AEG KO_FAVORIT 64800- User Manual

1

Ver 1, Nov 2004

SPICA Fuel Injection Roadside Fault Analysis and Repair

This guide is intended to aid the owner-mechanic in understanding and diagnosing Alfa Romeo SPICA injection pump malfunctions. It is not a substitute for the

official factory technical publications. No claim to absolute accuracy or utility is expressed or implied. The reader uses this guide at his own risk.

This section provides information for fault diagnosis and describes some simple improvised roadside repairs

that may allow self-recovery of the car to home or to a mechanic. The SPICA injection pump is generally

very reliable. There is only one injection pump failure that is serious enough to cause engine stoppage and is

common enough to be of practical concern. By far, most problems experienced by SPICA owners are fuel

supply

related and not within the injection pump itself. When troubleshooting, rule out ignition causes first,

then fuel supply, and only then, suspect the injection pump. The following are some possible injection pump

failure modes that might cause sudden engine failure:

1. Broken Compensator Link Retaining Spring. (somewhat common, especially in poorly maintained cars)

2. Shorted Fuel Cutoff Microswitch. (somewhat common in old pumps)

3. Broken Injection Pump Drive Belt (uncommon)

4. Broken Hairspring Clip (very uncommon)

5. Broken Barometric Compensator Bellows (very uncommon)

Given that many of these SPICA pumps have been in service for more than 30 years, it's not surprising that

some components such as Compensator Link Retaining Springs have corroded or fatigued over the years and

occasionally fail. The same is true of Fuel Cutoff Microswitches. That said, if you carry a few simple tools

and improvised repair parts in the trunk, you should never be stranded by your SPICA system. I recommend

carrying the following tools and parts with you in your trunk. Everything will fit it a small pouch.

1. Vice-Grips

2. Multi-screwdriver with assorted tips

3. Needle-nose pliers with integral wire cutter.

4. Bent-nose forceps

5. 2' length of mechanics wire

6. A few rubber bands

7. ¼" x 4" carriage bolt w/ 2 nuts

8. Small plastic wire ties

This guide assumes that you have a cursory knowledge of the SPICA system and know the location of basic

components, their nomenclature, and basic operating theory. When confronted with a malfunction on-the-

road, the first action is to find a safe place to park the car. Turn the ignition OFF and look under the car for

any leaks. An engine malfunction is more likely to be electrical in nature rather than fuel, so consider that

possibility first. Turn the ignition key on momentarily and listen for the whine of the fuel pump. If you don't

hear anything, check the fuse. (by the driver's left knee, separate small, two-fuse, fusebox).

If necessary, remove the air cleaner box and visually check all components for any

obvious

defects such as:

1. Fuel leaks from hoses, fittings, front fuel filter, injection pump, or SPICA high-pressure metal fuel tubes.

2. Wires detached from their terminals (fuel low -pressure switch, cold start solenoid, and fuel cutoff

solenoid, ignition wires, spade terminal underneath distributor base, coil connections).

3. Burnt wiring.