Component code | Name | Assembly reference |
A1 | Battery | 5530B |
A40 | Heater plug | - |
A40 | Heater plug | 5520C |
B1 | Junction unit | 5505A |
B5 | MAXI FUSE box-1 | - |
B5 | MAXI FUSE-1 box | - |
B11 | Controls lighting fuse | - |
B25 | Fuse for services controlled by ignition(15 / | - |
B25 | Ignition-dependent services supplyfuse (15 / 54) | - |
B35 | Injection memory and CODE fuse | - |
B35 | Injection memory and Code fuse | - |
B37 | Diesel plug and preheating fuse | - |
B39 | Diesel pre-heating fuse | - |
B41 | Fuel injection control unit supplyrelay | - |
B98 | Supplementary fuse box | 5505A |
B99 | Maxifuse box on battery | - |
B99 | Maxifuse box on battery | 5530B |
C10 | Front left earth | 5505A |
C15 | Facia earth, driver's side | 5505A |
C31 | Rear right earth | 5505A |
D1 | Front / dashboard connection | - |
D1 | Front / dashboard coupling | - |
D2 | Front / crossmember coupling | - |
D2 | Front /crossmember connection | - |
D4 | Front/engine connection | - |
D5 | Front / ABS couping | - |
D5 | Front / ABS coupling | - |
E10 | Speedometer | 5560B |
E15 | Rev counter | 5560B |
H1 | Ignition switch | 5520A |
I30 | Brake pedal switch | 5550D |
I31 | Clutch pedal switch | 1060G |
I50 | Inertia switch | 1040A |
I50 | Inertial switch | 1040A |
J10 | Fuel injection main relay | - |
J15 | Fuel pump relay | - |
J17 | Diesel preheating relay | - |
K36 | Engine temperature sender unit | - |
K36 | Engine temperature sender unit | 1060G |
K41 | Air flow meter | - |
K41 | Air flow meter | 1056B |
K41 | Air flow meter | 1060G |
K45 | Engine temperature sensor | 1056B |
K45 | Engine temperature sensor | 1060G |
K46 | Rpm sensor | - |
K46 | Rpm sensor | 1060G |
K47 | Timing sensor | - |
K47 | Timing sensor | 1060G |
K47 | Timing sensor. | - |
K47 | Timing sensor. | 1060G |
K55 | Accelerator pedal potentiometer | - |
K55 | Accelerator pedal potentiometer | 1068A |
K58 | Steering sensor | - |
K58 | Steering sensor | 3350E |
K81 | Fuel temperature sensor | - |
K81 | Fuel temperature sensor | 1060G |
K82 | Turbocharging sensor | - |
K82 | Turbocharging sensor | 1060G |
K83 | Fuel pressure sensor | - |
K83 | Fuel pressure sensor | 1060G |
L30 | EGR solenoid | - |
L30 | EGR solenoid | 1080C |
L30 | EGR solenoid | 1080C |
L36 | Variable geometry turbine solenoidvalve | 1064A |
L62 | Butterfly casing solenoid valve | - |
L62 | Butterfly casing solenoid valve | 1060G |
M10 | Engine management ECU | - |
M10 | Engine management control unit | - |
M10 | Engine management control unit | 1060G |
M15 | Plug preheating control unit | - |
M20 | CODE control unit | 5580E |
M50 | ABS control unit | 3340A |
N40 | Fuel pump and sender unit | 1040A |
N70 | Injector | - |
N70 | Injector | 1060F |
N77 | Fuel pressure regulator | - |
N77 | Fuel pressure regulator | 1060E |
O20 | Diesel heater resistance | 1044D |
O20 | Diesel heater resistor | 1044D |
O20 | Diesel preheating resistor | - |
R10 | Multiple tester connection | - |
Component code | Name | Assembly reference |
A1 | Battery | 5530B |
A40 | Heater plug | - |
A40 | Heater plug | 5520C |
B1 | Junction unit | 5505A |
B5 | MAXI FUSE box-1 | - |
B5 | MAXI FUSE-1 box | - |
B11 | Controls lighting fuse | - |
B25 | Fuse for services controlled by ignition(15 / | - |
B25 | Ignition-dependent services supplyfuse (15 / 54) | - |
B35 | Injection memory and CODE fuse | - |
B35 | Injection memory and Code fuse | - |
B37 | Diesel plug and preheating fuse | - |
B39 | Diesel pre-heating fuse | - |
B41 | Fuel injection control unit supplyrelay | - |
B98 | Supplementary fuse box | 5505A |
B99 | Maxifuse box on battery | - |
B99 | Maxifuse box on battery | 5530B |
C10 | Front left earth | 5505A |
C15 | Facia earth, driver's side | 5505A |
C31 | Rear right earth | 5505A |
D1 | Front / dashboard connection | - |
D1 | Front / dashboard coupling | - |
D2 | Front / crossmember coupling | - |
D2 | Front /crossmember connection | - |
D4 | Front/engine connection | - |
D5 | Front / ABS couping | - |
D5 | Front / ABS coupling | - |
E10 | Speedometer | 5560B |
E15 | Rev counter | 5560B |
H1 | Ignition switch | 5520A |
I30 | Brake pedal switch | 5550D |
I31 | Clutch pedal switch | 1060G |
I50 | Inertia switch | 1040A |
I50 | Inertial switch | 1040A |
J10 | Fuel injection main relay | - |
J15 | Fuel pump relay | - |
J17 | Diesel preheating relay | - |
K36 | Engine temperature sender unit | - |
K36 | Engine temperature sender unit | 1060G |
K41 | Air flow meter | - |
K41 | Air flow meter | 1056B |
K41 | Air flow meter | 1060G |
K45 | Engine temperature sensor | 1056B |
K45 | Engine temperature sensor | 1060G |
K46 | Rpm sensor | - |
K46 | Rpm sensor | 1060G |
K47 | Timing sensor | - |
K47 | Timing sensor | 1060G |
K47 | Timing sensor. | - |
K47 | Timing sensor. | 1060G |
K55 | Accelerator pedal potentiometer | - |
K55 | Accelerator pedal potentiometer | 1068A |
K58 | Steering sensor | - |
K58 | Steering sensor | 3350E |
K81 | Fuel temperature sensor | - |
K81 | Fuel temperature sensor | 1060G |
K82 | Turbocharging sensor | - |
K82 | Turbocharging sensor | 1060G |
K83 | Fuel pressure sensor | - |
K83 | Fuel pressure sensor | 1060G |
L30 | EGR solenoid | - |
L30 | EGR solenoid | 1080C |
L30 | EGR solenoid | 1080C |
L36 | Variable geometry turbine solenoidvalve | 1064A |
L62 | Butterfly casing solenoid valve | - |
L62 | Butterfly casing solenoid valve | 1060G |
M10 | Engine management ECU | - |
M10 | Engine management control unit | - |
M10 | Engine management control unit | 1060G |
M15 | Plug preheating control unit | - |
M20 | CODE control unit | 5580E |
M50 | ABS control unit | 3340A |
N40 | Fuel pump and sender unit | 1040A |
N70 | Injector | - |
N70 | Injector | 1060F |
N77 | Fuel pressure regulator | - |
N77 | Fuel pressure regulator | 1060E |
O20 | Diesel heater resistance | 1044D |
O20 | Diesel heater resistor | 1044D |
O20 | Diesel preheating resistor | - |
R10 | Multiple tester connection | - |
1060
E4023
E4020
E4021
E6021
E5020
E5060
Battery
A1A
A1B
A1C
A1C
A1C
A1C
A1D
A1D
A1D
A1D
A1
A1
A1
battery and leads
5530B10
5530B14
5530B18
Follow these precautions.769 On 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 3238420 See subassemblyCURRENT GENERATOR . 768 Proceed 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 ( 3238429 battery - r+r ). If the voltage without load is over 12.10V but less than 12.50 V, recharge the battery ( 3238430 battery - 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
5530
5530B10
5530B14
5530B22
5030B26
5030B40
5530B52
5530B10
Heater plug
A40A
A40A
A40B
A40B
A40C
A40C
A40D
A40D
A40E
A40E
cold starting system (diesel engines)
5520C10
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
5505A16
5505A18
7040G24
7040G20
7040A31
5505A30
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
5560B03
5560B06
5560B02
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
4110A11
7040A26
5550A12
5520A14
5520A16
5520A18
brake and reversing lights
5550D10
5550D14
5550D16
5550D17
5550D16
5550D18
3380A44
5550D22
5550D26
pressure pump electric control
1060G10
1048A50
5530B10
1060G14
5530B10
1060G16
1060G18
5530B10
1060G20
5530B10
1060G22
4450B10
7055B64
1092G10
1092A12
1032D12
1008C10
1016A10
1008C14
1032B14
1032B61
1032B62
1060G28
1016A10
1060G30
1016A10
7055B54
1044B10
1060G38
5530B10
1060G42
5530B10
1060G50
1016A10
1060G52
1016A10
1060G50
1060G58
1016A10
1060G70
1016A10
1060G72
1016A10
1060G80
5530B10
1060G88
1060G90
1016A10
7055B54
1076B70
Inertia switch
I50
I50
fuel tank and components
1040A10
7040B10
7050B18
1040A70
1040A14
1. Disconnect the handbrake cables (1a) from the mounting bracket(1b) and from the fastenings on the fuel tank (1c).2014028
1040A30
1040A70
1040A40
1040A66
7040B10
7050B18
7050A20
7050B10
7050A19
1040A70
1040A70
1040A74
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
1056B10
1056B17
1056B50
1048A34
5530B10
1056B51
1048A34
5530B10
1056B62
1056B66
1056B67
1056B68
1056B70
1056B81
1056B82
1056B90
1056B14
1048A34
1056B15
1016A40
1048A34
1056B19
1056B82
1056B40
1056B43
1056B46
1056B48
1056B60
1056B87
1056B89
1056B82
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
1068A14
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
1068A50
5530A10
7040A31
7040A65
1068A18
1068A18
1068A30
1068A31
1068A52
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 3238476 Refer toop..completestalk unit - r+r for versions with air bag .
5550A12
3350E30
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
1080C24
5530B10
1080C28
1016A10
1080C54
1080C58
1016A10
1080C80
1016A10
5530B10
5530B52
1048B50
7055B54
1080C74
1016A10
Variable geometry turbine solenoid valve
L36
turbo charger assembly
1064A19
5530B10
1064A20
1064A22
1016A10
7055B54
1064A30
7055B54
1016A10
1064A50
1064A19
1064A24
1016A10
7055B54
1088D24
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
7040A26
7040A37
5580E12
7040A37
5580E18
5040D22
7065C42
5570T80
2125C24
7040A60
5560C51
5580E22
7040H38
5580E24
7040A37
5580E26
5580E28
5580E30
5580E34
7040L40
7040H36
5580E46
7055B42
abs check/adjustment devices
3340A12
5530B10
3340A13
3340A12
5530B10
5530B52
3340A20
5530B10
3340A12
3340A30
3340A32
3340A34
3340A44
3340A48
3340A30
3340A34
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
5530B10
1060F36
1060F20
1060F30
5530B10
1060F36
1060F34
1060F36
5530B10
1060F50
5530B10
1060F52
Fuel pressure regulator
N77
N77
N77
N77
diesel pressure pump
1060E10
1008C10
1016A10
1008C14
4450B10
7055B64
1092G10
1092A12
1032B14
1084A16
1060E30
1060E30
1008C10
1016A10
1008C14
4450B10
7055B64
1092G10
1092A12
1032B14
1060E40
1008C10
1016A10
1008C14
4450B10
7055B64
1092G10
1092A12
1032B14
1084A16
1060E30
1060E10
1060E50
1016A10
1060E42
Diesel heater resistance
O20A
O20B
O20
O20
fuel heating device
1044D20
5530B10
1044D40
1044D10
1016A10
1044B10
1044B20