DescriptionAn electronic management system supervisesand governs all engine parameters. It optimises performance andfuel consumption by responding in real time to different serviceconditions.The Diesel engine is fitted with a COMMONRAIL UNIJET injection system. This uses high injection pressurecontrolled electronically. Fuel delivery, termed a pilot injection,is optimised by the electronic control unit via the injector and notmanaged by the pump.The system uses signals receivedfrom numerous sensors to control actuators. It is connected to thefollowing systems:fuel supply;air supply:glow plug preheating;accelerator pedal;engine cooling system;fuel preheating. For more details, 3232876Characteristic of working principle1060DIESEL FUEL INJECTION . The system is also controlled by means ofspecial relays located in the engine compartment near the battery.The supply lines to the control unit andthe various system components (sensors and actuators) are protectedby a specific maxifuse and other jumper fuses located next to thejunction unit.The heater plugs are protected by a specialmaxifuse, located near the battery.
Functional description The engine control unit M10 monitorsand controls the entire electronic injection system. Engine control unit M10 receivesa supply controlled by the ignition (15/54) at pin 13 of connectorB from the line protected by fuse B25 up to 2/99 or fuse F4 ofthe additional fuse box B98A from 2/99. The relay J10 controls the systemsupply: it is supplied by the battery, from the line for maxifuseEFI of B5 up to 2/99 or of B99 from 2/99, while thecoil is supplied by the line protected by fuse B35 up to2/99 or fuse F5 of the additional fuse box B98A from2/99. Pin 46 of connector C of control unit M10 sendsan enablement signal which energizes the relay J10 and sendsa supply to the control unit, to pins 7, 8 and 1 of connector A(the line which goes from J10 goes to pin 1 is also protected byfuse B41 up to 2/99 or fuse F3 of the additional fusebox B98A from 2/99). The relay J15 is also supplied bythe battery from the line of maxifuse EFI of B5 up to 2/99or of B99 from 2/99; up to 2/99: pins 30 and 52 of connectorC of control unit M10 send the signals which energize therelay J15 , which provides the supply to the fuel pump N40 , whichis connected to earth via the inertia switch l50. In caseof impact, this cuts off the circuit to prevent the danger of fueldelivery. from 2/99: a signal arrives from pin 52of connector C of the control unit M10 which energizes therelay J15, which provides the supply for the electric fuel pump N40 which is earthed via the inertia switch I50 . In case of impact, this cuts off the circuit to prevent the dangerof fuel delivery. The diesel pre-heating relay J17 issupplied by the battery via the lline protected by fuses B37 and B39 up to 2/99 or the GLOW maxifuse of B99 and fuse F2 ofthe additional fuse box B98A from 2/99.; it receives an ignition-controlledsupply (15/54) from the fuse B25 up to 2/99 or fuse F4 ofthe additional fuse box B98A from 2/99, and controls theoperation of the diesel heating resistor O20 : the thermalcontact (connector A of O20 ) deactivates the system whenheating has taken place. Control unit M15 , responsible forcontrolling preheating of heater plugs A40 , is supplied directlyby the battery via a line protected by fuse B37 up to 2/99 orthe GLOW maxifuse of B99 from 2/99. It receives controls from pins 38 and 51of connector C of M10 and sends a feedback signal to pin1 of connector B of the control unit. Pins 4, 5 and 6 of connector A of M10 areearthed. The engine control unit M10 receivessignals from the various sensors in order to monitor all engineservice conditions. Rpm sensor K46 supplies informationon engine speed via a frequency signal sent to pin 26 of connectorD of control unit M10 . It receives an earth signal from pin37 of control unit connector D. Both signals are weak and are thereforeshielded. Timing sensor K47 is supplied frompin 12 of connector D of control unit M10 . It receives areference earth from pin 2 of connector D of control unit M10 and sendsit a signal of frequency corresponding to the timing of pin 3 ofthe same connector.
<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
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal.1. Undo nuts (1a) and move fuel filter assembly (1b) away from theintake manifold.2. Undo nuts (2a) and move oil vapour separator (2b) away from theintake manifold.3. Undo the bolts (3a) and move the fuel return manifold pipe (3b)aside.4. Disconnect the electrical leads from the heater plugs.5. Undo and remove the heater plugs.2018707
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Unscrew the screw.2. Remove the frame (2a) and take it off the check clamps (2b).3. Unscrew the screws.4. Remove the speedometer/odometer (4a) from from support and moveit.5. Disconnect the electric connections (5a, 5b).2018847
5560B03
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Unscrew the screw.2. Remove the frame (2a) and take it off the check clamps (2b).3. Unscrew the screws.4. Extract the speedometer (4a) from the support (4b) e move it.5. Disconnect the electric connections (5a, 5b).2018848
5560B06
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21For the replacement of lampsof the speedometer/odometer proceed as follows.3238496-5560B02kilometre/mileometer - r r1. Turn and remove the lamp holder of the instrument lamp (1a) orthe lamp holder of the display lamp (1b).2. Remove the lamp from lamp holder. Pressure joint.2018849
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Unloose fixing screws and removesteering column guide.1. Detach down-lead cable.2018668
brake and reversing lights
5550D10
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Disconnect the electrical connection.2. Turn IU+2019 switch (2a) anticlockwisely of about 60° and extractit.To make the opening easier operate by a wrench on the exagonalsection (2b) of the IU+2019 switch. 2018839
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Open the boot lid, turn and undo the lower studs securing theupper trim.2. Lower upper trim (2a) and unscrew knob (2b) securing the thirdbrake light.3. Prise out the brake light and remove.4. Prise electrical connection (4a) out of support (4b) and disconnect.Recover the light cluster.2018841
5550D17
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238489-5550D16third stop light - r+r1. Unscrew the bolts and remove the mount from the light.2. Undo the bolts.3. Remove the bulb holder.4. Remove the bulbs (press-fit type)2018843
5550D18
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238117-3380A44handbrake/linkage protection- r+r1. Unscrew the screw.2. Move IU+2019switch.3. Disconnect the electrical connection and recover IU+2019switch.2018844
5550D22
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the car on an auto lift.1. Lift the car and disconnect the electrical connection of thereserving light switch.2. Unscrew and take the reserve light switch off.2018845
<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
1. Disconnect the handbrake cables (1a) from the mounting bracket(1b) and from the fastenings on the fuel tank (1c).2014028
1040A30
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the car on the lifting bridge.3237518-1040A70submerged pump assembly complete with level guagecontrol - r + rIntake fuel out of tank by ad-hoc tools.1. Remove plug for fuel filler pipe.2. Unscrew screws (2a) of fuel filler pipe (2b) to body.2014034
1040A40
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Open the access flap to the fuel fillerpipe cap.Undo and remove the fuel filler pipe cap.
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal.1. Undo the bolts (1a) and remove the protection for the inertiaswitch (1b).2. Undo the bolts (2a) and move the inertia switch (2b) forwards,then remove it after having disconnected the electrical connection(2c).2013536
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal.1. Disconnect the electrical connection from the hot-film air flowmeter. Move the relays fastened to the batterycradle to one side.2. Disconnect the pipe carrying air to the throttle body from theflow meter.3. Undo bolts (3a), remove half-rings (3b) and air flow meter (3c).2013556
1056B10
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in thestop position, then disconnect the battery negative terminal.1. Disconnect the electrical connection from the air flow meter.Move the relays fastened to the batterycradle to one side.2. Disconnect the pipe carrying air to the throttle body from theflow meter.3. Undo bolts (3a), remove half-rings (3b) and air flow meter (3c).2013557
1056B17
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in stopposition, then disconnect the battery negative terminal.1. Disconnect the oil vapour recirculation pipe from the right cylinderhead.2. Disconnect the corrugated hose from the throttle body and moveaside.2013558
1056B50
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in stopposition, then disconnect the battery negative terminal.3237529-1048A34sleeve(s) from flow meter to air supply capacitycase - r + r . 3238429-5530B10battery - r+r . 1. Disconnect the electrical connection from the engine coolanttemperature sensor.2. Undo and remove the engine coolant temperature sensor.2013560
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21- 1072B42 left hand or right hand inlet manifold (one) - r+r 767Before any interventions on componentsof the fuel system, discharge the pressure in the system using toolN. 1.870.684.000 connected to the specific valve located on thefuel distribution manifold.1. Disconnect the fuel inlet hose, then plug to prevent fuel escaping.2. Disconnect the electrical connections from the injectors.3. Undo the bolts (3a) and remove the complete fuel pipe (3b) completewith fuel injectors (3c).2013562
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Remove the retainers (1a) and remove the fuel injectors (1b)from the fuel manifold pipe.2. Remove the O-rings from the fuel injectors.2013564
<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. Working from the passenger compartment, undo bolts (1a) and removeinjection/ignition control unit guard (1b).2. Disconnect the electrical connections from the fuel injection/ignitioncontrol unit.767Follow the disconnection order:D - E - F - C - B - A.3. Undo nuts (3a) and remove injection/ignition control unit (3b).2013565
1056B90
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal.Raise the car.1. Disconnect the electrical connection for the air conditionercompressor electromagnet.2013568
1056B14
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213237529-1048A34sleeve(s) from flow meter to air supply capacitycase - r + r1. Disconnect the constant idle actuator electrical connection.2. Disconnect both coolant inlet and outlet pipes (2a-2b) from thethrottle body.3. Disconnect the throttle position switch (potentiometer) electricalconnection.4. Disconnect the accelerator cable.Release the pipes from the fasteners onthe bracket under the throttle body.5. Undo the four bolts (5a) and remove throttle body (5b) with itsgasket.2014090
1056B15
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in stopposition, then disconnect the battery negative terminal.3237652-1016A40ignition coil cover on cylinder head- r+r3237529-1048A34sleeve(s) from flow meter to air supply capacitycase - r + rDisconnect the electrical connection fromthe throttle body integral with the M.D.S.1. Disconnect electrical connections (1a) and (1b) from the injection/ignitioncontrol unit and earth lead (1c) from the throttle body integralwith the M.D.S.2. Disconnect the accelerator cable from the throttle body integralwith the M.D.S.3. Disconnect the injection/ignition wiring from the mounting bracket.4. Undo bolts (4a) and remove the throttle body integral with theM.D.S. (4b) complete with the injection/ignition control unit (4c).2014091
1056B19
<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.3237544-1056B82injection/ignition system e.c.u. (one) - r + r . 1. Disconnect the earth lead from the injection control unit support.2. Disconnect the oil vapour recovery pipe from the corrugated hose.3. Loosen the bands and remove the second section of the corrugatedhose after having released it from the bracket.4. Disconnect the electrical connection (4a) from the butterflycasing integrated with D.V.L. and release the wiring from the band(4b).2014095
1056B40
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Disconnect the electrical connection from the intake air temperaturesensor.2. Loosen collar (2a), withdraw air sleeve (2b) from the throttlebody and move to one side.3. Unscrew both power steering fluid reservoir bolts and move toone side.2014098
1056B43
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Disconnect the constant idle actuator electrical connection.2. Unscrew both retaining bolts and remove the throttle body actuator.Recover the seal.2014100
1056B46
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Disconnect the electrical connection from the intake air temperaturesensor.2. Withdraw and remove the intake air temperature sensor from theair sleeve.2014101
1056B48
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.
1056B60
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal.
1056B87
<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.1. Disconnect electrical connections (1a) and (1b) from the injection-ignitioncontrol unit.2. Release the electrical wiring from the fastening on the ignition/injectionsystem control unit mount.2014110
1056B89
<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.3237544-1056B82injection/ignition system e.c.u. (one) - r + r . 1. Disconnect the earth lead from the injection control unit support.2. Disconnect the oil vapour recovery pipe from the corrugated hose.3. Loosen the bands and remove the second section of the corrugatedhose after having released it from the bracket.4. Disconnect the electrical connection (4a) from the butterflycasing integrated with D.V.L. and release the wiring from the band(4b).2014117
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Remove the rubber accelerator pedal cover.
1068A14
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Withdraw clip (1a) and disconnect accelerator pedal link (1b)from the potentiometer. 2. Undo the nuts (2a), then move the bracket (2b) and acceleratorpedal (2c).2013581
1068A15
Remove the brake light switch from itsseat without disconnecting the electrical connection.Withdraw the retainer and disconnect theaccelerator pedal link from the potentiometer.1. Undo the nuts (1a), prise out counterspring (1b) and remove theaccelerator pedal (1c).2013583
1068A20
<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. Disconnect the electrical connection for the accelerator pedalpotentiometer.2. Undo the bolts (2a) and remove the accelerator pedal with potentiometerincorporated (2b).2013584
1068A50
<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. 32384225530A10alternator - r+r ) 3238795-7040A31flap assembly - r r . 3238803-7040A65passenger compartment box lock , one , r r . 1. Disconnect the electrical connection for the accelerator pedalpotentiometer. Release the potentiometer electrical wiringon the accelerator pedal from the securing bands and withdraw towardsthe pedal unit.2013585
1068A18
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Remove the clip (1a) and disconnect the rod (1b) from the acceleratorpedal potentiometer.2. Undo the nuts (2a), then move the bracket (2b) and acceleratorpedal (2c).2014144
1068A18
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in OFFposition, then disconnect the negative battery terminal.1. Disconnect the electrical connection for the accelerator pedalpotentiometer.2. Undo the bolts (2a) and remove the accelerator pedal with potentiometerincorporated (2b).2014145
1068A30
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Withdraw the end of the accelerator cable (1a) from pedal lever(1b).2014146
1068A31
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.Ensure that the ignition key is in stopposition, then disconnect the battery negative terminal.1. Withdraw clip (1a) and disconnect accelerator pedal link (1b)from the accelerator pedal.2014149
1068A52
<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.Remove the cover under the dashboard.1. Remove the clip (1a) and disconnect the rod (1b) from the acceleratorpedal potentiometer.2. Release the electrical wiring for the accelerator pedal potentiometerfrom the fixing bands, then disconnect the electrical connection.3. Undo the bolts (3a) and remove the accelerator pedal potentiometer(3b).2014152
<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. Release the buttons (1a) and remove the right console closingdevice (1b).2017928
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Disconnect the vacuum pipe from the E.G.R. valve.2. Undo nuts (2a) and remove the exhaust gas supply pipe from theE.G.R. valve to inlet manifold (2b) on the intake manifold side.3. Undo bolts (3a) and remove EGR valve (3b) together with thepipe carrying exhaust gas to the intake manifold.2015287
1080C24
<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 E.G.R. valve.2. Disconnect the vacuum intake pipe from the EGR system solenoid.3. Disconnect the EGR valve pipe from the EGR solenoid.4. Undo the nuts (4a) and remove the EGR system solenoid valve (4b).2015289
1080C28
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with the removal 3237758-1016A10sound-proofing cover- r + r . 1. Undo the bolts (1a) and (1b), then remove the engine oil returnpipe from EGR solenoid to throttle body (1c).2. Remove the gaskets.2015294
1080C54
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Disconnect the vacuum intake pipe from the EGR valve.2. Undo the nuts fixing the exhaust gas supply pipe from the E.G.R.valve to the inlet manifold.3. Undo the bolts (3a) fixing the E.G.R. valve (3b) to the exhaustmanifold, then remove it, complete with exhaust gas supply pipeto the inlet manifold (3c).2015296
1080C58
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213237758-1016A10sound-proofing cover - r + r . 1. Disconnect the remova the E.G.R. system vacuum pipe between theintermediate connector and the E.G.R. system solenoid valve.2. Disconnect the E.G.R. system vacuum pipe between the solenoidvalve and the E.G.R. valve (2a) and remove it after having undonethe bolts (2b).2015297
<anchor>1</anchor><span>Refitting</span><icon><imageid>21</imageid></icon>0Removing20Refit in its seating the E.G.R. solenoidcomplete with gasket and secure it with the bolts.Tighten the bolts securing the E.G.R. solenoidto the E.G.R. water/exhaust gas heat exchanger.Connect the electrical connection to theEGR solenoid. Proceed with refitting 3237758-1016A10sound-proofing cover- r + r . Connect the negative (-) battery terminal.
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp. Make sure that the ignition is OFF (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). Raise the vehicle.1. Undo nuts (1a) fixing the exhaust pipe attachment to the engine/manifold(1b), to the exhaust manifold.2. Undo nuts (2a) and remove reinforcement plate (2b).3. Undo bolts (3a) and remove turbocharger oil outlet pipe protection(3b).4. Disconnect the oil outlet pipe from the turbo.5. Disconnect the air supply hose to the heat exchanger from theturbocharger.2015180
1064A20
<anchor>0</anchor><span>Dismantling</span><icon><imageid>20</imageid></icon>1. Position the turbocharger assembly in a vice.2. Unscrew nuts (2a) and remove exhaust pipe coupling sleeve (2b).2015185
1064A22
<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 3237758-1016A10sound-proofing cover- r + r . Proceed with removal 3238966-7055B54under-engine guard -r r . 1. Undo the nuts securing the front section of the exhaust pipeto the sleeve joining the turbocharger to the exhaust manifold.2. Undo the bolts (2a) and (2b) and remove the exhaust pipe mountingbracket (2c).3. Remove the gasket.2015187
1064A30
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.3238966-7055B54under-engine guard - r r . 3237758-1016A10sound-proofing cover - r + r . 1. Undo the connector (1a) and disconnect the coolant outlet pipefrom the engine oil heat exchanger (1b), water pump rigid inletpipe side.767Recover the coolant which comesout in a suitable container.2. Disconnect the flexible pipe from the rigid coolant supply pipeto the engine oil heat exchanger.3. Undo the bolt fixing the rigid coolant supply pipe to the engineoil heat exchanger.Move the coolant inlet/outlet pipes fromthe engine oil heat exchanger, as necessary.2015219
Place the assembly in a vice fitted withprotective jaws.1. Undo the bolts (1a) and remove the exhaust gas inlet pipe tothe water/exhaust gas heat exchanger for the E.G.R. system, exhaustmanifold side.2. Undo the nuts (2a) and separate the variable geometry turbochargerassembly (2b) from the exhaust manifold (2b).2069136
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238793-7040A26steering column trim- r+r3238799-7040A37fuse box cover - r r1. Disconnect the antenna connection from the power unit.2. Remove the antenna from the starting block.3. Free the cable from the check clamps.4. Remove the antenna unit.2018926
5580E12
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238799-7040A37fuse box cover - r r1. Unscrew the shunt power unit screws .2. Remove the shunt power unit.3. Disconnect the anti-theft device power unit.4. Remove the anti-theft device power unit.5. Disconnect the electric connection.6. Disconnect thel'antenna connection.2018927
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238843-7040H38central pillar upperelement - r r1. Prise the volumetric sensor from its seat in the pillar trim.2018930
5580E24
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238799-7040A37fuse box cover - r r1. Disconnect electrical connections (1a), (1b).2. Undo the nut.3. Remove the switch and bridge.2018931
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Open the bonnet lid and remove the buttons retaining the uppertrim using the special tool.2. Lower the upper trim and disconnect the electrical connectionfor the receiver.3. Unscrew the nuts.4. Remove the receiver.2018932
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238964-7055B42Additional FRONT WHEELARCH (one), left or right - R.R.1. Unscrew the control unit bracket retaining nuts.2. Move control unit bracket (2a) and disconnect electrical connections(2b, 2c).3. Unscrew the nuts retaining the control unit to the bracket.4. Recover the control unit by taking off its bracket.2018935
abs check/adjustment devices
3340A12
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238429-5530B10battery - r+r1. Drain the brake-clutch fluid from the reservoir using a suitablesyringe.2. Disconnect the air inlet pipe from the inlet manifold.2017884
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative(-) terminal. 1. Disconnect the electrical connection for one of the front wheelrpm sensors.2. Undo the bolt (2a) and remove one of the the front wheel rpmsensors (2b) complete with electrical wiring.2017900
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative(-) terminal. 1. Disconnect the electrical connection for one of the rear wheelrpm sensors.2. Undo the bolt (2a) and remove the rpm sensor for one of the rearwheels (2b) complete with electrical wiring.2017901
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238429-5530B10battery - r+r3237804-1060F36lines to injectors - r rDisconnect the electrical connections fromthe injectors.1. Manually push springs (1a) and disconnect the fuel return pipefor lubricating the injectors (1b) from the injectors2. Undo the nuts on the brackets securing the fuel injectors withtheir washers.2015126
1060F20
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Undo the bolts and move the fuel returnmanifold pipe away from the air chamber.1. Undo the manifold side connector for the pipe from the pressurepump to the fuel manifold using a suitable spanner.2. Disconnect the pressure pump side connector from the pipe leadingfrom the pressure pump using a suitable spanner.3. Remove the pipe carrying fuel from the pressure pump to the singlefuel manifold pipe.767Fit a new high pressure pipe fromthe pressure pump to the fuel manifold upon reassembly. 2015128
1060F30
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238429-5530B10battery - r+r3237804-1060F36lines to injectors - r r1. Disconnect the electrical connection from the fuel pressure sensor.2. Loosen the manifold side connector for the supply pipe from thepressure pump to the manifold using a suitable spanner.3. Disconnect the pressure pump side connector from the pipe leadingfrom the pressure pump using a suitable spanner.4. Remove the fuel supply pipe from the single fuel manifold pipe.767Fit a new high pressure pipe fromthe pressure pump to the fuel manifold upon reassembly. 5. Undo the nuts (5a) and remove the single fuel manifold pipe (5b).2015130
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238429-5530B10battery - r+r1. Undo nuts (1a) and move fuel filter assembly (1b) away from theintake manifold.2. Undo nuts (2a) and move oil vapour separator (2b) away from theintake manifold.3. Undo the bolts (3a) and move the fuel return manifold pipe (3b)aside.4. Undo the manifold side connectors for the pipes from the fuelmanifold to the injectors using a suitable spanner.5. Undo the injector side connectors of the pipes leading fromthe fuel manifold to the injectors using a suitable spanner.6. Remove all the pipes from the fuel manifold to the injectors.767Fit new pipes from fuel manifoldto injectors upon reassembly.2015132
1060F50
<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. Disconnect the fuel return pipe for lubricating the injectorsfrom the manifold pipe.3. Disconnect the fuel return pipe from the pressure pump from thefuel return manifold pipe.4. Disconnect the fuel return pipe to the fuel tank from the fuelreturn manifold pipe. 5. Disconnect the fuel return pipe from the fuel filter from thefuel return manifold pipe. 6. Undo bolts (6a) and remove fuel return manifold pipe (6b).2015134
1060F52
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the pipe leading from the injectorsto the fuel recovery manifold from the fuel return manifold pipe:Remove the spring clips on the injectorsand remove the pipe from the injectors to the fuel recovery manifold.
<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. Undo the bolts (1a) and move aside the fuel return manifold pipe(1b) without disconnecting the pipes.2015116
1060E42
<anchor>0</anchor><span>Dismantling</span><icon><imageid>20</imageid></icon>1Reassembling21Place the pressure pump mounting in a vicefitted with protective jaws.1. Stop the rotation of the pressure pump pulley using two bolts.2. Undo the bolts (2a) and remove the safety flange (2b).3. Undo the pressure pump pulley nut.Undo the two bolts fitted previously tostop the rotation of the pressure pump pulley.2016610
<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 thermal switchfor the fuel heater.2. Undo and remove the thermal switch for the fuel heater.2015055
1044D40
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in thestop position, then disconnect the battery negative terminal.1. Undo the bolts (1a) and remove the protective cover (1b).2. Remove the fuel pre-heating relay2015056
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