Fuel supply circuit check
- Make
- Alfa Romeo
- Model
- Brera and Spider Factory Service Manual
- Year
- 2005–2010
- Section
- Fuel tank and pipes › Fuel supply circuit check
FUEL SUPPLY CIRCUIT CHECK
| CHECK TO BE PERFORMED | RESOLUTION IF THE CHECK IS NOT OK | |
|---|---|---|
| 1 | Check that there are no signs of damage, incorrect fitting or leaks at the fuel supply/return pipes or at the actual tank | Repair or, if necessary, replace the faulty components |
| 2 | Insert the ignition key (panel on). Check that there is a whilstling noise in the next 2 seconds coming from the fuel pump indicating that it is activated and then the pump should be deactivated. | Continue as instructed in the |
| 3 | Check the fuel level signalled by the gauge in the panel and make a note of it. Connect to the pump connector See N040 FUEL PUMP AND LEVEL GAUGE between Pins A and C and check that the resistance reading is consistent with the reading in the panel, following the instructions in the table below | Continue as instructed in the |
| Level | Full | 3/4 | 1/2 | 1/4 | Reserve | Empty |
| Resistance (Ohm) | 20 | 77 | 152,5 | 225 | 259,5 | 300 |
| CHECK TO BE PERFORMED | RESOLUTION IF THE CHECK IS NOT OK | |
|---|---|---|
| 4 | Refit the fuel pump and check that the level on the gauge is more than 1/4 of a tank. Move on to Step 9 | Move on to Step 5 |
| 5 | Add fuel until there is at least 1/4 of a tank. Carry out a road test trying to replicate the conditions in which the customer reported the problem. Check that the following parameters do not cause sudden changes and/or values that are not consistent with the driving conditions: - accelerator pedal position - load - injection time - requested engine torque - detected engine torque - throttle angle | Continue as described by the diagnostic equipment |
| 6 | Check that the fuel filter and the fuel supply pipes are not constricted | Repair or, if necessary, replace the faulty components |
| 7 | Check that the pump electrical connections See N040 FUEL PUMP AND LEVEL GAUGE are not faulty | Restore or, if necessary, replace the electrical wiring |
| 8 | Check that the quality of the fuel in the tank is not poor by carrying out the test | Remove the fuel from the tank and clean the actual tank |
| 9 | Press the START/STOP button (panel off). Connect a pressure gauge to the injectors. Press the START/STOP button (panel on). Check that the fuel pressure increases (whilst the pump is working) between 5.7 and 6.3 bar | Remove the constrictions in the fuel supply and/or return pipes. If necessary, replace them |
| 10 | Once the pressure has gone down again, check, within the space of a minute, that there has not been a fall in pressure of more than 0.3 bar | Continue as instructed in the |
| CHECK TO BE PERFORMED | RESOLUTION IF THE CHECK IS NOT OK | |
|---|---|---|
| 1 | Check that there are no signs of damage, incorrect fitting or leaks at the fuel supply/return pipes or at the actual tank | Repair or, if necessary, replace the faulty components |
| 2 | Insert the ignition key (panel on). Check that there is a whilstling noise in the next 2 seconds coming from the fuel pump indicating that it is activated and then the pump should be deactivated | Continue as instructed in the |
| 3 | Check the fuel level signalled by the gauge in the panel and make a note of it. Connect to the pump connector See N040 FUEL PUMP AND LEVEL GAUGE between Pins A and C and check that the resistance reading is consistent with the reading in the panel, following the instructions in the table below | Continue as instructed in the |
| Level | Full | 3/4 | 1/2 | 1/4 | Reserve | Empty |
| Resistance (Ohm) | 17÷23 | 78÷84 | 136÷142 | 207÷213 | 244÷250,1 | 296,7÷303,5 |
| CHECK TO BE PERFORMED | RESOLUTION IF THE CHECK IS NOT OK | |
|---|---|---|
| 4 | Refit the fuel pump and check that the level on the gauge is more than 1/4 of a tank. Move on to Step 9 | Move on to Step 5 |
| 5 | Add fuel until there is at least 1/4 of a tank. Carry out a road test trying to replicate the conditions in which the customer reported the problem. Check that the following parameters do not cause sudden changes and/or values that are not consistent with the driving conditions: - accelerator pedal position - load - injection time - requested engine torque - detected engine torque - throttle angle | Continue as described by the diagnostic equipment |
| 6 | Check that the fuel filter and the fuel supply pipes are not constricted | Repair or, if necessary, replace the faulty components |
| 7 | Check that the pump electrical connections See N040 FUEL PUMP AND LEVEL GAUGE are not faulty | Restore or, if necessary, replace the electrical wiring |
| 8 | Check that the quality of the fuel in the tank is not poor by carrying out the | The test is over. Remove the fuel from the tank and clean the actual tank |
| 9 | Press the START/STOP button (panel off). Connect a pressure gauge to the injectors. Press the START/STOP button (panel on). Check that the fuel pressure rises (whilst the pump is working) between 5.7 and 6.3 bar | Remove the constrictions in the fuel supply and/or return pipes. If necessary, replace them |
| 10 | Once the pressure has gone down again, check, within the space of a minute, that there has not been a fall in pressure of more than 0.3 bar | Continue as instructed in the |
The fuel system is highly sensitive. The work must be carried out with the greatest cleanliness and care. Any air in the system could damage the high pressure fuel pump. The vehicle must therefore never be driven with the fuel tank empty.
| CHECK TO BE PERFORMED | RESOLUTION IF THE CHECK IS NOT OK | |
|---|---|---|
| 1 | Check that the tank contains the correct type of fuel | Remove the content and wash the tank |
| 2 | The fuel reserve must be greater than 5 litres. | Put back a fuel quantity of at least 5 litres |
| 3 | Check for leaks in the fuel circuit. Check the hoss and connected pipes to identify any obstructions, damage etc. Check for breaks/scratches on the fuel supply or injection pipes. Check the fuel pipe fittings (quick-fit) Check that the oil pipes are not leaking. Check the condition of the three-way fastening elements. Check the fittings and seals are correctly fitted (use only Fiat Auto approved sealants). Check for blockages, leaks, air or water in the fuel system. | Repair or, if necessary, replace the faulty components |
| 4 | Check the tightening torques for the capscrews: | Restore component tightness to the correct values |
| 5 | Check the fuel filter | Restore the fuel filter to correct working order or replace if necessary Op. 1044B20 |
Parts & tools for this job Staging For 2005 Alfa Romeo Brera
- TOOLDigital multimeterSearch: automotive digital multimeter
- PARTAssorted fuse kitSearch: car fuse assortment kit
- TOOLWire crimper and connector kitSearch: wire crimper connector kit
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