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. - This uses high injection pressure controlled electronically. 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 more details, 3360139Characteristic of working principle1060DIESEL FUEL INJECTION .
Functional description The engine control unit M10 monitors and controls the entire electronic ignition and injection system. The supply controlled by the ignition (15/54) reaches pin 58 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: this is excited by a control signal (earth) received from pin 31 of connector A of control unit M10 and then sends power:to pin 4 of the actual control unit, via the line from fuse F17 of B1 ;to pin 5 of the actual control unit, via the line from fuse F22 of B1 ;to the oil level sensor K31 , 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 24 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 1, 2 and 3 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 23 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 F4 of B1. It is supplied, connector C, by the line for fuse F11 of B1 and exchanges command and control signals with pins 22 and 62 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 operating conditions. The rpm sensor K46 provides information concerning the engine speed through a frequency signal sent to pin 100 of the control unit M10 . It receives an earth signal from pin 99 of the control unit. Both signals are weak and are therefore suitably shielded by pin 101. Timing sensor K47 is supplied from pin 102 of M10. It receives a reference earth from pin 104 of the control unit M10 and sends it a signal of frequency corresponding to the timing of pin 103. The engine temperature sensor K36 , receives a reference earth from pin 85 of the control unit M10 and supplies a signal proportional to the temperature of the engine coolant to pin 84. The air flow meter K41 receives a general supply from the line for fuse 11 of B1 and a reference voltage from pin 88 of M10 . It is supplied by the control unit from pin 97 of M10 and sends a signal proportional to the air flow rate to pin 89. K41 also contains an air temperature sensor which sends an air temperature signal to pin 86 of M10 . Accelerator pedal K55 is fitted with two built-in potentiometers (a main one and a safety back-up). The first receives power and earth from pins 78 and 76 respectively of M10 and sends a corresponding signal to pin 77. The second receives power and earth from pins 81 and 79, respectively of M10 and sends the signal to pin 80. The fuel temperature sensor K81 measures the temperature of the diesel entering. It receives a reference earth from pin 83 of M10 and sends the fuel temperature signal to pin 82. The supercharging sensor K82 measures the turbocharger pressure. It is supplied by pin 93 of M10 and receives a reference earth from pin 95. The signal is sent to in 94 of the control unit. The fuel pressure sensor K83 is responsible for providing the injection control unit with a feedback signal for governing injection pressure and duration. It receives the power and reference earth from pin 90 and 92, respectively of M10 ; it then sends the pressure signal to pin 91. 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 108 and 109 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 16 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 17 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 15 of M10 . Pin 59 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 59 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 61 of M10 receives an earth 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 control unit sends commands to the injectors N70 from pins 119, 120, 121 and 114 of connector A for cylinders 1, 2, 3 and 4, respectively. The control unit M10 receives the minimum engine oil pressure sensor K30 signal at pin 98. The water in diesel filter sensor K31 ; is supplied by the line for fuse F11 of B1 and sends the corresponding signal to pin 105 of M10 . The control unit M10 is connected via the CAN network - pins 9, 10, 28 and 29 - 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 C 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 21 - 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 C of the Body Computer M1 - pin 7: it receives the signals from pin 48 from the control unit M10 via the specific tester line.
0Removing201Refitting21Disconnect the negative battery terminal.1. Remove the junction unit protective cover.192009560
5505A35
0Removing201Refitting213363098-5530B56BATTERY DRIP TRAY COVER- R.R.Disconnect the battery negative terminal.3363361-7040A44facia lh side cover - r r1. Disconnect the front electrical connectors of the junction unitcomplete with body computer.2. Unscrew the retaining bolts.3. Remove from its seating the junction unit complete with bodycomputer.4. Disconnect the rear electrical connectors of the junction unitcomplete with body computer.2027438
5505A36
0Removing201Refitting211. Separate the junction unit (1a) from the body computer (1b),by releasing the retaining lugs (1c).2027440
5505A41
0Removing201Refitting213363098-5530B56BATTERY DRIP TRAY COVER- R.R.Disconnect the battery negative terminal.3363151-5580C18air bag module - r+r . 769- 4110A16 steering wheel - r r for replacement or checks forversions with airbag and manual gearbox with hydraulic selection . 1. Disconnect the electrical connectors (1a) and remove the controlunit (1b) from its seating.2027441
0Removing201Refitting213363098-5530B56BATTERY DRIP TRAY COVER- R.R.1. Release the clips and remove the protective cover for the uniton the battery.2. Undo the bolts (2a) and remove the battery fixing bracket (2b).3. Slacken the nut and disconnect the battery's negative terminal.2027495
5530B52
0Removing201Refitting21Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.3363098Op. 5530B10 BATTERY - R+R3363096- Disconnect the engine management unit electrical connections.Release the wiring from the retaining bands.1. Undo the rear fixing bolt (1a), release the front fastenings (1b) and place the engine compartment junction unit (1c) at the side.192008351
5530B56
0Removing201Refitting211. Undo the fixing bolts (1a) and remove the battery cover (1b).2027502
0Removing201Refitting213363098-5530B56BATTERY DRIP TRAY COVER- R.R.Disconnect the battery negative terminal.3363357-7040A26steering column trim - r+r1. Undo the bolts fixing the analogue instrument panel trim.2. Remove the trim under the instrument panel.3. Undo the upper bolts fixing the instrument panel to the dashboard;then partly release the panel.2027547
767 It is not possible toorder a single lock barrel or to order barrels using a single partcode. When ordering barrels, observe the special procedure illustrated 3363161See assembly5580E anti-theft device .
0Removing201Refitting21Position the vehicle on a lift.Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.3363098Disconnect the negative battery terminal.Draw off the fuel from the tank using a special tool.1. Remove the protective cover (1a) to gain access to and loosen the nut (1b) tensioning the handbrake cables.192008943
1040A14
0Removing201Refitting213362949-4450B08right rear wheel r r- 7055B43 REAR WHEEL ARCH liner (one), left or right - R.R. 3362450-1040A10fuel tank - r + r and decant fuel1. Disconnect the rapid attachments for the fuel supply and returnpipes.2. Release the fuel supply and return pipes from the bands on thefuel tank and remove them.3. Use tool (3a) to unscrew lock collar (3b), then remove the fuelpump (3c) together with the level gauge.4. Disconnect the pipes (4a) from the tank and remove the fillerpipe assembly (4b).2024971
1040A30
0Removing201Refitting21Place the car on a ramp.Raise the vehicle.3362949-4450B08right rear wheel r r- 7055B43 REAR WHEEL ARCH liner (one), left or right - R.R. 1. Undo the bolts fixing the fuel filler pipe fitting to the bodyshell.2. Undo the nut fixing the filler pipe to the bodyshell wheel arch.3. Disconnect the flexible section of fuel filler pipe (3a) andreflux pipe (3b).4. Remove the complete fuel filler pipe.2024972
1040A37
0Removing201Refitting21Position the vehicle on a lift.Partly raise the lift.3362949-4450B08right rear wheel r r- 7055B43 REAR WHEEL ARCH liner (one), left or right - R.R. 1. Undo the bolts fixing the fuel filler pipe fitting to the bodyshell.2. Undo the nut fixing the fuel vapour filter mounting bracket.3. Gently lower the fuel filler pipe and remove the gasket.2024973
1040A40
0Removing201Refitting21Open the fuel flap.1. Unscrew the fuel filler cap, release the retaining eye (1a) fromits seat and remove the plug (1b).2024974
0Removing201Refitting21 1016A10 COPERCHIO INSONORIZZANTE - S.R.33550141. Remove the engine oil dipstick.2. Undo the bolts (2a) and remove the engine oil dipstick tube (2b).3. Remove the gasket.192008046
1084A22
0Removing201Refitting213362539-1016A10sound-proofing cover - r + r1. Disconnect the oil vapour recirculation pipes from the engineoil filler.2. Undo the bolts (2a) and withdraw the engine oil filler from itsseating (2b).2025237
1084A40
0Removing201Refitting21Place the car on a ramp.3363098-5530B56BATTERY DRIP TRAY COVER - R.R.Disconnect the battery negative terminal.Raise the lift.1. Disconnect the electrical connection from the switch.2. Undo and remove the engine oil pressure warning light switch.2025821
1084A42
0Removing201Refitting21Position the vehicle on a lift.Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.3363098.Disconnect the negative battery terminal.Raise the lift.1. Disconnect the electrical connector for the oil pressure switch.2. Undo the oil pressure switch.192008055
0Removing201Refitting213363098-5530B56BATTERY DRIP TRAY COVER - R.R.Disconnect the battery negative terminal.1. Disconnect the water temperature sensor electrical connection.2. Undo the thermostat water temperatur sensor and remove.2025763
0Removing201Refitting21Place the car on a ramp.3363098-5530B56BATTERY DRIP TRAY COVER - R.R.Disconnect the battery negative terminal.1. Disconnect the electrical connection for the rpm sensor.2. Undo bolts (2a) and remove rpm and timing sensor (2b).2025765
0Removing201Refitting213362539-1016A10sound-proofing cover - r + r1. Disconnect the solenoid electrical connection on the vacuum tankfor the throttle body pneumatic valve.2. Disconnect the vacuum pipe from the solenoid on the vacuum tankfor the throttle body pneumatic valve.3. Unscrew the bolt securing the pneumatic valve4. Remove the solenoid for the pneumatic valve on the vacuum tank.2025773
0Removing201Refitting213363098-5530B56BATTERY DRIP TRAY COVER - R.R.Disconnect the battery negative terminal.1. Disconnect the electrical connection from the injection electroniccontrol unit.2. Undo nut (2a) and release earth lead (2b).3. Undo the retaining bolts.4. Remove the engine management control unit from its housing.2025774
0Removing201Refitting213363098-5530B56BATTERY DRIP TRAY COVER - R.R. . Disconnect the battery negative terminal.1. Disconnect the electrical connection for the accelerator potentiometer.2. Undo the fixing bolts (2a) and remove the accelerator pedal (2b).2025003
0Removing201Refitting213362539-1016A10sound-proofing cover - r + r . Disconnect the battery negative terminal.1. Disconnect the engine oil vapour recovery pipe from the engineoil filler.Release the engine oil vapour recoverypipe from the fastening band and move it sideways.2062498
1080C26
0Removing201Refitting213362539-1016A10sound-proofing cover - r + r1. Disconnect the EGR valve self-regulation motor electrical connection.2. Unscrew the bolts securing the electric motor to the EGR electricvalve.3. Remove the EGR electric valve self-regulation motor from theengine bay.2025811
0Removing201Refitting211. Undo the bolts securing the fuel filter to the bodyshell.2. Disconnect the electrical connection for the water-in-filtersensor.Move the fuel filter outside the workingarea.2025812
1080C74
0Removing201Refitting213363098-5530B56BATTERY DRIP TRAY COVER - R.R.Disconnect the battery negative terminal.1. Undo the bolts securing the fuel filter to the bodyshell.2. Disconnect the electrical connection for the water-in-filtersensor.Move the fuel filter outside the workingarea.2025814
1080C76
0Removing201Refitting213362539-1016A10sound-proofing cover - r + r1. Undo the bolts securing the expansion joint to the throttle body.2. Undo the bolts securing the expansion joint to the EGR electricalvalve.3. Remove the expansion joint from its housing.2025816
0Removing201Refitting21Position the vehicle on a lift.Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.33634881. Undo the fixing bolts (1a) and remove the reinforcement bracket (1b) for the turbocharger assembly.2. Undo the fixing bolts (2a) and remove the metal protection (2b).3. Undo the fixing bolts (3a) and disconnect the engine oil return pipe (3b) from the turbocharger.192009056
1064A20
0Removing201Refitting211. Undo the retaining nuts.2. Remove the preconverter from the studs on the turbocharger.192009060
0Removing201Refitting21Place the turbocharger/exhaust manifold/catalytic pre-converter assembly in a vice.1. Undo the fixing nuts (1a) and separate the exhaust manifold (1b) from the turbocharger (1c).192009082
0Removing201Refitting21Disconnect the negative battery terminal.1. Disconnect the electrical connection for the PDA electropneumatic valve.2. Disconnect the two vacuum pipes from the PDA electropneumatic valve.3. Remove the PDA electropneumatic valve.192007968
1056B33
0Removing201Refitting21Disconnect the negative battery terminal.1. Disconnect the electrical connection for the PDA position sensor.2. Undo the retaining bolts (2a) and remove the PDA position sensor (2b).192007970
0Removing201Refitting213363098-5530B56BATTERY DRIP TRAY COVER - R.R. . Disconnect the battery negative terminal.Remove the injection wiring from the area.1. Disconnect the electrical connector for the sender unit.2. Undo and remove the sender unit.2024995
0Removing201Refitting21Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.3363098.Disconnect the negative battery terminal.1. Disconnect the electrical connection for the sensor.2. Undo the fixing bolt (2a) and remove the sensor (2b).192007915
1056B56
0Removing201Refitting21Disconnect the battery negative terminal.1. Disconnect the electrical connection from the engine idle speedself-adjustment motor.2. Undo the bolts (2a) and remove the engine idle speed self-adjustmentmotor (2b).2025359
0Removing201Refitting21Discharge the fuel pressure using the toolconnected to the valve on the fuel manifold pipe.1. Disconnect the rapid attachment for the fuel supply pipe andrelease the latter from the fixing band.2025196
0Removing201Refitting213363098-5530B56BATTERY DRIP TRAY COVER - R.R.Disconnect the battery negative terminal.1. Remove the clip securing the injector to the fuel manifold.2. Remove the injector from its seat.3. Remove the injector seals2025001
The manual procedure and the teser procedurefor re-initalising the electronic ignition/injection control unit isshown below.767When the car is first started,carry out the following operations whenever the throttle body or enginemanagement unit is replaced.769Procedure using testerMake sure that the ignition key is in theOFF position.Connect the tool to the tester input andplace the knob in position 3.Connect the Examiner diagnostic equipment.Turn the ignition key to ON position (engineoff).Wait for the test to be run on the throttlebody, when the tester will confirm that Turn the ignition key to the OFF position.Using the Examiner, check that the self-learningof idle speed has finished correctly ( LOWER THROTTLE BED SELFLEARNING-completed)767If the self-learning procedureis not correct, turn the ignition off (STOP position) and repeatthe above procecure. If the incorrectness continues, check thatthe diagnostic cable connection is secure and that the instrumentis working.Manual procedureTurn the ignition key to ON position (engineoff)Wait 60 seconds, the time required forthe control unit to check the throttle body's internal spring andthe butterfly's maximum/minimum angles.Turn the ignition key to the OFF positionWait 10 seconds, the time required forthe control unit to save the learnt values in EPROM.767After carrying out initialisation,the engine control unit may be deactivated (battery disconnection)without losing data.
1056B82
0Removing201Refitting213363098-5530B56BATTERY DRIP TRAY COVER - R.R. . Disconnect the battery negative terminal.1. Disconnect the electrical connections (1a) for the injectioncontrol unit (1b) using the lever (1c).2. Undo the fixing bolt (2a) and disconnect the control unit earthlead (2b).3. Undo the fixing nuts (3a) and remove the injection control unit(3b) from support (3b).2025002
0Removing201Refitting21Position the vehicle on a lift. 1016A10 COPERCHIO INSONORIZZANTE - S.R.3355014Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.3363098Disconnect the negative battery terminal.Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.33634881. Undo the nuts (1a) and move the cable duct protection (1b).2. Disconnect the electrical connection for the rpm sensor.3. Disconnect the electrical connection for the detonation sensor.4. Disconnect the electrical connection for the engine oil pressure warning light switch.5. Disconnect the electrical connection for the starter motor.6. Disconnect the electrical connection for the alternator.192007933
0Removing201Refitting213362539-1016A10sound-proofing cover - r + r3362665-1060F36lines 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.2025754
1060F20
0Removing201Refitting21 1016A10 sound-proofing cover - r + r33625391. Undo the nuts (1a) and release the return manifold (1b) from the intake manifold.2. Unscrew the pipe connector from the return manifold.3. Unscrew the pipe connector from the pressure pump.4. Remove the pipe from the pressure pump to the fuel manifold.192009022
1060F30
0Removing201Refitting21 1016A10 sound-proofing cover - r + r3362539Op. 1060F20 PIPE FROM PRESSURE PUMP TO FUEL MANIFOLD - R.R.3362662Release the wiring from the clips that secure it to the fuel manifold pipe.1. Disconnect the electrical connection from the solenoid on the vacuum tank.2. Disconnect the vacuum pipe from the brake servo vacuum pipe and the pneumatic valve on the throttle body.3. Undo the nuts (3a) and remove the vacuum reservoir (3b) complete with solenoid valve (3c).192009029
0Removing201Refitting213362539-1016A10sound-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. 2025759
1060F50
0Removing201Refitting21 1016A10 sound-proofing cover - r + r33625391. 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).192009044
1060F52
0Removing201Refitting213362539-1016A10sound-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. 2025761
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