AUTOMOTIVE ELECTRICIANS PORTAL - FZCO

Alfa Romeo 147 1.6 TS da 04/01 a 06/02 – STARTING AND RECHARING – – Cambio robotizzato – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION

Alfa Romeo 147 1.6 TS  da 04/01 a 06/02 – STARTING AND RECHARING –  – Cambio robotizzato – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION
Wiring diagram

Components
Component codeNameAssembly reference
A1Battery5530B
A10Alternator5530A
A20Starter' motor5520B
B1Engine compartment junction unit-
B1Engine compartment junction unit5505A
B2Junction unit under dashboard5505A
B5MAXI FUSE box-
B99Maxifuse box on battery5530B
D4Front / engine coupling-
D7Recharging / front connection-
E50Instrument panel5560B
H1Ignition switch5520A
J5Starting enablement relay-
M1Body computer5505A
M54"Selespeed transmission control unit"2127E
Location of components

Components
Component codeNameAssembly reference
A1Battery5530B
A10Alternator5530A
A20Starter' motor5520B
B1Engine compartment junction unit-
B1Engine compartment junction unit5505A
B2Junction unit under dashboard5505A
B5MAXI FUSE box-
B99Maxifuse box on battery5530B
D4Front / engine coupling-
D7Recharging / front connection-
E50Instrument panel5560B
H1Ignition switch5520A
J5Starting enablement relay-
M1Body computer5505A
M54"Selespeed transmission control unit"2127E
DescriptionThe ignition and recharging circuit comprises a battery, starter motor and alternator.The starter motor consists of a direct current motor supplied by the battery and an excitation solenoid. When the ignition key is turned to the extreme position (AVV), the starter motor windings are supplied, producing electro-magnetic forces which rotate the motor pinion. At the same time, the solenoid is energized and operates the mechanism for engaging the pinion in the flywheel ring gear, thus turning over the engine. In this version with robotized gearbox, the enablement for rotation of the starter motor is supplied by the Selespeed control unit. 3023642SeeE7051ROBOTIZED GEARBOX . The alternator recharges the battery during normal engine rotation. The alternator shaft (rotor) is turned by the crankshaft by means of a belt. When supplied with an excitation current, the rotor generates a magnetic field that induces an alternating current in the fixed winding (stator). A diode rectifying bridge located on the back of the alternator transforms the alternating current into a direct current, which is sent to recharge the battery.A voltage regulator, also built into the alternator, maintains a constant voltage supply (about 14V) throughout the load and engine speed ranges.The efficiency of the recharging system is controlled by the Body Computer, which measures the D+ signal coming from the alternator with the engine running (rpm over 700).If a fault is detected, the relevant warning light on the instrument panel is switched on.The Body Computer also acquires the battery voltage value in the 6-19V field. The informatio is then supplied to the CAN network for the controls unit node on the door which excludes some services in the case of a voltage drop (for example 3023248SeeE2510COURTESY LIGHTS .
Functional description When the ignition key is turned in the switch H1 to the extreme position (START) - pin 50 - the winding of the solenoid - pin 50 - of the starter motor A20 is supplied. This supply comes from the battery via the line of maxifuse IGN of B99 . However, this supply only occurs in the presence of an enablement signal - from pin 42 of connector A of the SELESPEED control unit M54 (while pin 76 of connector B of M54 receives the starting request signal); the starting enablement relay J05 - supplied under the ignition (15/54) by the line protected by the fuse F16 of the engine compartment unit B1 - then sends the supply to pin 50 of the starter motor A20 . The supply controlled by the ignition (15/54) reaches pin 28 of connector A of M54 . 3023642SeeE7051ROBOTIZED GEARBOX . Pin 30 of A20 , the actual starter motor, receives the voltage coming directly from the battery A1 . The direct current generated by the alternator A10 (pin B+) is sent to the battery A1 through motor A20 . When the alternator does not turn, and so does not recharge the battery, an earth signal is sent from pin D+ to the Body Computer - pin 19 of connector A: this is connected via the CAN line to the instrument panel E50 and manages, as described above, the switching on of the recharging warning light on the instrument panel E50 .

Battery



A1A



A1A



A1B



A1B



battery and leads



5530B10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Ensure that the ignition key is in the OFF position, then disconnectthe negative battery terminal (-).2. Open the maxi fuse box cover.3. Undo the bolts securing the 'maxi-fuse' box to the battery.4. Loosen the bolt fixing the battery terminal (+).5. Release the maxi fuse box from the battery and move it to theside.2004975

5530B14


Follow these precautions:769768768

5530B18


Follow these precautions.769On batteries with an opticam hydrometer,electrolyte level and battery charge status can be monitored qualitativelyby examining the indicator colour: a light, bright colour indicates low electrolytelevel: top up with distilled water;a dark colour without a green area in thecentre indicates that the electrolyte level is correct but chargeis low: recharge the battery; a dark colour with a green area in themiddle indicates that both electrolyte level and charge status arecorrect: no action is necessary. For further details, see DESCRIPTION ANDOPERATION - 5580.768Proceed as follows.Check the battery voltage without loadusing the test device recommended by the Service outlets (e.g. 'MICRO360'). Depending on the voltage values measured,which define the state of charge of the battery, proceed as follows:If the voltage without load is less than12.10 V, replace the battery (see op.). 5530B10).If the voltage without load is over 12.10V but less than 12.50 V, recharge the battery (see op. 5530B14).If the voltage without load is over 12.50V, the battery is efficient.If necessary, top up the electrolyte asfollows.Carefully remove the cap strip.Top up with distilled and deionized water,taking care not to allow electrolyte to splash out.768

5530B22


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025751-7025A12Engine front sound insulation COVER - R.R.3025752-7025A14Bonnet LID - R.R.

5530B26


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the vehicle on a lift.Open the bonnet lid.1. Release the retainers (1a) and remove the cover (1b).2004980

5530B40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Open the bonnet lid.1. Release the retainers (1a) and remove the cover (1b).2004986

5530B52


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Proceed with removal 3025534-5530B10battery - r+r .1. Remove the relay/fuse box cover.2. Undo the nut (2a) and disconnect the earth lead (2b) from therelay-fuse box.2004990

5530B60


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025534-5530B10battery - r+r1. Remove the battery drip tray.2. Unscrew bolts (2a) and loosen bolt (2b) securing the batterycradle.3. Move the battery cradle aside.4. Release the belt retaining stud.5. Remove the belt.2005002

Alternator



A10A



A10A



A10A



A10A



A10B



alternator and components



5530A10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-). Proceed with the removal 3025363-4450B10Front WHEEL (one) -R.R. (Right side).Proceed with the removal 3025916-7055B64Engine compartment DUSTshield in front wheel arch (one), left or right - R.R. (Rightside).Proceed with removal 3024921-1092G10single engine belt r r . Proceed with removal 3024856-1072C44exhaust manifold heatshield on bulkhead - r+r .

5530A18


3025530-5530A30alternator pulley orfan - r+r with alternator removed3025528-5530A24alternator voltage regulator - r r with alternatorremoved1. Undo the bolts fixing the diode rectifier plate.2. Using a metal-cutter, open the electrical connections (2a) retainingthe diode rectifier plate (2b). 3. Remove the diode rectifier plate.4. Undo the bolts fixing the half cover.2004965

5530A22



5530A24


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Undo the nuts fixing the cover.2. Remove the lid.3. Undo the nuts (3a) and the bolts (3b) fixing the voltage regulator.4. Remove the voltage regulator and brushes.2004969

5530A28


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21- 5530A14 alternator - r+r forversions with air conditioner 3025530-5530A30alternator pulley or fan - r+r with alternator removed

5530A30


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Fix the alternator in a viceat the bench.1. Use the special tool (1a) to keep the shaft still and undo thepulley fixing nut (1b).2004970

5530A40



5530A82


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025534-5530B10battery - r+r3024826-1048A34sleeve(s) from flow meter to air supply capacitycase - r + r3024842-1056B87ignition/injection system control unit mount - rr3024832-1056B17throttle body intergral with dvl - r r3025538-5530B26lead between battery and starter motor - r+rRaise the vehicle.1. Working underneath the engine, open the cover for the alternatorconnection.2. Undo the nut.3. Remove the electrical connection.Lower the vehicle.4. Working via the engine compartment, disconnect the cable retainingband.5. Recover the cable.2004974

Starter' motor



A20A



A20A



A20A



A20B



A20B



A20B



A20B



starter motor and components



5520B10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-).Proceed with removal 3025001-1016A10sound-proofing cover- r + r .Proceed with removal 3025915-7055B54under-engine guard -r r .1. Undo the lower starter motor retaining bolt.2004922

5520B12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.Ensure that the ignition key is in theOFF postition, then disconnect the battery negative terminal.

5520B14


3025520-5520B18starter motor solenoids- r+r with motor removed1. With the aid of a suitable bush (1a), slide the retaining ring(1b) and release the circlip (1c), then extract the retaining ring(1b) from the shaft. 2004926

5520B18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Fix the starter motor in avice at the bench.1. Disconnect the electrical supply terminal.2. Undo the solenoid fixing bolts.3. Remove the fixed section of the solenoid (3a) and recover thespring (3b). If necessary, remove the mobile part of the electromagnet(3c). Proceed as follows. 2004934

Engine compartment junction unit



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1B



B1B



B1B



B1B



B1C



B1C



B1C



B1C



B1C



B1D



B1E



B1E



B1X



B1X



B1E



multi-function components



5505A10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025802-7040A37fuse box cover - r r1. Disconnect the electrical connections at the front (1a, 1b, 1c,1d, 1e, 1f).2. Undo the bolts fixing the control unit.3. Undo the bolts shown fixing the dashboard cover.2004865

5505A13


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025751-7025A12Engine front sound insulation COVER - R.R.3025752-7025A14Bonnet LID - R.R.

5505A24



5505A28


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025751-7025A12Engine front sound insulation COVER - R.R.3025752-7025A14Bonnet LID - R.R.

5505A32



5505A33



Junction unit under dashboard



B2A



B2A



B2A



B2A



B2A



B2A



B2A



B2A



B2A



B2A



B2A



B2A



B2A



B2B



B2B



B2C



B2C



B2D



B2E



B2F



B2G



B2H



B2H



MAXI FUSE box



B5A



B5B



B5C



B5D



B5E



B5F



Maxifuse box on battery



B99A



B99A



B99B



B99C



B99D



Front / engine coupling



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



Recharging / front connection



D7



D7



Instrument panel



E50A



E50B



E50B



analogue control panel



5560B11


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Lower the steering wheel andmove it back to the end of travel position.3025799-7040A26steering column trim - r+r3025611-5580C18air bag module - r+r7693025282-4110A11steering wheel - r+r for replacement or check forversions with air bag1. Unscrew the bolts2005043

5560B56


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Release the retainers for the switch panel from the dashboardtrim.2. Disconnect the electrical connections.3. Recover the switch panel.2005045

Ignition switch



H1A



H1A



H1A



H1A



H1B



ignition switch



5520A12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025620-5580E08aerial for alpha code- r r1. Disconnect the electrical connections (1a, 1b) from the ignitionswitch.2. Use a drift and undo the headless bolts (2a); remove the ignitionswitch (2b).7682004913

5520A14


769

5520A16


769

5520A18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. If necessary, regulate the steering wheel height adjustment lever.2. Undo the bolts fixing the lower trim.3. Remove the lower trim, releasing it from the inner retainersand the steering wheel.2004920

Starting enablement relay



J5



J5



Body computer



M1A



M1A



M1A



M1A



M1A



M1A



M1A



M1A



M1A



M1A



M1A



M1A



M1A



M1A



M1B



M1C



M1C



M1D



M1E



M1E



M1F



M1G



"Selespeed transmission control unit"



M54A



M54A



M54A



M54B



M54B



electric speed selection system



2127E30


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF postition, then disconnect the battery negative terminal.1. Remove the trim, complete with CITY function selector buttonand A.S.R. off switch, from the housing in the centre console.2. Disconnect the electrical connection for the CITY function selectorbutton.Remove the trim, complete with CITY function selectorbutton and A.S.R. off switch.2003846

2127E08


Connect the Examiner diagnostic equipment.Select 'Alfa Selespeed' on the Examiner.Select 'Control Unit Test' on the Examinerand select the 'Marelli Selespeed Automatic Transmission'.Press 'Active Diagnosis' on the Examinerand select 'Service/end of line self-calibration'.Continue with the procedure on the Examiner.

2127E10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-). 1. Undo the nuts (1a) and remove the cover under the dashboard onthe passenger side (1b).2068266

2127E40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Proceed with removal 3025534-5530B10battery - r+r . Proceed with removal 3025540-5530B52Battery DRIP TRAY/SUPPORT- R.R. . Proceed with removal 3024822-1048A10air cleaner filtering element- replace . Proceed with removal 3025166-2127C48GEAR ENGAGEMENT ELECTRO-HYDRAULICSELECTION DEVICE - R.R. . 1. Loosen the bolts (1a) and remove the electro-hydraulic gear selectionposition sensor (1b).2068272

2127E42


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Proceed with removal 3025534-5530B10battery - r+r . Proceed with removal 3025540-5530B52Battery DRIP TRAY/SUPPORT- R.R. . Proceed with removal 3024822-1048A10air cleaner filtering element- replace . Proceed with removal 3025166-2127C48GEAR ENGAGEMENT ELECTRO-HYDRAULICSELECTION DEVICE - R.R. . 1. Undo the bolts (1a) and remove the electro-hydraulic gear selectionposition sensor (1b).2068273

2127E44


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Proceed with removal 3025534-5530B10battery - r+r . Proceed with removal 3025540-5530B52Battery DRIP TRAY/SUPPORT- R.R. . 1. Undo the bolts and move the clutch position sensor as necessary.2. Disconnect the electrical connection from the clutch positionsensor.3. Remove the electro-hydraulic selection gearbox position sensor.2068274

2127E50


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the rampConnect the Examiner diagnostic equipment.Select 'Alfa 147 speed' on the Examiner.Select 'Control Unit Test' on the Examinerand select the 'Marelli Selespeed Automatic Transmission'.Press 'Active Diagnosis' on the Examinerand select 'Accumulator depressurizing'.Continue with the procedure on the Examiner.Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-). Proceed with removal. 3025915-7055B54under-engine guard -r r1. Disconnect the electrical connection from the electro-hydraulicgear selection hydraulic circuit pressure sensor.2. Undo and remove the electro-hydrauilc gear selection hydrauliccircuit pressure sensor.2068275

2127E52


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Proceed with removal 3025534-5530B10battery - r+r . Proceed with removal 3025540-5530B52Battery DRIP TRAY/SUPPORT- R.R. . Proceed with removal 3024822-1048A10air cleaner filtering element- replace . 1. Disconnect the electrical connection from the electro-hydraulicgear selection input shaft speed sensor.2. Undo and remove the electro-hydraulic gear selection input shaftspeed sensor.2068276

2127E94


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Proceed with removal 3025534-5530B10battery - r+r . Proceed with removal 3025540-5530B52Battery DRIP TRAY/SUPPORT- R.R. . Proceed with removal 3024822-1048A10air cleaner filtering element- replace . 1. Disconnect the electrical connection for the manual gearbox electro-hydraulicselection system wiring on the selection unit.2068277