DescriptionAn electronic management system supervisesand governs all engine parameters. It optimises performance andfuel consumption by responding in real time to different service conditions.The Diesel engine is fitted with a COMMONRAIL UNIJET injection system. This features the use of high, electronically-controlledinjection pressure. Fuel delivery, termed a pilot injection, isoptimised by the electronic control unit via the injector and not managedby the pump.On this 4 valve per cylinder version, thecommon rail injection system uses MULTIJET technology, i.e. duringeach engine cycle it performs more than the normal number of two injectionsduring each engine stroke. It performs two pre-injections (beforethe piston reaches top dead centre), one main injection and twopost-injections.This solution improves fuel consumption,emissions, noise levels and performance because it allows greatercontrol of the temperature in the combustion chamber by loweringthe maximum level and extending the optimum combustion area.The system uses signals receivedfrom numerous sensors to control actuators. It is connected to thefollowing systems:fuel supply;air supply system;heater plugs;accelerator pedal;engine cooling;fuel preheating.Thanks to the electronic management describedabove, this engine conforms to the latest anti-pollution and continuouscontrol regulations in accordance with the EOBD system (EuropeanOn Board Diagnosis); The EOBD (European On Board Diagnosis) systemcarries out continuous diagnosis of the car's petrol fuel systemcomponents relating to emissions and indicates any deteriorationof these components by the warning light in the instrument panelcoming on.The aim of the system is:keeping the efficiency of the system under control;signalling an increase in emissions due to a vehicle malfunction;signalling the need to replace components which have deteriorated. For more details, 2427398Characteristic of working principle1060DIESEL FUEL INJECTION . The system is also controlled by means ofspecial relays located in the engine compartment unit; the supplylines to the control unit and the various system components (sensors andactuators) are protected by special fuses, also located in the enginecompartment.
Functional description The engine control unit M10 monitorsand controls the entire electronic injection system. The supply controlled by the ignition (15/54)reaches pin 23 of connector A of M10 from the line protectedby fuse F16 of the engine compartment unit B1.The main injection relay T9 of B1controls the entire system; the supply line is protected by fuseF18 of B1; it is energized by a control signal (earth) coming frompin 80 of the control unit M10, and thus sends a supply:to pin 5 of connector A of the actual control unit, viathe line from fuse F17 of B1;to pins 4 and 6 of connector A of the unit, via the lineprotected by fuse F22 of B1;to the air flow meter K41, to the solenoid valves L30and to the control unit M15 via the line from fuse F11 of B1 The fuel pump relay T10 of B1 issupplied by the line of the fuse F21 of B1 . It is energized by a control signal (earth)from pin 75 of connector A of control unit M10 and supplies powerto fuel pump N40, which is earthed through the inertia switch I50, whichcuts off the circuit in the case of a crash and so prevents thedangerous spilling of fuel. Pins 1, 2 and 3 of connector A of M10are earthed. The diesel pre-heating relay T19 of B1 issupplied by the line for fuse F20 of B1 . It is energized by a control signal (earth)coming from pin 76 of connector A of the control unit M10 andsupplies power to the diesel heating resistance located in K100. Control unit M15, responsible for controllingpreheating of heater plugs A40, is supplied directly by the batteryvia a line protected by shunt fuse B37. It is supplied, connectorC, by the line for fuse F11 of B1 and exchanges command and controlsignals with pins 24 and 70 of connector A of M10 which controlsthe timing. Connector B is connected to the heater plugs A40. The engine control unit M10 receivessignals from the various sensors in order to monitor all engineservice conditions. Rpm sensor K46 supplies information onengine speed via a frequency signal sent to pins 43 and 59 of connectorB of control unit M10. Timing sensor K47 is supplied from pin21 of connector B of control unit M10. It receives a referenceearth from pin 56 of connector B of control unit M10 and sendsit a signal of frequency corresponding to the timing of pin 25 ofthe same connector. The engine temperature sensor K36 ,receives a reference earth from pin 29 of the control unit M10 andsupplies a signal proportional to the temperature of the enginecoolant to pin 54 of connector B. The air flow meter K41 receives ageneral supply from the line for fuse F11 of B1 anda reference earth from pin 27 of connector B of M10 . Itis supplied by the control unit from pin 14 of connector B of M10,and sends pin 40 of connector B a signal proportional to the airflow. There is also an air temperature sensor inside K41which sends an air temperature signal to pin 10 of connector B ofM10. Accelerator pedal K55 is fitted with twobuilt-in potentiometers (a main one and a safety back-up). The formerreceives power and earth from pins 35 and 83 respectively of connectorA of M10 and sends a corresponding signal to pin 65. Thelatter receives a supply and earth from pins 15 and 32 of connectorA of M10, respectively and sends the signal to pin 41. The fuel temperature sensor K100 measuresthe temperature of the diesel entering. It receives a referenceearth from pin 13 of connector A of M10 and sends the fuel temperaturesignal to pin 611. The supercharging sensor K82 measuresthe pressure and temperature in the intake chamber, downstream ofthe turbocharger. It is supplied from pin 24 of connector Bof M10 and receives a reference earth from pin 23 of connectorB. The signal corresponding to the pressure value is sent topin 41 of connector B of the control unit. The fuel pressure sensor K83 is responsiblefor providing the injection control unit with a feedback signalfor governing pressure and injection duration. It receives powerand a reference earth from pins 38 and 6 respectively of connectorB of M10; it then sends the pressure signal to pin 8. The control unit M10 receives the signalfor the minimum engine oil pressure sensor K30 at pin 9 of connectorB. Pin 92 of M10 receives the signal comingfrom the brake lights switch I30, with the supply controlled bythe ignition (INT) from fuse F37 of the junction unit B2. Pin 68 of M10 receives the signal comingfrom the brake lights switch I30, with the supply controlled bythe ignition (INT) from fuse F35 of the junction unit B2. Pin 93 of M10 receives the signal comingfrom the clutch switch I31 (or, on versions with a robotized gearbox,from the starting enablement switch on the brake pedal I34). The water in diesel filter sensor K31 ;is supplied by the line controlled by the ignition (INT) for fuseF35 of B2 and sends the corresponding signal to pin 90 ofconnector A of M10 . The fuel pressure regulator N77 hasthe task of keeping the value of the fuel pressure in the accumulatorconstant. The two control signals come from pins 4 and 34 of connector Bof the control unit M10. The EGR solenoid L30 controls exhaustgas recirculation. it is supplied by the line for fuse F11 of B1and is controlled by a signal for pin 15 of connector B of M10. The injectors N70 are connected to theengine management control unit from pins 47-16, 49-17, 48-31, 46-1for cylinders 1, 2, 3 and 4, respectively.The control unit M10 is connectedvia the CAN network to the Body Computer M1 and the other nodeson the network: through this connection, it sends information concerning:system self-test, which can be used by connecting to connectorC of M1.engine water temperature, which is sent to the instrumentpanel E50 which manages the relevant gauge and warning light;rpm, which is sent to the rev counter of the instrumentpanel E50;engine oil minimum pressure, which is sent to instrumentpanel E50 which manages the relevant warning light;heater plugs pre-heating, which is sent to the instrumentpanel E50 which manages the appropriate warning light;water in diesel filter, which is sent to the instrumentpanel E50 which manages the display; It receives, via CAN, the speedometer signalgenerated by the ABS control unit M50 The self-test system of the control unit M10also generates a signal - which comes from pin 78 of connector A- which is connected directly to the 'EOBD' warning light located inthe instrument panel E50. The check function inside the instrumentpanel E50 also controls the intervention of the inertia switchand any faults in the engine temperature sensor, oil pressure sensorand diesel filter sensor: if faults are detected, the 'fault' warninglight is switched on. The self-test data can be read by connectingto connector C of the Body Computer M1 - pin 7: it receives thesignals from pin 88 of connector A from the control unit M10 viathe specific tester line.
0Removing201Refitting21Ensure that the ignition key is in theOFF position, then loosen the bolt and disconnect the battery negative(-) terminal.Undo the bolt and disconnect the batteryterminal (+).Undo the battery belt nut.Remove the battery.
5530B22
0Removing201Refitting212429398-5530B10battery - r+r2429401-5530B52Battery DRIP TRAY/SUPPORT - R.R.Open the bonnet lid.1. Disconnect the electrical connection (1a) from the negative batteryterminal (1b).2. Disconnect the electrical connection from the bodyshell.3. Disconnect the electrical connection from the gearbox casing.4. Keep the battery earth lead.2052930
5530B36
0Removing201Refitting21Place the vehicle on a lift.Raise the car.1. Undo the nut (1a) and disconnect the electrical connections (1b,1c) from the starter motor.2052931
5530B52
0Removing201Refitting21 Proceed with removal 2429398-5530B10battery - r+r . 1. Remove drip tray.2. Undo the fixing bolts (2a) and remove the battery cradle (2b)after releasing the electrical wiring from the bands on the cradle.2045035
0Removing201Refitting212429579-7040A30Left instrument panellower TRIM - R.R.1. Disconnect the electrical connections (1a, 1b, 1c, 1d, 1e, 1f).2. Undo the left-threaded bolt securing the facia trim mount beam.3. Undo the bolts securing the body computer/junction unit.4. Move facia trim (4a) slightly and move body computer/junctionunit (4b) downwards.5. Disconnect the electrical connections (5a, 5b, 5c).6. Recover the body computer/junction unit.2045005
0Removing201Refitting211. Disconnect electronic control unit electrical connections (1a),(1b), (1c).2. Undo the bolts.3. Recover the control unit2045007
0Removing201Refitting211. Disconnect electronic control unit electrical connections (1a),(1b), (1c).2. Undo the bolts.3. Recover the control unit2045008
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the brake light switch electrical connection.2. Turn and remove the brake light switch.2045071
5550D16
0Removing201Refitting21Open the tailgate.1. Prise up the rubber pads.2. Press the tail-light retainers in the arrowed direction and releasefrom the seat.2045072
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the reversing lightsswitch.2. Undo and remove the reversing lights switch.2045076
multi-point injection system (mpi)
1056B14
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-). Proceed with removal 2428915-1048A10air cleaner filtering element- replace . 1. Disconnect the accelerator cable (1a) from the throttle valvedrive (1b), release from the mounting bracket (1c) and move aside.2043751
1056B50
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-). Proceed with removal 2428915-1048A10air cleaner filtering element- replace . 1. Disconnect the electrical connection from the engine coolanttemperature sensor.2. Loosen the band and disconnect the coolant return pipe to theclimate control heater, engine coolant temperature sensor side.767Recover the coolant which comesout in a suitable container.3. Undo bolts (3a) and remove coolant temperature sensor (3b) bywithdrawing downwards.2043753
1056B51
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the cam angle sensor.2. Undo the bolt (2a) and remove the cam angle sensor (2b).2043754
1056B54
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the intake air temperature/pressuresensor.2. Undo the bolts (2a) and remove the intake air temperature/pressuresensor (2b).2043755
1056B60
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-). Proceed with removal 2428915-1048A10air cleaner filtering element- replace . 1. Undo the fuel manifold protection plug and use tool (1b) to discharge the pressure from the fuel system.767Recover the fuel which comes outin a suitable container.2043756
1056B68
0Removing201Refitting21 Proceed with removal ,remembering that you are working on all the fuel injectors.
1056B70
0Removing201Refitting211. Remove the safety clip.2. Remove the injector2043758
1056B78
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the switch on the clutchpedal.2. Rotate and remove the switch on the clutch pedal.2043759
1056B82
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-). Proceed with removal 2428915-1048A10air cleaner filtering element- replace . 1. Undo retainers (1a) 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).2043760
1056B15
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-). Proceed with removal 2428998-1048A32sleeve from air cleanerto intake manifold - r + r . 1. Disconnect the electrical connection from the throtle body integratedwith the M.D.S.2. Undo the bolts (2a) and move the mounting bracket (2b) aside,complete with injection-ignition system control unit (2c).3. Undo the remaining bolt (3a) and remove throttle body with integralMDS (3b)2043975
1056B87
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-). Proceed with removal 2428928-1056B82injection/ignition systeme.c.u. (one) - r + r . 1. Undo the bolts (1a) and remove the injection/ignition controlunit mounting (1b).2043984
1056B90
0Removing201Refitting21Position the vehicle on the ramp. Proceed with removal 2429398-5530B10battery - r+r . Proceed with removal 2429401-5530B52Battery DRIP TRAY/SUPPORT- R.R. . Proceed with removal 2428915-1048A10air cleaner filtering element- replace . 1. Loosen the band and disconnect the engine oil vapour intake pipeand the side of the sleeve from the air cleaner to the intake manifold2. Loosen the band, disconnect the hose from the air filter to theintake manifold, intake manifold side and remove it.2043985
0Removing201Refitting21Position the vehicle on the ramp.Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-). Proceed with removal 2428909-1040A70submerged pump assemblycomplete with level guage control - r + r . Drain the fuel from the tank using suitableequipment and appropriate protection to meet current safety requirements. Proceed with removal 2429602-7040L22REAR TRIM on TUNNEL-R.R. . 1. Slacken the handbrake cable adjustment nut.2043722
0Removing201Refitting21Position the vehicle on the ramp. Proceed with removal 2429260-4450B08right rear wheel r r . Proceed with removal 2429680-7055B45right hand rear supplementarywheel arch - r+r . 1. Undo the bolt securing the fuel filler pipe to the body.2. Loosen the band (2a) and disconnect the fuel filler pipe (2b)from the tank.3. Loosen the band (3a) and disconnect return pipe (3b).4. Remove the sleeve joining the fuel filler pipe to the tank.2043732
1040A40
0Removing201Refitting211. Open the access flap to the fuel filler pipe cap.2. Remove pin (2a) and disconnect safety cable (2b) from the body.3. Undo and remove the fuel filler pipe cap.2043733
1040A70
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).Lift the rear seat cushion lift the floorcovering to gain access to the fuel pump flap.1. Undo the bolts (1a) and remove the protective cover (1b).2. Disconnect the electrical connection from the fuel pump and level gauge.3. Disconnect the rapid attachment for the fuel supply pipe.4. Unscrew the ring nut (4a) using tool (4b).5. Remove the immersed pump assembly complete with gauge.2043736
1040A74
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Remove upper part of floor covering next to facia.2. Disconnect the electrical connection from the inertia switch.3. Undo retaining nuts (3a) and remove inertia switch (3b)2043737
0Removing201Refitting21Position the vehicle on the ramp.Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the engine oil pressurewarning light switch.2. Undo and remove the engine oil pressure warning light switch.2043815
1084A16
0Removing201Refitting211. Withdraw the oil level dipstick.2. Undo the bolts (2a) and remove the engine oil dipstick pipe (2b),after releasing the band from the electrical wiring.2052725
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inletsleeve from the rigid pipe, air flow meter side.3. Undo the bolts (3a) and remove the air flow meter (3b).2052636
1060G14
0Removing201Refitting21Position the vehicle on the ramp. Proceed with removal . 1. Loosen the band and disconnect the lower radiator coolant outlethose from the radiator, radiator side.767Collect the engine coolant ina suitable container.2052637
1060G16
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inletsleeve from the rigid pipe, air flow meter side.2052640
1060G20
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-). Proceed with removal . 1. Disconnect the electrical connection for the rpm sensor.2. Undo the bolt (2a) and remove the engine rpm sensor (2b).2052643
1060G22
0Removing201Refitting21Position the vehicle on the ramp.Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inletsleeve from the rigid pipe, air flow meter side.2052645
1060G28
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inletsleeve from the rigid pipe, air flow meter side.2052648
1060G38
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the switch on the brakepedal.2. Rotate and remove the switch on the brake pedal.2052652
1060G42
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the clutch pedal switch.2. Rotate the clutch pedal switch and remove it.2052653
1060G80
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inletsleeve from the rigid pipe, air flow meter side.2052654
1060G90
0Removing201Refitting21Position the vehicle on the ramp. Proceed with removal 2429398-5530B10battery - r+r . Proceed with removal 2429401-5530B52Battery DRIP TRAY/SUPPORT- R.R. . 1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inletsleeve from the rigid pipe, air flow meter side.2052657
Proceed with removal 2428915Refer toop..1048A10air cleanerfiltering element - replace . With the pedal at rest, pull the acceleratorcable through a travel of 3-6 mm and ensure the throttle valve doesnot open.If it does, adjust the accelerator pedalas described below.Ensure the accelerator pedal is in restposition.1. Remove the accelerator control cable clip.2. Adjust the sleeve of cable (2a) by moving it forward or backwardand then lock with clip (2b). Adjust cable (1c), checking that whenthe pedal is fully released (at rest) the throttle valve is closed(cable not under tension) and when the pedal is fully depressed(at the end of its travel) the throttle valve is fully open (cable undertension).2043761
0Removing201Refitting21 Proceed with removal 2428915-1048A10air cleaner filtering element- replace . 1. Disconnect the accelerator cable (1a) from the throttle valvecontrol (1b).2. Remove the clip (2a) and release accelerator cable from bracket(2b).2043764
1068A20
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Release the steering column universal joint (1a) undoing thebolt (1b) fixing it to the steering box.2043995
0Removing201Refitting21Position the vehicle on the ramp. Proceed with removal 2429398-5530B10battery - r+r . Proceed with removal 2429401-5530B52Battery DRIP TRAY/SUPPORT- R.R. . 1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inletsleeve from the rigid pipe, air flow meter side.2052702
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-). Proceed with removal 2429050-1060G22cam angle sensor - rr . 1. Disconnect the electrical connections from the injectors.2. Undo the bolts (2a) and move the electrical wiring (2b) aside.2052610
1060F20
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inletsleeve from the rigid pipe, air flow meter side.2052615
1060F30
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inletsleeve from the rigid pipe, air flow meter side.2052619
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inletsleeve from the rigid pipe, air flow meter side.2052628
1060F52
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inletsleeve from the rigid pipe, air flow meter side.2052633
0Removing201Refitting21 Proceed with removal 2429398-5530B10battery - r+r . Proceed with removal 2429401-5530B52Battery DRIP TRAY/SUPPORT- R.R. . Proceed with removal 2429179-3330D30vacuum pump - r+r . 1. Disconnect the rapid connector for the fuel supply pipe fromthe fuel filter to the pressure pump, pressure pump side.2. Undo the connectors (2a) and remove the pipe from the pressurepump to the fuel manifold (2b).767When refitting, fit a new pipefrom the pressure pump to the fuel manifold.3. Loosen the band and disconnect the fuel return pipe from thepressure pump, pressure pump side.2052602
1060E50
0Removing201Refitting21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-).1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inletsleeve from the rigid pipe, air flow meter side.2052606
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