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Alfa Romeo 159 Factory Service Manual (2005-2011)08 · Engine
08 · Engine

Single fuel manifold pipe - r.r.

Make
Alfa Romeo
Model
159 Factory Service Manual
Year
2005–2011
Section
Diesel injection system › Single fuel manifold pipe - r.r.
EngineSingle fuel manifold pipe - r.r.

SINGLE FUEL MANIFOLD PIPE - R.R.

Operation 1060F30 · INJECTORS AND PIPES

1.9 JTD 16V

Removing

- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

DescriptionConnector
BatterySee A001 BATTERY

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 1060F20 PIPE FROM PRESSURE PUMP TO FUEL MANIFOLD - R.R.

Op. 1060F36 PIPES (ALL) FROM FUEL MANIFOLD TO INJECTOR - R.R.

1. Disconnect the electrical connection from the fuel pressure sensor.

DescriptionConnector
1Fuel pressure sensorSee K083 FUEL PRESSURE SENSOR

2. Disconnect the electrical connection from the fuel pressure regulator on the injector single manifold.

DescriptionConnector
2Fuel pressure regulator on railSee N087 FUEL PRESSURE REGULATOR ON RAIL

3. Loosen the band and disconnect the fuel return pipe from the single fuel manifold pipe to the fuel return manifold, single fuel manifold pipe side.

4. Undo the bolts (4a) and remove the single fuel manifold pipe (4b) complete with fuel pressure sensor (4c) and fuel pressure regulator (4d).

SINGLE FUEL MANIFOLD PIPE - R.R.

Refitting

1. Fit the single fuel manifold pipe (1a) complete with fuel pressure sensor (1b) and fuel pressure regulator (1c), then secure it tightening the bolts (1d) to the recommended torque.

ComponentFasteningdiaValue (daNm)Validity
Single fuel manifold pipe (rail)BoltM8(cylinder head extension side) 2.3 - 2.8

1.9 JTD 16V

2.4 JTD 20V

2. Connect the fuel return pipe from the single fuel manifold pipe to the fuel return manifold, single fuel manifold pipe side and tighten the band.

3. Connect the electrical connection to the fuel pressure regulator on the injector single manifold.

4. Connect the electrical connection to the fuel pressure sensor.

SINGLE FUEL MANIFOLD PIPE - R.R.

Op. 1060F36 PIPES (ALL) FROM FUEL MANIFOLD TO INJECTOR - R.R.

Op. 1060F20 PIPE FROM PRESSURE PUMP TO FUEL MANIFOLD - R.R.

Op. 1016A10 SOUND-PROOFING COVER - R.R

- Connect the negative battery terminal.

1.9 JTD 8V

Removing

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 1048B27

Op. 1060G50 THROTTLE BODY - R.R

Op. 1080C24 E.G.R. SYSTEM SOLENOID - R + R

Op. 1060F36 PIPES (ALL) FROM FUEL MANIFOLD TO INJECTOR - R.R.

Op. 1060F20 PIPE FROM PRESSURE PUMP TO FUEL MANIFOLD - R.R.

1. Disconnect the electrical connection from the fuel pressure sensor.

DescriptionConnector
1Fuel pressure sensorSee K083 FUEL PRESSURE SENSOR
SINGLE FUEL MANIFOLD PIPE - R.R.

1. Loosen the band and disconnect the fuel return pipe, single fuel manifold pipe side.

2. Disconnect the electrical connection for the fuel pressure regulator.

DescriptionConnector
2Fuel pressure regulator on railSee N087 FUEL PRESSURE REGULATOR ON RAIL

3. Undo the bolts (3a) and move the bracket (3b) aside.

4. Undo the nuts (4a) and remove the single fuel manifold pipe assembly (4b).

SINGLE FUEL MANIFOLD PIPE - R.R.

- Position the single fuel manifold pipe in a vice fitted with protective jaws.

1. Undo the fuel pressure sensor and remove it.

2. Undo the fuel pressure regulator and remove it.

SINGLE FUEL MANIFOLD PIPE - R.R.

Refitting

- Place the fuel pressure regulator in its housing on the single fuel manifold pipe and tighten it to the recommended torque.

ComponentFasteningdiaValue (daNm)Validity
Fuel pressure regulator(fuel manifold side) 8.0 - 9.01.9 JTD 8v

- Place the fuel pressure sensor in its housing on the single fuel manifold pipe and tighten it to the recommended torque.

ComponentFasteningdiaValue (daNm)Validity
Fuel pressure sensor(fuel manifold side) 6.5 - 7.51.9 JTD 8v

- Remove the single fuel manifold pipe from the vice.

- Place the single fuel manifold pipe in its housing and secure it by tightening the nuts to the recommended torque.

ComponentFasteningdiaValue (daNm)Validity
Single fuel manifold pipe (rail)NutM8(intake manifold side) 2.3 - 2.81.9 JTD 8v

- Fit the bracket in its housing and secure it using the bolts.

- Connect the electrical connection to the fuel pressure regulator.

- Connect the fuel return pipe, single fuel manifold pipe side and tighten the band.

- Connect the electrical connection to the fuel pressure sensor.

Op. 1060F20 PIPE FROM PRESSURE PUMP TO FUEL MANIFOLD - R.R.

Op. 1060F36 PIPES (ALL) FROM FUEL MANIFOLD TO INJECTOR - R.R.

Op. 1080C24 E.G.R. SYSTEM SOLENOID - R + R

Op. 1060G50 THROTTLE BODY - R.R

Op. 1048B27

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

2.4 JTD 20V

Removing

- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

DescriptionConnector
BatterySee A001 BATTERY

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 1060F20 PIPE FROM PRESSURE PUMP TO FUEL MANIFOLD - R.R.

Op. 1060F36 PIPES (ALL) FROM FUEL MANIFOLD TO INJECTOR - R.R.

1. Detach the electrical connection from the fuel pressure sensor.

DescriptionConnector
1Fuel pressure sensorSee K083 FUEL PRESSURE SENSOR

2. Detach the electrical connection from the fuel pressure regulator on the injector single manifold.

DescriptionConnector
2Fuel pressure regulator on railSee N087 FUEL PRESSURE REGULATOR ON RAIL

3. Loosen the band and disconnect the fuel return pipe from the single fuel manifold pipe to the fuel return manifold, single fuel manifold pipe side.

4. Undo bolts (4a) and remove single fuel manifold pipe (4b), complete with fuel pressure sensor and fuel pressure regulator.

SINGLE FUEL MANIFOLD PIPE - R.R.

Refitting

- Fit the single fuel manifold pipe complete with fuel pressure sensor and fuel pressure regulator and secure it by tightening the bolts to the recommended torque.

ComponentFasteningdiaValue (daNm)Validity
Single fuel manifold pipe (rail)BoltM8(cylinder head extension side) 2.3 - 2.8

1.9 JTD 16V

2.4 JTD 20V

- Connect the fuel return pipe from the single fuel manifold pipe to the fuel return manifold, single fuel manifold pipe side, and tighten the band.

- Secure the electrical connection to the fuel pressure regulator on the injector single manifold.

- Secure the electrical connection to the fuel pressure sensor.

Op. 1060F36 PIPES (ALL) FROM FUEL MANIFOLD TO INJECTOR - R.R.

Op. 1060F20 PIPE FROM PRESSURE PUMP TO FUEL MANIFOLD - R.R.

Op. 1016A10 SOUND-PROOFING COVER - R.R

- Connect the negative battery terminal.

Parts & tools for this job Staging For 2005 Alfa Romeo 159

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