DescriptionThe climate control via the heater unitis insufficient when the engine is cold, especially in Diesel engineswhich are slow to warm up.These engines may optionally be fitted witha supplementary heater system. This remains active from the momentwhen the engine is turned on until a certain temperature is reached.The system consists of an additional heatingdevice, located on the engine coolant supply pipe to the heaterunit.This device contains three spark plugs (similarto those used to preheat the combustion chamber).The operation of the heater plugs is controlledby a special control unit which operates either one, two or threeof them giving 200W, 400W or 600W.This control logic depends on:the temperature of the engine coolant;the electrical power available (the battery voltage ischecked)the engine speed (which should be above a pre-set value)The supply of one, two or three heaterplugs is controlled by two relays:1. Level: activated by the first relay;2. Level: activated by the second relay;3. Level: activated by both relays.There is also a third relay/safety switchwhich interrupts the heater plugs supply if the contact to earthis not correct: the metal device containing the heater plugs isconnected to the engine earth by means of a special loom. For more details, 3232957see DESCRIPTION AND OPERATION:5020Ladditional heater . The control unit supply lines are protectedby a fuse in the junction unit and by the fuse which protects othersupplies controlled by the ignition.The safety relay supply line is protectedby a fuse located in the junction unit, whilst the one supplyingthe resistors is protected by a special maxifuse.
Functional description The additional heater control unit M75 receivesa supply controlled by the ignition (INT/A) at pins 15 and U fromthe line protected by the fuse B10 up to 2/99 or fuse F6 ofthe additional fuse box B98B from 2/99. The direct supply arrives from the battery(maxifuse J/B1 of B5 up to 2/99 or B99 from2/99) at pin TL through fuse F10 of junction unit B1 :this signal allows the battery voltage to be checked, i.e. the levelof electrical power available. Pin 31 of M75 is earthed. Pin N of M75 receives the enginerpm signal coming from the engine management control unit M10 . Pin TW, on the other hand, is connectedto the special temperature sensor K80 which measures thetemperature of the coolant near the additional heater. Relays J36 and J37 controlthe engagement of the resistors O25 . The supply at the contact of the relaysarrives from the battery from the line of the specific maxifuse B38 upto 2/99 or from the HEAT maxifuse, located directly on the battery A1 -connector D from 2/99, while the coils are energized by the controlunit M75 , which operates only relay J36 to switchon plug O35 A , only relay J37 to switch on plugs O35B and C, and both relays for all three plugs O35 . The safety relay J38 interrupts thesupply of the two above mentioned relays and consequently the heaterplugs if the contact to earth is not correct: the coil for J38 isconnected on one side to earth and on the other to the metal frame forthe device containing the heater plugs: this is connected to theengine earth C1 by means of a special earth loom C41 :if this connection is broken, relay J38 is energized andimmediately stops the current supply to the heater plugs.
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the car on a ramp.Undo the bolt securing the bracket on thebattery mount.Release the battery from the anchoragebracket complete with strap and remove.
5530B14
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 more details 3238420See subassembly5530 CURRENT GENERATOR . 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 ( 32384295530B10battery - r+r ). If the voltage without load is over 12.10V but less than 12.50 V, recharge the battery ( 32384305530B14battery - recharge ). 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>1Refitting21Place the car on the liftingbridge.1. Open engine compartment cap and disconnect battery negative terminal.2. Disconnect mass terminal on side member.3. Lift the car and disconnect mass terminal on gearbox.4. Lower the car again and remove battery earth lead.2018767
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Open the protective cover2. Loosen the nut and disconnect the ABS supply lead3. Loosen the nut and disconnect the starter motor supply lead4. Undo the clip and undo the box retaining bolts.5. Loosen the battery positive terminal nut.2018769
5530B52
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238429-5530B10battery - r+rRelease the air duct hose from the mountingbracket on the drip tray. Remove the relay shield.1. Release the relays from the battery drip tray and remove them.2. Undo the nut fixing the air filter mounting bracket to the batterydrip tray.3. Undo the two fixing nuts (3a) and move the connections/electricalwiring mounting bracket (3b) aside.4. Release the accelerator cable from the fastening on the bracket.2018771
1. Loosen the tension of the engine components single drive beltadjusting the tensioner.2. Lock the tensioner (2a) with the belt slack inserting a suitablepeg (2b).3. Remove the engine components single drive belt.2013371
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.DRAIN THE FUEL HIGH-PRESSURE SYSTEM AS DESCRIBEDBELOW. Start up the engine.Maintain idle for 2 minutes.Remove the fuel pump relay.Wait for the engine to stall.Try to start the engine: if the enginestarts within 10 seconds, wait for it to stall, then try to startit again; if the engine does not start within 10 seconds, continue crankingfor a further 5 seconds. Wait until the engine cools down. Proceed with removal 3238226-4450B12front or rear wheels (two)- r+r . Proceed with removal 3238967-7055B64Engine compartment DUSTshield in front wheel arch (one), left or right - R.R. . Proceed with removal 3238966-7055B54under-engine guard -r r . 1. Disconnect the lower coolant outlet hose from the radiator anddrain the engine coolant. 769Reconnect the rapid attachment for thebottom coolant outlet hose from the radiator. 2014272
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213237784-1048A50air inlet pipe to turbo charger - r + r Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). 1. Undo the bolts (1a) and move the relay holder backet (1b) awayfrom the battery drip tray.2. Disconnect the flow meter electrical connection.3. Undo the nuts (3a) and remove retaining plates (3b).4. Remove flow meter (4a) together with the sleeve from the flowmeter to turbocharger air intake pipe (4b) and the sleeve from thefilter to flow meter (4c).2015135
1060G14
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238429-5530B10battery - r+r1. Disconnect the electrical connection from the engine coolanttemperature sensor.2. Undo and remove the engine coolant temperature sensor.2015136
1060G16
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal. 1. Disconnect the electrical connection from the excess pressuresensor.2. Undo the bolt (2a), remove the excess pressure sensor (2b).2015137
1060G18
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). 1. Disconnect the electrical connection from the fuel temperaturesensor.2. Undo and remove the fuel temperature sensor from the fuel returnmanifold pipe.2015138
1060G20
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the lift.Raise the car. Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). 1. Disconnect the condensed oil return pipe from the sump.Disconnect the electrical connection forthe engine rpm and timing sensor.2. Undo the bolts (2a) and remove the rpm and timing sensor (2b).2015139
<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 (-). Proceed with removal 3237758-1016A10sound-proofing cover- r + r1. Disconnect the electrical connection from the fuel pressure sensoron the fuel manifold.2. Undo and remove the fuel pressure sensor on the fuel manifold.2068748
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). Disconnect the electrical connection fromthe switch on the brake pedal.Rotate and remove the switch on the brakepedal.
1060G42
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). Disconnect the electrical connection fromthe switch on the clutch pedal.Rotate and remove the switch on the clutchpedal.
1060G50
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with the removal 3237758-1016A10sound-proofing cover- r + r . 1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold (1b), throttle body connectorside. 2015145
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with the removal 3237758-1016A10sound-proofing cover- r + r . 1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold (1b), throttle body connectorside.2015155
1060G70
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in thestop OFF, then disconnect the battery negative terminal. Proceed with the removal 3237758-1016A10sound-proofing cover- r + r . 1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold (1b), throttle body connectorside.2015161
1060G72
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in thestop OFF, then disconnect the battery negative terminal. Proceed with the removal 3237758-1016A10sound-proofing cover- r + r . 1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold (1b), throttle body connectorside.2015169
1060G80
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is OFF (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). Working from the passenger compartmentin the front passenger-side wheel arch compartment, unscrew the boltand nut then remove the control unit protection.Disconnect the electrical connections afterturning the safety levers.Unscrew the nuts and remove the dieselelectronic injection system.
1060G88
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the battery negative terminal.1. Undo the nut (1a) and remove the protective cover (1b).2. Remove the diesel injection system relays.2015179
1060G90
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp. Proceed with removal 3237758-1016A10sound-proofing cover- r + r . Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-). Proceed with removal 3238966-7055B54under-engine guard -r r . Proceed with removal 3237866-1076B70exhaust pipe betweenpre-catalytic converter and catalytic converter - r r . 1. Disconnect the electrical connection from the engine oil pressurewarning light switch.2. Disconnect the electrical connection for the engine oil levelsensor.3. Disconnect the electrical connection for the rpm sensor.2069114
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Unscrew the motor retaining bolt.2. Disconnect the motor electrical connection.3. Remove the motor (3a) releasing the toothed wheel (3b) from thecam rack.2018552
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Unscrew the motor retaining bolt.2. Disconnect the electrical connections for the motor (2a, 2b,2c, 2d).3. Remove the motor (3a) releasing its connection (3b).2018560
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238966-7055B54under-engine guard - r r1. Working underneath the engine compartment, undo the nuts fixingthe bracket.2. Remove the bracket.3. Undo the nuts fixing the flange.4. Move the exhaust pipe to the side and fix it temporarily.2018371
5020L14
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238966-7055B54under-engine guard - r r1. Working underneath the engine compartment, undo the bolts fixingthe bracket.2. Remove the bracket.3. Undo the nuts fixing the flange.4. Move the exhaust pipe to the side and fix it temporarily.2018378
5020L20
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238966-7055B54under-engine guard - r rPosition a suitable container for collectingthe coolant under the right side of the radiator.1. Loosen the band fixing the right radiator pipe.2. Disconnect the right radiator pipe and drain the coolant.2018382
5020L24
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238966-7055B54under-engine guard - r r1. Working underneath the engine compartment, tighten the boltsfixing the bracket.2. Remove the bracket.3. Undo the nuts fixing the flange.4. Move the exhaust pipe to the side and fix it temporarily.2018387
5020L28
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238966-7055B54under-engine guard - r r1. Working underneath the engine compartment, undo the bolts fixingthe bracket.2. Remove the bracket.3. Undo the nuts fixing the flange.4. Move the exhaust pipe to the side and fix it temporarily.2018391
5020L44
769
5020L48
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Unscrew the nuts.2. Remove the right panel under the dashboard.3. Disconnect the base of the control unit from the bracket.4. Disconnect the control unit from the base.2018397
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