AUTOMOTIVE ELECTRICIANS PORTAL - FZCO

Alfa Romeo 147 1.6 TS da 03/03 a 09/03 – COMPRESSOR ENGAGEMENT – – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION

Alfa Romeo 147 1.6 TS  da 03/03 a 09/03 – COMPRESSOR ENGAGEMENT –  – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION
Wiring diagram

Components
Component codeNameAssembly reference
B1Engine compartment junction unit5505A
B5MAXI FUSE box-
B99Maxifuse box on battery5530B
D4Front / engine coupling-
D8Front coupling / air conditioner - with heating-
H1Ignition switch5520A
K104 stage pressure switch5040B
L20Air conditioning compressor engagement electro-magnet5040A
M10Engine management ECU1056B
M10Engine management ECU1060G
M70Climate control system control unit5040D
Location of components

Components
Component codeNameAssembly reference
B1Engine compartment junction unit5505A
B5MAXI FUSE box-
B99Maxifuse box on battery5530B
D4Front / engine coupling-
D8Front coupling / air conditioner - with heating-
H1Ignition switch5520A
K104 stage pressure switch5040B
L20Air conditioning compressor engagement electro-magnet5040A
M10Engine management ECU1056B
M10Engine management ECU1060G
M70Climate control system control unit5040D
DescriptionWhen required, the climate control system ECU automatically activates the cooling circuit and dehumidifies the air by operating the air conditioner compressor.The appropriate button in the climate control control panel enables operation of the air cooling circuit; when the button is pressed the LED comes on. The above button enables the operation of the air cooling circuit; the actual switching on of the compressor, however, also depends on the climate control system ECU operating strategy: for more details 3022514Characteristic of working principle5040AIR CONDITIONING CASING AND COMPONENTS . The compressor can also be switched off by the intervention of the four stage pressure switch or by the engine control unit 3022419Characteristic of working principle1056PETROL INJECTION SYSTEM . The compressor is controlled by means of a special relay located in the engine bay control unit. the supply line is protected by a specific fuse, again in the engine bay control unit.
Functional description Relay T5 of engine bay control unit B1 controls the compressor activation circuit The relay supply arrives from the line of maxifuse CVM located on the battery, connector B99 , via the line of special fuse F19 of engine bay control unit B1 . The power supply to the coil of relay T5 arrives from main injection relay T9 and ignition-opeated line (15/54) protected by fuse F16, both located in engine bay control unit B13023484SeeE5030PETROL ENGINE ELECTRONIC MANAGEMENT . Climate control system ECU M70 sends an enablement signal for compressor activation to 4-stage pressure switch K10 : if pressures in the coolant circuit are correct, the signal emerges from the pressure switch and reaches engine control ECU M10 , pin 6 of connector A. According to its inner control strategy, control unit M10 send a compressor activation command from pin 31 of connector A which excites relay T5 so that the electromagnet for activation of air conditioner compressor L20 is controlled at 12 V.

Engine compartment junction unit



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1B



B1B



B1B



B1B



B1C



B1C



B1C



B1C



B1C



B1D



B1E



B1E



B1X



B1X



B1E



multi-function components



5505A10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025802-7040A37fuse box cover - r r1. Disconnect the electrical connections at the front (1a, 1b, 1c,1d, 1e, 1f).2. Undo the bolts fixing the control unit.3. Undo the bolts shown fixing the dashboard cover.2004865

5505A13


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025751-7025A12Engine front sound insulation COVER - R.R.3025752-7025A14Bonnet LID - R.R.

5505A24



5505A28


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025751-7025A12Engine front sound insulation COVER - R.R.3025752-7025A14Bonnet LID - R.R.

5505A32



5505A33



MAXI FUSE box



B5A



B5B



B5C



B5D



B5E



B5F



Maxifuse box on battery



B99A



B99A



B99B



B99C



B99D



battery and leads



5530B10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Ensure that the ignition key is in the OFF position, then disconnectthe negative battery terminal (-).2. Open the maxi fuse box cover.3. Undo the bolts securing the 'maxi-fuse' box to the battery.4. Loosen the bolt fixing the battery terminal (+).5. Release the maxi fuse box from the battery and move it to theside.2004975

5530B14


Follow these precautions: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 further details, see DESCRIPTION ANDOPERATION - 5580.768Proceed 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 (see op.). 5530B10).If the voltage without load is over 12.10V but less than 12.50 V, recharge the battery (see op. 5530B14).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>1Refitting213025751-7025A12Engine front sound insulation COVER - R.R.3025752-7025A14Bonnet LID - R.R.

5530B26


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the vehicle on a lift.Open the bonnet lid.1. Release the retainers (1a) and remove the cover (1b).2004980

5530B40


<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).2004986

5530B52


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Proceed with removal 3025534-5530B10battery - r+r .1. Remove the relay/fuse box cover.2. Undo the nut (2a) and disconnect the earth lead (2b) from therelay-fuse box.2004990

5530B60


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025534-5530B10battery - r+r1. Remove the battery drip tray.2. Unscrew bolts (2a) and loosen bolt (2b) securing the batterycradle.3. Move the battery cradle aside.4. Release the belt retaining stud.5. Remove the belt.2005002

Front / engine coupling



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



Front coupling / air conditioner - with heating



D8A



D8A



D8A



D8A



D8A



D8A



D8B



D8B



D8B



D8B



D8B



D8B



Ignition switch



H1A



H1A



H1A



H1A



H1B



ignition switch



5520A12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025620-5580E08aerial for alpha code- r r1. Disconnect the electrical connections (1a, 1b) from the ignitionswitch.2. Use a drift and undo the headless bolts (2a); remove the ignitionswitch (2b).7682004913

5520A14


769

5520A16


769

5520A18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. If necessary, regulate the steering wheel height adjustment lever.2. Undo the bolts fixing the lower trim.3. Remove the lower trim, releasing it from the inner retainersand the steering wheel.2004920

4 stage pressure switch



K10



K10



K10



K10



system safety check devices



5040B14


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025915-7055B54under-engine guard -r r1. Disconnect the electrical connection.2. Undo and remove the multi-stage pressure switch.2004745

5040B30


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025915-7055B54under-engine guard -r r3024826-1048A34sleeve(s) from flow meter to air supply capacitycase - r + rDrain the coolant (3024733-0010T84coolant for air conditioningsystem dehydrate and recharge ).3025803-7040A65passenger compartment box lock , one , r r (leftand right sides)3025278-3380A44handbrake/linkage protection - r+r3025833-7040L20tunnel trim - r r3025804-7040A80compartment unit on facia r r3025597-5570T80car radio unit - r+r3025444-5040D18air conditioner control unit - r r7683025613-5580C26LOCK BARREL KEY/SWITCH for deactivating passenger'AIR BAG - R.R.3025802-7040A37fuse box cover - r r3025611-5580C18air bag module - r+r3025282-4110A11steering wheel - r+r for replacement or check forversions with air bag3025799-7040A26steering column trim - r+r3025570-5550A12complete stalk unit - r+r for versions with air bag3025590-5560B11analogue control panel - r+r or replace3025591-5560B56TRIM with SWITCHES/BUTTONS FOR MULTIFUNCTION DISPLAYAND HEADLAMP alignment ADJUSTMENT - R.R.3025403-5010D56solar sensor - r r after checking electrical system3025391-5010C12Windscreen demising VENT - R.R.3025801-7040A31flap assembly - r r3025795-7040A09passenger air bag compartment cover - r r3025612-5580C22AIR BAG MODULE - Passenger side - R.R.3025796-7040A10instrument facia trim - r+r3025386-5010B45duct from climate control system - r r (left andright sides)3025389-5010B56DUCT between climate control casing and air ductto rear seats - R.R.3025805-7040A95(One), REINFORCEMENT BRACKET left or right, betweenDASHBOARD supporting crossmember and bodyshell - R.R.3025836-7040L40front compartment scuff strip - r r (left side)3025480-5505A10electrical junction unit - r+r3025431-5040C10air conditioner box - r+r .(It is not necessary to separate the air conditioning casing fromthe crossmember).3025429-5040B32expansion valve (orifice tube) r r with air conditionercase removed

5040B32


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Undo the bolts fixing the shield for the expansion valve.2. Remove the shield.2004749

Air conditioning compressor engagement electro-magnet



L20



L20



L20



L20



air conditioner coolant circuit



5040A10


768

5040A14


768

5040A20


768

5040A25


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025916-7055B64Engine compartment DUST shield in front wheel arch(one), left or right - R.R. (right side).3025412-5040A20air conditioner compressor - r+r - includes fluidlevel check and top up if necessary1. Undo the bolts fixing the compressor mounting bracket.2. Remove the compressor mounting bracket.2004712

5040A26


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025915-7055B54under-engine guard - r r3025916-7055B64Engine compartment DUST shield in front wheel arch(one), left or right - R.R. (right side).3025412-5040A20air conditioner compressor - r+r - includes fluidlevel check and top up if necessary1. Undo the bolts fixing the compressor support.2. Remove the compressor support.2004714

5040A34


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Clamp the compressor intoa bench vice.1. Undo the self-locking nut.2. Remove the damping plate.3. Undo the retaining ring.4. Remove the pulley.5. Undo the electrical cable retaining bolt.6. Undo the retaining ring.7. Remove the electromagnetic coupling.2004715

5040A40


768

5040A44


768

5040A50


768

5040A52


768

5040A57



5040A60


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Observe the following precaution.768Place the vehicle on a lift.3025751-7025A12Engine front sound insulation COVER - R.R.3025752-7025A14Bonnet LID - R.R.Drain the coolant (3024733-0010T84coolant for air conditioningsystem dehydrate and recharge ).3025915-7055B54under-engine guard - r r3025916-7055B64Engine compartment DUST shield in front wheel arch(one), left or right - R.R.3025911-7055B42Additional FRONT WHEEL ARCH (one), left or right- R.R.3025960-7210E10R.R. FRONT BUMPER1. Working in front of the right front wheel, undo the bolts fixingthe air duct.2. Remove the air duct.2048806

5040A64


768

5040A73



5040A76



5040A80


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025915-7055B54under-engine guard -r r3024826-1048A34sleeve(s) from flow meter to air supply capacitycase - r + rDrain the coolant (3025410-5040A10Air conditioning refrigerantCIRCUIT - Draining and Refilling ).3025803-7040A65passenger compartment box lock , one , r r (leftand right sides)3025278-3380A44handbrake/linkage protection - r+r3025833-7040L20tunnel trim - r r3025804-7040A80compartment unit on facia r r3025597-5570T80car radio unit - r+r3025444-5040D18air conditioner control unit - r r7683025613-5580C26LOCK BARREL KEY/SWITCH for deactivating passenger'AIR BAG - R.R.3025802-7040A37fuse box cover - r r3025611-5580C18air bag module - r+r3025282-4110A11steering wheel - r+r for replacement or check forversions with air bag3025799-7040A26steering column trim - r+r3025570-5550A12complete stalk unit - r+r for versions with air bag3025590-5560B11analogue control panel - r+r or replace3025591-5560B56TRIM with SWITCHES/BUTTONS FOR MULTIFUNCTION DISPLAYAND HEADLAMP alignment ADJUSTMENT - R.R.3025403-5010D56solar sensor - r r after checking electrical system3025391-5010C12Windscreen demising VENT - R.R.3025801-7040A31flap assembly - r r3025795-7040A09passenger air bag compartment cover - r r3025612-5580C22AIR BAG MODULE - Passenger side - R.R.3025796-7040A10instrument facia trim - r+r3025386-5010B45duct from climate control system - r r (left andright sides)3025389-5010B56DUCT between climate control casing and air ductto rear seats - R.R.3025805-7040A95(One), REINFORCEMENT BRACKET left or right, betweenDASHBOARD supporting crossmember and bodyshell - R.R.3025836-7040L40front compartment scuff strip - r r (left side)3025480-5505A10electrical junction unit - r+r3025431-5040C10air conditioner box - r+r .(It is not necessary to separate the air conditioning casing fromthe crossmember).1. Undo the bolts fixing the shield for the expansion valve.2. Remove the shield.2004740

Engine management ECU



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10B



M10B



M10B



M10B



M10B



M10B



multi-point injection system (mpi)



1056B09


<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. Disconnect the electrical connection from the air flow meter.2. Loosen collars (2a) and remove air flow meter (2b) after disconnectingit from the air intake sleeves.2001588

1056B17


<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.Proceed with the removal 3024826-1048A34sleeve(s) from flowmeter to air supply capacity case - r + r . Proceed with the removal 3024842-1056B87ignition/injection systemcontrol unit mount - r r . 1. Undo the remaining bolt (1a) and remove the throttle body integratedwith D.V.L. (1b).2001589

1056B48


<anchor>1</anchor><span>Refitting</span><icon><imageid>21</imageid></icon>0Removing20Refit the variable valve timing electro-magnet and secure by tightening the bolts to the recommended torque.Connect the electrical connection to thevariable valve timing electro-magnet.Proceed with the refitting 3024766-1016A40ignition coil coveron cylinder head- r+r .Connect the battery terminal (-).

1056B50


<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. Disconnect the electrical connection from the air flow meter.Disconnect the electrical wiring for theflow meter from the fastening on the air intake sleeve.2. Disconnect the oil vapour recirculation pipe from the air intakeduct.3. Undo the bolts (3a) and remove the air intakehouse (3b) completewith air flow meter (3c).2002026

1056B51


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Proceed with the removal 3025363-4450B10Front WHEEL (one) -R.R. (Right side). Proceed with the removal 3025915-7055B54under-engine guard -r r . Proceed with the removal 3025916-7055B64Engine compartment DUSTshield in front wheel arch (one), left or right - R.R. (Rightside). Proceed with the removal 3024921-1092G10single engine belt rr . Proceed with the removal 3024919-1092A10Crankshaft servicesPULLEY - R.R. . Proceed with the removal 3024924-1092G20engine component singlebelt fixed tensioner - one - r + r . Proceed with the removal 3024922-1092G14engine component singlebelt mobile tensioner - r + r . Proceed with the removal 3024801-1032D12timing system protectivecover(s) - r + r . Proceed with the removal 3024940-1092E10counter-rotating shaftdrive toothed belt - r + r . Proceed with the removal 3024766-1016A40ignition coil coveron cylinder head- r+r . Proceed with the removal 3025500-5510C14ignition coil/s - r+r . Proceed with the removal 3024765-1016A20single cam cover - r+ r and replace gasket . Proceed with the removal 3024791-1032B10toothed timing belt- r + r for timing adjustment or replacement . Proceed with the removal 3024906-1088C14water pump - r + r withdrive belt removed . 1. Undo the bolt (1a) for the exhaust side driven pulley using thetools (1b) and (1c) for counter-torque.2. Remove the exhaust side driven pulley.2002028

1056B60


<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.Proceed with the removal 3024766-1016A40ignition coil coveron cylinder head- r+r . Discharge the fuel supply pressure withthe tool connected to the specific valve located on the side ofthe fuel manifold pipe.1. Disconnect the electrical connections from the injectors.2. Disconnect the rapid attachment of the fuel supply front pipe,fuel manifold pipe side.3. Release the front fuel delivery pipe from the fastening on theair chamber.2001601

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.2001605

1056B70


<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 injector2001606

1056B78


<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. Disconnect the electrical connection from the switch on the clutchpedal.2. Turn the switch clockwise through 90 degrees and remove.2001607

1056B81


Make sure that the ignition key is in theOFF position.Check that the air conditioner is off andthat the accelerator pedal is never pressed.Connect the tool to the diagnostic socketand place the knob in position 3.Connect the Examiner diagnostic equipment.Place the ignition key in the ON position.Using the Examiner, enter the 'ControlUnit Test' ambient.Using the Examiner, enter the 'Active Diagnosis' ambient,then select 'Reset self-adjustment parameters' and 'Idle actuator'.Using the Examiner, press 'Carry out activediagnosis'.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>1Refitting21Ensure that the ignition key is in theOFF postition, 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.2001608

1056B87


<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. 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.2001610

1056B90


<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 postition, then disconnect the battery negative terminal.1. Disconnect the fuel vapour recirculation pipe from the air inakesleeve.2. Disconnect the intake hose from the throttle body integratedwith D.V.L. and move to one side.2001616

1056B10


<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 3024825-1048A28vacuum air circuit resonatorpipe - r+r . 1. Disconnect the electrical connection from the air flow meter. 2. Undo the nuts (2s) and remove the brackets (2b) securing theair flow meter to the aiar filter cover.3. Remove the air flow meter (3a), complete with hose (3b).2067872

1056B62


<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 3024979-1072B42left hand or right handinlet manifold (one) - r+r .Discharge the fuel system pressure withthe tool connected to the bleed valves on the fuel pipe.1. Disconnect the quick-release connector for the front fuel supplypipe, fuel pipe side.2. Disconnect the electrical connections from the injectors.3. Undo the bolts (3a) and remove the fuel pipe (3b) complete withinjectors (3c).769Avoid working with the engine hot underall circumstances;Never use tools such as pliers, screwdrivers,etc. under any circumstances;If it is released, rotate the rapid connectorcover before acting on the release buttons;Check its condition (deformation/breakageof retaining lugs, release buttons) before reconnecting it;After re-engageing the rapid connector,check that it is correctly attached by pulling it;At the end of fitting, check that thereare no fuel leaks by starting up the engine again;If there is damage to the rapid connector,replace the complete right pipe.2067877

1056B66


<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 (-).Discharge the fuel system pressure withthe tool connected to the bleed valve on the left fuel pipe.1. Disconnect the electrical connections from the left injectors.2. Disconnect the quick-release connector for the front fuel supplypipe, fuel pipe side.3. Disconnect the rapid connector from the right fuel manifold pipeto the left one.769Avoid working with the engine hot underall circumstances;Never use tools such as pliers, screwdrivers,etc. under any circumstances;If it is released, rotate the rapid connectorcover before acting on the release buttons;Check its condition (deformation/breakageof retaining lugs, release buttons) before reconnecting it;After re-engageing the rapid connector,check that it is correctly attached by pulling it;At the end of fitting, check that thereare no fuel leaks by starting up the engine again;If there is damage to the rapid connector,replace the complete right pipe.4. Undo the bolts (4a) and remove the left fuel manifold pipe (4b)complete with injectors (4c).2067878

1056B67


<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 3024979-1072B42left hand or right handinlet manifold (one) - r+r .Discharge the fuel system pressure withthe tool connected to the bleed valve on the right fuel pipe.1. Disconnect the electrical connections from the right injectors.2. Disconnect the rapid connector connecting the right fuel manifoldpipe to the left one.769Avoid working with the engine hot underall circumstances;Never use tools such as pliers, screwdrivers,etc. under any circumstances;If it is released, rotate the rapid connectorcover before acting on the release buttons;Check its condition (deformation/breakageof retaining lugs, release buttons) before reconnecting it;After re-engageing the rapid connector,check that it is correctly attached by pulling it;At the end of fitting, check that thereare no fuel leaks by starting up the engine again;If there is damage to the rapid connector,replace the complete right pipe.3. Undo the bolts (3a) and remove the right fuel manifold pipe (3b)complete with injectors (3c).2067879

pressure pump electric control



1060G10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025534-5530B10battery - r+r1. Undo collar (1a) and remove the sleeve (1b) from air cleanerto flow meter.2. Disconnect the air flow meter from the underlying sleeve.3. Disconnect the electrical connection from the air flow meter.4. Remove the air flow meter.2002316

1060G14


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025534-5530B10battery - r+rDisconnect the battery negative terminal. 1. Disconnect the water temperature sensor electrical connection.2. Undo the thermostat water temperatur sensor and remove.2002317

1060G16


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal.3025001-1016A10sound-proofing cover - r + r1. Disconnect the electrical connection from the excess pressuresensor.2. Withdraw the retaining bolt.3. Remove the excess pressure sensor2002318

1060G18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Disconnect the electrical connection from the fuel temperaturesensor.2. Undo and remove the fuel temperature sensor.2002319

1060G20


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the car on a ramp.Disconnect the battery negative terminal.3025915-7055B54under-engine guard - r r1. Disconnect the electrical connection for the rpm sensor.2. Undo bolts (2a) and remove rpm and timing sensor (2b).2002320

1060G22


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r3024759-1008C10power unit upper reaction link r r3024947-1008C14engine link bracket - r r3025054-1060G80ds electric injection control unit - r r3025360-4450B04right front wheel r r3025915-7055B54under-engine guard - r r3025916-7055B64Engine compartment DUST shield in front wheel arch(one), left or right - R.R.3024921-1092G10single engine belt r r3024919-1092A10Crankshaft services PULLEY - R.R.3024791-1032B10toothed timing belt - r + r for timing adjustmentor replacement3025006-1032B40toothed-driven pulley (one) - r + r with timing beltremoved1. Undo the bolts (1a) and remove the side timing belt protection(1b).2. Disconnect the electrical connection for the cam angle sensorlocated near the engine oil dipstick tube.3. Undo the bolts (3a) and remove the cam angle sensor (3b).2002321

1060G28


<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 3025001-1016A10sound-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.2068090

1060G30


<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 3025001-1016A10sound-proofing cover- r + r . Proceed with removal 3025915-7055B54under-engine guard -r r . Proceed with removal 3025015-1044B10fuel filter assembly -r + r or replace . 1. Undo and remove the fuel filter water presence sensor.2068091

1060G38



1060g42


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Disconnect the electrical connection from the switch on the clutchpedal.2. Turn the switch clockwise through 90 degrees and remove.2002322

1060G50


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold.2002323

1060G52


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r3025050-1060G50Electro-pneumatically controlled THROTTLE CASING- R.R.1. Undo bolts (1a) and separate fitting (1b) from the throttle body.Remove the gasket.2002326

1060G56


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold.2002327

1060G58


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold.2002330

1060G80


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Disconnect the electrical connection from the injection electroniccontrol unit.2. Undo the retaining nuts.3. Remove the engine control unit from its seat on the strut.2002332

1060G70


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.Proceed with removal 3025751-7025A12Engine front sound insulationCOVER - R.R. .Proceed with removal 3025752-7025A14Bonnet LID - R.R. .Proceed with removal 3025001-1016A10sound-proofing cover- r + r .Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-).Proceed with removal 3025915-7055B54under-engine guard -r r .Proceed with removal 3025015-1044B10fuel filter assembly -r + r or replace .Proceed with removal 3025095-1080D34engine oil vapour separator- r + r .1. At the bench, undo the nuts (1a) and remove the vacuum reservoir(1b) complete with solenoid valve (1c) and pipes from the mountingbracket.2048340

1060G90


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.Proceed with removal 3025751-7025A12Engine front sound insulationCOVER - R.R. .Proceed with removal 3025752-7025A14Bonnet LID - R.R. .Proceed with removal 3025001-1016A10sound-proofing cover- r + r .Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-).Proceed with removal 3025915-7055B54under-engine guard -r r .Proceed with removal 3025092-1076B70exhaust 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.2048344

Climate control system control unit



M70



M70



M70



M70



air conditioner controls



5040D15


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025804-7040A80compartment unit onfacia r r3025597-5570T80car radio unit - r+r1. Unscrew the bolts2004827

5040D17


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025797-7040A12removable box on facia- arrange1. Unscrew the bolts2004830

5040D18



5040D28



5040D52


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025801-7040A31flap assembly - r r3025795-7040A09passenger air bag compartment cover - r r1. Disconnect the motor electrical connection.2. Unscrew the motor retaining bolts.3. Remove the motor (3a) releasing the intake (3b).2004834

5040D70


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Unscrew the motor retaining bolt.2. Disconnect the motor electrical connection.3. Remove the motor (3a) releasing the toothed wheel (3b) from thecam rack.2004835

5040D71



5040D72



5040D76


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025803-7040A65passenger compartmentbox lock , one , r r (left and rightsides)3025278-3380A44handbrake/linkage protection - r+r3025833-7040L20tunnel trim - r r3025804-7040A80compartment unit on facia r r3025597-5570T80car radio unit - r+r3025444-5040D18air conditioner control unit - r r7683025613-5580C26LOCK BARREL KEY/SWITCH for deactivating passenger'AIR BAG - R.R.3025802-7040A37fuse box cover - r r3025611-5580C18air bag module - r+r3025282-4110A11steering wheel - r+r for replacement or check forversions with air bag3025799-7040A26steering column trim - r+r3025570-5550A12complete stalk unit - r+r for versions with air bag3025590-5560B11analogue control panel - r+r or replace3025591-5560B56TRIM with SWITCHES/BUTTONS FOR MULTIFUNCTION DISPLAYAND HEADLAMP alignment ADJUSTMENT - R.R.3025403-5010D56solar sensor - r r after checking electrical system3025391-5010C12Windscreen demising VENT - R.R.3025801-7040A31flap assembly - r r3025795-7040A09passenger air bag compartment cover - r r3025612-5580C22AIR BAG MODULE - Passenger side - R.R.3025796-7040A10instrument facia trim - r+r3025447-5040D70air distribution flap control motor with facia removed

5040D84


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025915-7055B54under-engine guard -r r3024826-1048A34sleeve(s) from flow meter to air supply capacitycase - r + rDrain the coolant (3025410-5040A10Air conditioning refrigerantCIRCUIT - Draining and Refilling ).3025803-7040A65passenger compartment box lock , one , r r (leftand right sides)3025278-3380A44handbrake/linkage protection - r+r3025833-7040L20tunnel trim - r r3025804-7040A80compartment unit on facia r r ]3025597-5570T80car radio unit - r+r3025444-5040D18air conditioner control unit - r r7683025613-5580C26LOCK BARREL KEY/SWITCH for deactivating passenger'AIR BAG - R.R.3025802-7040A37fuse box cover - r r3025611-5580C18air bag module - r+r3025282-4110A11steering wheel - r+r for replacement or check forversions with air bag3025799-7040A26steering column trim - r+r3025570-5550A12complete stalk unit - r+r for versions with air bag3025590-5560B11analogue control panel - r+r or replace3025591-5560B56TRIM with SWITCHES/BUTTONS FOR MULTIFUNCTION DISPLAYAND HEADLAMP alignment ADJUSTMENT - R.R.3025403-5010D56solar sensor - r r after checking electrical system3025391-5010C12Windscreen demising VENT - R.R.3025801-7040A31flap assembly - r r3025795-7040A09passenger air bag compartment cover - r r3025612-5580C22AIR BAG MODULE - Passenger side - R.R.3025796-7040A10instrument facia trim - r+r3025386-5010B45duct from climate control system - r r (left andright sides)3025389-5010B56DUCT between climate control casing and air ductto rear seats - R.R.3025805-7040A95(One), REINFORCEMENT BRACKET left or right, betweenDASHBOARD supporting crossmember and bodyshell - R.R.3025836-7040L40front compartment scuff strip - r r (left side)3025480-5505A10electrical junction unit - r+r3025431-5040C10air conditioner box - r+r1. Unscrew the motor retaining bolt.2. Disconnect the motor electrical connection.3. Remove the motor (3a) releasing the intake (3b).2004836

5040D86


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025801-7040A31flap assembly - r r3025795-7040A09passenger air bag compartment cover - r r1. Unscrew the motor retaining bolt.2. Disconnect the motor electrical connection.3. Remove the motor (3a) releasing the intake (3b).2004838

5040D88


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Unscrew the motor retaining bolt.2. Disconnect the electrical connections for the motor (2a, 2b,2c, 2d).3. Remove the motor (3a) releasing its connection (3b).2004840

5040D90


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025915-7055B54under-engine guard -r r3024826-1048A34sleeve(s) from flow meter to air supply capacitycase - r + rDrain the coolant (3025410-5040A10Air conditioning refrigerantCIRCUIT - Draining and Refilling ).3025803-7040A65passenger compartment box lock , one , r r (leftand right sides)3025278-3380A44handbrake/linkage protection - r+r3025833-7040L20tunnel trim - r r3025804-7040A80compartment unit on facia r r3025597-5570T80car radio unit - r+r3025444-5040D18air conditioner control unit - r r7683025613-5580C26LOCK BARREL KEY/SWITCH for deactivating passenger'AIR BAG - R.R.3025802-7040A37fuse box cover - r r3025611-5580C18air bag module - r+r3025282-4110A11steering wheel - r+r for replacement or check forversions with air bag3025799-7040A26steering column trim - r+r3025570-5550A12complete stalk unit - r+r for versions with air bag3025590-5560B11analogue control panel - r+r or replace3025591-5560B56TRIM with SWITCHES/BUTTONS FOR MULTIFUNCTION DISPLAYAND HEADLAMP alignment ADJUSTMENT - R.R.3025403-5010D56solar sensor - r r after checking electrical system3025391-5010C12Windscreen demising VENT - R.R.3025801-7040A31flap assembly - r r3025795-7040A09passenger air bag compartment cover - r r3025612-5580C22AIR BAG MODULE - Passenger side - R.R.3025796-7040A10instrument facia trim - r+r3025386-5010B45duct from climate control system - r r (left andright sides)3025389-5010B56DUCT between climate control casing and air ductto rear seats - R.R.3025805-7040A95(One), REINFORCEMENT BRACKET left or right, betweenDASHBOARD supporting crossmember and bodyshell - R.R.3025836-7040L40front compartment scuff strip - r r (left side)3025480-5505A10electrical junction unit - r+r3025431-5040C10air conditioner box - r+r1. Disconnect the electrical connections for the motors (1a, 1b,1c, 1d).2. Disconnect the electrical connections of the sensors (2a, 2b,2c, 2d).3. Disconnect the electrical connections (3a, 3b, 3c).4. Disconnect the electrical connections of the additional heater(4a, 4b, 4c) (JTD version only). 5. Release the base with relay (JTD version only).6. Disconnect the wiring harness retaining collars.7. Remove the wiring harness assembly.2004841