AUTOMOTIVE ELECTRICIANS PORTAL - FZCO

Alfa Romeo 156 2.4 JTD 20v da 04/98 a 02/99 – SUPPLY – – Smart gearbox – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION

Alfa Romeo 156 2.4 JTD 20v  da 04/98 a 02/99 – SUPPLY –  – Smart gearbox – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION – WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION
Wiring diagram



Components
Component codeNameAssembly reference
A1Battery-
A1Battery5530B
B1Junction unit5505A
B5MAXI FUSE box-1-
B5MAXI FUSE-1 box-
B5MAXIFUSE box-1-
B6MAXI FUSE box - 2-
B6MAXI FUSE box-2-
B10Fuse controlled by ignition (INT/A)-
B10Key-dependent supply fuse (INT/A)-
B11Controls lighting fuse-
B12Headlamp washer fuse-
B13Fog lamp fuse-
B14Sun-roof fuse-
B15Power point fuse-
B17Rear electric windows fuse-
B20Seat heating fuse-
B25Fuse for services controlled by ignition(15 /-
B25Ignition-dependent services supplyfuse (15 / 54)-
B30ABS fuse and Air Bag-
B31ABS fuse-
B32Air Bag fuse-
B35Injection memory and CODE fuse-
B35Injection memory and CODE fuse-
B36Lambda sensor fuse-
B37Diesel plug and preheating fuse-
B38Additional heater fuse-
B39Diesel pre-heating fuse-
B40Fuel injection services supply fuse-
B41Fuel injection control unit supplyrelay-
B42Automatic transmission supply fuse-
B60Boot opening fuse-
B98Supplementary fuse box5505A
B99Maxifuse box on battery-
B99Maxifuse box on battery5530B
C1Battery earth-
C1Battery earth5530B
C10Front left earth5505A
D5Front / ABS couping-
D5Front / ABS coupling-
D8Front / air conditioning - heatercoupling-
D8Front coupling / air conditioner- with heating-
H1Ignition switch5520A
H5Steering column switch unit5550A
J10Fuel injection main relay-
J15Fuel pump relay-
J36Additional heater relay - 1-
J36Additional heater relay -1-
J37Additional heater relay - 2-
J40Foglamp relay-
J45Dipped beam maintenance relay-
J45dipped beam maintenance relay-
J50Headlamp washer relay-
J60Optional service relay-
J60Optional services relay-
M50ABS control unit3340A
Location of components

Components
Component codeNameAssembly reference
A1Battery-
A1Battery5530B
B1Junction unit5505A
B5MAXI FUSE box-1-
B5MAXI FUSE-1 box-
B5MAXIFUSE box-1-
B6MAXI FUSE box - 2-
B6MAXI FUSE box-2-
B10Fuse controlled by ignition (INT/A)-
B10Key-dependent supply fuse (INT/A)-
B11Controls lighting fuse-
B12Headlamp washer fuse-
B13Fog lamp fuse-
B14Sun-roof fuse-
B15Power point fuse-
B17Rear electric windows fuse-
B20Seat heating fuse-
B25Fuse for services controlled by ignition(15 /-
B25Ignition-dependent services supplyfuse (15 / 54)-
B30ABS fuse and Air Bag-
B31ABS fuse-
B32Air Bag fuse-
B35Injection memory and CODE fuse-
B35Injection memory and CODE fuse-
B36Lambda sensor fuse-
B37Diesel plug and preheating fuse-
B38Additional heater fuse-
B39Diesel pre-heating fuse-
B40Fuel injection services supply fuse-
B41Fuel injection control unit supplyrelay-
B42Automatic transmission supply fuse-
B60Boot opening fuse-
B98Supplementary fuse box5505A
B99Maxifuse box on battery-
B99Maxifuse box on battery5530B
C1Battery earth-
C1Battery earth5530B
C10Front left earth5505A
D5Front / ABS couping-
D5Front / ABS coupling-
D8Front / air conditioning - heatercoupling-
D8Front coupling / air conditioner- with heating-
H1Ignition switch5520A
H5Steering column switch unit5550A
J10Fuel injection main relay-
J15Fuel pump relay-
J36Additional heater relay - 1-
J36Additional heater relay -1-
J37Additional heater relay - 2-
J40Foglamp relay-
J45Dipped beam maintenance relay-
J45dipped beam maintenance relay-
J50Headlamp washer relay-
J60Optional service relay-
J60Optional services relay-
M50ABS control unit3340A
DescriptionThe entire electrical system has been designedand constructed in accordance with the most up-to-date guidelinesconcerning safety and protection, especially against fire risks.There are two main kinds of protection:active protection, aimed at reducing possible causes offaults 'at source';passive protection, aimed at minimizing the effects ofa possible fault.The first category involves careful designof wiring with thorough positioning and anchorage. Wiring is shieldedand protected and the routes are carefully determined. Modifications have therefore been made tothe alternator and starter motor cables, with the adoption of protectivecaps, etc.Passive protection instead includes allthe interventions, which have always been adopted on vehicles, toreduce high fault currents (overload and short circuit).All the fuses included in the system havebeen rated on the basis of the nominal absorption of the loads whichcannot be served simultaneously, and so as to ensure interventionin the case of a definite short circuit.All the electrical systems are suppliedby the battery at a voltage of 12. V. The battery is, in turn, recharged by thealternator 3234399SeeE5010STARTING AND RECHARING duringengine operation. The main supply lines are protected by maxifuses,grouped together in a box directly on the positive battery terminaland connected directly to it.The box contains up to eight maxifuses.The power supplies to all services and systemsare protected by fuses grouped in the junction unit or in two specialmultiple connectors, one for the front wiring and other other forthe facia wiring in accordance with a pre-established order.All the power supplies are thus protected,except for the starter motor cable (battery-starter motor) and rechargingcable (starter motor-alternator): these are protected by an additionalshielded sheath.Some circuits are supplied continuously,even if the vehicle is stopped and the ignition is off, as theyare connected directly to the battery.Other circuits are supplied by turningthe ignition key to various different positions:when the key is inserted and turned to the first click,the ignition is turned on (ON position) and several circuits aresupplied, which are thus called 'ignition-operated' (lines 'INT'and '15/54');the second click - AVV position - instead supplies thestarter motor (line '50')., disconnecting some circuits (thosewhich absorb most power), thus ensuring the maximum flow of currentto the starter motor; ('INT/A' line).on the other hand, by extracting the key and turning itin the opposite direction (and pressing the special button) thePARK position is engaged which supplies the side lights even withthe key switched off ('STAZ' and 'POS' lines);3233770SeeE2010SIDE LIGHTS / NO. PLATE LIGHTS767The lines through which the supplyis distributed to the various electrical devices are shown on thewiring diagrams relating to the various functions and systems.This general diagram shows all the lineswhich depart from the battery and the MAXIFUSE boxes; referenceshould be made to the specific diagrams for greater detail.
Functional description All the electrical equipment and systemsare supplied by the battery A1.The main supply lines are protectedby the MAXIFUSE box B99 which contains the fuses named accordingto the circuits protected: J/B1: supply for services through the junctionunit IGN : ignition switch supply; J/B2 : supply for services through the junctionunit A/C: air conditioning system supply EFI : supply for fuses and relays for engine management FAN1 : engine cooling fan supply; F/P: engine cooling fan supply; OIL: automatic transmission supply O/A : automatic transmission supplyThe fuse box also contains two 'MIDI'fuses located directly on the battery and named according to thecircuits protected. ABS: ABS supply: A1, connector C. Other circuits are supplied by turningignition key H1 to various different positions:in the ON position, numerous circuits and services controlledby the ignition (INT line) are supplied.in the AVV position - the starter motor is supplied; (line'50') (3234399SeeE5010STARTING AND RECHARING): In this position several circuits are disconnected (line 'INT/A'.in the PARK position the side lights are supplied ('STAZ'and 'POS' lines);3233770SeeE2010SIDE LIGHTS / NO. PLATELIGHTS

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

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



MAXI FUSE box - 2



B6A



B6A



B6A



B6B



Fuse controlled by ignition (INT/A)



B10



Controls lighting fuse



B11



B11



Headlamp washer fuse



B12



B12



Fog lamp fuse



B13



Sun-roof fuse



B14



Power point fuse



B15



Rear electric windows fuse



B17



Seat heating fuse



B20



B20



Fuse for services controlled by ignition (15 /



B25



B25



B25



B25



B25



B25



ABS fuse and Air Bag



B30



ABS fuse



B31



Air Bag fuse



B32



Injection memory and CODE fuse



B35



B35



B35



B35



Lambda sensor fuse



B36



Diesel plug and preheating fuse



B37



Additional heater fuse



B38



B38A



B38A



B38B



B38B



B38B



Diesel pre-heating fuse



B39



B39



Fuel injection services supply fuse



B40



B40



B40



B40



Fuel injection control unit supply relay



B41



B41



B41



B41



Automatic transmission supply fuse



B42



B42



Boot opening fuse



B60



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



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



Front / air conditioning - heater coupling



D8



D8



D8



D8



D8



D8



D8



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

Steering column switch unit



H5A



H5A



H5A



H5B



H5B



H5B



H5B



H5C



H5C



H5D



H5D



H5D



H5E



stalk unit



5550A12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213238527-5580C18air bag module - r+r7683238121-4110A11steering wheel - r+r for replacement or check forversions with air bag3238793-7040A26steering column trim - r+r3238525-5580C12clock spring for air bag module on steering wheelr rClosely follow the safety regulations established for this operation.1. Loosen the band fixing the steering column switch unit.2. Move the steering column switch unit.3. Disconnect the electrical connections (3a, 3b, 3c).2018830

Fuel injection main relay



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



J10



Additional heater relay - 1



J36



J36



J36



J36



Additional heater relay - 2



J37



J37



J37



J37



Foglamp relay



J40



J40



J40



J40



Dipped beam maintenance relay



J45



J45



J45



Headlamp washer relay



J50



J50



Optional service relay



J60



J60



J60



J60



J60



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