in fuel filter sensor 3 2 2 Bosch EDC 16C39 electronic control system EU 8 mu M ie RH SEA z amp n Ji Traccia Didattica Alfa 159 en ridotta 131 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Tank Fuel pump Fuel filter Damper Radial jet M PROP regulator Pressure regulator Rail Rail pressure sensor 10 Injectors 11 Air cleaner 12 Air mass meter 13 Compressor 14 Intercooler 15 Throttle 16 EGR 17 EGR cooler 18 Gas recirculation input 19 Supercharger sensor 20 Engine speed sensor 21 T
325. y consists of a heated film arranged in a measuring channel through which engine intake air flows The hot film is kept at a constant temperature of 120 C this is why a temperature sensor is present by a heating resistor The flow of intake air takes heat from the hot film causing a potential lowering of temperature the heat given up by the film is proportional to the intake air mass A certain current is circulated in the resistor to keep the film temperature constant this current is proportional to the given up heat Traccia Didattica Alfa 159 en ridotta 102 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training The current crosses a Wheatstone bridge which imbalances it and determines a potential difference which is detected The analogue flow meter has a 5 pin connector The connections to the engine ECU are CONNECTION TO ECU CONNECTOR DRAWING connector pin 1 to ECU pin 27 side Dabimetro A pin 2 power from ECU used to guarantee air flow signal output independent from battery voltage variations connector pin 3 to ECU pin 11 side A z X connector pin 4 to ECU pin 26 side o A connector pin 5 to ECU pin 12 side A ola ow UumIO Z ui a w uo e e Zb 12 Zi 11 STRUCTURE Female connector Cylindrical body Circuit cover Measuring conduit cover Measuring conduit Circuit Sensor Circuit assembly plate
326. y seat can be used on any type of vehicle ISOFIX mountings are therefore characterised by standard dimensions and reciprocal distance These mountings are firmly installed on rear seat backrests The robustness of the backrest and the bodyshell anchoring ensure correct use of the child safety seat in all collisions therefore offering adequate protection to the child Head restraints All outfits fit standard height adjustable locking head restraints on front seats and three head restraints on rear seats Some Alfa 159 versions also fit an anti whiplash device that in the event of rear end collisions move the head restraint towards the occupant s neck Traccia Didattica Alfa 159 en ridotta 15 318 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A ALFA 159 TRAINING MATERIAL After Sales Training Dashboard The constraints deriving from correct set up in passive safety perspective was taken into account for designing the dashboard The passenger airbag flap is on the top of the dashboard is positioned to make it impossible to place objects on top which could be thrown about if the airbag is deployed This arrangement also ensures that the passenger s airbag is inflated towards the windscreen rather than towards the occupant and only later stretches into the position where it provides the best protection The lower part of the dashboard is designed to ensure that there is no contact between the occupan
327. zzer negative from NCR Brake pedal switch positive signal setup for EHB electrohydraulic brake Engine oil level sensor power Engine oil level sensor signal GREY connector Oooo Fmcioen O Not connected Dimmed light n 6 j Notcomectd 0 0 8 j Notcomeded 000000000 O 9 Notcomeded S 11 Notconnected 0 O Not connected XD x sl else s Windscreen rear window liquid level signal Engine coolant level signal Not connected Engine oil pressure signal analogue signal Engine oil level pressure sensor ground Serial line setup for EHB electrohydraulic brake Heel PILE Engine oil temperature signal analogue signal Traccia Didattica Alfa 159 en ridotta doc 272 319 2004 Fiat Auto S p A Tutti i diritti sono riservati ELECTRICAL Fiat Auto S p A ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Auxiliary instrument panel pinout IN PINFUNCTION Serial line with NQS Ground connection to NQS 8 INT from F 37 connection to NOS 3 4 5 6 Not connected 9 4 COMPUTERISED SYSTEMS Various levels are available to suit all needs Traditional telephone setup Bluetooth telephone connection Convergence Map radio navigator RN Map radio navigator with integrated free hands telephone RNT Connect Nav radio navigator and telephone with information and rescue services VVVV WV Connect Nav

Alfa Romeo 159

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