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 features the use of high, electronically-controlledinjection pressure. Fuel delivery, termed a pilot injection, isoptimised by the electronic control unit via the injector and notmanaged by the pump.The common rail injection system on thisversion with 4 valves per cylinder uses Multijet technology: i.e.it carries out more than the usual two injections during each enginecycle: it carries out two pre-injections (before the piston is at TDC),one main injection and two post-injections.This solution improves consumption, emissions,quietness and performance because it allows better control of thetemperature in the combustion chamber, lowering the maximum valueand extending the optimum combustion zone.The system uses signals receivedfrom numerous sensors to control actuators. It is connected to thefollowing systems:fuel supply;air supply system;heater plugs;accelerator pedal;engine cooling;fuel preheating. For greater detail, see 3232876Characteristic of working principle1060DIESEL FUEL INJECTION . Thanks to the electronic management describedabove, this engine conforms to the latest anti-pollution and continuouscontrol regulations in accordance with the EOBD system (EuropeanOn Board Diagnosis); The EOBD (European On Board Diagnosis) systemcarries out continuous diagnosis of the car's petrol fuel systemcomponents relating to emissions and indicates any deteriorationof these components by the warning light in the instrument panelcoming 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 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 by other jumper fuses, located in theadditional fuse box.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. The supply for the engine control unit M10is controlled by the ignition (15/54) at pin 28 by the line protectedby fuse F4 of the additional fuse box B98A. The relay J10 controls the systemsupply: it is supplied by the battery, from the line for maxifuseEFI of B99 ; pin 72 of the control unit M10 sends the enablementsignal which excites relay J10 and sends power to the control unit,directly to pin 5 and, via the line of fuse F3 of the additionalfuse box B98A, to pin 1. The relay J15 is also supplied by thebattery, from the line for maxifuse EFI of B99; pin 91 of controlunit M10 sends the signals which energize the relay, which providesthe supply to the fuel pump N40, which is connected to earth throughthe inertia switch I50. In case of impact, this cuts off thecircuit to prevent the danger of fuel delivery. Pins 2, 4 and 6 ofconnector A of M10 are earthed. The diesel preheating relay J17 is suppliedby the battery via the line protected by the GLOW maxifuse of B99or fuse B39, and controls the operation of the diesel heating resistorO20; a signal from the control unit M10 (from pin 68) deactivatesthe system once heating has taken place. Control unit M15 , responsible forcontrolling preheating of heater plugs A40 , is supplied directlyby the battery via a line protected by the GLOW maxifuse of B99 .It is supplied - connector C - by the line of fuse F2 of theadditional fuse box B98A, and exchanges the command and controlsignals with pins 52 and 93 of M10 which controls the timer. ConnectorB is connected to the heater plugs A40. The engine control unit M10 receivessignals from the various sensors in order to monitor all engineservice conditions. Rpm sensor K46 supplies information onengine speed via a frequency signal sent to pins 12 and 27 of connectorB of control unit M10. Timing sensor K47 is supplied from pin11 of connector B of control unit M10. It receives a referenceearth from pin 20 of connector B of control unit M10 and sendsit a signal of frequency corresponding to the timing of pin 50 ofthe same connector. The engine temperature sensor K45, receivesa reference earth from pin 41 of the control unit M10 and suppliesa signal proportional to the temperature of the engine coolant topin 58 of connector B. The air flow meter K41 receives ageneral power supply from the line of fuse F2 of the additionalfuse box B98A ; a reference earth is received from pin 44 ofconnector B of M10. It is supplied by the control unit frompin 29 of connector B of M10, and sends pin 42 of connector Ba signal proportional to the air flow. There is also an airtemperature sensor inside K41 which sends an air temperaturesignal to pin 37 of connector B of M10. Accelerator pedal K55 is fitted with twobuilt-in potentiometers (a main one and a safety back-up). The formerreceives power and earth from pins 30 and 45, respectively of connectorA of M10 and sends a corresponding signal to pin 9. The latterreceives power and earth from pins 46 and 8, respectively of connectorA of M10 and sends a signal to pin 31. The fuel temperature sensor K81 measuresthe temperature of the diesel entering. It receives a referenceearth from pin 10 of connector A of M10 and sends the fuel temperaturesignal to pin 11. The supercharging sensor K82 measuresthe pressure and temperature in the intake chamber, downstream ofthe turbocharger. It is supplied from pin 13 of connector Bof M10 and receives a reference earth from pin 23 of connectorB. The signal corresponding to the pressure value is sent topin 40 of connector B of the control unit. There is also an airtemperature sensor inside K82 which sends a signal to pin 53of connector B of M10. The fuel pressure sensor K83 is responsiblefor providing the injection control unit with a feedback signalfor governing pressure and injection duration. It receives powerand a reference earth from pins 28 and 8 respectively of connectorB of M10; it then sends the pressure signal to pin 43. The fuel pressure regulator N77 hasthe task of keeping the value of the fuel pressure in the accumulatorconstant. The two control signals come from pins 4 and 34 of connectorB of the control unit M10. The EGR solenoid L30 controls exhaustgas recirculation. it receives a supply from the line for fuse F2of the additional fuse box B98A; , and is controlled by a signalfrom pin 60 of connector B of M10. The turbine variable geometry control solenoid L36 governs the operation of the turbine in accordance with engineload; it is supplied by the line of fuse F2 of the additional fusebox B98A and is controlled by a signal from pin 7 of connector Aof M10. The solenoid valve on the throttle casing L62shutters and closes the throttle, for example when the engine isswitched off; it receives a supply from the line for fuse F2of the additional fuse box B98A; and is controlled by a signalfrom pin 59 of connector B of M10. The engine management control unit sendsthe command to the injectors N70 from pins 16-47, 2-31, 1-46,17-33 and 18-48 of connector B of M10 for cylinders 1, 2, 3 , 4and 5, respectively. Pin 59 of M10 receives the signal comingfrom the brake lights switch I30, with the supply controlled bythe ignition (INT) from fuse F1 of the junction unit B1 or, dependingon the version, from fuse F4 of the additional fuse box B98 B. Pin 79 of M10 receives an earth signalcoming from the clutch pedal switch I31. Control unit M10 - pins 61 and 62 - communicateswith ABS control unit M50 via the CAN line: this line, on versionswith VDC, passes through steering sensor K58 and reaches ABS controlunit M50. The speedometer module E10 receives asupply controlled by the ignition (INT) from the line protectedby fuse F4 of the additional fuse box B98B; when the earth signalarrives from pin 71 of connector A of M10, the 'EOBD' warning lightcomes on. The rev counter module E15 also receivesa supply controlled by the ignition (INT) from the line protectedby fuse F4 of the additional fuse box B98B; when the earth signalarrives from pin 92 of connector A of M10, the 'heater plugs' warninglight comes on. The coolant temperature signal is sent tothe auxiliary instrument from pin 94 of connector A of M10 SeeE4023 DASHBOARD CENTRE AUXILIARY EQUIPMENT() . Control unit M10 is connected to theALFA ROMEO CODE control unit M20 via a line from pin 47 of connectorA; in this way if the ALFA ROMEO CODE unit does not detect acorrect code, it does not issue enablement and the engine is notstarted. The control unit is equipped with a self-diagnosticunit that may be used by connecting the unit to connector R10 viapin 25 of connector A. Control unit M10 sends from pin 48 ofconnector A, a signal proportional to the engine rpm SeeE4020 REV COUNTER INSTRUMENT ; a consumptionsignal leaves pin 27 of connector A for the speedometer 3234310SeeE4021SPEEDOMETER , The control unit M10 is connected withthe air conditioning system through pins 29 and 54. This makesit possible to adjust the engine idle speed as the load increaseseach time the compressor is switched on or to switch off the compressorin the case of high engine speed or load conditions 3234652SeeE6021COMPRESSOR ENGAGEMENT . The control unit also controls the enginecooling system: pins 69, 42, 81 and 90 control the engagement ofthe relevant fans 3234439SeeE5020ENGINE COOLING . Cruise control 3234591SeeE5060CRUISE CONTROL functionmanagement signals leave pins 80, 49, 77, 78, 56 and 38 of connectorA of M10.
0Removing201Refitting21Place 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
0Removing201Refitting21Place 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
0Removing201Refitting21Disconnect 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
0Removing201Refitting213238429-5530B10battery - 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
0Removing201Refitting21Disconnect 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
0Removing201Refitting211. 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
0Removing201Refitting211. 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
0Removing201Refitting21For 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
0Removing201Refitting21Unloose fixing screws and removesteering column guide.1. Detach down-lead cable.2018668
brake and reversing lights
5550D10
0Removing201Refitting211. 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
0Removing201Refitting211. 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
0Removing201Refitting213238489-5550D16third 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
0Removing201Refitting21Place 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
0Removing201Refitting213237784-1048A50air 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
0Removing201Refitting213238429-5530B10battery - r+r1. Disconnect the electrical connection from the engine coolanttemperature sensor.2. Undo and remove the engine coolant temperature sensor.2015136
1060G16
0Removing201Refitting21Disconnect 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
0Removing201Refitting21 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
0Removing201Refitting21Position 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
0Removing201Refitting21Ensure 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
0Removing201Refitting21 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
0Removing201Refitting21 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
0Removing201Refitting21 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
0Removing201Refitting21 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
0Removing201Refitting21Ensure 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
0Removing201Refitting21Ensure 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
0Removing201Refitting21 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
0Removing201Refitting21Ensure 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
0Removing201Refitting21Disconnect 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
0Removing201Refitting21Disconnect 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
0Removing201Refitting21Ensure 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
0Removing201Refitting21Ensure 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
0Removing201Refitting21- 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
0Removing201Refitting211. 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
0Removing201Refitting21Ensure 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
0Removing201Refitting21Disconnect the battery negative (-) terminal.Raise the car.1. Disconnect the electrical connection for the air conditionercompressor electromagnet.2013568
1056B14
0Removing201Refitting213237529-1048A34sleeve(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
0Removing201Refitting21Ensure 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
0Removing201Refitting21Ensure 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
0Removing201Refitting21Disconnect 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
0Removing201Refitting21Disconnect 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
0Removing201Refitting21Disconnect 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
0Removing201Refitting21Disconnect the battery negative terminal.
1056B60
0Removing201Refitting21Disconnect the battery negative (-) terminal.
1056B87
0Removing201Refitting21Ensure 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
0Removing201Refitting21Ensure 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
0Removing201Refitting21Remove the rubber accelerator pedal cover.
1068A14
0Removing201Refitting211. 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
0Removing201Refitting21Ensure 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
0Removing201Refitting211. 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
0Removing201Refitting21Ensure 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
0Removing201Refitting211. Withdraw the end of the accelerator cable (1a) from pedal lever(1b).2014146
1068A31
0Removing201Refitting21Position 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
0Removing201Refitting21Ensure 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
0Removing201Refitting21Ensure 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
0Removing201Refitting211. 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
0Removing201Refitting21 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
0Removing201Refitting21 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
0Removing201Refitting211. 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
0Removing201Refitting213237758-1016A10sound-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
1Refitting210Removing20Refit 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.
0Removing201Refitting21Position 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
0Dismantling201. Position the turbocharger assembly in a vice.2. Unscrew nuts (2a) and remove exhaust pipe coupling sleeve (2b).2015185
1064A22
0Removing201Refitting21Position 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
0Removing201Refitting21Position 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
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
0Removing201Refitting213238799-7040A37fuse 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
0Removing201Refitting213238799-7040A37fuse box cover - r r1. Disconnect electrical connections (1a), (1b).2. Undo the nut.3. Remove the switch and bridge.2018931
0Removing201Refitting211. 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
0Removing201Refitting213238964-7055B42Additional 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
0Removing201Refitting213238429-5530B10battery - r+r1. Drain the brake-clutch fluid from the reservoir using a suitablesyringe.2. Disconnect the air inlet pipe from the inlet manifold.2017884
0Removing201Refitting21Disconnect 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
0Removing201Refitting21Disconnect 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
0Removing201Refitting213238429-5530B10battery - 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
0Removing201Refitting21Undo 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
0Removing201Refitting213238429-5530B10battery - 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
0Removing201Refitting213238429-5530B10battery - 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
0Removing201Refitting21 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
0Removing201Refitting21Disconnect 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.
0Removing201Refitting21Ensure 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
0Dismantling201Reassembling21Place 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
0Removing201Refitting21 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
0Removing201Refitting21Ensure 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
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