AUTOMOTIVE ELECTRICIANS PORTAL - FZCO

Alfa Romeo 156 2.4 JTD 10v da 10/03 – DIESEL ENGINES ELECTRONIC MANAGEMENT – – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION

Alfa Romeo 156 2.4 JTD 10v  da 10/03 – DIESEL ENGINES ELECTRONIC MANAGEMENT –  – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION
Wiring diagram



Components
Component codeNameAssembly reference
A1Battery5530B
A40Heater plug-
A40Heater plug5520C
B1Junction unit5505A
B5MAXI FUSE box-1-
B5MAXI FUSE-1 box-
B11Controls lighting fuse-
B25Fuse for services controlled by ignition(15 /-
B25Ignition-dependent services supplyfuse (15 / 54)-
B35Injection memory and CODE fuse-
B35Injection memory and Code fuse-
B37Diesel plug and preheating fuse-
B39Diesel pre-heating fuse-
B41Fuel injection control unit supplyrelay-
B98Supplementary fuse box5505A
B99Maxifuse box on battery-
B99Maxifuse box on battery5530B
C10Front left earth5505A
C15Facia earth, driver's side5505A
C31Rear right earth5505A
D1Front / dashboard connection-
D1Front / dashboard coupling-
D2Front / crossmember coupling-
D2Front /crossmember connection-
D4Front/engine connection-
D5Front / ABS couping-
D5Front / ABS coupling-
E10Speedometer5560B
E15Rev counter5560B
H1Ignition switch5520A
I30Brake pedal switch5550D
I31Clutch pedal switch1060G
I50Inertia switch1040A
I50Inertial switch1040A
J10Fuel injection main relay-
J15Fuel pump relay-
J17Diesel preheating relay-
K36Engine temperature sender unit-
K36Engine temperature sender unit1060G
K41Air flow meter-
K41Air flow meter1056B
K41Air flow meter1060G
K45Engine temperature sensor1056B
K45Engine temperature sensor1060G
K46Rpm sensor-
K46Rpm sensor1060G
K47Timing sensor-
K47Timing sensor1060G
K47Timing sensor.-
K47Timing sensor.1060G
K55Accelerator pedal potentiometer-
K55Accelerator pedal potentiometer1068A
K58Steering sensor-
K58Steering sensor3350E
K81Fuel temperature sensor-
K81Fuel temperature sensor1060G
K82Turbocharging sensor-
K82Turbocharging sensor1060G
K83Fuel pressure sensor-
K83Fuel pressure sensor1060G
L30EGR solenoid-
L30EGR solenoid1080C
L30EGR solenoid1080C
L36Variable geometry turbine solenoidvalve1064A
L62Butterfly casing solenoid valve-
L62Butterfly casing solenoid valve1060G
M10Engine management ECU-
M10Engine management control unit-
M10Engine management control unit1060G
M15Plug preheating control unit-
M20CODE control unit5580E
M50ABS control unit3340A
N40Fuel pump and sender unit1040A
N70Injector-
N70Injector1060F
N77Fuel pressure regulator-
N77Fuel pressure regulator1060E
O20Diesel heater resistance1044D
O20Diesel heater resistor1044D
O20Diesel preheating resistor-
R10Multiple tester connection-
Location of components

Components
Component codeNameAssembly reference
A1Battery5530B
A40Heater plug-
A40Heater plug5520C
B1Junction unit5505A
B5MAXI FUSE box-1-
B5MAXI FUSE-1 box-
B11Controls lighting fuse-
B25Fuse for services controlled by ignition(15 /-
B25Ignition-dependent services supplyfuse (15 / 54)-
B35Injection memory and CODE fuse-
B35Injection memory and Code fuse-
B37Diesel plug and preheating fuse-
B39Diesel pre-heating fuse-
B41Fuel injection control unit supplyrelay-
B98Supplementary fuse box5505A
B99Maxifuse box on battery-
B99Maxifuse box on battery5530B
C10Front left earth5505A
C15Facia earth, driver's side5505A
C31Rear right earth5505A
D1Front / dashboard connection-
D1Front / dashboard coupling-
D2Front / crossmember coupling-
D2Front /crossmember connection-
D4Front/engine connection-
D5Front / ABS couping-
D5Front / ABS coupling-
E10Speedometer5560B
E15Rev counter5560B
H1Ignition switch5520A
I30Brake pedal switch5550D
I31Clutch pedal switch1060G
I50Inertia switch1040A
I50Inertial switch1040A
J10Fuel injection main relay-
J15Fuel pump relay-
J17Diesel preheating relay-
K36Engine temperature sender unit-
K36Engine temperature sender unit1060G
K41Air flow meter-
K41Air flow meter1056B
K41Air flow meter1060G
K45Engine temperature sensor1056B
K45Engine temperature sensor1060G
K46Rpm sensor-
K46Rpm sensor1060G
K47Timing sensor-
K47Timing sensor1060G
K47Timing sensor.-
K47Timing sensor.1060G
K55Accelerator pedal potentiometer-
K55Accelerator pedal potentiometer1068A
K58Steering sensor-
K58Steering sensor3350E
K81Fuel temperature sensor-
K81Fuel temperature sensor1060G
K82Turbocharging sensor-
K82Turbocharging sensor1060G
K83Fuel pressure sensor-
K83Fuel pressure sensor1060G
L30EGR solenoid-
L30EGR solenoid1080C
L30EGR solenoid1080C
L36Variable geometry turbine solenoidvalve1064A
L62Butterfly casing solenoid valve-
L62Butterfly casing solenoid valve1060G
M10Engine management ECU-
M10Engine management control unit-
M10Engine management control unit1060G
M15Plug preheating control unit-
M20CODE control unit5580E
M50ABS control unit3340A
N40Fuel pump and sender unit1040A
N70Injector-
N70Injector1060F
N77Fuel pressure regulator-
N77Fuel pressure regulator1060E
O20Diesel heater resistance1044D
O20Diesel heater resistor1044D
O20Diesel preheating resistor-
R10Multiple tester connection-
DescriptionAn electronic management system supervisesand governs all engine parameters. It optimises performance andfuel consumption by responding in real time to different serviceconditions.The Diesel engine is fitted with a COMMONRAIL UNIJET injection system. This uses high injection pressurecontrolled electronically. Fuel delivery, termed a pilot injection,is optimised by the electronic control unit via the injector and notmanaged by the pump.The system uses signals receivedfrom numerous sensors to control actuators. It is connected to thefollowing systems:fuel supply;air supply:glow plug preheating;accelerator pedal;engine cooling system;fuel preheating. For more details, 3232876Characteristic of working principle1060DIESEL FUEL INJECTION . The system is also controlled by means ofspecial relays located in the engine compartment near the battery.The supply lines to the control unit andthe various system components (sensors and actuators) are protectedby a specific maxifuse and other jumper fuses located next to thejunction unit.The heater plugs are protected by a specialmaxifuse, located near the battery.
Functional description The engine control unit M10 monitorsand controls the entire electronic injection system. Engine control unit M10 receivesa supply controlled by the ignition (15/54) at pin 13 of connectorB from the line protected by fuse B25 up to 2/99 or fuse F4 ofthe additional fuse box B98A from 2/99. The relay J10 controls the systemsupply: it is supplied by the battery, from the line for maxifuseEFI of B5 up to 2/99 or of B99 from 2/99, while thecoil is supplied by the line protected by fuse B35 up to2/99 or fuse F5 of the additional fuse box B98A from2/99. Pin 46 of connector C of control unit M10 sendsan enablement signal which energizes the relay J10 and sendsa supply to the control unit, to pins 7, 8 and 1 of connector A(the line which goes from J10 goes to pin 1 is also protected byfuse B41 up to 2/99 or fuse F3 of the additional fusebox B98A from 2/99). The relay J15 is also supplied bythe battery from the line of maxifuse EFI of B5 up to 2/99or of B99 from 2/99; up to 2/99: pins 30 and 52 of connectorC of control unit M10 send the signals which energize therelay J15 , which provides the supply to the fuel pump N40 , whichis connected to earth via the inertia switch l50. In caseof impact, this cuts off the circuit to prevent the danger of fueldelivery. from 2/99: a signal arrives from pin 52of connector C of the control unit M10 which energizes therelay J15, which provides the supply for the electric fuel pump N40 which is earthed via the inertia switch I50 . In case of impact, this cuts off the circuit to prevent the dangerof fuel delivery. The diesel pre-heating relay J17 issupplied by the battery via the lline protected by fuses B37 and B39 up to 2/99 or the GLOW maxifuse of B99 and fuse F2 ofthe additional fuse box B98A from 2/99.; it receives an ignition-controlledsupply (15/54) from the fuse B25 up to 2/99 or fuse F4 ofthe additional fuse box B98A from 2/99, and controls theoperation of the diesel heating resistor O20 : the thermalcontact (connector A of O20 ) deactivates the system whenheating has taken place. Control unit M15 , responsible forcontrolling preheating of heater plugs A40 , is supplied directlyby the battery via a line protected by fuse B37 up to 2/99 orthe GLOW maxifuse of B99 from 2/99. It receives controls from pins 38 and 51of connector C of M10 and sends a feedback signal to pin1 of connector B of the control unit. Pins 4, 5 and 6 of connector A of M10 areearthed. The engine control unit M10 receivessignals from the various sensors in order to monitor all engineservice conditions. Rpm sensor K46 supplies informationon engine speed via a frequency signal sent to pin 26 of connectorD of control unit M10 . It receives an earth signal from pin37 of control unit connector D. Both signals are weak and are thereforeshielded. Timing sensor K47 is supplied frompin 12 of connector D of control unit M10 . It receives areference earth from pin 2 of connector D of control unit M10 and sendsit a signal of frequency corresponding to the timing of pin 3 ofthe same connector.

Battery



A1A



A1B



A1C



A1C



A1C



A1C



A1D



A1D



A1D



A1D



A1



A1



A1



battery and leads



5530B10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the car on a ramp.Undo the bolt securing the bracket on thebattery mount.Release the battery from the anchoragebracket complete with strap and remove.

5530B14


769768768

5530B18


Follow these precautions.769On batteries with an opticam hydrometer,electrolyte level and battery charge status can be monitored qualitativelyby examining the indicator colour:a light, bright colour indicates low electrolytelevel: top up with distilled water;a dark colour without a green area in thecentre indicates that the electrolyte level is correct but chargeis low: recharge the battery;a dark colour with a green area in themiddle indicates that both electrolyte level and charge status arecorrect: no action is necessary. For more details 3238420See subassembly5530 CURRENT GENERATOR . 768Proceed as follows.Check the battery voltage without loadusing the test device recommended by the Service outlets (e.g. 'MICRO360').Depending on the voltage values measured,which define the state of charge of the battery, proceed as follows: If the voltage without load is less than12.10 V, replace the battery ( 32384295530B10battery - r+r ). If the voltage without load is over 12.10V but less than 12.50 V, recharge the battery ( 32384305530B14battery - recharge ). If the voltage without load is over 12.50V, the battery is efficient.If necessary, top up the electrolyte asfollows.Carefully remove the cap strip.Top up with distilled and deionized water,taking care not to allow electrolyte to splash out.768

5530B22


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the car on the liftingbridge.1. Open engine compartment cap and disconnect battery negative terminal.2. Disconnect mass terminal on side member.3. Lift the car and disconnect mass terminal on gearbox.4. Lower the car again and remove battery earth lead.2018767

5030B26



5030B40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Open the protective cover2. Loosen the nut and disconnect the ABS supply lead3. Loosen the nut and disconnect the starter motor supply lead4. Undo the clip and undo the box retaining bolts.5. Loosen the battery positive terminal nut.2018769

5530B52


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238429-5530B10battery - r+rRelease the air duct hose from the mountingbracket on the drip tray. Remove the relay shield.1. Release the relays from the battery drip tray and remove them.2. Undo the nut fixing the air filter mounting bracket to the batterydrip tray.3. Undo the two fixing nuts (3a) and move the connections/electricalwiring mounting bracket (3b) aside.4. Release the accelerator cable from the fastening on the bracket.2018771

Heater plug



A40A



A40A



A40B



A40B



A40C



A40C



A40D



A40D



A40E



A40E



cold starting system (diesel engines)



5520C10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal.1. Undo nuts (1a) and move fuel filter assembly (1b) away from theintake manifold.2. Undo nuts (2a) and move oil vapour separator (2b) away from theintake manifold.3. Undo the bolts (3a) and move the fuel return manifold pipe (3b)aside.4. Disconnect the electrical leads from the heater plugs.5. Undo and remove the heater plugs.2018707

Junction unit



B1A



B1A



B1B



B1B



B1B



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1D



B1D



B1D



B1D



B1D



B1D



B1D



B1D



B1D



B1D



B1D



B1D



B1D



B1D



B1D



B1E



B1E



B1E



B1F



B1F



B1G



B1G



B1G



B1G



B1H



B1H



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1J



B1J



B1J



B1J



B1J



multi-function components



5505A10


769

5505A16


769

5505A18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238830-7040G24switch for facia compartmentlight - r+r3238829-7040G20facia compartment light bulb holder - r+r3238795-7040A31flap assembly - r r1. Undo the bolts.2. Move the integrated service control unit slightly.3. Disconnect the electrical connections (3a, 3b, 3c).2018617

5505A30


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Remove components obstractingaccess to earth carrier node.1. Unscrew screw.2. Disjoin earth carrier node.2018618

5505A38



MAXI FUSE box-1



B5A



B5B



B5B



B5B



B5B



Controls lighting fuse



B11



B11



Fuse for services controlled by ignition (15 /



B25



B25



B25



B25



B25



B25



Injection memory and CODE fuse



B35



B35



B35



B35



Diesel plug and preheating fuse



B37



Diesel pre-heating fuse



B39



B39



Fuel injection control unit supply relay



B41



B41



B41



B41



Supplementary fuse box



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98A



B98B



B98B



B98B



B98B



B98B



B98C



B98C



B98C



Maxifuse box on battery



B99A



B99A



B99A



B99A



B99B



B99B



B99B



B99B



B99B



B99B



B99C



B99C



B99C



B99C



B99C



B99C



B99C



B99C



B99D



B99D



B99D



B99D



B99D



B99D



B99D



Front left earth



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10B



C10B



C10B



C10B



C10C



Rear right earth



C31



C31



C31



C31



C31



C31



C31



Front / dashboard connection



D1B



D1B



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



D1



Front / crossmember coupling



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2A



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2B



D2C



D2C



Front/engine connection



D4



D4



D4A



D4A



D4A



D4A



D4A



D4A



D4A



D4A



D4A



D4A



D4A



D4A



D4A



D4A



D4A



D4A



D4A



D4A



D4B



D4B



D4B



D4B



D4B



D4B



D4B



D4B



D4B



D4B



D4B



D4B



D4B



D4B



D4B



D4B



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



D4



Front / ABS couping



D5A



D5A



D5A



D5A



D5A



D5B



D5B



D5B



D5B



D5B



D5B



D5B



D5B



D5B



D5B



D5B



D5B



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



D5



Power supply and earths



E1010



E1020



E1020



E1020



E1010



E1010



E1010



E1010



E1010



E1010



E1010



E1010



E1010



E1010



E1010



E1010



E1010



analogue control panel



5560b02


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Unscrew the screw.2. Remove the frame (2a) and take it off the check clamps (2b).3. Unscrew the screws.4. Remove the speedometer/odometer (4a) from from support and moveit.5. Disconnect the electric connections (5a, 5b).2018847

5560B03


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Unscrew the screw.2. Remove the frame (2a) and take it off the check clamps (2b).3. Unscrew the screws.4. Extract the speedometer (4a) from the support (4b) e move it.5. Disconnect the electric connections (5a, 5b).2018848

5560B06


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21For the replacement of lampsof the speedometer/odometer proceed as follows.3238496-5560B02kilometre/mileometer - r r1. Turn and remove the lamp holder of the instrument lamp (1a) orthe lamp holder of the display lamp (1b).2. Remove the lamp from lamp holder. Pressure joint.2018849

5560B12



Rev counter



E15A



E15A



E15A



E15A



E15A



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



E15B



Ignition switch



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1A



H1B



H1B



H1B



H1B



H1B



H1B



ignition switch



5520A12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238121-4110A11steering wheel - r+rfor replacement or check for versions with air bag3238793-7040A26steering column trim - r+r3238476-5550A12complete stalk unit - r+r for versions with air bag1. Disconnect electric connection from ignition switch.2. Unscrew screws (2a) and remove starter switch (2b). 2018661

5520A14


769

5520A16


769

5520A18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Unloose fixing screws and removesteering column guide.1. Detach down-lead cable.2018668

brake and reversing lights



5550D10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Disconnect the electrical connection.2. Turn IU+2019 switch (2a) anticlockwisely of about 60° and extractit.To make the opening easier operate by a wrench on the exagonalsection (2b) of the IU+2019 switch. 2018839

5550D14



5550D16


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Open the boot lid, turn and undo the lower studs securing theupper trim.2. Lower upper trim (2a) and unscrew knob (2b) securing the thirdbrake light.3. Prise out the brake light and remove.4. Prise electrical connection (4a) out of support (4b) and disconnect.Recover the light cluster.2018841

5550D17


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238489-5550D16third stop light - r+r1. Unscrew the bolts and remove the mount from the light.2. Undo the bolts.3. Remove the bulb holder.4. Remove the bulbs (press-fit type)2018843

5550D18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238117-3380A44handbrake/linkage protection- r+r1. Unscrew the screw.2. Move IU+2019switch.3. Disconnect the electrical connection and recover IU+2019switch.2018844

5550D22


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the car on an auto lift.1. Lift the car and disconnect the electrical connection of thereserving light switch.2. Unscrew and take the reserve light switch off.2018845

5550D26



pressure pump electric control



1060G10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213237784-1048A50air inlet pipe to turbo charger - r + r Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). 1. Undo the bolts (1a) and move the relay holder backet (1b) awayfrom the battery drip tray.2. Disconnect the flow meter electrical connection.3. Undo the nuts (3a) and remove retaining plates (3b).4. Remove flow meter (4a) together with the sleeve from the flowmeter to turbocharger air intake pipe (4b) and the sleeve from thefilter to flow meter (4c).2015135

1060G14


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238429-5530B10battery - r+r1. Disconnect the electrical connection from the engine coolanttemperature sensor.2. Undo and remove the engine coolant temperature sensor.2015136

1060G16


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal. 1. Disconnect the electrical connection from the excess pressuresensor.2. Undo the bolt (2a), remove the excess pressure sensor (2b).2015137

1060G18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). 1. Disconnect the electrical connection from the fuel temperaturesensor.2. Undo and remove the fuel temperature sensor from the fuel returnmanifold pipe.2015138

1060G20


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the lift.Raise the car. Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). 1. Disconnect the condensed oil return pipe from the sump.Disconnect the electrical connection forthe engine rpm and timing sensor.2. Undo the bolts (2a) and remove the rpm and timing sensor (2b).2015139

1060G22



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 3237758-1016A10sound-proofing cover- r + r1. Disconnect the electrical connection from the fuel pressure sensoron the fuel manifold.2. Undo and remove the fuel pressure sensor on the fuel manifold.2068748

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 3237758-1016A10sound-proofing cover- r + r Proceed with removal 3238966-7055B54under-engine guard -r r Proceed with removal 3237725-1044B10fuel filter assembly -r + r or replace1. Undo and remove the fuel filter water presence sensor.2068749

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. 32384295530B10battery - r+r ). Disconnect the electrical connection fromthe switch on the brake pedal.Rotate and remove the switch on the brakepedal.

1060G42


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). Disconnect the electrical connection fromthe switch on the clutch pedal.Rotate and remove the switch on the clutchpedal.

1060G50


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with the removal 3237758-1016A10sound-proofing cover- r + r . 1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold (1b), throttle body connectorside. 2015145

1060G52


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with removal 3237758-1016A10sound-proofing cover- r + r . Proceed with removal 3237818-1060G50Electro-pneumaticallycontrolled THROTTLE CASING - R.R. .

1060G58


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with the removal 3237758-1016A10sound-proofing cover- r + r . 1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold (1b), throttle body connectorside.2015155

1060G70


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in thestop OFF, then disconnect the battery negative terminal. Proceed with the removal 3237758-1016A10sound-proofing cover- r + r . 1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold (1b), throttle body connectorside.2015161

1060G72


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in thestop OFF, then disconnect the battery negative terminal. Proceed with the removal 3237758-1016A10sound-proofing cover- r + r . 1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold (1b), throttle body connectorside.2015169

1060G80


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is OFF (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). Working from the passenger compartmentin the front passenger-side wheel arch compartment, unscrew the boltand nut then remove the control unit protection.Disconnect the electrical connections afterturning the safety levers.Unscrew the nuts and remove the dieselelectronic injection system.

1060G88


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the battery negative terminal.1. Undo the nut (1a) and remove the protective cover (1b).2. Remove the diesel injection system relays.2015179

1060G90


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp. Proceed with removal 3237758-1016A10sound-proofing cover- r + r . Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-). Proceed with removal 3238966-7055B54under-engine guard -r r . Proceed with removal 3237866-1076B70exhaust pipe betweenpre-catalytic converter and catalytic converter - r r . 1. Disconnect the electrical connection from the engine oil pressurewarning light switch.2. Disconnect the electrical connection for the engine oil levelsensor.3. Disconnect the electrical connection for the rpm sensor.2069114

Inertia switch



I50



I50



fuel tank and components



1040A10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.3238808-7040B10load platform (luggage platform) trim - r+r . 3238939-7050B18rear seat arm rest - r+r . 3237518-1040A70submerged pump assembly complete with level guagecontrol - r + r . Drain the fuel from the tank using suitableequipment.Remove the handbrake bush.1. Lift up the handbrake lever (1a), loosen the adjustment nut (1b),then lower the lever.2013502

1040A14


1. Disconnect the handbrake cables (1a) from the mounting bracket(1b) and from the fastenings on the fuel tank (1c).2014028

1040A30


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the car on the lifting bridge.3237518-1040A70submerged pump assembly complete with level guagecontrol - r + rIntake fuel out of tank by ad-hoc tools.1. Remove plug for fuel filler pipe.2. Unscrew screws (2a) of fuel filler pipe (2b) to body.2014034

1040A40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Open the access flap to the fuel fillerpipe cap.Undo and remove the fuel filler pipe cap.

1040A66


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with removal 3238808-7040B10load platform (luggageplatform) trim - r+r Proceed with removal 3238939-7050B18rear seat arm rest - r+r Proceed with removal 3238915-7050A20one-piece rear seat cushion- r r Proceed with removal 3238936-7050B10l/h or r/h head restraint(one) of rear seat - r+r Proceed with removal 3238914-7050A19rear seat squab - rr Proceed with removal 3237518-1040A70submerged pump assemblycomplete with level guage control - r + rRemove the submerged fuel pump assemblyfuel level gauge control.

1040A70


769

1040A74


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal.1. Undo the bolts (1a) and remove the protection for the inertiaswitch (1b).2. Undo the bolts (2a) and move the inertia switch (2b) forwards,then remove it after having disconnected the electrical connection(2c).2013536

Fuel injection main relay



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



Diesel preheating relay



J17



J17



J17



J17



Engine temperature sender unit



K36



K36



K36



K36



K36



K36



K36



K36



K36



multi-point injection system (mpi)



1056B09


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal.1. Disconnect the electrical connection from the hot-film air flowmeter. Move the relays fastened to the batterycradle to one side.2. Disconnect the pipe carrying air to the throttle body from theflow meter.3. Undo bolts (3a), remove half-rings (3b) and air flow meter (3c).2013556

1056B10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in thestop position, then disconnect the battery negative terminal.1. Disconnect the electrical connection from the air flow meter.Move the relays fastened to the batterycradle to one side.2. Disconnect the pipe carrying air to the throttle body from theflow meter.3. Undo bolts (3a), remove half-rings (3b) and air flow meter (3c).2013557

1056B17


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in stopposition, then disconnect the battery negative terminal.1. Disconnect the oil vapour recirculation pipe from the right cylinderhead.2. Disconnect the corrugated hose from the throttle body and moveaside.2013558

1056B50


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in stopposition, then disconnect the battery negative terminal.3237529-1048A34sleeve(s) from flow meter to air supply capacitycase - r + r . 3238429-5530B10battery - r+r . 1. Disconnect the electrical connection from the engine coolanttemperature sensor.2. Undo and remove the engine coolant temperature sensor.2013560

1056B51


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213237529-1048A34sleeve(s) from flow meter to air supply capacitycase - r + r3238429-5530B10battery - r+r1. Disconnect the electrical connection for the cam angle sensor.2. Undo bolt (2a) and remove cam angle sensor (2b) from the righthand cylinder head.2013561

1056B62


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21- 1072B42 left hand or right hand inlet manifold (one) - r+r 767Before any interventions on componentsof the fuel system, discharge the pressure in the system using toolN. 1.870.684.000 connected to the specific valve located on thefuel distribution manifold.1. Disconnect the fuel inlet hose, then plug to prevent fuel escaping.2. Disconnect the electrical connections from the injectors.3. Undo the bolts (3a) and remove the complete fuel pipe (3b) completewith fuel injectors (3c).2013562

1056B66



1056B67



1056B68


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Remove the retainers (1a) and remove the fuel injectors (1b)from the fuel manifold pipe.2. Remove the O-rings from the fuel injectors.2013564

1056B70



1056B81


769

1056B82


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal.1. Working from the passenger compartment, undo bolts (1a) and removeinjection/ignition control unit guard (1b).2. Disconnect the electrical connections from the fuel injection/ignitioncontrol unit.767Follow the disconnection order:D - E - F - C - B - A.3. Undo nuts (3a) and remove injection/ignition control unit (3b).2013565

1056B90


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal.Raise the car.1. Disconnect the electrical connection for the air conditionercompressor electromagnet.2013568

1056B14


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213237529-1048A34sleeve(s) from flow meter to air supply capacitycase - r + r1. Disconnect the constant idle actuator electrical connection.2. Disconnect both coolant inlet and outlet pipes (2a-2b) from thethrottle body.3. Disconnect the throttle position switch (potentiometer) electricalconnection.4. Disconnect the accelerator cable.Release the pipes from the fasteners onthe bracket under the throttle body.5. Undo the four bolts (5a) and remove throttle body (5b) with itsgasket.2014090

1056B15


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in stopposition, then disconnect the battery negative terminal.3237652-1016A40ignition coil cover on cylinder head- r+r3237529-1048A34sleeve(s) from flow meter to air supply capacitycase - r + rDisconnect the electrical connection fromthe throttle body integral with the M.D.S.1. Disconnect electrical connections (1a) and (1b) from the injection/ignitioncontrol unit and earth lead (1c) from the throttle body integralwith the M.D.S.2. Disconnect the accelerator cable from the throttle body integralwith the M.D.S.3. Disconnect the injection/ignition wiring from the mounting bracket.4. Undo bolts (4a) and remove the throttle body integral with theM.D.S. (4b) complete with the injection/ignition control unit (4c).2014091

1056B19


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the battery negative terminal.3237544-1056B82injection/ignition system e.c.u. (one) - r + r . 1. Disconnect the earth lead from the injection control unit support.2. Disconnect the oil vapour recovery pipe from the corrugated hose.3. Loosen the bands and remove the second section of the corrugatedhose after having released it from the bracket.4. Disconnect the electrical connection (4a) from the butterflycasing integrated with D.V.L. and release the wiring from the band(4b).2014095

1056B40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Disconnect the electrical connection from the intake air temperaturesensor.2. Loosen collar (2a), withdraw air sleeve (2b) from the throttlebody and move to one side.3. Unscrew both power steering fluid reservoir bolts and move toone side.2014098

1056B43


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Disconnect the constant idle actuator electrical connection.2. Unscrew both retaining bolts and remove the throttle body actuator.Recover the seal.2014100

1056B46


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Disconnect the electrical connection from the intake air temperaturesensor.2. Withdraw and remove the intake air temperature sensor from theair sleeve.2014101

1056B48


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.

1056B60


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal.

1056B87


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in thestop OFF, then disconnect the battery negative terminal.1. Disconnect electrical connections (1a) and (1b) from the injection-ignitioncontrol unit.2. Release the electrical wiring from the fastening on the ignition/injectionsystem control unit mount.2014110

1056B89


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the battery negative terminal.3237544-1056B82injection/ignition system e.c.u. (one) - r + r . 1. Disconnect the earth lead from the injection control unit support.2. Disconnect the oil vapour recovery pipe from the corrugated hose.3. Loosen the bands and remove the second section of the corrugatedhose after having released it from the bracket.4. Disconnect the electrical connection (4a) from the butterflycasing integrated with D.V.L. and release the wiring from the band(4b).2014117

Engine temperature sensor



K45



K45



K45



K45



Rpm sensor



K46



K46



K46



K46



K46



K46



K46



K46



K46



K46



Timing sensor



K47



K47



K47



K47



K47



K47



K47



K47



K47



K47



K47



accelerator pedal control



1068A12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Remove the rubber accelerator pedal cover.

1068A14


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Withdraw clip (1a) and disconnect accelerator pedal link (1b)from the potentiometer. 2. Undo the nuts (2a), then move the bracket (2b) and acceleratorpedal (2c).2013581

1068A15


Remove the brake light switch from itsseat without disconnecting the electrical connection.Withdraw the retainer and disconnect theaccelerator pedal link from the potentiometer.1. Undo the nuts (1a), prise out counterspring (1b) and remove theaccelerator pedal (1c).2013583

1068A20


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-).1. Disconnect the electrical connection for the accelerator pedalpotentiometer.2. Undo the bolts (2a) and remove the accelerator pedal with potentiometerincorporated (2b).2013584

1068A50


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 32384225530A10alternator - r+r ) 3238795-7040A31flap assembly - r r . 3238803-7040A65passenger compartment box lock , one , r r . 1. Disconnect the electrical connection for the accelerator pedalpotentiometer. Release the potentiometer electrical wiringon the accelerator pedal from the securing bands and withdraw towardsthe pedal unit.2013585

1068A18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Remove the clip (1a) and disconnect the rod (1b) from the acceleratorpedal potentiometer.2. Undo the nuts (2a), then move the bracket (2b) and acceleratorpedal (2c).2014144

1068A18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in OFFposition, then disconnect the negative battery terminal.1. Disconnect the electrical connection for the accelerator pedalpotentiometer.2. Undo the bolts (2a) and remove the accelerator pedal with potentiometerincorporated (2b).2014145

1068A30


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Withdraw the end of the accelerator cable (1a) from pedal lever(1b).2014146

1068A31


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.Ensure that the ignition key is in stopposition, then disconnect the battery negative terminal.1. Withdraw clip (1a) and disconnect accelerator pedal link (1b)from the accelerator pedal.2014149

1068A52


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the negative (-) battery terminal.Remove the cover under the dashboard.1. Remove the clip (1a) and disconnect the rod (1b) from the acceleratorpedal potentiometer.2. Release the electrical wiring for the accelerator pedal potentiometerfrom the fixing bands, then disconnect the electrical connection.3. Undo the bolts (3a) and remove the accelerator pedal potentiometer(3b).2014152

Steering sensor



K58



K58



K58



K58



vehicle direction control system vdc



3350E20


The VDC steering angle sensor is incorporatedin the steering column switch unit and cannot be dismantled on itsown. Therefore to remove it, proceed as described in 3238476Refer toop..5550A12completestalk unit - r+r for versions with air bag .

3350E30


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF postition, then disconnect the battery negative terminal.1. Release the buttons (1a) and remove the right console closingdevice (1b).2017928

Fuel temperature sensor



K81



K81



K81



Turbocharging sensor



K82



K82



K82



Fuel pressure sensor



K83



K83



K83



K83



EGR solenoid



L30



L30



L30



exhaust gas recirculation system (e.g.r.)



1080C10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Disconnect the vacuum pipe from the E.G.R. valve.2. Undo nuts (2a) and remove the exhaust gas supply pipe from theE.G.R. valve to inlet manifold (2b) on the intake manifold side.3. Undo bolts (3a) and remove EGR valve (3b) together with thepipe carrying exhaust gas to the intake manifold.2015287

1080C24


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is OFF (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). 1. Disconnect the electrical connection from the E.G.R. valve.2. Disconnect the vacuum intake pipe from the EGR system solenoid.3. Disconnect the EGR valve pipe from the EGR solenoid.4. Undo the nuts (4a) and remove the EGR system solenoid valve (4b).2015289

1080C28


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with the removal 3237758-1016A10sound-proofing cover- r + r . 1. Undo the bolts (1a) and (1b), then remove the engine oil returnpipe from EGR solenoid to throttle body (1c).2. Remove the gaskets.2015294

1080C54


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Disconnect the vacuum intake pipe from the EGR valve.2. Undo the nuts fixing the exhaust gas supply pipe from the E.G.R.valve to the inlet manifold.3. Undo the bolts (3a) fixing the E.G.R. valve (3b) to the exhaustmanifold, then remove it, complete with exhaust gas supply pipeto the inlet manifold (3c).2015296

1080C58


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213237758-1016A10sound-proofing cover - r + r . 1. Disconnect the remova the E.G.R. system vacuum pipe between theintermediate connector and the E.G.R. system solenoid valve.2. Disconnect the E.G.R. system vacuum pipe between the solenoidvalve and the E.G.R. valve (2a) and remove it after having undonethe bolts (2b).2015297

1080C80


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp. Proceed with removal 3237758-1016A10sound-proofing cover- r + r . Proceed with removal 3238429-5530B10battery - r+r . Proceed with removal 3238435-5530B52Battery DRIP TRAY/SUPPORT- R.R. . Proceed with removal 3237792-1048B50turbo charger intercooler- r + r . Proceed with removal 3238966-7055B54under-engine guard -r r . 1. Disconnect the rapid connector and disconnect the lower radiatorcoolant outlet hose, radiator side. 767Recover the coolant using a suitablecontainer.2069565

1080C74


<anchor>1</anchor><span>Refitting</span><icon><imageid>21</imageid></icon>0Removing20Refit in its seating the E.G.R. solenoidcomplete with gasket and secure it with the bolts.Tighten the bolts securing the E.G.R. solenoidto the E.G.R. water/exhaust gas heat exchanger.Connect the electrical connection to theEGR solenoid. Proceed with refitting 3237758-1016A10sound-proofing cover- r + r . Connect the negative (-) battery terminal.

Variable geometry turbine solenoid valve



L36



turbo charger assembly



1064A19


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp. Make sure that the ignition is OFF (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). Raise the vehicle.1. Undo nuts (1a) fixing the exhaust pipe attachment to the engine/manifold(1b), to the exhaust manifold.2. Undo nuts (2a) and remove reinforcement plate (2b).3. Undo bolts (3a) and remove turbocharger oil outlet pipe protection(3b).4. Disconnect the oil outlet pipe from the turbo.5. Disconnect the air supply hose to the heat exchanger from theturbocharger.2015180

1064A20


<anchor>0</anchor><span>Dismantling</span><icon><imageid>20</imageid></icon>1. Position the turbocharger assembly in a vice.2. Unscrew nuts (2a) and remove exhaust pipe coupling sleeve (2b).2015185

1064A22


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-). Proceed with removal 3237758-1016A10sound-proofing cover- r + r . Proceed with removal 3238966-7055B54under-engine guard -r r . 1. Undo the nuts securing the front section of the exhaust pipeto the sleeve joining the turbocharger to the exhaust manifold.2. Undo the bolts (2a) and (2b) and remove the exhaust pipe mountingbracket (2c).3. Remove the gasket.2015187

1064A30


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.3238966-7055B54under-engine guard - r r . 3237758-1016A10sound-proofing cover - r + r . 1. Undo the connector (1a) and disconnect the coolant outlet pipefrom the engine oil heat exchanger (1b), water pump rigid inletpipe side.767Recover the coolant which comesout in a suitable container.2. Disconnect the flexible pipe from the rigid coolant supply pipeto the engine oil heat exchanger.3. Undo the bolt fixing the rigid coolant supply pipe to the engineoil heat exchanger.Move the coolant inlet/outlet pipes fromthe engine oil heat exchanger, as necessary.2015219

1064A50


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213237827-1064A19TURBOCHARGER - EXHAUST MANIFOLD - EXHAUST PIPE CONNECTINGHOSE - R.R.1. Position the turbocharger assembly in a vice.2. Unscrew nuts (2a) and remove exhaust pipe coupling sleeve (2b).2015223

1064A24


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp Proceed with removal 3237758-1016A10sound-proofing cover- r + r Proceed with removal 3238966-7055B54under-engine guard -r r Proceed with removal 3237711-1088D24rigid pipe for coolantinlet to water pump - r + r1. Undo the bolts (1a) and remove the exhaust manifold heat shield(1b). 2069125

1064A26


Place the assembly in a vice fitted withprotective jaws.1. Undo the bolts (1a) and remove the exhaust gas inlet pipe tothe water/exhaust gas heat exchanger for the E.G.R. system, exhaustmanifold side.2. Undo the nuts (2a) and separate the variable geometry turbochargerassembly (2b) from the exhaust manifold (2b).2069136

Engine management ECU



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10A



M10B



M10B



M10B



M10B



M10B



M10B



M10B



M10B



M10B



M10B



M10B



M10B



M10B



M10C



M10C



M10C



M10D



M10D



M10D



M10D



M10E



M10E



M10E



M10E



M10F



M10



M10A



M10A



M10A



Plug preheating control unit



M15A



M15A



M15A



M15A



M15B



M15B



M15B



M15B



M15C



M15C



M15C



M15C



M15C



CODE control unit



M20



M20



M20



M20



M20



M20



M20



M20



M20



M20



M20



M20



M20



M20



M20



M20



M20



anti-theft device



5580E08


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238793-7040A26steering column trim- r+r3238799-7040A37fuse box cover - r r1. Disconnect the antenna connection from the power unit.2. Remove the antenna from the starting block.3. Free the cable from the check clamps.4. Remove the antenna unit.2018926

5580E12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238799-7040A37fuse box cover - r r1. Unscrew the shunt power unit screws .2. Remove the shunt power unit.3. Disconnect the anti-theft device power unit.4. Remove the anti-theft device power unit.5. Disconnect the electric connection.6. Disconnect thel'antenna connection.2018927

5580E18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238343-5040D22control (one) of airconditioner control support - arrange3238986-7065C42ashtray (one) r+r3238514-5570T80car radio unit - r+r3237934-2125C24gear lever knob - r + r3238802-7040A60under facia trim - r+r3238501-5560C51combined analogue control panel - r+r or replace1. Working from inside the facia, prise the led out of its seat.2. Disconnect the electrical connection and recover the led.2018928

5580E22


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238843-7040H38central pillar upperelement - r r1. Prise the volumetric sensor from its seat in the pillar trim.2018930

5580E24


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238799-7040A37fuse box cover - r r1. Disconnect electrical connections (1a), (1b).2. Undo the nut.3. Remove the switch and bridge.2018931

5580E26



5580E28



5580E30


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Open the bonnet lid and remove the buttons retaining the uppertrim using the special tool.2. Lower the upper trim and disconnect the electrical connectionfor the receiver.3. Unscrew the nuts.4. Remove the receiver.2018932

5580E34


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238853-7040L40front compartment scuff strip - r r (right side). 3238841-7040H36central trim lower element - r r (right side). 1. Lift up the carpet slightly in the area of the tilt sensor.2. Unscrew the bolts3. Move the tilt sensor slightly and disconnect the electrical connection.2018934

5580E46


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238964-7055B42Additional FRONT WHEELARCH (one), left or right - R.R.1. Unscrew the control unit bracket retaining nuts.2. Move control unit bracket (2a) and disconnect electrical connections(2b, 2c).3. Unscrew the nuts retaining the control unit to the bracket.4. Recover the control unit by taking off its bracket.2018935

abs check/adjustment devices



3340A12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238429-5530B10battery - r+r1. Drain the brake-clutch fluid from the reservoir using a suitablesyringe.2. Disconnect the air inlet pipe from the inlet manifold.2017884

3340A13


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238091-3340A12A'B.S. system. - electronicand hydraulic CONTROL UNIT R.R.3238429-5530B10battery - r+r3238435-5530B52Battery DRIP TRAY/SUPPORT - R.R.Disconnect the various pipes from the bandson the A.B.S. control unit mounting.1. Undo the bolts (1a) and remove the A.B.S. control unit mounting(1b).2017897

3340A20


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with the removal 3238429-5530B10battery - r+r . Proceed with the removal 3238091-3340A12A'B.S. system. - electronicand hydraulic CONTROL UNIT R.R. . 1. At the bench, undo the bolts (1a) and separate ABS electroniccontrol unt (1b) from the hydraulic assembly. 2017898

3340A30


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative(-) terminal. 1. Disconnect the electrical connection for one of the front wheelrpm sensors.2. Undo the bolt (2a) and remove one of the the front wheel rpmsensors (2b) complete with electrical wiring.2017900

3340A32



3340A34


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative(-) terminal. 1. Disconnect the electrical connection for one of the rear wheelrpm sensors.2. Undo the bolt (2a) and remove the rpm sensor for one of the rearwheels (2b) complete with electrical wiring.2017901

3340A44



3340A48



Fuel pump and sender unit



N40



N40



Injector



N70A



N70A



N70A



N70A



N70A



N70A



N70A



N70A



N70A



N70A



N70A



N70A



N70B



N70B



N70B



N70B



N70B



N70B



N70B



N70B



N70B



N70B



N70B



N70C



N70C



N70C



N70C



N70C



N70C



N70C



N70C



N70C



N70C



N70C



N70D



N70D



N70D



N70D



N70D



N70D



N70D



N70D



N70D



N70D



N70D



N70E



N70E



N70E



N70E



N70E



N70F



N70F



N70B



N70C



N70D



injectors and lines



1060F10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238429-5530B10battery - r+r3237804-1060F36lines to injectors - r rDisconnect the electrical connections fromthe injectors.1. Manually push springs (1a) and disconnect the fuel return pipefor lubricating the injectors (1b) from the injectors2. Undo the nuts on the brackets securing the fuel injectors withtheir washers.2015126

1060F20


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Undo the bolts and move the fuel returnmanifold pipe away from the air chamber.1. Undo the manifold side connector for the pipe from the pressurepump to the fuel manifold using a suitable spanner.2. Disconnect the pressure pump side connector from the pipe leadingfrom the pressure pump using a suitable spanner.3. Remove the pipe carrying fuel from the pressure pump to the singlefuel manifold pipe.767Fit a new high pressure pipe fromthe pressure pump to the fuel manifold upon reassembly. 2015128

1060F30


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238429-5530B10battery - r+r3237804-1060F36lines to injectors - r r1. Disconnect the electrical connection from the fuel pressure sensor.2. Loosen the manifold side connector for the supply pipe from thepressure pump to the manifold using a suitable spanner.3. Disconnect the pressure pump side connector from the pipe leadingfrom the pressure pump using a suitable spanner.4. Remove the fuel supply pipe from the single fuel manifold pipe.767Fit a new high pressure pipe fromthe pressure pump to the fuel manifold upon reassembly. 5. Undo the nuts (5a) and remove the single fuel manifold pipe (5b).2015130

1060F34



1060F36


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238429-5530B10battery - r+r1. Undo nuts (1a) and move fuel filter assembly (1b) away from theintake manifold.2. Undo nuts (2a) and move oil vapour separator (2b) away from theintake manifold.3. Undo the bolts (3a) and move the fuel return manifold pipe (3b)aside.4. Undo the manifold side connectors for the pipes from the fuelmanifold to the injectors using a suitable spanner.5. Undo the injector side connectors of the pipes leading fromthe fuel manifold to the injectors using a suitable spanner.6. Remove all the pipes from the fuel manifold to the injectors.767Fit new pipes from fuel manifoldto injectors upon reassembly.2015132

1060F50


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). 1. Disconnect the electrical connection from the fuel temperaturesensor. 2. Disconnect the fuel return pipe for lubricating the injectorsfrom the manifold pipe.3. Disconnect the fuel return pipe from the pressure pump from thefuel return manifold pipe.4. Disconnect the fuel return pipe to the fuel tank from the fuelreturn manifold pipe. 5. Disconnect the fuel return pipe from the fuel filter from thefuel return manifold pipe. 6. Undo bolts (6a) and remove fuel return manifold pipe (6b).2015134

1060F52


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the pipe leading from the injectorsto the fuel recovery manifold from the fuel return manifold pipe:Remove the spring clips on the injectorsand remove the pipe from the injectors to the fuel recovery manifold.

Fuel pressure regulator



N77



N77



N77



N77



diesel pressure pump



1060E10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213237453-1008C10power unit upper reaction link r r3237758-1016A10sound-proofing cover - r + r . 3237454-1008C14engine link bracket - r r3238224-4450B10Front WHEEL (one) - R.R.3238967-7055B64Engine compartment DUST shield in front wheel arch(one), left or right - R.R.3237644-1092G10single engine belt r r3237642-1092A12crankshaft pulley - r+r for versions with air conditioner3237490-1032B14toothed timing belt - r + r for timing adjustmentor replacement versions with air conditioner3237609-1084A16oil dip stick pipe - r r3237796-1060E30pressure pump pulley - r r1. Disconnect the electrical connection for the timing sensor.2. Disconnect the electrical connection from the fuel temperaturesensor.3. Disconnect the electrical connection from the pressure regulatoron the pressure pump.2015085

1060E30



1060E40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213237453-1008C10power unit upper reaction link r r3237758-1016A10sound-proofing cover - r + r . 3237454-1008C14engine link bracket - r r3238224-4450B10Front WHEEL (one) - R.R.3238967-7055B64Engine compartment DUST shield in front wheel arch(one), left or right - R.R.3237644-1092G10single engine belt r r3237642-1092A12crankshaft pulley - r+r for versions with air conditioner3237490-1032B14toothed timing belt - r + r for timing adjustmentor replacement versions with air conditioner3237609-1084A16oil dip stick pipe - r r3237796-1060E30pressure pump pulley - r r3237795-1060E10pressure pump - r rRaise the vehicle.1. Disconnect the electrical connection for the rpm sensor.2. Undo bolts (2a) and remove electrical wiring brackets (2b).3. Disconnect the electrical connections from the alternator.2015101

1060E50


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in thestop OFF, then disconnect the battery negative terminal. Proceed with the removal 3237758-1016A10sound-proofing cover- r + r . 1. Undo the bolts (1a) and move aside the fuel return manifold pipe(1b) without disconnecting the pipes.2015116

1060E42


<anchor>0</anchor><span>Dismantling</span><icon><imageid>20</imageid></icon>1Reassembling21Place the pressure pump mounting in a vicefitted with protective jaws.1. Stop the rotation of the pressure pump pulley using two bolts.2. Undo the bolts (2a) and remove the safety flange (2b).3. Undo the pressure pump pulley nut.Undo the two bolts fitted previously tostop the rotation of the pressure pump pulley.2016610

Diesel heater resistance



O20A



O20B



O20



O20



fuel heating device



1044D20


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 32384295530B10battery - r+r ). 1. Disconnect the electrical connection from the thermal switchfor the fuel heater.2. Undo and remove the thermal switch for the fuel heater.2015055

1044D40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in thestop position, then disconnect the battery negative terminal.1. Undo the bolts (1a) and remove the protective cover (1b).2. Remove the fuel pre-heating relay2015056

1044D10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Proceed with removal 3237758-1016A10sound-proofing cover- r + r . Proceed with removal 3237725-1044B10fuel filter assembly -r + r or replace . Proceed with removal 3237779-1044B20fuel filter filtering element- replace . 1. Undo the fitting (1a) and remove fuel heater (1b).2069474

Multiple tester connection



R10



R10



R10



R10



R10



R10



R10



R10



R10



R10



R10



R10



R10



R10



R10



R10



R10



R10



R10



R10



R10