Alfa Romeo 159 - Training Material Manual

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ALFA 159 TRAINING MATERIAL

Fiat Auto S.p.A.

After Sales Training

Alfa Romeo 159

Main Page

Table of Contents3
Briefing9
General Technical Data9
Presentation9
The Car9
Style9
Dimensions10
The Dimensions in Brackets Refer to Versions Fitting 215/55 R16 Tyres10
Interiors10
Outfits and Characteristics11
Engine Versions11
Transmission12
The Transmissions Available at Time of Release Are Shown in Bold Print12
Bodyshell12
Suspensions13
Active Safety14
Passive Safety14
Alarm System16
Tyres and Wheels17
Roominess18
Climate Control System18
Sunroof19
Sound System19
Navigator19
Materials Used20
Production Process20
Aerodynamics21
Anti-Corrosion and Cosmetic Warranty21
Range22
Product Grid According to Outfit Level23
Lineaccessori24
Technical Data27
Engine27
Engine Type27
Engine Specifications27
Timing Angles27
Injection/Ignition28
Characteristic Curves of the Engine28
Engine Cooling30
Transmission30
Clutch30
Gearbox30
Differential31
Brakes31
Braking System31
Front Brakes32
Rear Brakes32
Steering32
Front Suspensions33
Helical Springs33
Shock Absorbers33
Stabiliser33
Rear Suspensions34
Helical Springs34
Shock Absorbers34
Roll Bar34
Trim and Characteristic Angles34
Trim (Std. a Conditions)34
Front Suspension (Std. a Conditions)35
Rear Suspension (Std. a Conditions)35
Alternator36
Characteristic Data36
Starter Motor36
Battery36
Fluids and Lubricants36
Oils and Fluids36
Greases37
Lubricant Capacity37
Grease Amounts37
Vehicle Features38
Dimensions38
Performance38
Capacities39
Consumptions39
Emissions39
Tyres and Inflation Pressures (Bars)39
Service Schedule40
Engine42
And 2.2 Litre Direct Injection Petrol Engines42
Features42
Engine (Suction Side)43
Engine (Exhaust Side)43
Specifications: 1.9 Litre Engine43
Specifications: 2.2 Litre Engine44
Engine Specifications Compared45
Engine Performance46
Code Location on Engines46
Engine Components47
Engine Mounts47
Cylinder Block49
Pistons and Connecting Rods50
Crankshaft51
Flywheel51
Timing59
Camshaft60
Drive Chains60
Camshaft Tensioners63
Utility Drive Belt64
Balancing Countershafts65
Continuous Cam Variable Timing System65
Cooling System68
Lubrication System70
Blow-By System72
Air Intake System73
Fuel Injection System77
Sensors93
Exhaust System110
Exhaust Diagram - Cold Part111
Bosch MED 7.6.1 ECU Operating Logic111
Alfa Code Recognition112
Self-Learning112
System Self-Adaptation112
Cold Start-Up Control112
Combustion Control - Lambda Sensors112
Knock Control116
Acceleration Mixture Enrichment Control117
Accelerator Pedal Fuel Cut-Off118
Fuel Vapour Recovery119
Maximum Engine Speed Control120
Fuel Pump Control121
Climate Control System Connection122
Cylinder Position Acknowledgment122
Optimal Injection Time for each Cylinder123
Fan Control125
ABS/ASR ECU Connection126
Variable Timing Management126
Engine Maintenance Special Tools128
2.4 Mjet Dpf Engine129
Fuel Feed Rail (Common Rail)129
Features129
Construction129
Fuel Pump130
Fuel Filter130
Bosch EDC-16C39 Electronic Control System131
Engine Speed Sensor136
Cam Angle (Timing) Sensor137
Intake Air Pressure and Temperature Signal137
Engine Coolant Temperature Sensor138
HFM 6 Digital Air Mass Meter138
Motorised Throttle143
Fuel Pressure Sensor144
Accelerator Pedal Potentiometer145
Bosch CP1H High Pressure Pump146
High Pressure Pump Operation146
Radialjet Pump Specifications147
Low Pressure Regulator Solenoid Valve147
Injectors148
Injector Structure148
IMA Injector Classification149
Variable Geometry Intake Actuator149
GARRETT VGT 17 Turbo Charger151
Exhaust Gas Recirculation System153
Bosch EDC-16C39 ECU Logic158
Alfa Code Recognition158
Electrical Features of Sensor174
Tachometer Sensor Electrical Features174
Timing Sensor Electrical Features175
Supercharger Sensor Features176
Coolant Temperature Sensor Electrical Features177
Air Mass Meter177
Fuel Pressure Sensor178
Accelerator Pedal Potentiometer179
Electrical Features of Actuators179
Injector180
VGT Solenoid Valve181
Fuel Pump181
Glow Plug Pre-Heater ECU182
Clutch185
Clutch Assembly185
XTEND" Plate Wear Take-Up Device185
Driven Friction Plate189
Valeo Clutch189
Clutch Assembly189
SAT" (Self Adjusting Technology) Plate Wear Take-Up System189
Driven Friction Plate191
Luk Flywheel/Clutch192
Dual Mass Flywheel192
Clutch Assembly194
Clutch Release197
M32 Gearbox198
Features198
Gearbox Interfaces199
Transmission Ratios200
Gearbox Structure200
Meshing Diagram201
First and Second Gear201
Third and Fourth Gear202
Fifth and Sixth Gear202
Reverse203
Gears203
Shafts203
Primary Shaft203
Upper Secondary Shaft204
Lower Secondary Shaft204
Synchronisers205
Mounts206
Gear Shifting System206
Differential207
Axle Shafts207
Axle Shaft Structure208
Tripod Joint208
Braking System210
Features210
Braking System Components210
Pedal Board210
Brake Booster211
Brake Actuators212
Abs213
Electro-Hydraulic Control Unit213
ABS Wiring Diagram215
Speed Sensor215
EBD Function216
VDC System216
Electro-Hydraulic Control Unit216
VDC Wiring Diagram217
Steering Angle Sensor (SAS) and Steering Angle Node (NAS)218
Yaw/Lateral Acceleration Sensor219
Hill Holder220
Asr/Tcs/Msr222
Hydraulic Brake Assist223
VDC Signals223
Warning Light Functions223
ASR and VDC Deactivation224
Steering225
Features225
Hydraulic System225
Steering System Components226
Steering Box226
Steering Column227
Yield Point Fastening227
Suspensions228
Features228
Front Suspension228
Front Suspension Components229
Rear Suspensions234
Rear Suspension Components234
Rear Suspension Yield Fasteners236
Angle and Vehicle Trim Inspections238
Geometrical Trim Adjustment239
Rear Suspension240
Electrical System241
Overview of the Electrical System241
The Mini F.l.ore.n.C.e Architecture241
Electrical System Layout242
System Electrical Component Classification243
Ground Points243
Electronic Components244
User Control Modules245
Fuse and Relay Box245
Networks and Serial Lines245
The LIN Concept245
Fuses246
Mini F.l.ore.n.C.e.' Architecture Diagram249
Diagnostic Architecture253
Logistic Mode Function254
Trw Smart Key System256
Functions256
Structure256
Operative Procedures257
Overview of Fundamental Operations260
Code System Programming and Component Management261
Procedures for Replacing Components262
NTR Diagnostic Procedures263
On-Board Instruments267
HIGH and MEDIUM Instrument Panels267
BASIC Instrument Panels269
Notions on the Service Function270
Computerised Systems273
Connect NAV273
CONNECT Button (A)276
Tyre Pressure Detection System277
Overview277
Structure277
Operation278
TPMS Deactivation278
Tyre Pressure Monitoring System279
Initiator279
Control Unit279
Operating Details279
Key-On/Key-Off Strategies280
Parking Assistance281
Notions for Calculating Distance from Obstacles281
Structure282
Electronic Control Unit282
Ultrasound Sensors282
Buzzers282
Switching the System on and off282
Coverage Area283
Diagnostics283
Component Characteristics283
ECU Pinout284
Ultrasound Sensor285
Airbags285
Overview285
Airbag System Diagram285
Knee Airbag Modules286
Front Seat Belt Pretensioners287
Front Seat Belt Reminder Sensors287
Airbag System Warning Lights287
Airbag System Failure Warning Light288
Passenger Airbag Deactivated Warning Light288
Seat Belt Reminder288
Clock Contact Pinout289
FRONT LIGHT CLUSTER (Xenon Gas Discharge Version)291
Xenon Bulb292
Rear Headlight View293
Wiring Diagram and Optical Cluster Connector Pinout293
Automatic Headlight Position Corrector293
Adjustment Actuator294
Self-Diagnostics295
Recovery295
Resetting295
Climate Control System296
Climate Control System Overview296
Manual Climate Control System296
Structure296
Operation296
Supplementary Heater296
One-Zone Climate Control System297
One-Zone Climate Control System Wiring Diagram298
Two and Three-Zone Automatic Climate Control System299
Two-Zone System299
Front Two/Three-Zone Controls299
Three-Zone System299
Rear Three-Zone Controls299
Notes on Sensor Operation300
Two/Three-Zone Climate Control System Wiring Diagram302
One-Zone ECU Pinout303
Two/Three-Zone ECU Pinout304
Head Control Rear Connector Pinout304
Bodywork305
Sunroof305
Sunroof Components305
Operation of the Sunroof306
Operating Logic306
Manual Control Via Pre-Selector307
Remote Control307
Notes307
Pinch Force Safety Function308
Emergency Operation308
Initialisation Procedure308
Wiring Diagram309
Seats309
Features of the Seats309
Front Seats309
Rear Seats311
Front Seat Structure312
Anti-Whiplash System312
Electrically Adjustable Seats313
Electrical Seat Diagrams314
Passenger Presence Sensor (SBR)317
Seat Operation317

Alfa Romeo 159 - Training Material Manual

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