Alfa Romeo 159 Training Material page 4

CONTENTS
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................................................................................................................................................................................ 37
2.14.4 Grease amounts .................................................................................................................................................................................. 37
2.15 VEHICLE FEATURES ...................................................................................................................................................... 38
2.15.1 Dimensions .......................................................................................................................................................................................... 38
2.15.2 Performance ........................................................................................................................................................................................ 38
2.15.3 Capacities ............................................................................................................................................................................................ 39
2.15.4 Consumptions...................................................................................................................................................................................... 39
2.15.5 Emissions ............................................................................................................................................................................................ 39
2.15.6 Tyres and inflation pressures (bars) .................................................................................................................................................... 39
2.16 SERVICE SCHEDULE...................................................................................................................................................... 40
3. ENGINE ..................................................................................................................................................................42
3.1 1.9 AND 2.2 LITRE DIRECT INJECTION PETROL ENGINES ............................................................................................ 42
3.1.1 Features ................................................................................................................................................................................................ 42
Engine (suction side).................................................................................................................................................................................. 43
Engine (exhaust side) ................................................................................................................................................................................ 43
Specifications: 1.9 litre engine ................................................................................................................................................................... 43
Specifications: 2.2 litre engine ................................................................................................................................................................... 44
Engine specifications compared ................................................................................................................................................................ 45
Engine performance................................................................................................................................................................................... 46
Code location on engines........................................................................................................................................................................... 46
3.1.2 Engine components ............................................................................................................................................................................... 47
Engine mounts ........................................................................................................................................................................................... 47
Cylinder block............................................................................................................................................................................................. 49
Pistons and connecting rods ...................................................................................................................................................................... 50
Crankshaft.................................................................................................................................................................................................. 51
Flywheel ..................................................................................................................................................................................................... 51
Timing ........................................................................................................................................................................................................ 59
Camshaft.................................................................................................................................................................................................... 60
Drive chains ............................................................................................................................................................................................... 60
Camshaft tensioners .................................................................................................................................................................................. 63
Utility drive belt........................................................................................................................................................................................... 64
Balancing countershafts............................................................................................................................................................................. 65
Continuous cam variable timing system..................................................................................................................................................... 65
Cooling system........................................................................................................................................................................................... 68
Lubrication system ..................................................................................................................................................................................... 70
Blow-by system .......................................................................................................................................................................................... 72
Air intake system........................................................................................................................................................................................ 73
Fuel injection system.................................................................................................................................................................................. 77
Sensors ...................................................................................................................................................................................................... 93
Exhaust system........................................................................................................................................................................................ 110
Exhaust diagram - cold part ..................................................................................................................................................................... 111
3.1.3 Bosch MED 7.6.1 ECU operating logic................................................................................................................................................ 111
3.1.4 Operating strategies ............................................................................................................................................................................ 113
Alfa Code recognition............................................................................................................................................................................... 113
Self-learning ............................................................................................................................................................................................. 114
System self-adaptation............................................................................................................................................................................. 114
Cold start-up control................................................................................................................................................................................. 114
Combustion control - lambda sensors...................................................................................................................................................... 115
Knock control ........................................................................................................................................................................................... 116
Acceleration mixture enrichment control .................................................................................................................................................. 117
Accelerator pedal fuel cut-off ................................................................................................................................................................... 118
Fuel vapour recovery ............................................................................................................................................................................... 119
Maximum engine speed control ............................................................................................................................................................... 120
Fuel pump control .................................................................................................................................................................................... 121
Climate control system connection .......................................................................................................................................................... 122
Cylinder position acknowledgment........................................................................................................................................................... 122
Optimal injection time for each cylinder ................................................................................................................................................... 123
Fan control ............................................................................................................................................................................................... 125
ABS/ASR ECU connection....................................................................................................................................................................... 126
Variable timing management ................................................................................................................................................................... 126
3.1.5 Engine maintenance special tools ....................................................................................................................................................... 128
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ALFA 159 TRAINING MATERIAL
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