DescriptionAn electronic management system supervises and governs all engine parameters. It optimises performance and fuel consumption by responding in real time to different service conditions.The Diesel engine is fitted with a COMMON RAIL UNIJET injection system.In addition, a timing system with 4 valves per cylinder has been introduced on this version to make the engine in question more powerful and reduce consumption.The COMMON RAIL system features the use of high, electronically-controlled injection pressure. Fuel delivery, termed a pilot injection, is optimised by the electronic control unit via the injector and not managed by the pump.The system uses signals received from numerous sensors to control actuators. It is connected to the following systems:fuel supply;air supply system;heater plugs;accelerator pedal;engine cooling;fuel preheating. For greater detail, see 3022443Characteristic of working principle1060DIESEL FUEL INJECTION . Starting from September 2003, thanks to the electronic management described above, this engine conforms to the latest anti-pollution and continuous control regulations in accordance with the EOBD system (European On Board Diagnosis); The EOBD (European On Board Diagnosis) system carries out continuous diagnosis of the car's petrol fuel system components relating to emissions and indicates any deterioration of these components by the warning light in the instrument panel coming on. The aim of the system is:keeping the efficiency of the system under control;signalling an increase in emissions due to a vehicle malfunction;signalling the need to replace components which have deteriorated.The system is also controlled by means of special relays located in the engine compartment unit; the supply lines to the control unit and the various system components (sensors and actuators) are protected by special fuses, also located in the engine compartment.
Functional description The engine control unit M10 monitors and controls the entire electronic injection system. The system is supplied directly by the battery via a line protected by the maxifuse CVM located on the battery, connector B99 . The supply controlled by the ignition (15/54) reaches pin 28 of connector A of M10 from the line protected by fuse F16 of the engine compartment unit B1.The main injection relay T9 of B1 controls the entire system; the supply line is protected by fuse F18 of B1; it is energized by a control signal (earth) coming from pin 72 of the control unit M10, and thus sends a supply:to pin 1 of connector A of the actual control unit, via the line from fuse F17 of B1;to pin 5 of connector A of the actual control unit, via the line from fuse F22 of B1;to the air flow meter K41, to the solenoid valves L30, L36; L62, to the control unit M15 , via the line from fuse F11 of B1 The fuel pump relay T10 of B1 is supplied by the line of the fuse F21 of B1 . It is energized by a control signal (earth) from pin 91 of connector A of control unit M10 and supplies power to fuel pump N40, which is earthed through the inertia switch I50, which cuts off the circuit in the case of a crash and so prevents the dangerous spilling of fuel. Pins 2, 4 and 6 of connector A of M10 are earthed. The diesel pre-heating relay T19 of B1 is supplied by the line for fuse F20 of B1 . It is energized by a control signal (earth) coming from pin 68 of connector A of the control unit M10 and supplies power to the diesel heating resistance O20. Control unit M15, which manages preheating of spark plugs A40, is supplied directly from the battery via a lline protected by fuse F1 of B1. It is supplied, connector C, by the line for fuse F11 of B1 and exchanges command and control signals with pins 52 and 93 of M10 which controls the timing. Connector B is connected to the heater plugs A40. The engine control unit M10 receives signals from the various sensors in order to monitor all engine service conditions. Rpm sensor K46 supplies information on engine speed via a frequency signal sent to pins 12 and 27 of connector B of control unit M10. Timing sensor K47 is supplied from pin 11 of connector B of control unit M10. It receives a reference earth from pin 20 of connector B of control unit M10 and sends it a signal of frequency corresponding to the timing of pin 50 of the same connector. The engine temperature sensor K45, receives a reference earth from pin 41 of the control unit M10 and supplies a signal proportional to the temperature of the engine coolant to pin 58 of connector B. The air flow meter K41 receives a general supply from the line for fuse F11 of B1 and a reference earth from pin 44 of connector B of M10. It is supplied by the control unit from pin 29 of connector B of M10, and sends pin 42 of connector B a signal proportional to the air flow. There is also an air temperature sensor inside K41 which sends an air temperature signal to pin 37 of connector B of M10. Accelerator pedal K55 is fitted with two built-in potentiometers (a main one and a safety back-up). The former receives power and earth from pins 30 and 45, respectively of connector A of M10 and sends a corresponding signal to pin 9. The latter receives power and earth from pins 46 and 8, respectively of connector A of M10 and sends a signal to pin 31. The fuel temperature sensor K81 measures the temperature of the diesel entering. It receives a reference earth from pin 10 of connector A of M10 and sends the fuel temperature signal to pin 11. The supercharging sensor K82 measures the pressure and temperature in the intake chamber, downstream of the turbocharger. It is supplied from pin 13 of connector B of M10 and receives a reference earth from pin 23 of connector B. The signal corresponding to the pressure value is sent to pin 40 of connector B of the control unit. There is also an air temperature sensor inside K82 which sends a signal to pin 53 of connector B of M10. The fuel pressure sensor K83 is responsible for providing the injection control unit with a feedback signal for governing pressure and injection duration. It receives power and a reference earth from pins 28 and 8 respectively of connector B of M10; it then sends the pressure signal to pin 43. The fuel pressure regulator N77 has the task of keeping the value of the fuel pressure in the accumulator constant. The two control signals come from pins 4 and 34 of connector B of the control unit M10. The EGR solenoid L30 controls exhaust gas recirculation. it is supplied by the line for fuse F11 of B1 and is controlled by a signal for pin 60 of connector B of M10. The variable geometry solenoid valve L36 regulates the operation of the turbine according to the engine load: it is supplied by the line for fuse F11 of B1 and is controlled by a signal for pin 15 of connector B of M10. The solenoid valve on the throttle casing L62 shutters and closes the throttle, for example when the engine is switched off; it is supplied by the line for fuse F11 of B1 and is controlled by a signal for pin 59 of connector B of M10. Pin 17 of connector A of M10 receives the signal coming from the brake lights switch I30, with the supply controlled by the ignition (INT) from fuse F37 of the junction unit B2. Pin 79 of connector A of M10 receives the signal coming from the clutch switch I31. The injectors N70 receive the opening go ahead supply from pins 117 (cylinders 1 and 2) and 118 (cylinders 3 and 4) of M10 . The engine management control unit sends the command to the injectors N70 from pins 16-47, 2-31, 1-46, 17-33 of connector B of M10 for cylinders 1, 2, 3 and 4, respectively. The control unit M10 receives the signal for the minimum engine oil pressure sensor K30 at pin 35 of connector B. The water in diesel filter sensor K31 ; is supplied by the line controlled by the ignition (INT) for fuse F51 of B2 and sends the corresponding signal to pin 74 of connector A of M10.The control unit M10 is connected via the CAN network to the Body Computer M1 and the other nodes on the network: through this connection, it sends information concerning:system self-test, which can be used by connecting to connector G of M1 .engine water temperature, which is sent to the instrument panel E50 which manages the relevant gauge and warning light;rpm, which is sent to the rev counter of the instrument panel E50 ;engine oil minimum pressure, which is sent to instrument panel E50 which manages the relevant warning light;heater plugs pre-heating, which is sent to the instrument panel E50 which manages the appropriate warning light;water in diesel filter, which is sent to the instrument panel E50 which manages the display. It receives, via CAN, the speedometer signal generated by the ABS control unit M50 The self-test system of the control unit M10 also generates a signal - which comes from pin 71 of connector A - which is connected directly to the 'EOBD' warning light located in the instrument panel E50. The self-test data can be read by connecting to connector G of the Body Computer M1 - pin 7: it receives the signals from pin 25 of connector A from the control unit M10 via the specific tester line.
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Proceed with removal 3025001-1016A10sound-proofing cover- r + r . Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-). 1. Disconnect the electrical connections from the heater plugs.2. Undo and remove the glow plugs.2048842
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025802-7040A37fuse box cover - r r1. Disconnect the electrical connections at the front (1a, 1b, 1c,1d, 1e, 1f).2. Undo the bolts fixing the control unit.3. Undo the bolts shown fixing the dashboard cover.2004865
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF postition, then disconnect the battery negative terminal.1. Disconnect the electrical connection from the air flow meter.2. Loosen collars (2a) and remove air flow meter (2b) after disconnectingit from the air intake sleeves.2001588
<anchor>1</anchor><span>Refitting</span><icon><imageid>21</imageid></icon>0Removing20Refit the variable valve timing electro-magnet and secure by tightening the bolts to the recommended torque.Connect the electrical connection to thevariable valve timing electro-magnet.Proceed with the refitting 3024766-1016A40ignition coil coveron cylinder head- r+r .Connect the battery terminal (-).
1056B50
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF postition, then disconnect the battery negative terminal.1. Disconnect the electrical connection from the air flow meter.Disconnect the electrical wiring for theflow meter from the fastening on the air intake sleeve.2. Disconnect the oil vapour recirculation pipe from the air intakeduct.3. Undo the bolts (3a) and remove the air intakehouse (3b) completewith air flow meter (3c).2002026
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF postition, then disconnect the battery negative terminal.Proceed with the removal 3024766-1016A40ignition coil coveron cylinder head- r+r . Discharge the fuel supply pressure withthe tool connected to the specific valve located on the side ofthe fuel manifold pipe.1. Disconnect the electrical connections from the injectors.2. Disconnect the rapid attachment of the fuel supply front pipe,fuel manifold pipe side.3. Release the front fuel delivery pipe from the fastening on theair chamber.2001601
1056B68
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Remove the clips (1a) and remove the injectors (1b) from thesingle fuel manifold pipe.2. Remove the seals from the injectors.2001605
1056B70
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Remove the clips (1a) and remove the injectors (1b) from thesingle fuel manifold pipe.2. Remove the seals from the injector2001606
1056B78
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF postition, then disconnect the battery negative terminal.1. Disconnect the electrical connection from the switch on the clutchpedal.2. Turn the switch clockwise through 90 degrees and remove.2001607
1056B81
Make sure that the ignition key is in theOFF position.Check that the air conditioner is off andthat the accelerator pedal is never pressed.Connect the tool to the diagnostic socketand place the knob in position 3.Connect the Examiner diagnostic equipment.Place the ignition key in the ON position.Using the Examiner, enter the 'ControlUnit Test' ambient.Using the Examiner, enter the 'Active Diagnosis' ambient,then select 'Reset self-adjustment parameters' and 'Idle actuator'.Using the Examiner, press 'Carry out activediagnosis'.Place the ignition key in the OFF positionand wait for 30 seconds.Place the ignition key in the ON positionand wait for 30 seconds.Using the Examiner, re-establish the dialoguewith the engine control system.Using the Examiner, enter the 'Parameters'ambient and select the following tests from the menu - 'Idle recognitiontest - carried out' and 'Idle recognition signals - synchronized'.767If at least one of the parametersdoes not conform, place the ignition key in the OFF position andrepeat the procedure. If this non conformity persists, check thatthe diagnostic cable is correctly connected and check the operationof the instrument.Place the ignition key in the OFF positionand wait for 30 seconds.Start up the engine without acting on theaccelerator pedal.Disconnect the diagnostic equipment.Test the vehicle by driving for severalkilometres then, with the engine warmed up, check that it is idlingcorrectly.
1056B82
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF postition, then disconnect the battery negative terminal.1. Disconnect electrical connections (1a) and (1b) from the injection-ignitioncontrol unit.2. Release the electrical wiring from the fastening on the ignition/injectionsystem control unit mount.2001608
1056B87
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF postition, then disconnect the battery negative terminal.1. Disconnect electrical connections (1a) and (1b) from the injection-ignitioncontrol unit.2. Release the electrical wiring from the fastening on the ignition/injectionsystem control unit mount.2001610
1056B90
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.Ensure that the ignition key is in theOFF postition, then disconnect the battery negative terminal.1. Disconnect the fuel vapour recirculation pipe from the air inakesleeve.2. Disconnect the intake hose from the throttle body integratedwith D.V.L. and move to one side.2001616
1056B10
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-). Proceed with removal 3024825-1048A28vacuum air circuit resonatorpipe - r+r . 1. Disconnect the electrical connection from the air flow meter. 2. Undo the nuts (2s) and remove the brackets (2b) securing theair flow meter to the aiar filter cover.3. Remove the air flow meter (3a), complete with hose (3b).2067872
1056B62
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-).Proceed with removal 3024979-1072B42left hand or right handinlet manifold (one) - r+r .Discharge the fuel system pressure withthe tool connected to the bleed valves on the fuel pipe.1. Disconnect the quick-release connector for the front fuel supplypipe, fuel pipe side.2. Disconnect the electrical connections from the injectors.3. Undo the bolts (3a) and remove the fuel pipe (3b) complete withinjectors (3c).769Avoid working with the engine hot underall circumstances;Never use tools such as pliers, screwdrivers,etc. under any circumstances;If it is released, rotate the rapid connectorcover before acting on the release buttons;Check its condition (deformation/breakageof retaining lugs, release buttons) before reconnecting it;After re-engageing the rapid connector,check that it is correctly attached by pulling it;At the end of fitting, check that thereare no fuel leaks by starting up the engine again;If there is damage to the rapid connector,replace the complete right pipe.2067877
1056B66
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-).Discharge the fuel system pressure withthe tool connected to the bleed valve on the left fuel pipe.1. Disconnect the electrical connections from the left injectors.2. Disconnect the quick-release connector for the front fuel supplypipe, fuel pipe side.3. Disconnect the rapid connector from the right fuel manifold pipeto the left one.769Avoid working with the engine hot underall circumstances;Never use tools such as pliers, screwdrivers,etc. under any circumstances;If it is released, rotate the rapid connectorcover before acting on the release buttons;Check its condition (deformation/breakageof retaining lugs, release buttons) before reconnecting it;After re-engageing the rapid connector,check that it is correctly attached by pulling it;At the end of fitting, check that thereare no fuel leaks by starting up the engine again;If there is damage to the rapid connector,replace the complete right pipe.4. Undo the bolts (4a) and remove the left fuel manifold pipe (4b)complete with injectors (4c).2067878
1056B67
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-).Proceed with removal 3024979-1072B42left hand or right handinlet manifold (one) - r+r .Discharge the fuel system pressure withthe tool connected to the bleed valve on the right fuel pipe.1. Disconnect the electrical connections from the right injectors.2. Disconnect the rapid connector connecting the right fuel manifoldpipe to the left one.769Avoid working with the engine hot underall circumstances;Never use tools such as pliers, screwdrivers,etc. under any circumstances;If it is released, rotate the rapid connectorcover before acting on the release buttons;Check its condition (deformation/breakageof retaining lugs, release buttons) before reconnecting it;After re-engageing the rapid connector,check that it is correctly attached by pulling it;At the end of fitting, check that thereare no fuel leaks by starting up the engine again;If there is damage to the rapid connector,replace the complete right pipe.3. Undo the bolts (3a) and remove the right fuel manifold pipe (3b)complete with injectors (3c).2067879
pressure pump electric control
1060G10
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025534-5530B10battery - r+r1. Undo collar (1a) and remove the sleeve (1b) from air cleanerto flow meter.2. Disconnect the air flow meter from the underlying sleeve.3. Disconnect the electrical connection from the air flow meter.4. Remove the air flow meter.2002316
1060G14
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025534-5530B10battery - r+rDisconnect the battery negative terminal. 1. Disconnect the water temperature sensor electrical connection.2. Undo the thermostat water temperatur sensor and remove.2002317
1060G16
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative (-) terminal.3025001-1016A10sound-proofing cover - r + r1. Disconnect the electrical connection from the excess pressuresensor.2. Withdraw the retaining bolt.3. Remove the excess pressure sensor2002318
1060G18
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Disconnect the electrical connection from the fuel temperaturesensor.2. Undo and remove the fuel temperature sensor.2002319
1060G20
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the car on a ramp.Disconnect the battery negative terminal.3025915-7055B54under-engine guard - r r1. Disconnect the electrical connection for the rpm sensor.2. Undo bolts (2a) and remove rpm and timing sensor (2b).2002320
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-). Proceed with removal 3025001-1016A10sound-proofing cover- r + r . 1. Disconnect the electrical connection from the fuel pressure sensoron the fuel manifold.2. Undo and remove the fuel pressure sensor on the fuel manifold.2068090
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Disconnect the electrical connection from the switch on the clutchpedal.2. Turn the switch clockwise through 90 degrees and remove.2002322
1060G50
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold.2002323
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold.2002327
1060G58
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold.2002330
1060G80
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Disconnect the battery negative terminal.1. Disconnect the electrical connection from the injection electroniccontrol unit.2. Undo the retaining nuts.3. Remove the engine control unit from its seat on the strut.2002332
1. Using the dipstick, check that the engine oil level is betweenthe MIN and MAX marks on the actual dipstick.767This check should be carried outwith the vehicle on a flat surface, several minutes after the enginehas been switched off.2. If necessary, top up the level introducing the recommended oilafter having removed the cap.767The table shows the quantity forperiodic replacement.For a distinctly sporty performance, usethe recommended oil for the engine lubrication circuit.767The table shows the quantity forperiodic replacement.For the optimum operation of the enginein particularly harsh climatic conditions (temperatures below -15degrees C), use the recommended oil for the engine lubrication circuit.767The table shows the quantity forperiodic replacement.7692001755
1084A16
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Proceed with the removal 3024856-1072C44exhaust manifold heatshield on bulkhead - r+r . 1. Remove the engine oil dipstick.2. Undo the nut (2a) and remove the engine oil dipstick pipe (2b).2001756
1084A42
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the ramp.Ensure that the ignition key is in theOFF postition, then disconnect the battery negative terminal.Proceed with the removal 3024856-1072C44exhaust manifold heatshield on bulkhead - r+r .
1084A46
<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 3025360-4450B04right front wheel rr .Proceed with removal 3025911-7055B42Additional FRONT WHEELARCH (one), left or right - R.R. .1. Disconnect the electrical connection from the engine oil temperaturesender unit.2. Undo and remove the engine oil temperature sender unit.2067996
1084A40
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the car on a ramp.Disconnect the battery negative terminal.Raise the lift.3025915-7055B54under-engine guard - r r1. Undo the nut (1a) and bolt (1b) and remove the power unit rearrigid mount reinforcement (1c).2002379
1084A22
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-). Proceed with removal 3025001-1016A10sound-proofing cover- r + r . 1. Loosen the band and disconnect the engine oil vapour recoverypipe from the engine oil filler. 2. Disconnect the electrical connection from the engine coolanttemperature sensor. 2048452
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Remove the rubber accelerator pedal cover.
1068A20
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Ensure that the ignition key is in theOFF postition, then disconnect the battery negative terminal.1. Disconnect the electrical connection for the accelerator pedalpotentiometer.2. Undo the bolts (2a) and remove the accelerator pedal with potentiometerincorporated (2b).2001638
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r1. Loosen band (1a) and disconnect the air delivery sleeve fromheat exchanger to intake manifold (1b).2002370
1080C74
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + rDisconnect the battery negative terminal.1. Undo the bolts securing the expansion joint to the EGr electricalvalve.2. Undo the botls and nut securing the EGR electrical valve to theintake manifold.3. Disconnect the EGR valve actuator electrical connection.4. Remove the EGR electrical valve from the engine bay.2002374
1080C76
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r1. Undo the bolts securing the expansion joint to the intake manifold2. Undo the bolts securing the expansion joint to the EGR electricalvalve.3. Remove the expansion joint from its housing.2002375
1080C24
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Proceed with removal 3025001-1016A10sound-proofing cover- r + r . Ensure that the ignition key is in theOFF position, then disconnect the negative battery terminal (-). 1. Loosen the band and disconnect the engine oil vapour recoverypipe from the engine oil filler. 2. Release the engine oil vapour recovery pipe from the fasteningband and move it aside.2048433
1080C80
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on the rampProceed with removal 3025001-1016A10sound-proofing cover- r + r . Proceed with removal 3025534-5530B10battery - r+r . Proceed with removal 3025540-5530B52Battery DRIP TRAY/SUPPORT- R.R. . Proceed with removal 3025915-7055B54under-engine guard -r r . 1. Loosen the band and disconnect the coolant supply to from thewater/exhaust gas heat exchanger for the E.G.R. system, heat exchangerside. 2. Loosen the band and disconnect the coolant outlet pipe from thewater/exhaust gas heat exchanger for the E.G.R. system, heat exchangerside. 3. Loosen the band and disconnect the coolant return pipe to theclimate control heater, thermostat side. 767Collect the coolant which comesout in a suitable container. 2048439
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Place the car on a ramp.3025915-7055B54under-engine guard - r rPosition a suitable container under theengine for recovering the coolant fluid.Open the lower radiator pipe collar anddrain the coolant completely into the underlying container.1. Undo nuts (1a) securing the front section of the exhaust pipeto the sleeve joining the turbocharger to the exhaust manifold (1b).Recover the underlying gasket.2. Undo the bolt (2a) fixing the reinforcement bracket (2b).2002333
1064A26
Fit the variable geometry turbochargerassembly in a vice.1. Unscrew the bolt (1a) securing the metal collar (1b) and removethe sleeve joined to the exhaust pipe (1c).2002340
1064A28
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r3025534-5530B10battery - r+r3025540-5530B52Battery DRIP TRAY/SUPPORT - R.R.1. Undo the nut securing the actuator to the bracket.2. Disconnect the electrical connection from the vane actuatorsolenoid.3. Disconnect the vacuum hoses from coupling (3a) with the vacuumpipe from fitting (3b) on the solenoid.4. Remove the turbocharger vane actuator solenoid.2002342
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r3025036-1060F36lines to injectors - r rDisconnect the pipe from the injectorsto the fuel recovery manifold from the manifold and injectors.Disconnect the injector electrical connections1. Undo the injector anchoring brackets securing nuts.2. Fit injector removal device (2a). Ensure lifting bracket (2b)is fitted beneath the polygonal area of the injector.3. Fit the second lifting bracket (3a) of the device under injectorsecuring bracket (3b).4. Tighten device nut (4a) and remove the injector (4b).Repeat the operation for the remaininginjectors.7672002309
1060F20
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + rRelease the return manifold from the intakemanifold. 1. Unscrew the pipe connector from the return manifold. 2. Unscrew the pipe connector from the pressure pump. 3. Remove the pipe from the pressure pump to the fuel manifold.2002310
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + rDisconnect the battery negative terminal. 1. Disconnect the electrical connections from the injectors.2. Undo the connectors for the pipes from the injectors.3. Undo the connectors of the pipes from the single fuel manifold.4. Remove the fuel manifold and injector connection pipes. 2002313
1060F50
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r1. Disconnect the fuel return pipes from the injectors.2. Disconnect the fuel return pipe from the pressure pump.3. Disconnect the return pipe to the tank.4. Disconnect the return pipe to the fuel filter.5. Undo nuts (5a) and remove the single fuel manifold pipe (5b).2002314
1060F52
<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213025001-1016A10sound-proofing cover - r + r1. Disconnect the pipe from the injectors to the fuel recovery manifold,manifold side.2. Push clips (2a) by hand and disconnect the pipe from fittings(2b) on the injectors. 2002315
<anchor>0</anchor><span>Dismantling</span><icon><imageid>20</imageid></icon>1Reassembling21Ensure that the ignition key is in OFFposition, then disconnect the battery negative terminal (-). Proceed with removal 3025001-1016A10sound-proofing cover- r + r . Proceed with removal 3025037-1060F50fuel return manifold -r r . Clean the high pressure pump using coldcleaning products and dry with compressed air.767The cold cleaning products shouldnot penetrate inside the electrical connection.1. Disconnect the electrical connection from the fuel pressure regulator. 2. Undo the bolts fixing the fuel pressure regulator.767Check that the fixing bolts arenot damaged, otherwise they must be replaced. Fixing bolts that arenot damaged can be reused.3. Rotate the pressure regulator, by hand, in an anti-clockwisedirection and remove it. 767Do not use any tools for removingthe fuel pressure regulator from the pressure pump. 2068150
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.2003381
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