AUTOMOTIVE ELECTRICIANS

Alfa Romeo 166 2.4 JTD 10v da 04/01 a 02/02 — WINDSCREEN WASH/WIPE — — WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION — WIRING DIAGRAM, LOCATION COMPONENTS, OPERATIONAL DESCRIPTION

Wiring diagram

Components
Component codeNameAssembly reference
B1Junction unit5505A
B2Dashboard junction unit (CPL)-
B2Junction unit-
B2Junction unit5505A
B5MAXI FUSE box-
B45Luggage compartment junction unit (CVB)-
B99Battery fuses junction unit (CBA)5530B
C10Front left earth-
C11Right front earth-
C13Front earth on left side panel5505A
C15Facia earth, driver's side-
C25Earth on steering column-
D1Front-dashboard coupling-
D6Rear - front coupling-
D19Dashboard / battery coupling-
D20Dashboard-rear coupling-
D42Dashboard-courtesy lights coupling-
H1Ignition switch5520A
H5Steering column switch unit5550A
K85Rain sensor-
N15Windscreen wiper motor-
N20Windscreen washer pump motor-
N20Windscreen washer pump motor5540B
N20Windscreen washer pump motor5540B
N20Windscreen washer pump motor5540B
Location of components

Components
Component codeNameAssembly reference
B1Junction unit5505A
B2Dashboard junction unit (CPL)-
B2Junction unit-
B2Junction unit5505A
B5MAXI FUSE box-
B45Luggage compartment junction unit (CVB)-
B99Battery fuses junction unit (CBA)5530B
C10Front left earth-
C11Right front earth-
C13Front earth on left side panel5505A
C15Facia earth, driver's side-
C25Earth on steering column-
D1Front-dashboard coupling-
D6Rear - front coupling-
D19Dashboard / battery coupling-
D20Dashboard-rear coupling-
D42Dashboard-courtesy lights coupling-
H1Ignition switch5520A
H5Steering column switch unit5550A
K85Rain sensor-
N15Windscreen wiper motor-
N20Windscreen washer pump motor-
N20Windscreen washer pump motor5540B
N20Windscreen washer pump motor5540B
N20Windscreen washer pump motor5540B
DescriptionThe windscreen wash/wipe system is operated by a stalk switch on the right side of the steering wheel. The stalk switch can be set to five positions that correspond to different functions:windscreen wiper off (standstill);intermittent operation;continuous slow operation;continuous medium-fast operation;temporary fast operation (unstable stalk position).When the stalk switch is set to intermittent operation position, four different speeds can be selected by turning the relevant ring:slow intermittent;medium intermittent;medium-fast intermittent;fast intermittent.If the car is equipped with a rain sensor, windscreen wiper operation is automatic and sweep frequency and speed alter according to the amount of water on the windscreen.The rain sensor is activated by turning the stalk switch to 'intermittent operation' position and turning the ring to choose one of four levels of sensitivity:minimum sensitivity;medium sensitivity;high sensitivity;maximum sensitivity.By adjusting the sensitivity, automatic windscreen wiper operation can be adjusted to specific visibility conditions, such as fog with condensation on the windscreen, spray thrown up by other vehicles, drizzle etc.When the key is turned to STOP position, the rain sensor is deactivated and does not reactivate the next time the engine is started up. To reactivate the sensor, the stalk must be moved to another position and then back to the intermittent setting, or the sensitivity selection ring must be moved to another position.The rain sensor is secured to the windscreen within the swept area of glass. It is controlled by an electronic control unit that also controls the windscreen wiper motor.Each time the car is started, the rain sensor automatically stabilises (within about 2 minutes) at a temperature of 40° C in order to remove condensation from the detection surface and prevent ice formation.The rain sensor is able to identify and adapt automatically to the presence of specific conditions that require different intervention sensitivities as follows:impurities on the detection surface (salt deposits, dirt, etc.)water smears caused by worn windscreen wiper bladesdifferences between day and night (the human eye finds it less easy to deal with a wet windscreen surface by night than by day).The windscreen wiper function is operated by pulling the stalk switch slightly toward the steering wheel. This action operates the washer pump. If the stalk switch is held in position, the windscreen wiper also operates (continuous operation). The windscreen wiper carries on working for a few sweeps after the stalk switch is released.The entire system is governed by an electronic device which is responsible for controlling the intermittent function and also the windscreen wiper motor and washer pump.The windscreen wash/wipe circuit and rain sensor circuit are protected by special fuses and controlled by an ignition-operated cut-out relay located in the junction unit.The windscreen wiper and washer can be operated with the ignition key turned to ON.
Functional description The windscreen wiper control on the steering column switch unit H5 selects the various operating modes of the windscreen wash/wipe. The stalk unit H5 is supplied at pin 3 of connector D from the ignition-operated line (INT/A) of the relay R1 protected by the fuse F14 : both are contained in the junction unit B1 . The same line supplies the electronic device in the windscreen wiper motor N15 : - pin 3 of the connector B - and returns - from pin 1 of connector B - to the stalk unit H5 . The windscreen wiper motor N15 is then connected to earth - pin 1 of connector A. Depending on the pre-selected function, the stalk unit H5 (connector D) sends the following control signals to the internal electronic device to the windscreen wiper motor N15:from pin 3 of connector C for continuous fast operation: the signal reaches pin 5 of connector A of the motor N15 ;from pin 1 of connector D for continuous slow operation: the signal reaches pin 4 of connector A of motor N15 ;from pin 10 of connector D for intermittent/automatic operation: the signal reaches pin 2 of connector A of the motor N15 and the rain sensor K85 pin 5: this signal differs depending on the position of the intermittent function adjuster ring, which connects none, one or several resistors on the line, thus obtaining the different intermittent speeds. When operated, the windscreen washer switch of the stalk unit H5 sends a signal from pin 5 of connector D to pin 4 of connector B of N15 : this controls the operation of the windscreen washer N20 - from pin 3 of connector A. The same signal is also sent as a command to operate the headlamp washer delay unit R3 contained in B1 - pin 20 of connector F. ( 3309383SeeE3022HEADLAMP WASHER ). The system can also be connected to a rain sensor K85 which automatically adjusts the windscreen wiper sweep frequency. The sensor K85 is supplied at pin 2 from the ignition-operated line (INT/A) of relay R1 protected by the fuse F9 : both are contained in the junction unit B1 ; pin 3 is earthed. Pin 5 receives the intermittent/automatic operation signal coming from the stalk unit H5 : this enables the operation of the system and at the same time establishes the sensor's sensitivity. Pins 1 and 6 connect to the windscreen wiper motor N15 : - pin 2 connector B - indicating, in accordance with the logic described above, the type of automatic operation to be set.

Junction unit



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1B



B1B



B1B



B1B



B1B



B1B



B1B



B1B



B1B



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1D



B1D



B1D



B1G



B1E



B1E



B1E



B1E



B1E



B1E



B1E



B1E



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1H



B1H



B1H



B1H



B1H



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1X



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1A



B1B



B1B



B1B



B1B



B1B



B1B



B1B



B1B



B1B



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1C



B1D



B1D



B1D



B1G



B1E



B1E



B1E



B1E



B1E



B1E



B1E



B1E



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1F



B1H



B1H



B1H



B1H



B1H



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1I



B1X



multi-function components



5505A10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314824-5505A18multi-function controlunit - r r . 1. Undo the bolt (1a) and push back the junction unit as far asnecessary to disconnect the electrical connections (1b).767For precise identification ofthe electrical connections, see Wiring Diagrams Section.2. Remove the junction unit.2010592

5505A13


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r (left). 3315197-7040D14engine bay rear side cover (one) lh or rh - r r (left).

5505A18


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 1. Unscrew bolt (1a) and open fuse access cover (1b).2. Undo the bolt (2a) and remove the integrated multiservices unit(2b) after having disconnected the electrical connections (2c),(2d), (2e), (2f) and (2g).2010595

5505A29


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Open the bonnet lid.1. Release the retainers (1a) and remove the cover (1b) for theadditional junction unit.2071293

Dashboard junction unit (CPL)



B2



B2A



B2B



B2C



B2E



B2F



B2G



B2G



B2H



B2I



B2I



B2I



B2I



B2I



B2I



B2



B2A



B2B



B2C



B2E



B2F



B2G



B2G



B2H



B2I



B2I



B2I



B2I



B2I



B2I



MAXI FUSE box



B5A



B5C



B5D



B5D



B5A



B5C



B5D



B5D



Luggage compartment junction unit (CVB)



B45A



B45B



B45A



B45B



Battery fuses junction unit (CBA)



B99A



B99C



B99D



B99E



B99G



B99A



B99C



B99D



B99E



B99G



battery and leads



5530B10


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314864-5530B54battery cover - r+r . Make sure that the ignition key is in theOFF position.1. Disconnect the battery negative and positive terminals.2. Undo the bolt (2a) fixing the battery retaining bracket (2b).3. Remove the battery.2010647

5530B40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314864-5530B54battery cover - r+r1. Press and release the retainers (1a), then remove the cover (1b)for the supply box on the battery. 2071303

5530B52


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314864-5530B54battery cover - r+r . 3314861-5530B10battery - r+r . 1. Remove the battery fluid collection reservoir.2010648

5530B54


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Working in the luggage compartment, undo the knob for the batterycover.2. Remove the battery cover.2010650

Front left earth



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10B



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10A



C10B



Right front earth



C11



C11



C11



C11



C11



C11



Earth on steering column



C25A



C25A



C25A



C25B



C25B



C25B



C25



C25A



C25A



C25A



C25B



C25B



C25B



C25



Dashboard-i.e coupling.



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



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1B



D1B



D1B



D1B



D1B



D1B



D1B



D1B



D1B



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1D



D1D



D1D



D1D



D1D



D1D



D1D



D1D



D1D



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



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1A



D1B



D1B



D1B



D1B



D1B



D1B



D1B



D1B



D1B



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1C



D1D



D1D



D1D



D1D



D1D



D1D



D1D



D1D



D1D



Rear - front coupling



D6C



D6C



D6C



D6C



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6B



D6B



D6C



D6C



D6C



D6C



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6



D6B



D6B



Dashboard / battery coupling



D19



D19



D19



D19



Dashboard-rear coupling



D20A



D20A



D20A



D20A



D20B



D20B



D20C



D20C



D20A



D20A



D20A



D20A



D20B



D20B



D20C



D20C



Dashboard-courtesy lights coupling



D42



D42



D42



D42



D42



D42



D42



D42



D42



D42



D42



D42



D42



D42



Ignition switch



H1A



H1A



H1A



H1A



H1A



H1A



H1B



H1B



H1B



H1A



H1A



H1A



H1A



H1A



H1A



H1B



H1B



H1B



ignition switch



5520A12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3314931-5580C18air bag module - r+r . 7693315174-7040A26steering column trim - r+r . 3314624-4110A11steering wheel - r+r for replacement or check forversions with air bag . 3314902-5550A12complete stalk unit - r+r for versions with air bag . 1. Release the aerial for the electronic key from the ignition switch.2. Release the electrical wiring from the fixing band and disconnectthe electrical connection for the ignition switch.2010621

5520A14


768

Steering column switch unit



H5A



H5A



H5A



H5B



H5B



H5B



H5C



H5C



H5D



H5D



H5D



H5A



H5A



H5A



H5B



H5B



H5B



H5C



H5C



H5D



H5D



H5D



stalk unit



5550A12


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213314931-5580C18air bag module - r+r . 7693315174-7040A26steering column trim - r+r . 3314624-4110A11steering wheel - r+r for replacement or check forversions with air bag . 1. Undo the bolts (1a) and remove the complete steering column switchunit (1b) after having disconnected the electrical connections (1c),(1d), (1e) and (1f).2010691

Rain sensor



K85



K85



Windscreen wiper motor



N15A



N15A



N15A



N15A



N15B



N15B



N15B



N15A



N15A



N15A



N15A



N15B



N15B



N15B



Windscreen washer pump motor



N20



N20



N20



N20



N20



N20



N20



N20



headlamps



5540B16


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on thelift. Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 3315300-7055B42Additional FRONT WHEEL ARCH (one), left or right- R.R. . 3315286-7055A43central front grille - r r . 3315285-7055A41RIGHT FRONT GRILLE - R.R. . 1. Undo the lower bolts fixing the bumper to the lower radiatorcrossmember.2. Unscrew the bolts retaining the bumper to the body.3. Unscrew the upper bolts securing the bumper to the body.2010660

5540B22


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 1. Release the retaining spring (1a) and remove the protective cover(1b).2. Disconnect the electrical connection from the lamp.3. Release the retaining spring (3a) and remove the lamp (3b) fromthe light cluster.767If the lamp is working properly,avoid touching the bulb with your hands. If this does happen, cleanthe bulb with alcohol.2010662

5540B26


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 1. Rotate the bulb holder (1a) in an anti-clockwise direction untilit is released from the light cluster (1b).2. Disconnect the electrical connection (2a) and extract the bulbholder.3. Separate the lamp from the bulb holder (press fit).767If the lamp is working properly,avoid touching the bulb with your hands. If this does happen, cleanthe bulb with alcohol.2010663

5540B38


Prepare the vehiclecomplete with spare wheel, tools, fluids, fuel reserve.Check that the tyre inflation pressureis correct.Place the headlamp alignment switch inposition '0'.Position the vehicle on a flat surface,perpendicular to a screen with an opaque surface, 10 metres away, whichcontains the following lines.1. V - V: vertical corresponding to the trace of the vehicle symmetryplane.2. C - C: traces of the vertical planes passing through the referencecentres of the light clusters.3. HC - HC: horizontal corresponding to the height from the groundof the reference centres for the light clusters.4. AC - AC: horizontal 11 cm below the HC - HC line.5. Lines inclined at 15° as illustrated in the diagram.2010664

5540B40


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on theramp. Make sure that the ignition is OFF (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r . 1. Disconnect the electrical connection from the exhaust gas headlampcontrol unit.2. Disconnect the electrical connection from the headlamp alignmentmotor.2010666

5540B42


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21Position the vehicle on theramp. Make sure that the ignition is off (STOPposition), then disconnect the negative battery terminal (referto op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r . 3315298-7055B39front additional wheel arch half (one), lh or rh,front element - r r . 3315285-7055A41RIGHT FRONT GRILLE - R.R. . 3315286-7055A43central front grille - r r . 3315293-7055B10Front BUMPER - R.R. . 3314879-5540B40Gas discharge LEFT LIGHT CLUSTER CONTROL UNIT (one)- R.R . . 1. At the bench, rotate the exhaust gas headlamp control unit torelease it from the fastening on the light cluster.2010668

5540B43


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting211. Undo the control unit fixing bolts.2071307

5540B44


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r . 1. Disconnect the electrical connection from the exhaust gas headlampcontrol unit.2010672

5540B46


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r . 1. Disconnect the electrical connection from the exhaust gas headlampcontrol unit.2010675

5540B48


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting21 Make sure that the ignitionis off (STOP position), then disconnect the negative battery terminal(refer to op. 33148615530B10battery - r+r ). 3315196-7040D12engine front side cover (one) lh or rh - r r . 1. Disconnect the electrical connection from the exhaust gas headlampcontrol unit.2010678

5540B81


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213315196-7040D12engine front side cover (one) lh or rh - r r (rightand left) 3315198-7040D30engine bay front beam cover - r r3315284-7055A40radiator shield - r r3315285-7055A41RIGHT FRONT GRILLE - R.R. (right andleft) 3315298-7055B39front additional wheel arch half (one), lh or rh,front element - r r (right and left) 3315293-7055B10Front BUMPER - R.R.1. Undo the light cluster fixing bolts.2. Move the light cluster assembly slightly.2071316

5540B82


<anchor>0</anchor><span>Removing</span><icon><imageid>20</imageid></icon>1Refitting213315196-7040D12engine front side cover (one) lh or rh - r r (rightand left) 3315198-7040D30engine bay front beam cover - r r3315284-7055A40radiator shield - r r3315285-7055A41RIGHT FRONT GRILLE - R.R. (right andleft) 3315298-7055B39front additional wheel arch half (one), lh or rh,front element - r r (right and left) 3315293-7055B10Front BUMPER - R.R.1. Undo the light cluster fixing bolts.2. Move the light cluster assembly slightly.2071318
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