Page 2 Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL After Sales Training CHANGES/UPDATES Date Ref. File Name Description © 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.
Page 3: Table Of Contents
Fiat Auto S.p.A. CONTENTS ALFA 159 TRAINING MATERIAL After Sales Training CONTENTS CONTENTS ..................................3 1. BRIEFING.................................9 1.1 GENERAL TECHNICAL DATA ............................. 9 1.1.1 Presentation......................................9 1.2 T ....................................9 HE CAR 1.2.1 Style .........................................9 1.2.2 Dimensions ......................................10 The dimensions in brackets refer to versions fitting 215/55 R16 tyres.......................10 1.2.3 Interiors ........................................10...
Page 4 Fiat Auto S.p.A. CONTENTS ALFA 159 TRAINING MATERIAL After Sales Training 2.11.1 Characteristic data....................................36 2.12 STARTER MOTOR................................36 2.12.1 Characteristic data....................................36 2.13 BATTERY ..................................36 2.14 FLUIDS AND LUBRICANTS ............................. 36 2.14.1 Oils and fluids ...................................... 36 2.14.2 Greases ....................................... 37 2.14.3 Lubricant capacity....................................
Page 5 Fiat Auto S.p.A. CONTENTS ALFA 159 TRAINING MATERIAL After Sales Training 3.2 1.9 / 2.4 MJET DPF ENGINE ............................129 3.2.1 Fuel feed rail (common rail) .................................129 Features ........................................129 Construction ......................................129 Fuel pump ........................................130 Fuel filter........................................130 3.2.2 Bosch EDC-16C39 electronic control system............................131 Engine speed sensor....................................136...
Page 6 Fiat Auto S.p.A. CONTENTS ALFA 159 TRAINING MATERIAL After Sales Training Lower secondary shaft ..................................... 204 5.2.4 Synchronisers ...................................... 205 5.2.5 Mounts ......................................... 206 Gear shifting system ....................................206 5.2.6 Differential ......................................207 5.2.7 Axle shafts ......................................207 Axle shaft structure ....................................208 Tripod joint .......................................
Page 7 Fiat Auto S.p.A. CONTENTS ALFA 159 TRAINING MATERIAL After Sales Training 9.2.1 Functions ......................................255 9.2.2 Structure ......................................255 9.2.3 Operative procedures ..................................256 9.2.4 Overview of fundamental operations ..............................259 9.2.5 Code system programming and component management........................260 9.2.6 Procedures for replacing components ..............................261 9.2.7 NTR diagnostic procedures .................................262...
Page 8 Fiat Auto S.p.A. CONTENTS ALFA 159 TRAINING MATERIAL After Sales Training 10.5.3 Three-zone system.................................... 298 10.5.4 Rear three-zone controls ................................... 298 10.5.5 Notes on sensor operation ................................299 10.5.6 Two/three-zone climate control system ............................. 300 10.5.7 Two/three-zone climate control system wiring diagram........................302 One-zone ECU pinout ....................................
Page 9: 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...
Page 10: Dimensions
The speedometer, 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.
Page 11: Outfits And Characteristics
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.
Page 12: Transmission
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’...
Page 13: Suspensions
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 features of the 156 which has already shown its worth.
Page 14: Active Safety
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.
Page 15 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.
Page 16: Alarm System
(for versions/markets where fitted). Volumetric protection can be cut-out. CAUTION. The engine immobilizer function is ensured by the Alfa Romeo Code system which is activated automatically when the key is removed from the switch.
Page 17: Tyres And Wheels
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.
Page 18: Roominess
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 seat.
Page 19: Sunroof
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.
Page 20: Materials Used
OUTER SIDE ROOF ASSEMBLY SEAM 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. The roof laser welding cabin © 2004 Fiat Auto S.p.A. - All rights reserved...
Page 21: Aerodynamics
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.
Page 22: Range
1.2.22 Range The complete Alfa 159 range is shown in the following table. DISPLACEMENT POWER (HP) TRANSMIS...
Page 23: Product Grid According To Outfit Level
Fiat Auto S.p.A. BRIEFING ALFA 159 TRAINING MATERIAL After Sales Training 1.2.23 Product grid according to outfit level Contents Multistage SMART 2 front airbag system Driver’s knee bag Passenger’s knee bag SBR (Seat Belt Reminder) and alarm Key switch for deactivating passenger’s airbag and knee bag...
Page 24: Lineaccessori
The specifically stylistic elements were designed by Centro Stile Alfa Romeo and developed at the same time as the car to 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.
Page 25 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: Alloy rims and tyres responding to the severest quality and safety criteria while accentuating the car’s dynamic...
Page 26 Fiat Auto S.p.A. BRIEFING ALFA 159 TRAINING MATERIAL After Sales Training A Car Care Kit for cleaning interiors and exteriors. Safety ‘Lineaccessori’ offers useful elements for the safety of the car and occupants alike. 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.
Page 27: Technical Data
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 1.9 JTS 2.2 JTS 1.9 M-jet 8V 1.9 M-jet 16V 2.4 M-jet 20V 939A6000 939A5000 939A1000 939A2000 939A3000 Type code...
Page 28: Injection/Ignition
1-2-4-5-3 Firing order 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 Didattica Alfa 159-en-ridotta...
Page 29 Fiat Auto S.p.A. TECHNICAL DATA ALFA 159 TRAINING MATERIAL After Sales Training 2.2 JTS engine Maximum torque: 230 Nm @ 4500 rpm Maximum power: 136 KW @ 6500 rpm 1.9 Multijet 8V 120 HP engine Maximum torque: 280 Nm @ 2000 rpm Maximum power: 88 KW @ 4000 rpm 1.9 Multijet 16V 150 HP engine...
Page 30: Engine Cooling
3rd gear ratio 1.146 1.146 0.959 4th gear ratio 0.943 0.943 0.744 5th gear ratio 0.861 0.861 0.614 6th gear ratio 3.545 3.545 3.545 Reverse gear ratio © 2004 Fiat Auto S.p.A. - All rights reserved 30/318 Traccia Didattica Alfa 159-en-ridotta...
Page 31: Differential
Fiat Auto S.p.A. TECHNICAL DATA ALFA 159 TRAINING MATERIAL After Sales Training 2.4 Multijet 20V 1.9 Multijet16V 2.4 Multijet 20V automatic Aisin AF40-6 Type I, II, III, IV, V, VI, R I, II, III, IV, V, VI, R Synchronisers helical teeth...
Page 32: Front Brakes
(total steering) Steering box ratio (mm/turn) Steering wheel/wheel angle ratio Rack stroke Force on steering wheel when stationary (Nm) Rack diameter (mm) Link diameter (mm) © 2004 Fiat Auto S.p.A. - All rights reserved 32/318 Traccia Didattica Alfa 159-en-ridotta...
Page 33: Front Suspensions
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 and medium 1.9 JTS 2.2 JTS 1.9 M-jet 8V 1.9 M-jet16V 2.4 M-jet 20V outfits 13.6 ±0.05 13.6 ±0.05...
Page 34: Rear Suspensions
235/40 R18 2.10.1 Trim (Std. A conditions) Front suspension trim measurement Standard A: vehicle in running order with full tank and tyres inflated at specified pressure © 2004 Fiat Auto S.p.A. - All rights reserved 34/318 Traccia Didattica Alfa 159-en-ridotta...
Page 35: Front Suspension (Std. A Conditions)
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) Version and outfit 113.4...
Page 36: Alternator
Tutela GI / E Tutela GI / E fluid Paraflu Up 50% Paraflu Up 50% Paraflu Up 50% Paraflu Up 50% Paraflu Up 50% Radiator fluid © 2004 Fiat Auto S.p.A. - All rights reserved 36/318 Traccia Didattica Alfa 159-en-ridotta...
Page 37: Greases
Fiat Auto S.p.A. TECHNICAL DATA ALFA 159 TRAINING MATERIAL After Sales Training 2.14.2 Greases Recommended product specifications 1.9 JTS 2.2 JTS 1.9 M-jet 8V 1.9 M-jet16V 2.4 M-jet 20V Tutela MRM Front CV joint Tutela MRM Zero Tutela MRM Zero...
Page 38: Vehicle Features
The values in brackets refer to versions fitting 215/55 R16 tyres. 2.15.2 Performance 1.9 JTS 2.2 JTS 1.9 M-jet 8V 1.9 M-jet16V 2.4 M-jet 20V Top speed (km/h) Acceleration (S) (0-100) © 2004 Fiat Auto S.p.A. - All rights reserved 38/318 Traccia Didattica Alfa 159-en-ridotta...
Page 39: Capacities
Fiat Auto S.p.A. TECHNICAL DATA ALFA 159 TRAINING MATERIAL After Sales Training 2.15.3 Capacities 1.9 JTS 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 8,15 8,15 and HVAC (litres)
Page 40: Service Schedule
Change brake fluid (or every two years) Replace pollen filter (*) 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...
Page 41 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.
Page 42: 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 power out in excess of 60kW/l, output torque higher than 100Nm/l).
Page 43: Engine (Suction Side)
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Engine (suction side) Engine (exhaust side) Specifications: 1.9 litre engine Type 1.9 XHR Displacement 1859 cm Bore 86 mm Stroke 80 mm Suction valve diameter 35.1 mm Exhaust valve diameter 30.1 mm...
Page 44: Specifications: 2.2 Litre Engine
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training 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...
Page 45: Engine Specifications Compared
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Engine specifications compared 1.9 litres 2.2 litres ================================================================== Bore (mm) Stroke 94.6 (mm) Number of cylinders Displacement 1859 2198 (cc) Bore x stroke ratio 0.93 1.10 Connecting rod length 145.5...
Page 46: Engine Performance
Fiat Auto S.p.A. ENGINE 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...
Page 47: Engine Components
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training 3.1.2 Engine components Engine mounts Engine pad engine side Engine bracket engine side Engine pad gearbox side Engine bracket gearbox side Engine rod engine side Rod anchoring bracket gearbox side to gearbox...
Page 48 Fiat Auto S.p.A. ENGINE 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 handling comfort.
Page 49: Cylinder Block
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Cylinder block Oil filter housing Crankshaft shaft speed sensor Oil pressure switch Knock sensors Cylinder block Bottom plate 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...
Page 50: Pistons And Connecting Rods
Fiat Auto S.p.A. ENGINE 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.
Page 51: Crankshaft
Fiat Auto S.p.A. ENGINE 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.
Page 52 Fiat Auto S.p.A. ENGINE 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.
Page 53 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Transmission diagram of a traditional one-mass flywheel: 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:...
Page 54 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Primary flywheel Secondary flywheel 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.
Page 55 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Planetary gear Axial bearing Radial bearing DMF TWO STAGE CHARACTERISTIC - A two-stage torque fluctuation damping curve can be expected from this type of flywheel for effective, targeted reduction of vibrations and transmission roughness.
Page 56 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training The configuration with planetary in home position without torque transmission. Configuration with planetary at first stage end of stroke (first stiffness ramp). Configuration with planetary at second stage end of stroke (second stiffness ramp) with guide shoes packed.
Page 57 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training 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...
Page 58 Fiat Auto S.p.A. ENGINE 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.
Page 59: Timing
The cam profile 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).
Page 60: Camshaft
Fiat Auto S.p.A. ENGINE 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 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.
Page 61 Fiat Auto S.p.A. ENGINE 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.
Page 62 Fiat Auto S.p.A. ENGINE 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 Timing system Output marking on camshaft actuator pulley drive chain...
Page 63: Camshaft Tensioners
Fiat Auto S.p.A. ENGINE 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 must be positioned with a specific tool. The markings on the torsional vibration damper and the timing box must be aligned in this position.
Page 64: Utility Drive Belt
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Utility drive belt FEATURES: The alternator and A/C compressor drive belt is maintenance-free. The belt is pulled by an automatic tensioner. The power steering pump is controlled by a second, narrower belt.
Page 65: Balancing Countershafts
Fiat Auto S.p.A. ENGINE 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.
Page 66 Fiat Auto S.p.A. ENGINE 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.
Page 67 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Variable timing exploded view Stator Block system Screws Pulley Rotor Adapter Plate Return spring Cover Variable timing control valves FEATURES: The proportioning hydraulic valve is part of the variable timing hydraulic system. Actuation is electromagnetic with return spring.
Page 68: Cooling System
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Hydraulic features Working using engine oil Flow > 3.8 l/min Working pressure < 10 bars Filters integrated on valves (fine mesh 300 µm). Electrical characteristics: Frequency signal in range from 200 to 250 Hz.
Page 69 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Thermostat housing Thermostat Thermostat cover Pipe O-ring (pipe) Coolant pump O-ring (pump) Pump draining nut Coolant temperature sensor The thermostat unit is connected to the crankcase with screws. The temperature sensor is fastened to the unit with a threaded connection.
Page 70: Lubrication System
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Lubrication system Oil pump Pressure regulator valve Stator 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.
Page 71 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After 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 FUNCTION: To contain lubrication oil and cool it by effect of air while the vehicle is travelling.
Page 72: Blow-By System
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Oil filter Oil filter housing Oil filter cover 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.
Page 73: Air Intake System
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Air intake system Intake plenum Canister bleeder valve Brake booster vacuum port Blow-by valve Electronic throttle Supporting bracket fastening FUNCTION: The plenum contains the air that is taken in by the cylinders and conduits that convey the air evenly to the various cylinders.
Page 74 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Additional component fastening Coupling element Oil indicator tube housing Water pipe housing Brake booster vacuum port OIL LEVEL GAUGE PIPE HOUSING: The oil gauge pipe is fastened to the plenum by a screw.
Page 75 Fiat Auto S.p.A. ENGINE 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...
Page 76 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training OPERATING PRINCIPLE: The air flow is controlled by the 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).
Page 77: Fuel Injection System
Fiat Auto S.p.A. ENGINE 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 side K - connector pin 2 to ECU pin 61...
Page 78 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Injection system architecture 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...
Page 79 Fiat Auto S.p.A. ENGINE 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.
Page 80 Fiat Auto S.p.A. ENGINE 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.
Page 81 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Knock sensor signal 2 (pin 1) Knock sensor signal 1 (pin 2) Not connected Cylinder coil 1 (pin 6) High pressure injector cylinder 2 + (pin 1) High pressure injector cylinder 2 - (pin 2)
Page 82 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Not connected Not connected Not connected Not connected Cruise control signal from stalk Not connected Not connected Not connected Not connected Not connected Not connected Planar λ sensor 1 (post-cat) (pin 3) Linear λ...
Page 83 Fiat Auto S.p.A. ENGINE 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.
Page 84 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Fuel pump in tank Fuel pump Float level gauge arm 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.
Page 85 Fiat Auto S.p.A. ENGINE 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...
Page 86 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training High pressure fuel circuit SYSTEM ACTUATORS: High pressure fuel pump Injection piping High pressure injector Pressure regulator valve Fuel high and low pressure line Ignition coil module High pressure fuel pump OBJECTIVE: The high pressure fuel pump increases input fuel pressure (equal to 3.5 bars) to 120 bars for supplying...
Page 87 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Low pressure tube fitting Pressure regulator valve High pressure tube fitting Pressure sensor High pressure injectors 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.
Page 88 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL 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 +)
Page 89 Fiat Auto S.p.A. ENGINE 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): (0 986 616 098) (0 986 616 099) Tool A holds the seal 1;...
Page 90 Fiat Auto S.p.A. ENGINE 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 side A - connector pin 2 to power wire TECHNICAL SPECIFICATIONS: All data refer to a temperature of 23°C and control voltage of 14 V ±...
Page 91 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Fuel high and low pressure line High pressure connection Fuel pump fastening element Fuel pump fastening shelf High pressure fuel rail fastening element Low pressure fuel rail fastening element...
Page 92 Fiat Auto S.p.A. ENGINE 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.
Page 93: Sensors
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Sensors Engine speed sensor Camshaft 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)
Page 94 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Engine speed sensor ELECTRICAL SPECIFICATIONS: Electrical resistance equal to approximately 1 kOhm. SENSOR FEATURES Variable alternating voltage, maximum value and OUTPUT SIGNAL TYPE frequency proportional to flywheel speed Examiner with SAM (Examiner Smart) module is needed to view the signal, considering its type.
Page 95 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training The sensor connections to the engine ECU are: CONNECTION TO ECU CONNECTOR DRAWING Timing sensor 1 - connector pin 1 to ECU pin 7 side A (ground) - connector pin 2 to ECU pin 41...
Page 96 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training ELECTRICAL SPECIFICATIONS: 5V power from the ECU SENSOR FEATURES Variable voltage signal in time, maximum value and frequency according to pulse waveform (square wave) OUTPUT SIGNAL TYPE when sensor meets phonic wheel teeth. Two long teeth are followed by two short teeth.
Page 97 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL 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 - connector pin 3 to ECU pin 24 side A (power) REMOVAL/REFITTING: The sensor is part of the injection rail and is fastened onto the rail.
Page 98 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training ELECTRICAL SPECIFICATIONS: Nominal specifications: - Power voltage: 5 V SENSOR FEATURES - Power current 12 mA Variable voltage according to measured pressure. OUTPUT SIGNAL TYPE Linear characteristic from 0.5 V (0 MPa) to 4.5 V (14 MPa).
Page 99 Fiat Auto S.p.A. ENGINE 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...
Page 100 Fiat Auto S.p.A. ENGINE 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...
Page 101 Fiat Auto S.p.A. ENGINE 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 powered to pick up the output signal.
Page 102 Fiat Auto S.p.A. ENGINE 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.
Page 103 Fiat Auto S.p.A. ENGINE 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:...
Page 104 Fiat Auto S.p.A. ENGINE 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. Air mass meter Throttle body ELECTRICAL SPECIFICATIONS: Air flow characteristic:...
Page 105 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Temperature characteristic: SENSOR FEATURES 14V power Refer to the air flow voltage characteristic and resistance to OUTPUT SIGNAL TYPE the temperature characteristic. Temperature sensor Set multimeter to resistance mode (ohmmeter).
Page 106 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training The connections to the engine ECU are: CONNECTION TO ECU DRAWING Linear sensor 1 - connector pin 1 to ECU pin 56 side - connector pin 2 to ECU pin 55 side...
Page 107 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Linear sensor 2 - connector pin 1 to ECU pin 58 side - connector pin 2 to ECU pin 57 side - connector pin 3 to ECU pin 51 side...
Page 108 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training SENSOR FEATURES 12/14V power Variable voltage signal according to characteristics of the exhaust gas and OUTPUT SIGNAL TYPE engine speed increases and decreases. Signal peaks are interference. The ECU must be powered to pick up the output signal. Examiner with...
Page 109 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training The connections to the engine ECU are: CONNECTION TO ECU DRAWING Planar sensor 1 - connector pin 1 to ECU pin 75 side - connector pin 2 to ECU pin 74 side...
Page 110: Exhaust System
Fiat Auto S.p.A. ENGINE ALFA 159 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.
Page 111: Exhaust Diagram - Cold Part
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Exhaust diagram - cold part Flexible coupling Central muffler Rear muffler The 1.9 litre version has a single rear muffler configuration with one tailpipe. ENGINE 2.2 Flexible coupling Central muffler Rear mufflers The 2.2 litre version has a rear double rear muffler configuration with one tailpipe.
Page 112: Alfa Code Recognition
Fiat Auto S.p.A. ENGINE 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’;...
Page 113 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training The main reasons for adjustments are explained below. INTAKE: OPENING The exhaust gas inertia combined at the same time with valve opening lets more fresh ADVANCE air into the cylinder.
Page 114 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Self-learning The ECU implements self-learning logic in the following conditions: installation of a new injection ECU installation of a new throttle actuator removal/refitting of engine speed sensor or phonic wheel for misfire acknowledgment.
Page 115 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Engine temperature sensor Pressure regulator Control voltage on pin: A- Voltage signal on pin A-22 MED 7.6.1 Engine speed sensor...
Page 116: Knock Control
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Engine speed sensor Pressure regulator Frequency on pins A55 Control voltage on pin: A- MED 7.6.1 and A40 Pre-cat lambda sensors...
Page 117: Acceleration Mixture Enrichment Control
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Engine speed sensor Ignition coils Frequency on pins A55 MED 7.6.1 and A40 Voltage disconnected from pins A-46; A-31; A-01; A-16...
Page 118: Accelerator Pedal Fuel Cut-Off
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Engine speed sensor Injectors Frequency on pins A55 MED 7.6.1 and A40 Voltage to pins: A-50, A-49; A-47, A-48;...
Page 119: Fuel Vapour Recovery
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Brake pedal switch Pressure regulator Voltage on pin K-14 MED 7.6.1 Control voltage on pin: A-20 Clutch pedal switch...
Page 120: Maximum Engine Speed Control
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Engine temperature Fuel vapour intake sensor solenoid valve Voltage signal on pin A- MED 7.6.1 Control voltage to pin A-18...
Page 121: Fuel Pump Control
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL 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;...
Page 122: Climate Control System Connection
Fiat Auto S.p.A. ENGINE 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.
Page 123: Optimal Injection Time For Each Cylinder
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Engine speed sensor Frequency on pins A55 and MED 7.6.1 Injectors • Voltage to pins: CONTROLS THE A-50, A-49; A-47, A-48;...
Page 124 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Engine speed sensor Injectors Voltage to pins: Frequency on pins A55 and MED 7.6.1 A-50, A-49; A-47, A-48; A- 32, A-33;...
Page 125: Fan Control
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Engine speed sensor Frequency on pins A55 and MED 7.6.1 Motorised throttle Accelerator potentiometer implements idling Voltage to pins A-15...
Page 126: Abs/Asr Ecu Connection
Fiat Auto S.p.A. ENGINE 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:...
Page 127 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training independently manages two variable timing systems continuously with timing angles in the range from 0 to 50 degrees, controls the two proportioning solenoid valves to ensure careful timing management and better control over emissions and engine output torque.
Page 128: Engine Maintenance Special Tools
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL 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 gasket (timing side) USE EQUIVALENT FIAT TOOL...
Page 129: 2.4 Mjet Dpf Engine
Fiat Auto S.p.A. ENGINE 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...
Page 130: Fuel Pump
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Fuel pump Electrical motor Pump impeller 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.
Page 131: Bosch Edc-16C39 Electronic Control System
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training metal filtering element cartridge water in fuel filter sensor bleeder from fuel pump to high pressure pump to high pressure pump FUNCTION: To filter the fuel before it is sent to the high pressure pump.
Page 132 Fiat Auto S.p.A. ENGINE 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.
Page 133 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Auxiliary fuel pump 17. Air pressure and temperature signal Swirl mechanism 18. Timing sensor VGT solenoid valve 19. Engine speed sensor A/C compressor 20. Speedometer EGR solenoid valve 21. Battery Tachometer 22.
Page 134 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Compressor relay control negative signal (T5) Accelerator pedal potentiometer 1 - Accelerator pedal potentiometer 2 Post particulate trap (DPF) temperature sensor signal Post particulate trap (DPF) temperature sensor -...
Page 135 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Water in fuel filter sensor signal Not connected Not connected ON Cruise Control SET + Cruise Control 79 (*) Clutch pedal contact signal - Brake pedal contact signal + (NC)
Page 136: Engine Speed Sensor
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Cylinder 4 injector - Fuel pressure regulator on rail + Diagnostic feedback (swirl) Not connected Air temperature sensor (air mass meter) Not connected Driven throttle ground Pressure signal from air pressure/temperature sensor...
Page 137: Cam Angle (Timing) Sensor
Fiat Auto S.p.A. ENGINE 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 to count the teeth on the phonic wheel.
Page 138: Engine Coolant Temperature Sensor
Fiat Auto S.p.A. ENGINE 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.
Page 139 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Digital air mass meter Analogue air mass meter Air flow inlet proportional to total flow Resistive sensitive element Signal detection and amplification circuit Interference shielding Connector 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.
Page 140 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL 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.
Page 141 Fiat Auto S.p.A. ENGINE 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.
Page 142 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL 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.
Page 143: Motorised Throttle
Fiat Auto S.p.A. ENGINE 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).
Page 144: Fuel Pressure Sensor
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Fuel pressure sensor ground output signal power Engine ECU pins (connector A) Connector pins Pin 8 Pin 43 Pin 28 LOCATION: The sensor is fastened directly onto the end of the fuel rail as shown in the figure.
Page 145: Accelerator Pedal Potentiometer
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Tensione segnale Pressione 1800 Bar FUNCTION: This sensor provides a feedback signal to the injection ECU to: adjust pressure inside the fuel rail adjust injection time. Accelerator pedal potentiometer LOCATION: The accelerator pedal potentiometer consists of an armature fastened to the accelerator pedal.
Page 146: Bosch Cp1H High Pressure Pump
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Engine ECU pins (connector B) Connector pins 1. Potentiometer positive 2 2. Potentiometer positive 1 3. Potentiometer signal 1 4. Potentiometer negative 1 5. Potentiometer negative 2 6. Potentiometer signal 2...
Page 147: Radialjet Pump Specifications
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Radialjet pump specifications Type Radialjet radial pumps Number of pumps Total displacement 0,697 cm /rev. (4 cylinders) 0.794 cm /rev. (5 cylinders) Volumetric efficiency >76% at 1600 bars 1000 pump rpm 40°C fuel...
Page 148: Injectors
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Injectors spring 11. calibrated shim electromagnet 12. reference dowel anchor 13. atomiser ring 14. nozzle valve 15. electrical connector ball pintle 16. fitting pressure rod 17. “Z” body 18. Vc control port spring 19.
Page 149: Ima Injector Classification
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training ATOMISER ACTUATOR: The actuator/atomiser consists of the nozzle and the pressure rod-pin assembly. 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.
Page 150 Fiat Auto S.p.A. ENGINE ALFA 159 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 a set of throttles fitted on each of the two intake manifold for each cylinder.
Page 151: Garrett Vgt 17 Turbo Charger
Fiat Auto S.p.A. ENGINE 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.
Page 152 Fiat Auto S.p.A. ENGINE 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 charger side). FUNCTION: To increase cylinder filling by providing more air mass given equivalent volume available in the combustion chamber.
Page 153: Exhaust Gas Recirculation System
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Exhaust gas recirculation system EGR solenoid valve injection ECU heat exchanger exhaust manifold throttle body FUNCTION: The EGR system aspirates a variable part (from 5 to 15%) of the exhaust gas in certain conditions of operation.
Page 154 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training The DPF system consists of: sensor and actuators 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.
Page 155 Fiat Auto S.p.A. ENGINE 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.
Page 156 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training The process is explained in the following graph: 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.
Page 157 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Accumulation Regenerated trap Accumulating trap Regeneration Spontaneous regeneration occurs when: [Vehicle speed > 40km/h for at least 15 minutes; Particulate mass charge < 200% ] Regeneration is managed fully autonomously by the engine ECU according to:...
Page 158: Bosch Edc-16C39 Ecu Logic
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training 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. NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS...
Page 159 Fiat Auto S.p.A. ENGINE 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).
Page 160 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Engine coolant temperature Pressure regulator sensor Resistance between pins A-41 Control voltage between pins: A- EDC-16C39 and A-58 49 and A-19...
Page 161 Fiat Auto S.p.A. ENGINE 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: controls the pressure regulator; adapts injector injection times. NPUT PARAMETERS...
Page 162 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Engine speed sensor Rail pressure regulator Frequency on pins A27 - A12 EDC-16C39 Control voltage between pins: A-4 A-34...
Page 163 Fiat Auto S.p.A. ENGINE 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.
Page 164 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Accelerator pedal sensor Pump pressure regulator Control voltage between pins: Voltage to pins: B-9 and B-31 EDC-16C39 A-49 and A-19...
Page 165 Fiat Auto S.p.A. ENGINE 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: ONTROLLER UTPUT PARAMETERS PERATING CONDITIONS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Cold start...
Page 166 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training PERATING CONDITIONS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Cut-off EGR solenoid valve Voltage to pins: PWM signal from pin A-60 for B-9 and B-31 EDC-16C39 fixed opening 1%...
Page 168 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Intake control according to climate control system The ECU controls the A/C compressor as follows by: switching the compressor on/off when the respective button is pressed; switching the compressor off temporarily (approximately 6 seconds) during sudden acceleration or when maximum engine power is required.
Page 169 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Key-on Fuel pump enable Voltage to pin B-28 EDC-16C39 Voltage to pin B-91 Regardless of engine speed, the ECU:...
Page 170 Fiat Auto S.p.A. ENGINE 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. NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY...
Page 171 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Overpressure sensor Injectors Voltage to pins: A-16, A-47; A-2, A-31; Voltage to pins A-13 and A-40 EDC-16C39 A-1, A-46; A-17, A-33...
Page 172 Fiat Auto S.p.A. ENGINE 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).
Page 173 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Throttle closing control while stopping The injection ECU immediately closes the throttle to intake to limit shaking when the engine is stopped. The throttle is in all other conditions.
Page 174: Electrical Features Of Sensor
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training NPUT PARAMETERS ONTROLLER UTPUT PARAMETERS LECTRICAL QUANTITY OGIC LECTRICAL QUANTITY Coolant temperature sensor Throttle open actuator EDC-16C39 Voltage between pins: Voltage signal from pin: A-41 and A-58 A-45 Engine speed sensor...
Page 175: Timing Sensor Electrical Features
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training SENSOR FEATURES Electrical resistance equal to approximately 1 kOhm. Variable alternating voltage, maximum value and frequency proportional to OUTPUT SIGNAL TYPE flywheel speed An oscilloscope or Examiner with SMA (Examiner Smart) module is needed to view the signal, considering its type.
Page 176: Supercharger Sensor Features
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training 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.
Page 177: Coolant Temperature Sensor Electrical Features
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Coolant temperature sensor electrical features SENSOR FEATURES NTC thermistor sensor Variable resistance from a maximum of 45kOhm to -40°C (60 OUTPUT SIGNAL TYPE Ohm) to 150°C. MEASURING METHOD Set multimeter to resistance mode (ohmmeter).
Page 178: Fuel Pressure Sensor
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Fuel pressure sensor SENSOR FEATURES Piezoelectric pressure sensor Variable voltage according to measured pressure. Nominal specifications: OUTPUT SIGNAL TYPE Fuel feed: +5V Working range: 0 -1800 bars Linear characteristic: 500mV (0 bar) - 4500mV (1500 bar)
Page 179: Accelerator Pedal Potentiometer
Fiat Auto S.p.A. ENGINE 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°...
Page 180: Injector
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Solenoid valve: ELECTRICAL SPECIFICATIONS OF Resistance: 2.07-2.53 [Ω] @ 20°C ACTUATOR Maximum current 2.5A Control with PWM signal; maximum voltage 12V (carrier COMMAND TYPE 360Hz) MEASURING METHOD Oscilloscope or analogue tool (Examiner with SMA) 3.2.4 Injector...
Page 181: Vgt Solenoid Valve
Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training VGT solenoid valve 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...
Page 182: Glow Plug Pre-Heater Ecu
Fiat Auto S.p.A. ENGINE 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...
Page 183 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training ST/K G1...G5 Ton rele' <10mS Toff rele' <10ms 183/318 Traccia Didattica Alfa 159-en-ridotta © 2004 Fiat Auto S.p.A. - All rights reserved...
Page 184 Fiat Auto S.p.A. ENGINE ALFA 159 TRAINING MATERIAL After Sales Training Normal power voltage 12 volt Drawn power < 10W Maximum working voltage 24 volt for 1 minute (23°C) Admitted voltage variations during normal 6…16 volt operation Glow plug power off >...
Page 185: Clutch
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.
Page 186 Fiat Auto S.p.A. CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training Traditional clutch possible wear take-up positions: Between flywheel and mechanism Between membrane spring and thrust plate C. Between membrane spring and clutch box Thrust plate wear and movement No wear...
Page 187 Fiat Auto S.p.A. CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training Wear detection: Positioning rings compressed by the membrane spring Adjuster detects lining wear Wear take-up Adjuster activation OPERATING PRINCIPLE 187/318 Traccia Didattica Alfa 159-en-ridotta © 2004 Fiat Auto S.p.A. - All rights reserved...
Page 188 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).
Page 189: Driven Friction Plate
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: reduces hub wear 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.
Page 190 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 SYSTEM OPERATION OVERVIEW 1 - NEW PLATE ENGAGEMENT: The toothed plate (1) is pressed against the top of the gear tooth (7).
Page 191: Driven Friction Plate
Fiat Auto S.p.A. CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training 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.
Page 192: Luk Flywheel/Clutch
Fiat Auto S.p.A. CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training Buffer damping springs Splined hub 4.4 LUK FLYWHEEL/CLUTCH CHARACTERISTICS: The LUK flywheel/clutch is fitted on 2.4 M-jet 20V versions and presents the following features: dry single plate clutch push release system: this means that the clutch is released when the sleeve pushes the diaphragm spring reversing its concavity dual mass flywheel.
Page 193 Fiat Auto S.p.A. CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training A two-stage torque fluctuation damping curve can be expected from this type of flywheel for effective, targeted reduction of vibrations and transmission roughness. Primary flywheel Primary flywheel cover Friction plate...
Page 194: Clutch Assembly
Fiat Auto S.p.A. CLUTCH ALFA 159 TRAINING MATERIAL 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.
Page 195 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: 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.
Page 196 Fiat Auto S.p.A. CLUTCH ALFA 159 TRAINING MATERIAL After Sales Training Friction plate diagram Spline support Main plate Rivet Friction lining support sheet Rivet Friction lining Some technical specifications are: Nominal load 5750 N Minimum load 70 N Lift-off 1.05 mm Drive torque 0.3 Nm...
Page 197: Clutch Release
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 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.
Page 198: M32 Gearbox
Fiat Auto S.p.A. GEARBOX ALFA 159 TRAINING MATERIAL 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.
Page 199: Gearbox Interfaces
Fiat Auto S.p.A. GEARBOX TRACCIA DIDATTICA ALFA 159 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 space for dual mass flywheel and wear take-up clutch...
Page 200: Transmission Ratios
Fiat Auto S.p.A. GEARBOX ALFA 159 TRAINING MATERIAL 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 1st gear ratio 3.818 3.818 2nd gear ratio 2.353...
Page 201: Meshing Diagram
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.
Page 202: Third And Fourth Gear
Fiat Auto S.p.A. GEARBOX ALFA 159 TRAINING MATERIAL After Sales Training 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.
Page 203: Reverse
Fiat Auto S.p.A. GEARBOX TRACCIA DIDATTICA ALFA 159 After Sales Training Reverse 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.
Page 204: Upper Secondary Shaft
Fiat Auto S.p.A. GEARBOX ALFA 159 TRAINING MATERIAL After Sales Training 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.
Page 205: Synchronisers
Fiat Auto S.p.A. GEARBOX TRACCIA DIDATTICA ALFA 159 After Sales Training 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).
Page 206: Mounts
Fiat Auto S.p.A. GEARBOX ALFA 159 TRAINING MATERIAL 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.
Page 207: Differential
Fiat Auto S.p.A. GEARBOX TRACCIA DIDATTICA ALFA 159 After Sales Training 5.2.6 Differential 5.2.7 Axle shafts 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.
Page 208: Axle Shaft Structure
Fiat Auto S.p.A. GEARBOX ALFA 159 TRAINING MATERIAL 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/°...
Page 209 Fiat Auto S.p.A. GEARBOX TRACCIA DIDATTICA ALFA 159 After Sales Training Tulip Tripod joint Protective boot 209/318 Traccia Didattica Alfa 159-en-ridotta © 2004 Fiat Auto S.p.A. - Tutti i diritti sono riservati...
Page 210: Braking System
Fiat Auto S.p.A. BRAKING SYSTEM ALFA 159 TRAINING MATERIAL 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 of a failure to one of the circuits.
Page 211: Brake Booster
Fiat Auto S.p.A. BRAKING SYSTEM ALFA 159 TRAINING MATERIAL 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 pedal stroke and better exploitation of the brake booster characteristics in addition to providing optimal braking progression.
Page 212: Brake Actuators
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.
Page 213: Abs
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.
Page 214 Fiat Auto S.p.A. BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training ECU PINOUT C-CAN L C-CAN H Not connected Not connected Not connected K diagnostic line Right front sensor positive Right front sensor signal Right rear sensor positive Right rear sensor signal...
Page 215: Abs Wiring Diagram
Fiat Auto S.p.A. BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training processes acquired data controls the braking process detects braking system component failures transmits and receives data via the diagnostic socket interfaces with the engine ECU transmits and receives data via the C-CAN line.
Page 216: Ebd Function
Fiat Auto S.p.A. BRAKING SYSTEM ALFA 159 TRAINING MATERIAL 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.
Page 217: Vdc Wiring Diagram
Fiat Auto S.p.A. BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training CAN L line CAN H line ASR off switch ASR off warning light Not connected K diagnostic line Right front sensor positive Right front sensor negative Right rear sensor positive...
Page 218: Steering Angle Sensor (Sas) And Steering Angle Node (Nas)
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).
Page 219: Yaw/Lateral Acceleration Sensor
Fiat Auto S.p.A. BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training Yaw/lateral acceleration sensor The yaw/lateral acceleration sensor detects the 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.
Page 220: Hill Holder
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) •1 2-3: HH on (uphill with first gear •3 engaged) •2 PARKING UPHILL: 1-2: HH on (uphill with reverse engaged) •1...
Page 221 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.
Page 222: Asr/Tcs/Msr
Fiat Auto S.p.A. BRAKING SYSTEM ALFA 159 TRAINING MATERIAL 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).
Page 223: Hydraulic Brake Assist
Fiat 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.
Page 224: Asr And Vdc Deactivation
Fiat Auto S.p.A. BRAKING SYSTEM ALFA 159 TRAINING MATERIAL After Sales Training System state ASR LED HH warning on button warning warning warning light on NQS light on light on light on Check (4s) EBD/ABS/ASR ESP/HH.OFF for the first 500 ms...
Page 225: Steering
Fiat Auto S.p.A. STEERING ALFA 159 TRAINING MATERIAL 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...
Page 226: Steering System Components
Fiat Auto S.p.A. STEERING ALFA 159 TRAINING MATERIAL 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.
Page 227: Steering Column
Fiat Auto S.p.A. STEERING ALFA 159 TRAINING MATERIAL After Sales Training 7.1.4 Steering column With telescopic sleeves, the column ensures: vertical rotation with a stroke of ± 2° 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.
Page 228: Suspensions
Fiat Auto S.p.A. SUSPENSIONS ALFA 159 TRAINING 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.
Page 229: Front Suspension Components
Fiat Auto S.p.A. SUSPENSIONS ALFA 159 TRAINING MATERIAL After Sales Training Front suspension components 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.
Page 230 Fiat Auto S.p.A. SUSPENSIONS 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.
Page 231 Fiat Auto S.p.A. SUSPENSIONS ALFA 159 TRAINING MATERIAL After Sales Training 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.
Page 232 Fiat Auto S.p.A. SUSPENSIONS ALFA 159 TRAINING MATERIAL After Sales Training Front suspension yield fasteners FUNCTION Special flanged six-lobe head screw with cylindrical-conical end for front fastening of engine frame to body Special flanged six-lobe head screw with cylindrical-conical end for central fastening of engine frame to body...
Page 233 Fiat Auto S.p.A. SUSPENSIONS ALFA 159 TRAINING MATERIAL After Sales Training 233/318 Traccia Didattica Alfa 159-en-ridotta © 2004 Fiat Auto S.p.A. - Tutti i diritti sono riservati...
Page 234: Rear Suspensions
Fiat Auto S.p.A. SUSPENSIONS ALFA 159 TRAINING MATERIAL After Sales 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.
Page 235 Fiat Auto S.p.A. SUSPENSIONS 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.
Page 236: Rear Suspension Yield Fasteners
Fiat Auto S.p.A. SUSPENSIONS ALFA 159 TRAINING MATERIAL After Sales Training chassis fastening to body 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...
Page 237 Fiat Auto S.p.A. SUSPENSIONS ALFA 159 TRAINING MATERIAL After Sales Training 237/318 Traccia Didattica Alfa 159-en-ridotta © 2004 Fiat Auto S.p.A. - Tutti i diritti sono riservati...
Page 238: Angle And Vehicle Trim Inspections
Fiat Auto S.p.A. SUSPENSIONS ALFA 159 TRAINING MATERIAL After Sales Training 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).
Page 239: Geometrical Trim Adjustment
Fiat Auto S.p.A. SUSPENSIONS 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) 1.9 JTD 8v/16v and L850 2.4 JTD 3.2 v6 Std.
Page 240: Rear Suspension
Fiat Auto S.p.A. SUSPENSIONS ALFA 159 TRAINING MATERIAL After Sales Training Rear suspension camber adjustment screw 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.
Page 241: Electrical System
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 242: Electrical System Layout
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 243: System Electrical Component Classification
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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. TECHNOLOGICAL CLASS...
Page 244: Electronic Components
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 245: User Control Modules
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 246: Fuses
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 247 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training CFO fusebox (optional fusebox) This component is wired to the front wiring harness and connected to the CBA. CODE COMPONENT In[A] F-74 PTC1 SUPPLEMENTARY HEATER FUSE (JTD versions)
Page 248 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Engine compartment fusebox (CVM) In[A] CODE APPLICATION mod. FUSES +30 CPL2, CVB FUSE +30 CLIMATE CONTROL SYSTEM FAN FUSE NBS FUSE NFR1 FUSE NFR2 FUSE ENGINE COOLING FAN LOW SPEED (one/two-fan configurations), HIGH SPEED MOTOR...
Page 249: Mini F.l.ore.n.c.e.' Architecture Diagram
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 9.1.11 ‘Mini F.L.Ore.N.C.E.’ architecture diagram 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.
Page 250 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL 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.
Page 251 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL 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.
Page 252 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL 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.
Page 253: Diagnostic Architecture
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 254: Logistic Mode Function
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 255 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Vehicle accessibility During logistic mode activation, accessibility to the vehicle must always be guaranteed. The following functions are deactivated: Centralised locking system Anti-theft protection (dead lock, alarm, etc.), except for the Code system Remote controls (TEG) Electrical window winders (it must be possible to operate the driver’s window at least while travelling).
Page 256: Trw Smart Key System
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 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: remotely control locking and unlocking of doors and boot release the steering start the engine.
Page 257: Operative Procedures
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 258 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL 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 connecting the +30 battery power from accidentally locking the doors.
Page 259 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training ignition (pressing PAV with brake/clutch pedal pressed) vehicle speed > 10 km/h vehicle speed error engine running state change to key-off This strategy is needed to prevent the following cases:...
Page 260: Overview Of Fundamental Operations
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.
Page 261: Code System Programming And Component Management
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Cranking The engine is cranked (+50) when the clutch or brake pedal is pressed and the start/stop button is 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.
Page 262: Procedures For Replacing Components
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 263: Ntr Diagnostic Procedures
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 9.2.7 NTR diagnostic 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:...
Page 264 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Wiring diagram Legend Component Location/destination CBA Battery fusebox On battery CVM Engine compartment ECU Engine compartment, next to battery CVB Boot ECU Boot on left-hand side CPL Dashboard fusebox...
Page 265 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training NBS pinout FUNCTION INT 2 to CPL B CAN A B CAN B GROUND CLUTCH SWITCH (NO) TEG PRESENT NPE ENABLE (not connected) +30 PROTECTED 2 FOR PAV POWER (PIN 5)
Page 266 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training NTR pinout FUNCTION 8 pin connector p/n AMP C_174955_E TEG inserted position output (12V=TEG inserted) CAN-B Vbatt (+30) Power positive GROUND Power negative CAN-A PAV pinout + 15 start/stop symbol light...
Page 267: On-Board Instruments
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: HIGH MEDIUM BASIC A auxiliary instrument panel is inserted in the middle of the dashboard. Four auxiliary instrument panels are available:...
Page 268 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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°.
Page 269: Basic Instrument Panels
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).
Page 270: Notions On The Service Function
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Buttons (BASIC version) The following buttons are fitted on the left-hand steering stalk: ‘MENU’ ‘MENU +’ ‘MENU -’ for the following functions: setup menu, dimming and night panel.
Page 271 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 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) there are thirty or fewer days before the deadline.
Page 272 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Main instrument panel pinout grey black BLACK connector PIN FUNCTION INT from F-37 +30 from F-53 B - CAN L B - CAN H Analogue signal on LH stalk: ‘Mode, -, +’...
Page 273: Computerised Systems
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Auxiliary instrument panel pinout PIN FUNCTION Serial line with NQS Ground (connection to NQS) INT from F-37 (connection to NQS) 4 – 5- - 6 Not connected 9.4 COMPUTERISED SYSTEMS...
Page 274 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL 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...
Page 275 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.).
Page 276: Connect Button (A)
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 277: Tyre Pressure Detection System
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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).
Page 278: Operation
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Anteriore Anteriore C.P.P. Initiator Initiators Initiator K L Linee D iagnosi Programmazione (per tutte le vetture) A-BUS N.B.C. B - CAN Initiator Initiator N.Q.S. Posteriore Posteriore Legend: Instrument panel node...
Page 279: Tyre Pressure Monitoring System
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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).
Page 280: Key-On/Key-Off Strategies
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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)
Page 281: Parking Assistance
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Tyre pressure ECU Pin N. Description LF_Supply TPM_Request_RL_Output TPM_Request_FL_Output TPM_Request_FR_Output TPM_Request_RR_Output Not_Used Not_Used Not_Used Not_Used LF_Ground LF_Ground LF_Ground LF_Ground K_Line A_Bus 9.6 PARKING ASSISTANCE The parking assistance system provides information on distance between obstacles in front of and behind the car while parking.
Page 282: Structure
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL 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:...
Page 283: Coverage Area
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 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.
Page 284: Ecu Pinout
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 9.6.10 ECU pinout 8-channel configuration Connector A Signal Key-on (+15) Rear buzzer signal (-) Not connected Parking system on/off button Negative signal from trailer ECU (where fitted) Not connected...
Page 285: Ultrasound Sensor
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 9.6.11 Ultrasound sensor Sensor pinout Signal Sensor power supply Sensor signal Sensor ground 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.
Page 286: Knee Airbag Modules
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 287: Front Seat Belt Pretensioners
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 288: Airbag System Failure Warning Light
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL 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 light will go out after the four-second diagnostic procedure.
Page 289: Clock Contact Pinout
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 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).
Page 290 ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Airbag 1st level (-) Airbag 1st level (+) ECU pinout A - Front connector (dashboard wiring harness, blue) SIGNAL Ground Key-on power (Not connected) (Not connected) Front collision sensor ground...
Page 291: Front Light Cluster (Xenon Gas Discharge Version)
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training B - Rear connector (rear wiring harness, black) SIGNAL Driver window airbag (-) Driver window airbag (+) Passenger window airbag (+) Passenger window airbag (-) Driver side airbag (-)
Page 292: Xenon Bulb
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training xenon bulb headlight reflecting surface controlling electronic (ballast) automatic beam height correction. Each light cluster integrates the components needed for operating the discharge bulb (bulb, reactor, ECU and control motor).
Page 293: Rear Headlight View
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Warm-up The ballast adjusts brightness for approximately two minutes detecting the physical state of the bulb and its impedance (closed loop). Steady state: The light beam is continuously controlled in a closed loop also during steady state conditions.
Page 294: Adjustment Actuator
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL 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: a stepper actuator for each headlight two load sensors connected to the front and rear suspensions on the right-hand side.
Page 295: Self-Diagnostics
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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.
Page 296: Climate Control System
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 10. CLIMATE CONTROL SYSTEM The vehicle may be equipped with one of three types of climate control system configurations: One-zone manual Two-zone automatic 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.
Page 297: One-Zone Climate Control System
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 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: no section is operated if the battery voltage is under 12.2 V...
Page 298: One-Zone Climate Control System Wiring Diagram
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Supplementary heater PTC housing (diesel versions) Climate control system body Heater Heater piping Supplementary heater PTC unit (diesel versions) 10. 11. Climate control system wiring connectors with dashboard wiring harness 12.
Page 299: Two And Three-Zone Automatic Climate Control System
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM 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 passenger compartment two different levels for the driver/rear seat and the front seat passenger.
Page 300: Notes On Sensor Operation
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 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...
Page 301 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.
Page 302: Two/Three-Zone Climate Control System Wiring Diagram
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training 10.5.7 Two/three-zone climate control system wiring diagram 302/318 Traccia Didattica Alfa 159-en-ridotta © 2004 Fiat Auto S.p.A. - Tutti i diritti sono riservati...
Page 303: One-Zone Ecu Pinout
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training One-zone ECU pinout Connector A Signal description Colour Signal description Colour Ground (Gnd) Black A2 coil Recirculation Brown/blue +30 battery voltage (Vbatt) Red/green B2 coil Recirculation Grey/brown Not used...
Page 304: Two/Three-Zone Ecu Pinout
ELECTRICAL Fiat Auto S.p.A. ALFA 159 TRAINING MATERIAL SYSTEM After Sales Training Two/three-zone ECU pinout Front control head connector pinout: (NCL) Pin 1 Pin 26 Signal Wire colour Pin Signal Wire colour Ground (Gnd) Black Not used +30 battery voltage (Vbatt)
Page 305: Bodywork
Fiat Auto S.p.A. BODYWORK 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.
Page 306: Operation Of The Sunroof
Fiat Auto S.p.A. BODYWORK ALFA 159 TRAINING MATERIAL After Sales Training The sunroof consists of the following parts: 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).
Page 307: Manual Control Via Pre-Selector
Fiat Auto S.p.A. BODYWORK ALFA 159 TRAINING MATERIAL After Sales Training Manual control via pre-selector key-on PRESELECTOR SUNROOF MOTOR COMMAND key-off t<2 min doors closed The sunroof can be moved to one of the programmed positions by turning the selector knob in the following cases: at key-on during the first two minutes after key-off or until one of the doors is opened.
Page 308: Pinch Force Safety Function
Fiat Auto S.p.A. BODYWORK ALFA 159 TRAINING MATERIAL 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.
Page 309: Wiring Diagram
Fiat Auto S.p.A. BODYWORK ALFA 159 TRAINING MATERIAL After Sales Training 11.1.6 Wiring diagram Component code Description B001 Engine compartment fusebox B002 Fusebox under dashboard B099 Maxi fusebox on battery C020 Dashboard ground on driver’s side C030 Ground on central tunnel...
Page 310 Fiat Auto S.p.A. BODYWORK ALFA 159 TRAINING MATERIAL After Sales Training 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.
Page 311: Rear Seats
Fiat Auto S.p.A. BODYWORK ALFA 159 TRAINING MATERIAL After Sales Training Optional tilt function for both front seats Side bag installed inside seat upholstery Adjustable lumbar support Rear seats The standard rear seat is split (40/60) and the cushion can be tipped.
Page 312: Front Seat Structure
Fiat Auto S.p.A. BODYWORK ALFA 159 TRAINING MATERIAL After Sales Training 11.2.2 Front seat structure Right front seat with height adjustment and tilting Left front seat with height adjustment and tilting system system 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.
Page 313: Electrically Adjustable Seats
Fiat Auto S.p.A. BODYWORK ALFA 159 TRAINING MATERIAL 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. Electrically-adjustable front seat structure...
Page 314: Electrical Seat Diagrams
Fiat Auto S.p.A. BODYWORK ALFA 159 TRAINING MATERIAL After Sales Training Electrical seat diagrams Wiring diagram of driver’s seat SID E-BA G Forw ard/backw ard m otor Cuscion up/dow n Tilt up/dow n Backrest forw ard/backw ard Pretensionatore Buckle switch electro-pneum atic lum bar forw ard/backw ard –...
Page 315 Fiat Auto S.p.A. BODYWORK ALFA 159 TRAINING MATERIAL After Sales Training Wiring diagram of passenger’s seat Forward/backward m otor Cuscion up/down Tilt up/down Backrest forward/backward SIDE-BAG Pretensionatore electro-pneum atic lumbar forward/backward – up/down Buckle switch Upper chamber Lower chamber Cushion heater...
Page 316 Fiat Auto S.p.A. BODYWORK ALFA 159 TRAINING MATERIAL After Sales Training Front seat interface pinout DRIVER’S SIDE FUNCTION Heater power Heater control light (Not connected) Not connected Not connected NAG/NAP power ground +30 NAG/NAP B-CAN A B-CAN B NAG/NAP signal ground...
Page 317: Passenger Presence Sensor (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).
Page 318 Fiat Auto S.p.A. BODYWORK ALFA 159 TRAINING MATERIAL 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.

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