DescriptionAn electronic management system supervises and governs all engine parameters. It optimises performance and fuel consumption by responding in real time to different service conditions.The Diesel engine is fitted with a COMMON RAIL UNIJET injection system. This uses high, electronically-controlled injection pressure. Fuel delivery, termed a pilot injection, is optimised by the electronic control unit via the injector and not managed by the pump.The system uses signals received from numerous sensors to control actuators. It is connected to the following systems:fuel supply;air supply system;heater plugs;accelerator pedal;engine cooling;fuel preheating. For more details, 3308489see DESCRIPTION AND OPERATION:1060DIESEL FUEL INJECTIONSupply lines to the control unit and the various system components (sensors and actuators) are protected by a special maxifuse and another protects the steering wheel fuses, located with the relays in a service tank (behind the engine bulkhead).Glow plug preheating is protected by a dedicated maxifuse located in the engine bay.
Functional description Engine control unit M10 monitors and controls the UNIJET electronic injection system. Engine control unit M10 is supplied when the ignition is turned on (INT/A) at pin 13 of connector B from a line protected by fuse F16 from junction unit B1. Relay J10 governs supply to the system: it is supplied by the battery via a line protected by maxifuse B80 . Pin 46 of connector C of control unit M10 sends an enablement signal that excites relay J10 and sends power to the control unit, to pins 7, 8 and 1 of connector A; the line supplying power to pin 1 is also protected by shunt fuse B35 . Relay J15 is also supplied by the battery via a line protected by maxifuse B80 : from pins 30 and 52 of connector C of control unit M10 send signals that excite relay J15 , which supplies - via a line protected by fuse F3 of junction unit B1 - power to fuel pump N40 , which is earthed through inertia switch I50 . In case of impact, this cuts off the circuit to prevent the danger of fuel delivery. Diesel preheating relay J17 is supplied directly via a line protected by fuse B39 and excited by a recharging signal from the alternator. Under these conditions (i.e. engine running with alternator recharging) it controls the operation of diesel heating coil O20 , connector B: the thermal contact (connector A of O20 ) deactivates the system when it has heated sufficiently. Control unit M15 , responsible for controlling preheating of heater plugs A40 , is supplied directly by the battery via a line protected by fuse F37 . It receives controls from pins 38 and 51 of connector C of M10 and sends a feedback signal to pin 1 of connector B of the control unit. Pins 4, 5 and 6 of connector A of M10 are earthed. The engine control unit M10 receives signals from the various sensors in order to monitor all engine service conditions. Rpm sensor K46 supplies information on engine speed via a frequency signal sent to pin 26 of connector D of control unit M10 . It receives an earth signal from pin 37 of control unit connector D. Both signals are weak and are therefore shielded. Timing sensor K47 is supplied from pin 12 of connector D of control unit M10 . It receives a reference earth from pin 2 of connector D of control unit M10 and sends it a signal of frequency corresponding to the timing of pin 3 of the same connector. Engine temperature sender unit K36 receives a reference earth from pin 27 of connector D of control unit M10 and supplies a signal proportional to coolant temperature to pin 36 of the same connector. Air flow meter K41 receives a general power supply from pin 11 of control unit connector D and a reference voltage from control unit pin 1. It sends pin 14 of connector D a signal proportional to air flow. K41 also contains an air temperature sensor: the sensor reference earth is supplied by pin 4 of connector D of M10, while an air temperature signal is received by pin 23 of connector A. Accelerator pedal K55 is fitted with two built-in potentiometers (a main one and a safety back-up). The first receives power and earth from pins 5 and 23 respectively of connector C of M10 and sends a corresponding signal to pin 10 of the same connector. The second receives power and earth from pins 21 and 8 respectively of connector C of M10 and sends a corresponding signal to pin 9 of connector C. Fuel temperature sensor K81 fitted on the return manifold measures the temperature of diesel leaving the injectors. It receives a reference earth from pin 1 of connector C of M10 and sends a fuel temperature signal to pin 24. The turbocharging sensor K82 records turbo pressure. It is supplied from pin 8 of conector D of M10 and receives a reference earth from control unt pin 7. The signal is sent to pin 6 of control unit connector D. Fuel pressure sensor K83 is responsible for providing the injection control unit with a feedback signal for governing pressure and injection duration. It receives the power and reference earth from pins 13 and 34 respectively of connector D of M10 ; it then sends the pressure signal to pin 24 of the same connector. Fuel pressure regulator N77 maintains fuel pressure level constant in the accumulator. Both control signals are produced by pins 31 and 21 of control unit connector D. The EGR solenoid L30 controls exhaust gas recirculation. It is supplied from pin 37 of connector C of M10 and sends a signal to control unit pin 50. Pin 8 of connector C of M10 receives a signal from brake light switch I30 , ignition-operated (INT/A) through a line protected by fuse F1 in junction unit B1 ( 3309181SeeE2021BRAKE LIGHTS ). Pin 2 of connector C of M10 receives a signal from the second contact of clutch pedal switch I31 , ignition-operated (INT/A) through a line protected by fuse F1 in junction unit B1 . Injectors N70 receive a power supply to enable opening from pin 4 (cylinders 1, 3 and 4) and 1 (cylinders 2 and 5) of connector E of M10 . The engine management unit sends commands to the injectors from pins 5, 9, 8, 7 and 3 of connector E, for cylinders 1, 2, 3, 4 and 5 respectively. Instrument panel E50 is supplied with an ignition-operated power supply (INT/A) via a line protected by fuse F1 of control unit B1 . When an earth signal reaches pin 48 of connector C, an injection failure warning light comes on, when an earth signal reaches pin 43 of connector C, the glow plug preheating warning light comes on. The speedometer signal (vehicle speed) reaches pin 26 of connector C of the control unit M10 ( 3309717SeeE4010INSTRUMENT PANEL ); the signal is generated by the ABS control unit M50 . A coolant temperature sensor is sent to the instrument from pin 49 of connector C of M10 ( 3309717SeeE4010INSTRUMENT PANEL ). Control unit M10 is connected to the ALFA ROMEO CODE control unit M20 via a line from pin 13 of connector C; in this way if the ALFA ROMEO CODE unit does not detect a correct code, it does not issue enablement and the engine is not started. The control unit is equipped with a self-diagnostic unit that may be used by connecting the unit to connector R10 via pin 28 of connector C. Control unit M10 sends out a signal proportional to engine rpm ( 3309717SeeE4010INSTRUMENT PANEL ) from pin 40 of connector C. Control unit M10 is connected to the air conditioning system via pin 32 of connector D and pin 3 of connector B. This allows engine idling speed to be adjusted to increased engine load whenever the compressor is activated, or to turn off the compressor in the case of high speeds or high engine loads ( 3309931SeeE6021COMPRESSOR ENGAGEMENT ). The control unit also controls the engine cooling system: pin 23 of connector B, pin 15 of connector D and 20, 45 of connector C control activation of the relevant fan ( 3309782SeeE5020ENGINE COOLING ).
<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. 33148615530B10battery - r+r ). 1. Undo the nuts (1a) and move the fuel filter (1b) away from theair capacity body.2. Undo the nuts (2a) and move the oil vapour separator (2b) awayfrom the air chamber.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.2010632
5520C20
<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 3314409-1016A10sound-proofing cover- r + r . 1. Disconnect the electrical connection (1a) from the diesel electronicinjection system control unit and release the electrical wiringfrom the band (1b).2. Undo the fixing nut and move the heater plugs control unit asmuch as necessary.2071298
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314824-5505A18multi-function controlunit - r r . 1. Undo the bolt (1a) and push back the junction unit as far asnecessary to disconnect the electrical connections (1b).767For precise identification ofthe electrical connections, see Wiring Diagrams Section.2. Remove the junction unit.2010592
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 1. Unscrew bolt (1a) and open fuse access cover (1b).2. Undo the bolt (2a) and remove the integrated multiservices unit(2b) after having disconnected the electrical connections (2c),(2d), (2e), (2f) and (2g).2010595
5505A29
<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) for theadditional junction unit.2071293
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314864-5530B54battery cover - r+r . Make sure that the ignition key is in theOFF position.1. Disconnect the battery negative and positive terminals.2. Undo the bolt (2a) fixing the battery retaining bracket (2b).3. Remove the battery.2010647
5530B40
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314864-5530B54battery cover - r+r1. Press and release the retainers (1a), then remove the cover (1b)for the supply box on the battery. 2071303
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Working in the luggage compartment, undo the knob for the batterycover.2. Remove the battery cover.2010650
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314917-5560B11analogue control panel- r+r or replace . 1. At the bench, remove the bulbs from the panel using suitablepliers.2010702
5560B11
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). Lower the steering wheel and move it back.1. Undo the bolts (1a) and remove the upper half casing for thesteering column (1b).2010703
5560B12
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). Open the fuse carrier compartment flap.1. Using the tool (1a) and pushing the fuse carrier compartment,remove the surround (1b) complete with switches.2. Disconnect the elelectrical connections (2a), (2b) and (2c) andremove the surround complete with switches.2010706
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 1. Remove the caps (1a) and undo the bolts (1b) fixing the thirdbrake light to the rear parcel shelf.2. Disconnect the electrical connection (2a) and remove the thirdbrake light (2b).2010698
5550D17
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3314911-5550D16third stop light - r+r . 1. Undo the bolts (1a) and remove the bulb holder (1b).2010699
5550D18
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3315223-7040L20tunnel trim - r r1. Undo the nut (1a) and disconnect the earth lead (1b).2. Disconnect the electrical connection from the handbrake warninglight switch.3. Undo the nut (3a) and remove the handbrake warning light switch(3b).2010701
<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. 33148615530B10battery - r+r ). 1. Disconnect the air supply hose from the air chamber.2. Disconnect the electrical connection from the engine coolanttemperature sensor.3. Undo and remove the engine coolant temperature sensor.2008717
1060G16
<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. 33148615530B10battery - r+r ). 1. Disconnect the electrical connection from the excess pressuresensor.2. Undo the bolt (2a), remove the excess pressure sensor (2b).2008718
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. 33148615530B10battery - r+r ). 1. Disconnect the electrical connection from the fuel temperaturesensor.2. Undo and remove the fuel temperature sensor from the fuel returnmanifold pipe.2008719
1060G20
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the lift. Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 3315302-7055B54under-engine guard - r r . 1. Disconnect the condensation oil return pipe from the separatorfrom the sump.2. Disconnect the electrical connection for the engine rpm and timingsensor.3. Undo the bolt (3a) and remove the engine timing and rpm sensor(3b).2008720
<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 3314409-1016A10sound-proofing cover- r + r . 1. Disconnect the electrical connection from the fuel pressure sensoron the fuel manifold.2. Undo and remove the fuel pressure sensor on the fuel manifold.2070776
1060G30
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal ( 3314861-5530B10battery - r+r ). Proceed with the removal 3314409-1016A10sound-proofing cover- r + r . 1. Release the fuel supply and return pipes from the band.2008722
1060G38
<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. 33148615530B10battery - 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. 33148615530B10battery - 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 3314409-1016A10sound-proofing cover- r + r . 1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold (1b), throttle body connectorside.2. Loosen the band (2a) and disconnect the vacuum pipe (2b) fromthe vacuum unit.2008725
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with the removal 3314409-1016A10sound-proofing cover- r + r . 1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold (1b), throttle body connectorside.2008729
1060G70
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal ( 3314861-5530B10battery - r+r ). Proceed with the removal 3314409-1016A10sound-proofing cover- r + r . 1. Disconnect the electrical connection from the solenoid on thevacuum tank.2008731
1060G72
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal ( 3314861-5530B10battery - r+r ). Proceed with the removal 3314409-1016A10sound-proofing cover- r + r . 1. Disconnect the electrical connection from the solenoid on thevacuum tank.2. Disconnect the vacuum pipes from the solenoid on the vacuum tank.3. Undo the upper bolt (3a), loosen the lower bolt (3b), then releaseand remove the solenoid valve on the vacuum reservoir (3c), completewith lower pad. Recover the upper bolt pad.2008735
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. 33148615530B10battery - r+r ). 1. Remove the buttons (1a) using the tool (1b) and remove the protection(1c).2. Open the two protective covers (2a) and undo the nuts (2b) underneathfixing the control unit cover.3. Undo the bolts (3a) and remove the control unit cover (3b).2008736
<anchor>1</anchor><span>Refitting</span><icon><imageid>21</imageid></icon>0Removing20.767The fuel tank is supplied by theParts Dept. together with the multifunction valves (which cannotbe dismantled) and the immersed pump assembly complete with gauge.Therefore if the tank has to be replaced it is not possible to reuse theimmsered pump assembly complete with gauge removed, but a new pre-assembledunit consisting of a tank - pump - multifunction valves suppliedby the Parts Dept. must be fitted.Move the fuel tank closer to its housingusing the hydraulic jack and connect the supply pipes to the fuel vapourseparator.Refit the fuel tank in its seating andsecure with its bolts.Remove the hydraulic jack from under thefuel tank.1. Replace the rear suspension crossmeber (1a) in its housing usingthe hydraulic jack (1b) and fix it tightening the bolts (1c) tothe recommended torque.Remove the hydraulic jack from under thecrossmember.2007293
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the lift.3315188-7040B10load platform (luggage platform) trim - r+r . 3314100-1040A70submerged pump assembly complete with level guagecontrol - r + r . Drain the fuel from the tank using suitableequipment.3314704-4450B11WHEEL (one) rear - R.R. (right) Undo the bolts and remove the rear partof the right rear wheel arch liner.1. Disconnect the connecting pipes to the valves on the tank fromthe fuel vapour separator.2. Disconnect the rapid attachment for the fuel vapour supply pipeto the canister.3. Undo the bolts fixing the fuel filler pipe to the bodyshell.4. Loosen the band fixing the fuel filler pipe to the hose.2007299
<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.
1040A70
769
1040A74
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21- 7045A10 l/h or r/h front seat (one) - r+r . 1. Cut the floor carpet along the marked line.2. Undo the bolts fixing the inertia switch to the bodyshell.3. Disconnect the electrical connection (3a) and remove the inertiaswitch (3b).2007309
<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. 33148615530B10battery - r+r ). 3314048-1016A40ignition coil cover on cylinder head- r+r . 3314111-1048A48throttle heater sleeve - r r . 1. Disconnect the electrical connection from the butterfly casingintegrated with the M.D.S.2. Disconnect the electrical connections (2a) and (2b) from theinjection/ignition control unit and the earth lead (2c) from thebutterfly casing integrated with the M.D.S.3. Disconnect the accelerator cable from the butterfly casing integratedwith the M.D.S.4. Disconnect the injection/ignition wiring from the mounting bracket.5. Undo the bolts (5a) and remove the butterfly casing integratedwith the M.D.S. (5b) complete with the injection/ignition controlunit (5c).2007326
1056B21
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal ( 3314861-5530B10battery - r+r ). Proceed with the removal 3315197-7040D14engine bay rear sidecover (one) lh or rh - r r (Right side). 1. Loosen the band (1a) and disconnect the oil vapour recirculationpipe (1b) from the corrugated hose.2. Loosen the bands (2a) and remove the hose between resonator andthrottle body (2b), complete with resonator (2c).2007327
1056B48
<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. 33148615530B10battery - r+r ). 3314048-1016A40ignition coil cover on cylinder head- r+r . 1. Disconnect the electrical connection from the phase transformerelectro-magnet.2. Undo the bolts (2a) and remove the phase transformer electro-magnet(2b).2007334
1056B50
<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. 33148615530B10battery - r+r ). 3314110-1048A28vacuum air circuit resonator pipe - r+r1. Disconnect the electrical connection from the engine coolanttemperature sensor.2. Undo and remove the engine coolant temperature sensor.2007335
<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. 33148615530B10battery - r+r ). 3314048-1016A40ignition coil cover on cylinder head- r+r . Discharge the fuel supply pressure (seeGroup 10 Warnings).1. Disconnect the rapid attachment for the fuel supply pipe.2. Disconnect the electrical connections from the injectors (2a)and the electrical connection from the phase transformer electro-magnet(2b).3. Undo the two bolts (3a) and remove the single fuel manifold pipe(3b) complete with injectors (3c).2007337
1056B68
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Remove the clips (1a) and remove the injectors (1b) from thesingle fuel manifold pipe.2. Remove the seals from the injectors.2007338
Make sure that the ignition key is in theOFF position. Check that: the air conditioning is switchedoff, the accelerator pedal is never pressed and the accelerator cableis correctly positioned (refer to op. 33141321068A30accelerator control cable - r + r ). Connect the tool to the diagnostic socketand place the knob in position 3.Connect the Examiner diagnostic equipment.Connect the Examiner diagnostic equipment.Using the Examiner, enter the "ControlUnit Test" ambient.Place the ignition key in the ON position.Using the Examiner, enter the "ActiveDiagnosis" ambient, then select "Reset self-adjustmentparameters" and "Idle actuator".Using the Examiner, press "Carry outactive diagnosis".Place the ignition key in the OFF positionand wait for 30 seconds.Place the ignition key in the ON positionand wait for 30 seconds.Using the Examiner, re-establish the dialoguewith the engine control system.Using the Examiner, enter the "Parameters"ambient and select the following tests from the menu - "Idle recognitiontest - carried out" and "Idle recognition signals - synchronized".767If at least one of the parametersdoes not conform, place the ignition key in the OFF position andrepeat the procedure. If this non conformity persists, check thatthe diagnostic cable is correctly connected and check the operationof the instrument.Place the ignition key in the OFF positionand wait for 30 seconds.Start up the engine without acting on theaccelerator pedal.Disconnect the diagnostic equipment.Test the vehicle by driving for severalkilometres then, with the engine warmed up, check that it is idlingcorrectly.
1056B82
<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. 33148615530B10battery - r+r ). 1. Release and disconnect the electrical connections (1a) and (1b)from the injection/ignition system control unit.2. Undo the nuts (2a) and remove the injection/ignition controlunit (2b).2007339
1056B82
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal ( 3314861-5530B10battery - r+r ). Proceed with the removal 3315197-7040D14engine bay rear sidecover (one) lh or rh - r r (Right side). 1. Loosen the band (1a) and disconnect the oil vapour recirculationpipe (1b) from the corrugated hose.2. Loosen the bands (2a) and remove the hose between resonator andthrottle body (2b), complete with resonator (2c).2007340
<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. 33148615530B10battery - r+r ). 1. Disconnect the electrical connection from the intake air temperaturesensor.2. Undo and remove the intake air temperature sensor.2007791
1056B62
<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. 33148615530B10battery - r+r ). Discharge the fuel pressure (see GR 10- WARNINGS).1. Disconnect the electrical connections from the injectors.2007793
<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. 33148615530B10battery - r+r ). 1. Disconnect the electrical connection from the altitude corrector. 2. Undo the attachments and remove the altitude corrector.2007796
1056B79
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Remove the buttons (1a) using the tool (1b) and remove the protection(1c).2. Open the two protective covers (2a) and undo the nuts (2b) underneathfixing the control unit cover.3. Undo the bolts (3a) and remove the control unit cover (3b).2007797
<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. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r (rightand left). 3315198-7040D30engine bay front beam cover - r r . 1. Disconnect the electrical connections from the engine radiatorfan resistance.2. Disconnect the electrical connection from the engine coolingfan.Release the electrical wiring from thesecuring bands.3. Undo the bolts (3a) and remove the engine cooling fan (3b).2007448
1088E20
<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. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r (rightand left). 3315198-7040D30engine bay front beam cover - r r . 1. Disconnect the electrical connections (1a) and (1b) from theresistance for the engine cooling fan.2. Undo the bolts (1a) and remove the resistance for the enginecooling fan (1b).2007449
1088E11
<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. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r (rightand left). 3315198-7040D30engine bay front beam cover - r r . 1. Disconnect the electrical connections for the engine radiatorfan resistances (1a) and (1b).2. Disconnect the electrical connections from the engine coolingfans (2a) and (2b).3. Release the electrical wiring from the securing bands.2008921
<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. 33148615530B10battery - r+r ). 1. Disconnect the high tension leads from the ignition coil.2. Disconnect the electrical connection from the ignition coil.3. Undo the bolts (3a) and remove the ignition coil (3b).2010599
5510C14
<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. 33148615530B10battery - r+r ). 3314048-1016A40ignition coil cover on cylinder head- r+r . 1. Disconnect the electrical connections from the ignition coils.2. Disconnect the electrical connection for the air conditioningcompressor electro-magnet coupling.3. Disconnect the earth lead from the ignition coils mounting bracket.Release the electrical wiring from thebands on the tappet cover and move it aside.2010600
5510C16
<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. 33148615530B10battery - r+r ). 3314293-1016A42left hand cylinder head ignition coil cover - r+r . 1. Disconnect the electrical connections from the ignition coils.1. Undo the bolts (1a) and remove the electrical wiring securingbrackets (1b).Move the electrical wiring to the side.2010607
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the lift. Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 1. Disconnect the electrical connection for the rpm and timing sensor.2010611
<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. Disconnect the end of the accelerator cable (1a) from the acceleratorpedal (1b).2. Remove the clip (2a), undo the bolts (2b) and remove the acceleratorpedal (2c).2007347
1068A30
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Disconnect the end of the accelerator cable (1a) from the acceleratorpedal (1b).2007351
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Remove the passenger side carpet.1. Undo bolts (1a) and remove passenger side footrest (1b).2008240
1068A53
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Working from the right side of the passenger compartment, undothe upper bolts retaining the pedal unit to the bodyshell.2. Loosen the nuts retaining the pedal unit to the bodyshell.2008252
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213315196-7040D12engine front side cover (one) lh or rh - r r (leftand right). 3315198-7040D30engine bay front beam cover - r r . 1. Disconnect the vacuum pipe from the E.G.R. valve.2. Undo the nuts (2a) and disconnect the exhaust gas supply pipe(2b) from the air chamber.3. Undo the bolts (3a) and remove the protection (3b).4. Undo the bolts (4a) and remove the E.G.R. valve (4b), completewith exhaust gas supply pipe (4c) to the air chamber.2008827
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. 33148615530B10battery - r+r ). 1. Disconnect the electrical connection from the E.G.R. valve.2. Disconnect the vacuum pipes from the E.G.R. valve.3. Undo the nuts (3a) and remove the E.G.R. valve (3b).2008828
1080C28
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with the removal 3314409-1016A10sound-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.2008832
1080C54
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213315198-7040D30engine bay front beam cover - r r . 1. Undo the bolts (1a) and remove the guard (1b).2. Undo the nuts (2a) and remove the exhaust gas supply pipe fromthe E.G.R. valve to the inlet manifold (2b).3. Remove gaskets.2008833
1080C80
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp. Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal ( 3314861-5530B10battery - r+r ). Proceed with the removal 3315302-7055B54under-engine guard -r r . 1. Undo the drain plug in the radiator and drain the engine coolant.767Collect the coolant in a suitablecontainer.2008834
1080C74
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-). Proceed with removal 3314409-1016A10sound-proofing cover- r + r . 1. Disconnect the electrical connection from the EGR solenoid. 2. Tighten the bolts securing the E.G.R. solenoid to the E.G.R.water/exhaust gas heat exchanger.3. Undo the bolts (3a) and remove the E.G.R. solenoid (3b).Remove the gasket.2071139
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 1. Unscrew bolt (1a) and open fuse access cover (1b).2. Undo the nuts (2a) and remove the electronic key anti-theft controlunit (2b) after having disconnected the electrical connections (2c)and (2d).2010733
5580E18
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314734-5010C30central air outlet onfascia - r+r . 1. At the bench, remove the anti-theft device on warning light fromthe centre air vent in the dashboard.2010734
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition keyis in stop position, then disconnect the battery negative terminal3314911-5550D16third stop light - r+r . 1. Undo the bolts fixing the anti-theft remote control receiverto the rear parcel shelf.2. Remove the anti-theft device remote control receiver (2a) afterhaving disconnected the electrical connection (2b).2010735
5580E46
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3315190-7040B13load compartment/load platform right side trim -r r . 1. Undo the bolt (1a) and the nut (1b) fixing the anti-theft devicealarm/control unit.2. Disconnect the electrical connections (2a) and (2b), then removethe anti-theft device alarm/control unit (2c).2010736
5580E50
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Press in the direction of the arrow and lower the volumetricsensor unit (1a), releasing it from the inner retainers (1b) and(1c). 2071341
abs check/adjustment devices
3340A12
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on theramp. Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r (left). 3315197-7040D14engine bay rear side cover (one) lh or rh - r r (left). Remove the cap with built-in brake fluidlevel switch and drain the brake/clutch fluid from the reservoir usinga suitable syringe.1. Disconnect the comb from the A.B.S. hydraulic and electroniccontrol unit.2. Release the A.B.S. pipes from their clip.3. Disconnect the pipes from the A.B.S. hydraulic and electroniccontrol unit and move them aside.2009904
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on thelift. Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r (right) 3315197-7040D14engine bay rear side cover (one) lh or rh - r r (right) 1. Release the front right wheel speed sensor wiring from its clamp.2. Disconnect the electrical connection for the front right wheelspeed sensor.3. Release the rubber cable pass for the front right wheel speedsensor wiring from the bodywork.2009919
3340A35
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on thelift.3314864-5530B54battery cover - r+r . 3314861-5530B10battery - r+r . 3314863-5530B52Battery DRIP TRAY/SUPPORT - R.R. . 1. Disconnect the electrical connection (1a) for the rear rightwheel speed sensor and release the wiring from the clip (1b).2. Release the rubber cable pass from the rear left wheel speedsensor from the bodywork.2009921
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 1. Release the retaining spring (1a) and remove the protective cover(1b).2. Disconnect the electrical connection from the lamp.3. Release the retaining spring (3a) and remove the lamp (3b) fromthe light cluster.767If the lamp is working properly,avoid touching the bulb with your hands. If this does happen, cleanthe bulb with alcohol.2010662
5540B26
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 1. Rotate the bulb holder (1a) in an anti-clockwise direction untilit is released from the light cluster (1b).2. Disconnect the electrical connection (2a) and extract the bulbholder.3. Separate the lamp from the bulb holder (press fit).767If the lamp is working properly,avoid touching the bulb with your hands. If this does happen, cleanthe bulb with alcohol.2010663
5540B38
Prepare the vehiclecomplete with spare wheel, tools, fluids, fuel reserve.Check that the tyre inflation pressureis correct.Place the headlamp alignment switch inposition '0'.Position the vehicle on a flat surface,perpendicular to a screen with an opaque surface, 10 metres away, whichcontains the following lines.1. V - V: vertical corresponding to the trace of the vehicle symmetryplane.2. C - C: traces of the vertical planes passing through the referencecentres of the light clusters.3. HC - HC: horizontal corresponding to the height from the groundof the reference centres for the light clusters.4. AC - AC: horizontal 11 cm below the HC - HC line.5. Lines inclined at 15° as illustrated in the diagram.2010664
5540B40
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on theramp. Make sure that the ignition is OFF (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r . 1. Disconnect the electrical connection from the exhaust gas headlampcontrol unit.2. Disconnect the electrical connection from the headlamp alignmentmotor.2010666
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Undo the control unit fixing bolts.2071307
5540B44
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r . 1. Disconnect the electrical connection from the exhaust gas headlampcontrol unit.2010672
5540B46
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r . 1. Disconnect the electrical connection from the exhaust gas headlampcontrol unit.2010675
5540B48
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r . 1. Disconnect the electrical connection from the exhaust gas headlampcontrol unit.2010678
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314362-1060F36lines to injectors - r r . 1. Disconnect the electrical connections from the injectors, thenmove the electrical wiring after having released it from the bands.2008706
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 connector for the pipe from the pressure pump to thefuel manifold, manifold side, using a suitable spanner2. Undo the connector for the pipe from the pressure pump to thefuel manifold, pump side, using a suitable spanner.3. Remove the pipe from the pressure pump to the fuel manifold.767Fit a new high pressure pipe fromthe pressure pump to the fuel manifold upon reassembly. 2008708
1060F30
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314362-1060F36lines to injectors - r r . 1. Disconnect the electrical connection from the fuel pressure sensor.2. Undo the connector for the pipe from the pressure pump to thefuel manifold, manifold side, using a suitable spanner3. Undo the connector for the pipe from the pressure pump to thefuel manifold, pump side, using a suitable spanner.4. Remove the pipe from the pressure pump to the fuel manifold.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).2008710
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Undo the nuts (1a) and move the fuel filter (1b) away from theair capacity body.2. Undo the nuts (2a) and remove the oil vapour separator (2b) awayfrom the air chamber.3. Undo the bolts (3a) and move the fuel return manifold pipe (3b)aside.4. Undo the connectors for the pipes from the fuel manifold to theinjectors, injector side, using a suitable spanner.5. Undo the connectors for the pipes from the fuel manifold to theinjectors, injector side, 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.2008712
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. 33148615530B10battery - r+r ). 1. Disconnect the electrical connection from the fuel temperaturesensor.2.Disconnect the following from thefuel return manifold pipe:the fuel return pipe for lubricating the injectors (2a),the fuel return pipe from the pressure pump (2b),the fuel return pipe to the tank (2c),the fuel return pipe from the filter (2d).2008714
1060F52
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the pipe from the injectorsto the fuel recovery manifold, manifold side.Remove the springs on the injectors andremove the pipe from the injectors to the fuel recovery manifold.
<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. 33148615530B10battery - 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.2008667
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