Lamborghinni Manual

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® Automobili Lamborghini S.p.A.

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A Car Model B
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Structure
Main grouS 6XEJURXS 7LWOHLGHQWL¿FDWLRQ
00 General information 00 General information 00 Description
01 Equipment 01 Check (control)
02 Special tools 02 Adjustment
03 2LOVJUHDVHOXEULFDQWVDQGOLTXLGV 03 'LVDVVHPEOH
04 Engine 04 Cleaning
05 0DQXDOJHDUER[ 05 $VVHPEOH
06 E-gear 06 Bleeding
07 Body 07 )OXLGVVXEVWLWXWLRQ
08 Torque 08 Filling and topping up
09 Electrical information 09 Overhaul
10 Scrapping 10 Error code
11 &DUVHOÀHYHOOLQJNLW 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
12 Accessory kit 12 Running-in
13 6HULDOQXPEHU 13 Adjustment coding
88 Check list 14 'LDJQRVLVVRIWZDUH
89 PDI (pre-delivery checks) 86 Frequency 1
90 Maintenance plan and frequency 87 Frequency 2
91 Car general presentation 88 Frequency 3
89 Frequency 4
90 Frequency 5
91 Frequency 6
92 Frequency 7
93 Frequency 8
94 Frequency 9
95 Frequency 10
96 Frequency 11
97 Frequency 12
98 Frequency 13
2
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0DLQJURXS 6XEJURXS 7LWOHLGHQWL¿FDWLRQ

01 Engine 00 $VVHPEOLHV 00 Description
01 $X[LOLDU\EHOW 01 Check (control)
03 Crankcase, cylinder, cylinder head 02 Adjustment
05 Crankshaft, connecting rods 03 'LVDVVHPEOH
07 Pistons, rings, pins, liners 04 Cleaning
09 Camshaft, valves 05 $VVHPEOH
15 Oil pump 06 Bleeding
16 9DULDEOHYDOYHWLPLQJPHFKDQLVP 07 )OXLGVVXEVWLWXWLRQ
17 Oil cooler 08 Filling and topping up
19 Air intercooler 09 Overhaul
21 Water cooling 10 Error code
22 Water pump 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
27 Fuel pump & lines 12 Running-in
28 Injection system 13 Adjustment coding
29 Air intake manifold 14 'LDJQRVLVVRIWZDUH
30 2LO¿OWHU
31 Catalyst
33 ,QWDNHDLU¿OWHU
41 &OXWFK)O\ZKHHO
42 Automatic clutch (E-gear)
45 7XUERFKDUJHU
90 Timing system
98 Repair kit
99 )L[LQJDQGVXVSHQVLRQ
3
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02 )XHOWDQNH[KDXVWV\VWHPKHDWLQJ 00 $VVHPEOLHV 00 Description
Climate system 01 Fuel tank 01 Check (control)
02 ([KDXVWSUHVVXUHFRQWURO 02 Adjustment
03 Fuel system parts 03 'LVDVVHPEOH
09 Fuel cooling 04 Cleaning
51 ([KDXVWV\VWHP 05 $VVHPEOH
53 2[\JHQVHQVRU 06 Bleeding
54 Catalyst temperature sensor 07 )OXLGVVXEVWLWXWLRQ
60 Air conditioning, engine parts (+ sensors) 08 Filling and topping up
61 $X[LOOLDU\KHDWHU 09 Overhaul
65 Geater 10 Error code
90 &RQWUROQXPEHU 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
98 Repair kit 12 Running-in
99 )L[LQJZLWKVXVSHQVLRQ 13 Adjustment coding
14 'LDJQRVLVVRIWZDUH
4
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03 Transmission 00 $VVHPEOLHV 00 Description
01 Transmission housing 01 Check (control)
07 Gears & shafts 02 Adjustment
08 Rods / Forks 03 'LVDVVHPEOH
09 Selespeed sensor 04 Cleaning
11 6\QFKURQL*HDUV 05 $VVHPEOH
17 Oil cooler 07 )OXLGVVXEVWLWXWLRQ
21 Transmission housing e-gear 08 Filling and topping up
23 Shifting / lever 09 Overhaul
25 $XWRPDWLFWUDQVFRQWURO 10 Error code
31 Disc sets 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
41 Transfer case 12 Running-in
90 &RQWUROQXPEHU 13 Adjustment coding
98 Repair kit 14 'LDJQRVLVVRIWZDUH
99 )L[LQJZLWKVXVSHQVLRQ
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04 )URQWD[OHVWHHULQJ 00 $VVHPEOLHV 00 Description
01 )URQWD[OHEHDP 01 Check (control)
02 Viscous coupling 02 Adjustment
03 Lifting system 03 'LVDVVHPEOH
04 Wheel alignment 04 Cleaning
07 )URQWZKHHOEHDULQJVDQGKXEV 05 $VVHPEOH
09 Front differential 06 Bleeding
10 $QWLUROOEDU 07 )OXLGVVXEVWLWXWLRQ
11 Front springs 08 Filling and topping up
12 Suspension strut, front 09 Overhaul
13 6KRFNDEVRUEHUV 10 Error code
19 Steering (rack) 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
22 3RZHUVWHHULQJ 12 Running-in
23 3XPSSRZHUVWHHULQJ 13 Adjustment coding
25 Steering damper 14 'LDJQRVLVVRIWZDUH
90 &RQWUROQXPEHU
98 Repair kit
6
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05 5HDUD[OH 00 $VVHPEOLHV 00 Description
01 Rear drive shaft 01 Check (control)
04 Wheel alignment 02 Adjustment
05 5HDUD[OHFDUULHU 03 'LVDVVHPEOH
07 5HDUZKHHODQGUHDUKXEV 04 Cleaning
09 Rear differential 05 $VVHPEOH
10 $QWLUROOEDU 06 Bleeding
11 Rear springs 07 )OXLGVVXEVWLWXWLRQ
12 Suspension strut, rear 08 Filling and topping up
13 6KRFNDEVRUEHU 09 Overhaul
17 'LIIHUHQWLDOJHDUPDQXDOJHDUER[ 10 Error code
19 Differential gear e-gear 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
21 3URSHOOHUVKDIW*HDU)URQWGLII 12 Running-in
23 3RZHUVWHHULQJSXPS 13 Adjustment coding
25 14 'LDJQRVLVVRIWZDUH
90 &RQWUROQXPEHU
98 Repair kit
7
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06 Wheels, Brakes 00 $VVHPEOLHV 00 Description
01 'LVNZKHHOWLUHV 01 Check (control)
02 3DUNLQJEUDNH 02 Adjustment
07 Brakes, caliper 03 'LVDVVHPEOH
09 %UDNHVK\GUO 04 Cleaning
11 Brake cylinder and circuits 05 $VVHPEOH
12 6HUYREUDNH 06 Bleeding
14 $%6DQGEUDNLQJIRUFHDGMXVWLQJV\VWHP 07 )OXLGVVXEVWLWXWLRQ
15 'LVFEUDNH EUDNHSDG 08 Filling and topping up
16 Self levelling system 09 Overhaul
17 TCS-system 10 Error code
18 ESP-system 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
90 &RQWUROQXPEHU 12 Running-in
98 Repair kit 13 Adjustment coding
99 )L[LQJZLWKVXVSHQVLRQ 14 'LDJQRVLVVRIWZDUH
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07 Running gear / chassis 00 $VVHPEOLHV 00 Description
01 Running gear 01 Check (control)
03 Frame accessory parts 02 Adjustment
05 Running gear 03 'LVDVVHPEOH
11 +DQGOHYHUFRQWUROPDQXDOJHDUER[ 04 Cleaning
13 Lever control e-gear 05 $VVHPEOH
21 Pedal cluster 06 Bleeding
23 Pedal cluster e-gear 07 )OXLGVVXEVWLWXWLRQ
77 Test 08 Filling and topping up
90 &RQWUROQXPEHU 09 Overhaul
98 Repair kit 10 Error code
99 )L[LQJZLWKVXVSHQVLRQ 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
12 Running-in
13 Adjustment coding
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Main group Subgroup Subgroup 7LWOHLGHQWL¿FDWLRQ

08 Body 00 $VVHPEOLHV 41 Wing door 00 Description
01 )ORRUDVVHPEO\IRRWUHVW 43 Sliding door 01 Check (control)
02 Pedal cluster 45 :LQGRZJODVV ZHDWKHUVWULSV 02 Adjustment
03 Engine compartment panels 47 6LGHZLQGRZV 03 'LVDVVHPEOH
04 Frame 53 6LGHPHPEHUV 04 Cleaning
05 Front end upholstery 54 Trim & protection strip inner 05 $VVHPEOH
06 )URQWHQGERQQHWZLWKFGKROGHU 57 Interior equipment 06 Bleeding
07 Bumper 58 Imperial roof accessories 07 )OXLGVVXEVWLWXWLRQ
09 VACS side spoilers 59 Interior equipment 08 Filling and topping up
10 Side panel 60 Optional equipment 09 Overhaul
11 ([WHUQDOUHDUYLHZPLUURU 61 Optional equipment 10 Error code
13 Rear end 62 Optional equipment 11 0HDVXUHPHQWEORFNUHDGLQJ
14 Rear end 63 Tunnel 12 Running-in
15 Heater 64 Insulation and sound damping 13 Adjustment coding
16 $LUFRQGLWLRQLQJDLU¿OWHUV 67 Inner trim and licence plates 14 'LDJQRVLVVRIWZDUH
17 Imperial roof, molding 68 Inner trim
19 $X[+HDWHU YHQW6\VWHP 71 FRQ7RS
20 Body 72 FRQ7RS
21 )URQWDQGEDFNIHQGHUZKHHODUFK 75 6WHHULQJZKHHO
23 Hood 80 6DIHW\HTXLSPHQWSDVV6LGH
25 )ORRUERWWRPV 81 Front seat
27 Rear trunk, fan grille spoiler 82 Front seat
29 Tailgate and side gate 83 ([WHUQDOSDLQWZRUN±&RORXUFRGH
31 'RRUERG\SODLQIURQW 87 &RQWUROQXPEHU
33 'RRUERG\LQZKLWHUHDU 90 Reserved
37 'RRU GZLQGRZSDUWVIURQW 98 Repair kit
39 'RRU GZLQGRZSDUWUHDU 99 )L]LQJZLWKVXVSHQVLRQ
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09 Electrical equipment 00 $VVHPEOLHVZLULQJGLDJUDP 60 Cooling circuit fans 00 Description
01 Electric drive 62 (OHFWU&HQWUDOORFNLQJV\VWHP 01 Check (control)
03 Alternator 63 (OHFWU3DUWVDX[LOOLDU\KHDWHU 02 Adjustment
05 ,JQLWLRQV\VWHPLQWHUI6XSSUHVVLRQ 65 (OHFWU3DUWVZDWHUKHDWLQJFRROLQJ 03 'LVDVVHPEOH
06 Electric parts, LIE 70 Module harnesses 04 Cleaning
07 Engine control systems 71 (OHFWULFZLULQJ 05 $VVHPEOH
09 Control unit coded programming 72 (OHFWULFZLULQJ 06 Bleeding
10 6RIWZDUH 73 (OHFWULFZLULQJ 07 )OXLGVVXEVWLWXWLRQ
11 Starter 74 Linee elettriche 08 Filling and topping up
15 Battery 75 Radio system, rear camera 09 Overhaul
19 Side markers, front 79 &DEOHVHWVLQJOHZLULQJ 10 Error code
20 6LGHPDUNHUVEDFN 80 Safety equipment 11 0HDVXUHPHQWEORFNUHDGLQJ
25 (OHFWULFGDVKERDUGDFFHVVRULHV 81 Control units 12 Running-in
27 (OHFWULFFRQWDFWVSHGDOFOXVWHUWUDQVPLVVLRQEUDNH 82 TPMS 13 Adjustment coding
37 Central electric 90 &RQWUROQXPEHU 14 'LDJQRVLVVRIWZDUH
41 /LJKWLQJGHYLFHVKHDGODPS 97 ([FKDQJHDEOHFRQWUROXQLWV
43 /LJKWLQJGHYLFHVOLFHQFHSODWHOLJKW 98 Repair kit
45 /LJKWLQJGHYLFHVEUDNH WDLOOLJKWUHÀHFWRU 99 )L[LQJDQGVXVSHQVLRQ
47 Interior light
49 Parking lamp
51 Horn
53 Turn signal
55 :LQGVKLHOGZLSHU
56 $LUEDJFRQWUROXQLW
57 Speedometer, speed regulator
58 52%FRQWUROXQLW5ROOEDU
59 (OHFWU)RUYHQWLODWLRQZLQGRZOLIWHU VHDWDGMXVW
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Main group Subgroup 7LWOHLGHQWL¿FDWLRQ

10 Diagnosis 00 $LUEDJ 00 Description
01 Engine 01 Check (control)
02 Transmission 02 Adjustment
03 ABS 03 'LVDVVHPEOH
04 6KRFN$EVRUEHUV 04 Cleaning
08 Air conditioning 05 $VVHPEOH
09 ILM control unit 06 Bleeding
16 SMLS control unit 07 )OXLGVVXEVWLWXWLRQ
17 Instrument cluster 08 Filling and topping up
33 GFA-LIE scan tool 09 Overhaul
37 Navigation 10 Error code
45 Volumetric antitheft and alarm interior monitoring 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
46 ZKE 12 Running-in
54 Spoiler 13 Adjustment coding
56 Radio 14 'LDJQRVLVVRIWZDUH
90 Information LaRa-AS
91 Information LDAS-32
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Main grouS 6XEJURXS 7LWOHLGHQWL¿FDWLRQ

70 5HWUR¿W 2SWLRQDO 00 General information 00 Description
General information 01 Equipment 01 Check (control)
02 Special tools 02 Adjustment
03 2LOVJUHDVHOXEULFDQWVDQGOLTXLGV 03 'LVDVVHPEOH
04 Engine 04 Cleaning
05 0DQXDOJHDUER[ 05 $VVHPEOH
06 E-gear 06 Bleeding
07 Body 07 )OXLGVVXEVWLWXWLRQ
08 Torque 08 Filling and topping up
09 Electrical information 09 Overhaul
10 Scrapping 10 Error code
11 &DUVHOÀHYHOOLQJNLW 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
12 Accessory kit 12 Running-in
13 6HULDOQXPEHU 13 Adjustment coding
88 Check list 14 'LDJQRVLVVRIWZDUH
89 PDI (pre-delivery checks) 86 Frequency 1
90 Maintenance plan and frequency 87 Frequency 2
91 Car general presentation 88 Frequency 3
89 Frequency 4
90 Frequency 5
91 Frequency 6
92 Frequency 7
93 Frequency 8
94 Frequency 9
95 Frequency 10
96 Frequency 11
97 Frequency 12
98 Frequency 13
13
L714 00 00 00

71 5HWUR¿W 2SWLRQDO 00 $VVHPEOLHV 00 Description
Engine 01 $X[LOLDU\EHOW 01 Check (control)
03 Crankcase, cylinder, cylinder head 02 Adjustment
05 Crankshaft, connecting rods 03 'LVDVVHPEOH
07 Pistons, rings, pins, liners 04 Cleaning
09 Camshaft, valves 05 $VVHPEOH
16 9DULDEOHYDOYHWLPLQJPHFKDQLVP 07 )OXLGVVXEVWLWXWLRQ
17 Oil cooler 08 Filling and topping up
19 Air intercooler 09 Overhaul
21 Water cooling 10 Error code
22 Water pump 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
27 Fuel pump & lines 12 Running-in
28 Injection system 13 Adjustment coding
29 Air intake manifold 14 'LDJQRVLVVRIWZDUH
30 2LO¿OWHU
31 Catalyst
33 ,QWDNHDLU¿OWHU
41 &OXWFK)O\ZKHHO
42 Automatic clutch (E-gear)
45 7XUERFKDUJHU
90 Timing system
98 Repair kit
99 )L[LQJDQGVXVSHQVLRQ
14
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)XHOWDQNH[KDXVWV\VWHPKHDWLQJ 01 Fuel tank 01 Check (control)
Climate system 02 ([KDXVWSUHVVXUHFRQWURO 02 Adjustment
03 Fuel system parts 03 'LVDVVHPEOH
09 Fuel cooling 04 Cleaning
51 ([KDXVWV\VWHP 05 $VVHPEOH
53 2[\JHQVHQVRU 06 Bleeding
54 Catalyst temperature sensor 07 )OXLGVVXEVWLWXWLRQ
60 Air conditioning, engine parts (+ sensors) 08 Filling and topping up
61 $X[LOOLDU\KHDWHU 09 Overhaul
65 Geater 10 Error code
90 &RQWUROQXPEHU 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
98 Repair kit 12 Running-in
99 )L[LQJZLWKVXVSHQVLRQ 13 Adjustment coding
15
L714 00 00 00

Transmission 01 Transmission housing 01 Check (control)
07 Gears & shafts 02 Adjustment
08 Rods / Forks 03 'LVDVVHPEOH
09 Selespeed sensor 04 Cleaning
11 6\QFKURQL*HDUV 05 $VVHPEOH
17 Oil cooler 07 )OXLGVVXEVWLWXWLRQ
21 Transmission housing e-gear 08 Filling and topping up
23 Shifting / lever 09 Overhaul
25 $XWRPDWLFWUDQVFRQWURO 10 Error code
31 Disc sets 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
41 Transfer case 12 Running-in
90 &RQWUROQXPEHU 13 Adjustment coding
98 Repair kit 14 'LDJQRVLVVRIWZDUH
16
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)URQWD[OHVWHHULQJ 01 )URQWD[OHEHDP 01 Check (control)
02 Viscous coupling 02 Adjustment
03 Lifting system 03 'LVDVVHPEOH
04 Wheel alignment 04 Cleaning
07 )URQWZKHHOEHDULQJVDQGKXEV 05 $VVHPEOH
09 Front differential 06 Bleeding
10 $QWLUROOEDU 07 )OXLGVVXEVWLWXWLRQ
11 Front springs 08 Filling and topping up
12 Suspension strut, front 09 Overhaul
13 6KRFNDEVRUEHUV 10 Error code
19 Steering (rack) 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
22 3RZHUVWHHULQJ 12 Running-in
23 3XPSSRZHUVWHHULQJ 13 Adjustment coding
25 Steering damper 14 'LDJQRVLVVRIWZDUH
90 &RQWUROQXPEHU
98 Repair kit
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5HDUD[OH 01 Rear drive shaft 01 Check (control)
04 Wheel alignment 02 Adjustment
05 5HDUD[OHFDUULHU 03 'LVDVVHPEOH
07 5HDUZKHHODQGUHDUKXEV 04 Cleaning
09 Rear differential 05 $VVHPEOH
10 $QWLUROOEDU 06 Bleeding
11 Rear springs 07 )OXLGVVXEVWLWXWLRQ
12 Suspension strut, rear 08 Filling and topping up
13 6KRFNDEVRUEHU 09 Overhaul
17 'LIIHUHQWLDOJHDUPDQXDOJHDUER[ 10 Error code
19 Differential gear e-gear 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
21 3URSHOOHUVKDIW*HDU)URQWGLII 12 Running-in
23 3RZHUVWHHULQJSXPS 13 Adjustment coding
25 14 'LDJQRVLVVRIWZDUH
90 &RQWUROQXPEHU
98 Repair kit
18
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Wheels, Brakes 01 'LVNZKHHOWLUHV 01 Check (control)
02 3DUNLQJEUDNH 02 Adjustment
07 Brakes, caliper 03 'LVDVVHPEOH
09 %UDNHVK\GUO 04 Cleaning
11 Brake cylinder and circuits 05 $VVHPEOH
12 6HUYREUDNH 06 Bleeding
14 $%6DQGEUDNLQJIRUFHDGMXVWLQJV\VWHP 07 )OXLGVVXEVWLWXWLRQ
15 'LVFEUDNH EUDNHSDG 08 Filling and topping up
16 Self levelling system 09 Overhaul
17 TCS-system 10 Error code
18 ESP-system 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
90 &RQWUROQXPEHU 12 Running-in
98 Repair kit 13 Adjustment coding
99 )L[LQJZLWKVXVSHQVLRQ 14 'LDJQRVLVVRIWZDUH
19
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Running gear / chassis 01 Running gear 01 Check (control)
03 Frame accessory parts 02 Adjustment
05 Running gear 03 'LVDVVHPEOH
11 +DQGOHYHUFRQWUROPDQXDOJHDUER[ 04 Cleaning
13 Lever control e-gear 05 $VVHPEOH
21 Pedal cluster 06 Bleeding
23 Pedal cluster e-gear 07 )OXLGVVXEVWLWXWLRQ
77 Test 08 Filling and topping up
90 &RQWUROQXPEHU 09 Overhaul
98 Repair kit 10 Error code
99 )L[LQJZLWKVXVSHQVLRQ 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
12 Running-in
13 Adjustment coding
20
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78 5HWUR¿W 2SWLRQDO 00 $VVHPEOLHV 41 Wing door 00 Description
Body 01 )ORRUDVVHPEO\IRRWUHVW 43 Sliding door 01 Check (control)
02 Pedal cluster 45 :LQGRZJODVV ZHDWKHUVWULSV 02 Adjustment
03 Engine compartment panels 47 6LGHZLQGRZV 03 'LVDVVHPEOH
04 Frame 53 6LGHPHPEHUV 04 Cleaning
05 Front end upholstery 54 Trim & protection strip inner 05 $VVHPEOH
06 )URQWHQGERQQHWZLWKFGKROGHU 57 Interior equipment 06 Bleeding
07 Bumper 58 Imperial roof accessories 07 )OXLGVVXEVWLWXWLRQ
09 VACS side spoilers 59 Interior equipment 08 Filling and topping up
10 Side panel 60 Optional equipment 09 Overhaul
11 ([WHUQDOUHDUYLHZPLUURU 61 Optional equipment 10 Error code
13 Rear end 62 Optional equipment 11 0HDVXUHPHQWEORFNUHDGLQJ
14 Rear end 63 Tunnel 12 Running-in
15 Heater 64 Insulation and sound damping 13 Adjustment coding
16 $LUFRQGLWLRQLQJDLU¿OWHUV 67 Inner trim and licence plates 14 'LDJQRVLVVRIWZDUH
17 Imperial roof, molding 68 Inner trim
19 $X[+HDWHU YHQW6\VWHP 71 FRQ7RS
20 Body 72 FRQ7RS
21 )URQWDQGEDFNIHQGHUZKHHODUFK 75 6WHHULQJZKHHO
23 Hood 80 6DIHW\HTXLSPHQWSDVV6LGH
25 )ORRUERWWRPV 81 Front seat
27 Rear trunk, fan grille spoiler 82 Front seat
29 Tailgate and side gate 83 ([WHUQDOSDLQWZRUN±&RORXUFRGH
31 'RRUERG\SODLQIURQW 87 &RQWUROQXPEHU
33 'RRUERG\LQZKLWHUHDU 90 Reserved
37 'RRU GZLQGRZSDUWVIURQW 98 Repair kit
39 'RRU GZLQGRZSDUWUHDU 99 )L]LQJZLWKVXVSHQVLRQ
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79 5HWUR¿W 2SWLRQDO 00 $VVHPEOLHVZLULQJGLDJUDP 60 Cooling circuit fans 00 Description
Electrical equipment 01 Electric drive 62 (OHFWU&HQWUDOORFNLQJV\VWHP 01 Check (control)
03 Alternator 63 (OHFWU3DUWVDX[LOOLDU\KHDWHU 02 Adjustment
05 ,JQLWLRQV\VWHPLQWHUI6XSSUHVVLRQ 65 (OHFWU3DUWVZDWHUKHDWLQJFRROLQJ 03 'LVDVVHPEOH
06 Electric parts, LIE 70 Module harnesses 04 Cleaning
07 Engine control systems 71 (OHFWULFZLULQJ 05 $VVHPEOH
09 Control unit coded programming 72 (OHFWULFZLULQJ 06 Bleeding
10 6RIWZDUH 73 (OHFWULFZLULQJ 07 )OXLGVVXEVWLWXWLRQ
11 Starter 74 Linee elettriche 08 Filling and topping up
15 Battery 75 Radio system, rear camera 09 Overhaul
19 Side markers, front 79 &DEOHVHWVLQJOHZLULQJ 10 Error code
20 6LGHPDUNHUVEDFN 80 Safety equipment 11 0HDVXUHPHQWEORFNUHDGLQJ
25 (OHFWULFGDVKERDUGDFFHVVRULHV 81 Control units 12 Running-in
27 (OHFWULFFRQWDFWVSHGDOFOXVWHUWUDQVPLVVLRQEUDNH 82 TPMS 13 Adjustment coding
37 Central electric 90 &RQWUROQXPEHU 14 'LDJQRVLVVRIWZDUH
41 /LJKWLQJGHYLFHVKHDGODPS 97 ([FKDQJHDEOHFRQWUROXQLWV
43 /LJKWLQJGHYLFHVOLFHQFHSODWHOLJKW 98 Repair kit
45 /LJKWLQJGHYLFHVEUDNH WDLOOLJKWUHÀHFWRU 99 )L[LQJDQGVXVSHQVLRQ
47 Interior light
49 Parking lamp
51 Horn
53 Turn signal
55 :LQGVKLHOGZLSHU
56 $LUEDJFRQWUROXQLW
57 Speedometer, speed regulator
58 52%FRQWUROXQLW5ROOEDU
59 (OHFWU)RUYHQWLODWLRQZLQGRZOLIWHU VHDWDGMXVW
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Main group Subgroup 7LWOHLGHQWL¿FDWLRQ

80 5HWUR¿W 2SWLRQDO 00 $LUEDJ 00 Description
Diagnosis 01 Engine 01 Check (control)
02 Transmission 02 Adjustment
03 ABS 03 'LVDVVHPEOH
04 6KRFN$EVRUEHUV 04 Cleaning
08 Air conditioning 05 $VVHPEOH
09 ILM control unit 06 Bleeding
16 SMLS control unit 07 )OXLGVVXEVWLWXWLRQ
17 Instrument cluster 08 Filling and topping up
33 GFA-LIE scan tool 09 Overhaul
37 Navigation 10 Error code
45 Volumetric antitheft and alarm interior monitoring 11 0HDVXUHPHQWEORFNUHDGLQJRUSDUDPHWHUV
46 ZKE 12 Running-in
54 Spoiler 13 Adjustment coding
56 Radio 14 'LDJQRVLVVRIWZDUH
90 Information LaRa-AS
91 Information LDAS-32
23
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The manufacturer’s liability
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Airbag unit replacement after an accident
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L714 00 00 00
Recommendations for the operator

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7RROVIRU¿WWLQJWKHPDLQVKDIWDQGOD\VKDIW
on intermediate plate (2 pieces)
&ORVHW
3XQFKIRU¿WWLQJUROOHUEHDULQJ372VKDIW
(on housing)
&ORVHW
31c 'UDZHU 3RVLWLRQF
34
00 02 00
7RROIRUSLQLRQKHDGEHDULQJ¿WWLQJ
&ORVHW
'UDZHU 3RVLWLRQD
32a
7RROIRUGLIIHUHQWLDORXWSXWVKDIW¿WWLQJ
&ORVHW
'UDZHU 3RVLWLRQE
32b
62300006 Kickback tool for ring-nut
&ORVHW
'UDZHU 3RVLWLRQF
32c
35
00 02 00
7RROIRUSLQLRQEHDULQJVRXWHUULQJV¿WWLQJ
&ORVHW
'UDZHU 3RVLWLRQD
33a
62300008 Tool for pinion supporting
&ORVHW
'UDZHU 3RVLWLRQE
33b
7RROIRUVKDQNSLQLRQEHDULQJ¿WWLQJ
&ORVHW
'UDZHU 3RVLWLRQF
33c
36
00 02 00
3XQFKIRUEHDULQJ¿WWLQJRQGLIIHUHQWLDO
&ORVHW
'UDZHU 3RVLWLRQD
34a
3XQFKIRUUDGLDOVKDIWVHDO¿WWLQJ
&ORVHW
'UDZHU 3RVLWLRQE
34b
3XQFKIRUUROOHUEHDULQJRXWHUULQJ¿WWLQJRQÀDQJH
support
&ORVHW
37
00 02 00
3XQFKIRU¿WWLQJEDOOEHDULQJ
&ORVHW
'UDZHU 3RVLWLRQD
35a
3XQFKIRUEHDULQJ¿WWLQJRQGLIIHUHQWLDOKRXVLQJ
(viscous coupling)
&ORVHW
69195227 Universal trolley
2XWRIWKHFORVHW
35c
38
00 02 00
69195228 Loose basin for the trolley
2XWRIWKHFORVHW
36a
.LWRIEUDFNHWV A % &
69195236 differential bracket (A)
69195237 bracket for engine (%)
69195238 bracket for engine (&)
69195239 gearbox bracket (')
36b 69195240 gearbox bracket (central slinging) (()
2XWRIWKHFORVHW
' (
39
00 02 00
7RROVIRU¿WWLQJWKHPDLQVKDIWDQGOD\VKDIWRQ
intermediate plate
&ORVHW
'UDZHU 3RVLWLRQD
37a
62300015 Tool for pinion head bearing outer ring disassembly
&ORVHW
'UDZHU 3RVLWLRQE
37b
62300016 Window cover
&ORVHW
'UDZHU 3RVLWLRQF
37c
40
00 02 00
62451025 Tool for testing and positioning outside manual

gearbox control
&ORVHW
'UDZHU 3RVLWLRQD
38a
62395054 Tool for measuring the height of the rear differential

pinion
&ORVHW
62395068 Tool for measuring the height of the front differential

pinion
&ORVHW
41
00 02 00
%RG\DQGFKDVVLV
69495546 Pneumatic glue gun
2XWRIWKHFORVHW
39a
69495516 Static guards kit
2XWRIWKHFORVHW
39b
69495563 Guards kit
2XWRIWKHFORVHW
39c
42
00 02 00
69451002 Aluminium tools cabinet

A
2XWRIWKHFORVHW
40a
69451005 Pneumatic riveter A

2XWRIWKHFORVHW
40b
69451004 Crack detection kit A
2XWRIWKHFORVHW
40c
A )RUUHSDLURIDOXPLQLXPERG\RQO\
43
00 02 00
69451006 Glue gun

A
2XWRIWKHFORVHW
41a
69451008 Storage container for small parts A

2XWRIWKHFORVHW
41b
69451012 Saw for car body A
2XWRIWKHFORVHW
41c
44
00 02 00
69451003 Body reference gauge

A
2XWRIWKHFORVHW
42a
49451011 Electric cutter for aluminum A

2XWRIWKHFORVHW
42b
69451007 Grinding wheel holder A
2XWRIWKHFORVHW
42c
45
00 02 00
69453001 Positioning of the soft-top front closure housings
%2;
43a
69453002 Centering bridge
%2;
43b
69453003 Side window alignment A

(A) RH Arm
(%) LH Arm
(&) Spacer cross member
43c %
%2;
&
46
00 02 00
69453004 Side plate attachment % A
(A) LH Arm
(%) RH Arm
44a %2;
69453005 Positioning of the rear window (RWM)
%2;
44b
69453006 Positioning the engine hood hinge on the chassis
(A) LH Jig
(%) RH Jig
44c
%2;
A %
47
00 02 00
'LDJQRVLV
006134045 Diagnosis reset connector
2XWRIWKHFORVHW
45a
009250157 LM Console
2XWRIWKHFORVHW
45b
006038128 R45 Connector
2XWRIWKHFORVHW
45c
48
00 02 00
964300004 R46 connector
2XWRIWKHFORVHW
46a
0043010644 2.0 OHM Airbag male connector
2XWRIWKHFORVHW
46b
964300002 Airbag/ABS diagnostics interface
2XWRIWKHFORVHW
46c
49
00 02 00
69190056 PC Can Interface (A) A %
69190193 PC Can Interface - USB (%)
Index C*
47a
2XWRIWKHFORVHW
C* allows to read parameters and error codes, and to program

control units
900000126* MY03-04 WIRING DIAGRAM CD ROM
2XWRIWKHFORVHW
47b
* ROADSTER model not included
69190074 Lamborghini-Audi* OBD adaptor
2XWRIWKHFORVHW
47c
* allows to connect VAS tester to the vehicle
50
00 02 00
66095011 Diagnostics interface for LARA-AS connection

(Basic XS)
2XWRIWKHFORVHW
48a
66095012 Cable for LARA-AS diagnostics interface

(My 08 and older models) color grey
69190206 Cable for LARA-AS diagnostics interface

48b (mY 09) color black
2XWRIWKHFORVHW
69190063 Diagnostics PC
2XWRIWKHFORVHW
48c
51
00 02 00
991000402 Laptop bag
2XWRIWKHFORVHW
49a
66100019 Kit of diagnostic tools

A %
66100020 Break Out Box (A)
66100021 Adaptercable LIE + Egear 52-pol. & 28-pol. (%)
66100022 Adaptercable 42-pol. (ABS) (&)

'
66100023 Frontpanel LIE + Egear (')
49b 66100024 Frontpanel ABS (()

&
66100025 AIR BAG Simulator ())

(
66100026 Case (G) - optional -

) G
2XWRIWKHFORVHW
52
00 02 00
69190203 VAS 5054 interface
2XWRIWKHFORVHW
50a
900000155 Kit DVD Off-line until MY08
2XWRIWKHFORVHW
50b
900000161 Kit VAS PC Software
2XWRIWKHFORVHW
50c
53
00 02 00
(OHFWULFDOV\VWHP
69190082 Battery charger
2XWRIWKHFORVHW
51a
69190083 Tester
2XWRIWKHFORVHW
51b
69190081 Wiring harness repair kit
2XWRIWKHFORVHW
51c
54
00 02 00
% +L¿QDYLJDWRUH[WUDFWRU
2XWRIWKHFORVHW
52a
900000171 DVD Off-line MY09
2XWRIWKHFORVHW
52b
52c
55
L714 00 03 00
Amount
Ref. Fluid Oil type
(liters)
A. Fuel tank 90
B. Tank for windshield and headlight
5,5
washer system
C. Engine oil for:
L B E G A C
normal use VW 504 00 (Consigliato: Castrol SLX
8,3
LongLife III SAE 5W-30)
racing VW 504 00 (Consigliato: Castrol SLX
8,3
in cold countries (-20 to -30°C) VW 504 00 (Consigliato: Castrol SLX
8,3
Amount of engine oil to be replaced
8,3
ZKHQWKH¿OWHULVFKDQJHG
D. Gearbox, rear differential oil )LUVW¿OOLQJ4,75
BURMAH 70W-75 171 01 Substitution 4,00
E. Front differential oil BURMAH SAF-AG4 )LUVW¿OOLQJ1,50
Substitution 1,40
BASF HYDRAULAN 404
F. %UDNHFOXWFKÀXLG 0,75 F I H A M D
PAKELO BRAKE FLUID 404
G. Engine coolant BASF G12++ (TL-VW-774G) 21
Fig.1
H. $LUFRQGLWLRQHUÀXLG R134A ECOLOGICAL Kg 0,550
I. 3RZHUVWHHULQJÀXLG PENTOSIN N052 146 01 1,7
L. Lifting System AGIP ATF II D 0,3
M. (JHDUFLUFXLWÀXLG PENTOSIN N052 146 01 only for topping up
1
L714 00 04 00
(QJLQH
• Mid engine, longitudinal layout

• Type CEH 10 V cylinders (90°)
• Total displacement 5,204 cm3
• Bore 84.5 mm
• Stroke 92.8 mm
• Maximum power 412 kW (560 PS) at 8,000 rpm
• Maximum torque 540 Nm at 6,500 rpm
• Liquid cooling system with pressurized circuit and double radiator
• Intake system with tumble valve
• Chain controlled 4-camshaft timing with 4 valves per cylinder and electronic continuous intake and exhaust
variable valve timing
• Lubrication with dry pan
• Fuel: 98 RON unleaded fuel
:$51,1*
• 1HYHUVWDUWWKHHQJLQHLQFORVHGRUFRQ¿QHGHQYLURQPHQWVZKHUHWKHUHLVLQDGHTXDWHYHQWLODWLRQ7KH
HQJLQHH[KDXVWJDVFRQWDLQVFDUERQPRQR[LGH&2DFRORUOHVVDQGRGRUOHVVJDVWKDWFRXOGEHIDWDO
• 1HYHUOHDYHWKHHQJLQHUXQQLQJZKHQXQDWWHQGHG$QXQDWWHQGHGYHKLFOHZLWKDUXQQLQJHQJLQHLVD
KD]DUGDQGFRPSURPLVHVRSHUDWRUVDIHW\
• (YHU\YHKLFOH¶VHQJLQHFRPSDUWPHQWLVDSRWHQWLDOGDQJHU%HIRUHZRUNLQJLQWKHHQJLQHFRPSDUWPHQW
WXUQRIIWKHHQJLQHUHPRYHWKHLJQLWLRQNH\DQGOHWWKHHQJLQHFRRO&RQWDFWZLWKRYHUKHDWHGHQJLQH
components could cause serious burns.
• ,IWKHHQJLQHPXVWEHWXUQHGRQZKLOHZRUNLQJRQFRPSRQHQWVLQWKHFRPSDUWPHQWFKHFNWKDWWKHYHKLFOH
LVQRWLQJHDU$OZD\VHQVXUHWKDWWKHJHDUOHYHURUHJHDULVLQWKHQHXWUDOSRVLWLRQDQGWKHSDUNLQJEUDNHLV
¿UPO\SXOOHG“ ”,IWKLVLVQRWWKHFDVHDQ\LQFUHDVHLQHQJLQHUHYROXWLRQVFRXOGPRYHWKHYHKLFOHHYHQ
ZKHQWKHSDUNLQJEUDNHLVHQJDJHG
• &DOLIRUQLD3URSRVLWLRQQ(QJLQHH[KDXVWPDQLIROGVWKHLUSDUWVDQGFHUWDLQHOHPHQWVRIYHKLFOHV
FRQWDLQDQGHPLWFKHPLFDOVXEVWDQFHVWKDWIRUWKHVWDWHRI&DOLIRUQLDFDXVHFDQFHUFRQJHQLWDOGHIHFWV
DQGKLQGHUUHSURGXFWLRQ)XUWKHUPRUHVRPHOLTXLGVFRQWDLQHGLQYHKLFOHVDQGFHUWDLQSURGXFWVIRU
SUHYHQWLQJZHDUFRQWDLQDQGHPLWFKHPLFDOVXEVWDQFHVWKDWIRUWKHVWDWHRI&DOLIRUQLDFDXVHFDQFHU
congenital defects and hinder reproduction.
1
L714 00 05 00
*HDUER[
For vehicles equipped with manual gearbox:
• 6 quick clutch ratios with cable control.
Gear ratios
1st gear 1 : 3,313
2nd gear 1 : 2,053
3rd gear 1 : 1,458
4th gear 1 : 1,138
5th gear 1 : 0,939
6th gear 1 : 0,784
Reverse 1 : 2,813
1
L714 00 06 00
*HDUER[
For vehicles equipped with egear system:
• robotised, with 6 ratios and electro-hydraulic control.

• 5 operating modes: NORMAL, AUTOMATIC, SPORT, SPORT+AUTOMATIC and CORSA.
Gear ratios
1st gear 1 : 3,313
2nd gear 1 : 2,053
3rd gear 1 : 1,458
4th gear 1 : 1,138
5th gear 1 : 0,939
6th gear 1 : 0,784
Reverse 1 : 2,813
1
L714 00 07 00
Chassis
High-tensile box-type aluminium structure with cast parts and metal sheet panels.
%RG\ZRUN
Aluminium and thermo-plastic resin body, aluminium doors with reinforcement bars.
Electronically controlled rear spoiler.
'LPHQVLRQVDQGZHLJKW
Length L mm 4345
Width B mm 1900
Width with side mirrors open A mm 2164
Height, unladen H mm 1165
Ride height HT mm 126
Wheelbase P mm 2560
HT
Angle of approach degrees 8
P
Angle of departure degrees 22
L
Gross vehicle weight kg 1800
Kerb weight (unladen weight) kg 1410
Maximum front axle weight kg 950
Maximum rear axle weight kg 1050 H
1RWH
• $OOZHLJKWVDSSO\WRYHKLFOHVPDUNHWHGLQWKH(87KH¿JXUHVIRUYHKLFOHVH[SRUWHGWRRWKHUFRXQWULHVPD\
be different. Please note that the details listed in the vehicle’s registration documents can be taken as
correct. B
• The kerb weight value (minimum values according to EU standard 95/48/EC) applies to the basic model
ZLWKWKHWDQNIXOOZLWKQRVSHFLDOHTXLSPHQW7KH¿JXUHVLQFOXGHDQDGGLWLRQDONJWRDOORZIRUWKH
weight of the driver. A
1
L714 00 08 00
DESCRIPTION TIGHTENING TORQUE (Nm) PICTURE
7LJKWHQLQJWKHULJLGEUDNHSLSH
Use a yellow permanent marker to indicate it has been tightened.
A. Tightening torque of pipe 16

1a
A
PDM 400611-048
Tightening the power steering hydraulic pipes B
A. Tightening screw 47 A
1b
B. Tightening screw 35
PDM 400422-018
7LJKWHQLQJRIORZHUSDUWRIWKHFUDQNFDVHWRFUDQNFDVHFHQWUDOMRXUQDOV 18 14 11 15 19
A. Tightening screw 30 ± 3 8 4 1 5 9
(50 ± 3) + (180° ± 10°)
1c B. Tightening screw 20 ± 3
A B
7 3 2 6 10
(40 ± 3) + (135° ± 10°)
17 13 12 16 20
EXCEL 079100991D
Tightening of pulley on propeller shaft to front differential A

Use a yellow permanent marker to indicate it has been tightened.
1d A. Tightening torque 170 ± 17
PDM 400521-010
1
L714 00 08 00
7LJKWHQLQJWKHGDPSHUDQGSXOOH\RQWRWKHFUDQNVKDIW
A. Tightening torque 15
1
22 + 90° 8 3
2a 7 4
6 5
2
A
EXCEL 079100991D
7LJKWHQLQJWKHÀ\ZKHHORQWRWKHFUDQNVKDIW
1
A. Tightening torque (60 ± 3) + (90° ± 10°) 10 3
2b 8
5
7
6
4 9
2
A
EXCEL 079100991D
7LJKWHQLQJWKHORZHUSDUWRIFUDQNFDVHWRFUDQNFDVHVHDPEROWV
2c B. Tightening torque 10
B
A
A
2c
B
2d
B
EXCEL 079100991D
2
L714 00 08 00
Fastening the power steering pipe in the rear area

Align the two references before tightening the unions

3a
A
PDM 400422-032
7LJKWHQLQJWKHVSDUNSOXJVRQULJKWDQGOHIWKHDGV
A
A. Spark plug tightening (101905619) - with the grease 18 ± 5%
3b A. Spark plug tightening (101905611C) - without the grease 25 ÷ 30
EXCEL 079100991D
7LJKWHQLQJWKHLQWDNHPDQLIROGRQWRWKHKHDGV
A. Tightening torque of screw

3c
A
EXCEL 079100991D
7LJKWHQLQJWKHJHDUER[DVVHPEO\RQWRWKHHQJLQHDVVHPEO\
1 6
A 7
A. Tightening torque
3d 5
8
4
2
EXCEL 079100991D 3 9
3
L714 00 08 00
7LJKWHQLQJWKHVWDUWHURQWRWKHJHDUER[DVVHPEO\
A
4a
EXCEL 079100991D
7LJKWHQLQJWKHFOXWFKDVVHPEO\RQWRWKHÀ\ZKHHO 2
1
3
A
4b 3
2
1
1
2 3
EXCEL 079100991D
7LJKWHQLQJWKHWLPLQJER[RQWRWKHFUDQNFDVH
A. Tightening torque 25 ± 5%
4c
A
4c
B. Tightening torque 10 ± 5%
B
4d
B B
EXCEL 079100991D
4
L714 00 08 00
)DVWHQLQJWKHVXEÀRRUSRZHUVWHHULQJSLSHV
A
5a
B. Tightening torque of pipe 40 B
PDM 400422-033
7LJKWHQLQJWKHEXONKHDGVRQWRWKHJHDUER[D[OHVKDIWV
A
A. Tightening torque A
5b
PDM 400501-055
7LJKWHQLQJWKHYDULDEOHYDOYHWLPLQJPHFKDQLVPV
A A
2 3
+
5c 90°
1 4
EXCEL 079100991D
7LJKWHQLQJWKHQR]]OHVRQWRWKHFUDQNFDVH
5d A
5
L714 00 08 00
7LJKWHQLQJWKHSKRQLFZKHHORQWRWKHÀ\ZKHHO 1
A
6a 3
2
EXCEL 079100991D
7LJKWHQLQJWKHRLOZDWHUSXPSRQWRWKHORZHUSDUWRIWKHFUDQNFDVH
6b
A
EXCEL 079100991D
7LJKWHQLQJWKHWLPLQJV\VWHPSDUWVRQWRWKHFUDQNFDVH
A. Tightening torque 10 ± 5% C
B. Tightening torque 22 ± 5% B
6c C. Tightening torque 10 ± 5%
C
A
6c
D. Tightening torque 10 ± 5%
E. Tightening torque 42 ± 5%
E
6d
D
EXCEL 079100991D
6
L714 00 08 00
Tightening the oil-water pump supports
7a A A
EXCEL 079100991D
7LJKWHQLQJWKHIXHOSLSHVRQWRWKHLQWDNHPDQLIROG
A. Tightening torque 25 ± 5% A
7b
EXCEL 079100991D
Secondary air circuit
7c A
EXCEL 079100991D
7LJKWHQLQJWKH6HOHVSHHGDFWXDWRURQWRWKHJHDUER[
B A
7d B. Tightening torque 10 ± 5%
PDM 086300-014
7
L714 00 08 00
Tightening the engine support screws
8a
A
PDM 400199-111
7LJKWHQLQJWKHULJKWDQGOHIWKHDGFRYHU 2
13 7 8 14
8b 6 1 3 9 15
12
A 11 5 4 10 16
EXCEL 079100991D
Tightening the right and left heads

A 9 7 1
3 5
11
Tighten in the following order:
1. Tightening torque A 06D103385E 30 ± 5%
8c 2. Tightening torque A 06D103385E 60 ± 5%
3. Tightening torque A 06D103385E 90° ± 1° 12 6 4 2 8 10
4. Tightening torque A 06D103385E 90° ± 1°
EXCEL 079100991D
Tightening the U-bolts onto the camshafts (mechanical phase)

A A
8d
EXCEL 079100991D
8
L714 00 08 00
Tightening the connecting rod cap – connecting rod beam A
A. Tightening torque 40 ± 3
+
9a 120° ± 10°
EXCEL 079100991D
Tightening the power steering pump support
9b
A
PDM 400422-038
Tightening the clutch actuator support and sensor
A. Tightening torque 6 ± 3% B
9c
A
EXCEL 079100991D
7LJKWHQLQJWKHWLPLQJV\VWHPSDUWVRQWRWKHFUDQNFDVH A
C
C. Tightening torque 10 ± 5%
B
EXCEL 079100991D
9
L714 00 08 00
Fastening the power steering pipe in the front area


10a
A
PDM 400422-045
Tightening the pulley onto the alternator
10b A
EXCEL 079100991D
7LJKWHQLQJWKHR[\JHQVHQVRUVRQWRWKHFDWDO\WLFFRQYHUWHUV
A
10c
EXCEL 079100991D
A
Tightening the alternator cable
10d
EXCEL 079100991D
10
L714 00 08 00
Tightening the cable onto the starter A
11a
EXCEL 079100991D
Tightening the right and left timing shoes onto the heads
11b +
90° A A
EXCEL 079100991D
7LJKWHQLQJWKHJHDUVXSSRUWRQWRWKHFUDQNFDVH
A
A
11c
B
EXCEL 079100991D
7LJKWHQLQJWKHXQLRQRQWRWKHJHDUER[DQGEOHHGHU
B
11d B. Tightening torque 9 ± 5% A C
C. Tightening torque 49 ± 5%
PDM 086300-011
11
L714 00 08 00
)DVWHQLQJWKHSDUNLQJEUDNH
A
A. Tightening torque of screw 15
12a
PDM 400609-072
Tightening the clutch hose hollow screw
12b
A
PDM 086300-018
7LJKWHQLQJWKHYDULDEOHYDOYHWLPLQJFRYHUVFUHZV
12c A A
EXCEL 079100991D
7LJKWHQLQJWKHKHDGVFUHZVRQWRWKHFUDQNFDVH
12d
A
EXCEL 079100991D
12
L714 00 08 00
7LJKWHQLQJWKHRLOSXPSJDVNHWFRYHU
13a A
EXCEL 079100991D
7LJKWHQLQJWKHÀDQJHRQWRWKHRLOSXPS
A. Tightening torque 16 A
13b
PDM 400117-045
7LJKWHQLQJWKHRLOWDQNSLSHRQWRWKHRLOSXPS
13c
A
PDM 400117-045
7LJKWHQLQJWKHRLOSLSHRQWRWKH¿OWHU
A B
EXCEL 079100991D
13
L714 00 08 00
$VVHPEO\RIWKHUHDUXSSHUWUDQVYHUVDOVXVSHQVLRQDUPKRXVLQJV
A. Tightening torque of nut 110

14a
A
PDM 400501-018
$VVHPEO\RIWKHUHDUORZHUWUDQVYHUVDOVXVSHQVLRQDUPKRXVLQJV
A. Tightening torque of nut 120 ± 10 A

14b
PDM 400501-020
7LJKWHQLQJWKHZDWHUSXPSFRYHU
14c A
A
EXCEL 079100991D
Tightening the alternator belt tightener
14d
EXCEL 079100991D A
14
L714 00 08 00
Tightening the alternator support
B. Tightening torque 35 ± 5% B A
15a
EXCEL 079100991D
7LJKWHQLQJWKH$&V\VWHPFRPSUHVVRUVXSSRUW
15b A
EXCEL 079100991D
7LJKWHQLQJWKHHQJLQHOLIWLQJKRRNV
15c
A B A B A B A B
Tightening the front suspension lower nuts after alignment
A. Tightening torque of M8 nuts 30

15d
A
PDM 400400-040
15
L714 00 08 00
Tightening the plugs on the oil pan
16a
A
EXCEL 079100991D
Tightening the plugs on the oil ducts
16b A A
EXCEL 079100991D
Tightening the power steering support onto the power steering

Assemble the power steering pump support onto the power steering pump and center with tool 64095018.
16c A
EXCEL 079100991D
Tightening the union onto the power steering pump
A. Tightening torque 50 A
16d
PDM 400422-040
16
L714 00 08 00
$VVHPEO\RIWKHIURQWEUDNHKRVHEUDFNHWV A
17a B. Tightening torque 25
B
PDM 400615-012
Fastening the lifting system pump pipe

17b
A
PDM 400616-010
Tightening the lifting system support LEFT DRIVE RIGHT DRIVE
A
A. Tightening torque of screw 9 ± 10%
17c A
PDM 400616-010
Assembly of airbag control unit

Once tightened, apply yellow paint to the nuts using the special marker.
17d A. &RQWUROXQLW¿[LQJQXWV 8 ± 8% A
A
17
L714 00 08 00
Assembly of passenger AIRBAG module

Once tightened, apply yellow paint to the nuts and bolts using the special marker A A
A. Tightening torque of screws 8 ± 8%

18a
$VVHPEO\RIVWHHULQJFROXPQRQVWHHULQJER[
A
Once tightened, apply yellow paint to the nuts and bolts using the special marker
18b A. Tightening torque of screws 33
PDM 400422-019
)DVWHQLQJWKHVWHHULQJER[WRWKHFKDVVLV A
A. Tightening torque of screws 47

18c
PDM 400422-012
Assembling the seatbelts

Once tightened, apply yellow paint to the nuts and bolts using the special marker.
18d A. Tightening torque of screws 24.5 ± 5%

A
B
B. Tightening torque of screws 49 ± 5%
18
L714 00 08 00
Assembling the head mount

A B
B. Tightening torque of screws 10
19a
EXCEL 079100991D
Assembly of pedal cluster

A
19b A. Tightening torque of screws 25
PDM 401721-011
A
6HFXULQJWKHUHDUD[OHVKDIW
To oil the bolt thread, with oil of one of the following types: Agip Sint 2000 Evolution SAE 5W/40 - Agip TecSint - Castrol TXT Softec
SAE 5W/40 4
19c A. Pre-torque of bolts 50

5 3
+ A
B. Tightening torque of bolts 45° 6 2
PDM 400501-050 1
Assembly of seats
A
19d A. Tightening torque of screw M8 23 ± 1.65%
19
L714 00 08 00
Tightening torque of wheel studs
A. Tightening torque of bolts 140

20a
A
PDM 400601-010
Securing the front differential supports

B
20b A. Tightening torque of screws for front 95
B. Tightening torque of screws for rear 20
PDM 400199-530 A
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A
PDM 400825-073
20
L714 00 08 00
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A. Tightening torque of plug 40 A

21a
EXCEL 079100991D
Tightening the rails to the fuel pipe A
A. Tightening torque of the rail 128

21b
PDM 400201-058
Tightening the air conditioning system pressure sensor

A. Tightening torque of the sensor 5±1

21c
A
PDM 400260-015
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21d
PDM 400260-036
21
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22a + A
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A. Tightening torque of screw 200 + 180°

22b A
PDM400400-052
Securing the front differential A

A. Tightening torque of screws for front 40

22c B. STightening torque of screws for rear 55
PDM 400199-510-520-530 B
Securing the front hub carrier onto the bearing

22d A A
PDM 400400-010
22
L714 00 08 00
Securing the front of the propeller shaft

A. Tightening torque of screw 30 ± 3

23a A
PDM 400521-010
Tightening the rear suspension nuts after alignment

23b
A
PDM 400501-040
Assembly of the water system radiator

A
A. Tightening torque of M6 screw 20 ± 5%
B. Tightening torque of M8 screw 20 ± 5%
23c
PDM 400121-015 B
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23d
PDM 400501-052
23
L714 00 08 00
Securing the rear hub carrier onto the bearing

A A
24a
PDM 400501-010
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24b
A A
PDM 400501-026/040
Securing the rear of the propeller shaft

A. Tightening torque of screw 30 ± 3

24c
A
PDM 400521-010
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A. Tightening torque of screws 20 ± 3
PDM 400521-012
24
L714 00 08 00
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A
A. Tightening torque of the bolt 55
25a
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25b
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PDM 400615-010/019
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A. Tightening torque of banjo nut 16

B
25c B. Tightening torque of banjo nut 12 A
PDM 400615-014/022
Securing the upper rear suspension onto the hub carrier

25d
PDM 400501-022
A
25
L714 00 08 00
Tightening the lower rear suspension onto the hub carrier

26a
A
PDM 400501-022
Assembling the steering wheel

26b A. Tightening torque of screw 50 ± 5% A
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26c
A
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PDM 400201-030
26
L714 00 08 00
Assembling the windshield wiper

A
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B. Tightening torque of nut M8 20 ± 10%
27a
B
PDM 400955-012
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Electromagnetic sensor assembly

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A
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A
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A A
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27
L714 00 08 00
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A. Tightening torque of cap 49 ± 5%

28a
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28b
A
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28d
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Attachment of the DLU¿OWHUVXSSRUW

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29b
PDM 400133-018
Tightening of front anti-roll bar mounting bolts
A. Tightening torque of bolt 30

29c
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29d
PDM 400400-032
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L714 00 08 00
Tightening of rear anti-roll bar mounting bolts
A. Tightening torque of bolt 30 A

30a
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30b
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PDM 400035-010
Tightening the front suspension upper nuts after alignment

A A
30d
PDM 400400-040
30
L714 00 08 00
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31a A
PDM 400400-022
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A
31c
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31d A. Tightening torque 100 ± 5% A
31
L714 00 08 00
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Tightening torque of middle plate

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Attachment of gear unit ring nut

32d
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32
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33d
33
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34d A. Tightening torque of screw 30 ± 20%

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35a
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35b
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Attachment of tire pressure control sensor (TPMS sensor)

A
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35c
PDM 400601-010
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35d A
35
L714 00 08 00
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A
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36a
Attachment the engine on the engine supports

A A
36b
PDM 400199-115
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PDM 400199-315
Assembly of fuel pipes
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36d
PDM 400201-035
36
L714 00 08 00
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37a
PDM 400251-010
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A
C. Lambda sensor 50 ± 8
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37c
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PDM 400907-090
Fastening the windshield wiper motor A A

B
39b
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Fastening the pedal cluster support

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39c
PDM 401721-010
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L714 00 08 00
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40a
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Fastening the rear suspension rod

40c
A
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Fastening the arm ratchet

40d
PDM 400400-042 A
40
L714 00 08 00
Clamping of support to rear chassis
A. Screw tightening torque 20

41a
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41b
41c
41d
41
L714 00 09 00
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• Static ignition with single coils (one for each spark plug)
• BOSCH MOTRONIC high pressure multipoint electronic injection.
• Emission control system using three-way catalytic converters and oxygen sensors
• Electronic continuous intake and exhaust variable valve timing
• Electronic drive-by-wire air supply system with two throttle bodies
• Electronic traction control system
• Electronic front differential locking system
• Stability control system
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To avoid operator injury and damage to the vehicle, disconnect the battery before carrying out any maintenance/
repair work by switching the battery isolator to OFF. If work must be done with the battery connected, be extremely
careful and follow the safety operations reported in the manual.

L714 00 10 00
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The following vehicle components are considered dangerous to the environment: vehicle disposal must therefore
provide for the removal of these components and their processing by specialized companies.
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• Disposing of engine coolant by depositing it in garbage dumps or drainage systems is prohibited.

• The collection and disposal of used oil is regulated by law. Disposing of oily residues by depositing them in
garbage dumps or drainage systems is prohibited.
• The collection and disposal of dead batteries is regulated by law. The disposal of batteries in garbage dumps is
prohibited.
• &RQVXPDEOHPDWHULDOVEUDNHSDGV¿OWHUVPDWHULDOVRDNHGZLWKIXHOHWFPD\QRWEHGLVSRVHGRILQQRUPDO
garbage dumps and must be set aside and disposed of according to current laws.
Ferrous, light alloy and plastic materials should also be separated for recycling.
Battery
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Catalytic converters
Windows
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Residual fuel
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Coolant
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• Remove side airbag (. )LJ
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pressure required for alignment.
Table A
)URQW Rear
Vehicle height from ground (mm.) 130±5 140±5
Caster (°) 6° 15’ +/- 0° 15’ -
Total toe-in* (°) 0° 20’ +/- 0° 04’ 0° 20’ +/- 0° 04’
Camber (°) -1° 00’ +/- 0° 05’ -1° 25’ +/- 0° 05’
,QÀDWLRQSUHVVXUHEDU 2.4 ± 0.1 2,2 ± 0,1
* Note: Total toe-in indicates the toe-in angle generated by the toe-in of both wheels. The individual toe-in value is logically half the total value.
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The wheel alignment values in table A should be used on vehicles at customer service centers.
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Vehicle height from ground
130 ± 5 140 ± 5
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Vehicle height from ground
127 ± 5 136 ± 5
with full fuel tank (mm.)
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B. WKHULJKWIURQWZLQGVFUHHQ
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Manufacturer’s plate
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1 (XURSHDQW\SHDSSURYDOQXPEHU 1
2 VIN e3*2001/116*0000*00
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3 )XOOORDGZHLJKW 3 1800 Kg
4 0D[SHUPLWWHGZHLJKW 4 1800 Kg
950 Kg
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1050 Kg
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C. Engine serial number
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L714 00 88 00
CHECKLIST
Order number Service manager Number plate Registration date
Engine number Gearbox number Gearbox type Km/Mls
VIN Model Model Year Date
Mechanic’s name Delivery date Car number Type of job carried out
Description i.o. non i.o. Repaired
On-board documentation
Check whether this VIN is affected by any recall or service campaign to be performed
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Check the exhaust gas expiry date and the M.O.T./service date
Inside the vehicle
Electric windows, folding mirrors and electric top check positioning
Adjust the digital clock
Check all switches, electrical devices, indicators and other elements function correctly
Ensure the controls on the pushbutton panel are complete
Check the interior compartment for any visual faults
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i.o. = in order NOTES: Date:

not i.o. = out of order
Repaired = the problem has been cleared up Signature:
1
L714 00 88 00
CHECKLIST
Outside the vehicle
Check and/or replace the windscreen wiper blades (if agreed beforehand with the customer)
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Check the exterior for any visual faults
Windscreen wiper blades: ensure the parked wiper position is correct. If the blades “scrape”, check whether they are set at the correct angle
Electrical system
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Check the height of the front headlamps and adjust if necessary
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Interior compartment lights: interior lights, reading lights, passenger glove box light, door clearance lights and puddle lights.
Battery: check the charge status, the electrolyte level (top up with distilled water if necessary) and ensure the battery poles have not oxidised
Diagnosis: read, if possible archive, and then delete any error codes

2
L714 00 88 00
CHECKLIST
Engine compartment (rear)
Engine and engine compartment: visually check for any leaks and/or faults
Engine oil: check the oil level and top up if necessary
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Gearbox: check the oil level and top up if necessary
Luggage compartment (front)
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Lower part of the vehicle
Engine, gearbox, differentials, steering, coupling covers: visual check to ensure there are no leaks and/or damage
Brake system: visual check to ensure there are no leaks and/or damage

3
L714 00 88 00
CHECKLIST
Steering tie rod heads: ensure the steering tie rod heads are properly secured and ensure the clearance is correct. Check the bellow seals
Exhaust system: visual check to ensure there are no leaks and/or damage
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Front left tyre: check the pressure, check the condition of the tread and ensure the wear of the tread is even. Thickness in mm _________
Front right tyre: check the pressure, check the condition of the tread and ensure the wear of the tread is even. Thickness in mm _________
Rear left tyre: check the pressure, check the condition of the tread and ensure the wear of the tread is even. Thickness in mm _________
Rear right tyre: check the pressure, check the condition of the tread and ensure the wear of the tread is even. Thickness in mm _________
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Climate control system check the climate control system functions correctly
Navigator (if present)/Radio: check the navigator and/or radio function correctly

4
L714 00 88 00
CHECKLIST
Test drive: carry out
After servicing, complete and stamp the space provided in the warranty booklet and complete the sticker (001200) to be applied onto the door ledge

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IMMEDIATELY AFTER SWITCHING THE VEHICLE OFF
Description OK
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Install the windscreen wipers and the windscreen wiper guards for haulage.
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VIN Number NOTES: Date:

Vehicle collection date
Date of delivery to the client Signature:
Please include date and signature

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Then brake strongly 3 times with the vehicle at high speed complying with the speeding limit and in respect of saifty
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I Left/right radiator: visual inspection of the radiating surface
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7KH HQJLQHGULYH DVVHPEO\ FDQ EH UHPRYHG IURP WKH UHDU SDUW RI WKH YHKLFOH RQFH LW KDV EHHQ
FRUUHFWO\VOXQJE\PHDQVRIDKRLVWDQGRQFHDOOWKHPHFKDQLFDOHOHPHQWVZLULQJKDUQHVVHVSLSHV
DQGKRVHVZKLFKFRQQHFWLWWRWKHFKDVVLVERG\KDYHEHHQGLVFRQQHFWHG
• Disconnect the battery (091503).
• Lift the vehicle on the car lift (000000).
• 5HPRYHWKHFDUÀRRUV(082503).
• Remove the rear wheels (060103).
• Remove the rear combination lights (094503).
• Remove the rear bumper (080703).
• Disassemble the engine hood (082703).
• Remove the internal panels of the engine compartment and the corresponding support brackets (081303).
• Disassemble the rear wheel arch (082103).
• Disassemble the upper panel (081303).
• 5HPRYHWKHDLU¿OWHUDVVHPEO\(013303).
• Remove the exhaust silencer (025103).
• Remove the rear torsion bar (051003).
'LVDVVHPEOLQJWKHHQJLQH
Disassembling the engine cross member A

1. Remove the 8 lateral screws (4 per side) (A-Fig.1).
7RUHDFKWKH¿[LQJVFUHZVRIWKHHQJLQHFURVVPHPEHU\RXKDYHWRUHPRYH
• power steering oil tank and its support bracket (042303).
• vacuum tank and its support bracket (061103).
Fig.1
1
L714 01 00 03
2. Disconnect the wiring harness (%)LJ) from the cross member by removing its mounting clamps.
%
• Remove the engine oil tank (011503).
Fig.2
3. Remove the cross member spacers (C-Fig.3) positioned in the 4 cross member support points on the chassis.
C
Set aside the spacers and put them back in the same position when assembling.
4. Remove the cross member.
• Empty the coolant tank (012107).
• Empty the air conditioning system tank (026007). Fig.3
2
L714 01 00 03
Removing the vehicle engine

1. Unscrew the 4 screws (2 per side) (A-Fig.4) of the engine support. A
Fig.4
2. )UHHWKHSURSHOOHUVKDIWE\XQVFUHZLQJWKH¿[LQJVFUHZV%)LJ) and removing their spacers.
3. Remove the protective cover (C-Fig.5) of the alternator cables.
4. Disconnect the positive cable (')LJ) of the alternator.
5. Remove the clamps (()LJ).
6. 5HPRYHWKH¿[LQJVFUHZF-Fig.5) connecting the cable to the chassis. F
C ' (
Fig.5
3
L714 01 00 03
7. Free the axle shafts from the gearbox following this procedure
• insert 5 nuts (G-Fig.6 LQWR WKH ZKHHO GLVF WR NHHS LW VWHDG\ ZKLOH WKH D[OH VKDIW ¿[LQJ VFUHZV DUH EHLQJ
removed;
'RQRWWLJKWHQWKHQXWVFRPSOHWHO\EXWMXVWDVPXFKDVQHFHVVDU\WRORFNLW.
G
H
• XQVFUHZ WKH D[OH VKDIW ¿[LQJ EROWV H-Fig.6) while keeping the disc steady with the help of the nuts
mounted on it;
• perform the operations for both axle shafts.
'RQRWXVHRWKHUWRROVRUSURFHGXUHVIRUORFNLQJWKHGLVFVWKHGLVFVFRXOGEHGDPDJHG
Fig.6
8. 8QVFUHZWKH¿[LQJEROWRIWKHJURXQGH\HI-Fig.7) of the starter and remove the ground cable.
Fig.7
4
L714 01 00 03
9. 5HPRYHWKHWZRJHDUER[VXSSRUW¿[LQJEROWV(L-Fig.8).
L L
Fig.8
Disassembling the manual gearbox involves releasing the gear selection cables (a-Fig.9) and the clamp
(b-Fig.9).
a b
Fig.9
5
L714 01 00 03
10. 5HPRYHWKH¿[LQJVFUHZVRIWKHJHDUER[RLOUDGLDWRU±JHDUER[RLOWDQNSLSHV(M-Fig.10).
Fig.10
6
L714 01 00 03
11. 'LVFRQQHFWWKHHQJLQH±UDGLDWRUUHWXUQSLSH1)LJE\ORRVHQLQJWKHVFUHZVVHFXULQJWKHÀDQJH
12. 'LVFRQQHFWWKHRLOWDQN±HQJLQHSLSHO-Fig.11E\ORRVHQLQJWKHVFUHZVVHFXULQJWKHÀDQJH O 1
13. 5HPRYHWKHRLOWDQN±HQJLQHSLSHO-Fig.11) (the end connected to the oil tank was already disconnected when
the tank was removed).
:KLOHUHPRYLQJWKHSLSHVSUHSDUHDV\VWHPIRUFROOHFWLQJWKHRLOVWLOOLQVLGHWKHSLSHV
Fig.11
7
L714 01 00 03
14. 'LVFRQQHFWWKHSRZHUVWHHULQJSLSHE\XQVFUHZLQJLWIURPLWV¿WWLQJ3)LJ) and remove the screw securing

the clamp (Q-Fig.12) to the chassis.
:KLOHUHPRYLQJWKHSLSHSUHSDUHDV\VWHPIRUFROOHFWLQJWKHRLOVWLOOLQVLGHWKHSLSHV
Q
Fig.12
8
L714 01 00 03
15. Disconnect the A/C system pipe (R-Fig.13E\UHPRYLQJWKHÀDQJHZLWKWKHUHOHYDQWVFUHZ
16. Disconnect the A/C system pipe (S-Fig.13) by unscrewing the relevant screw from the receiver-drier.
• Remove the coolant tank (nourice) (012103). S
Fig.13
9
L714 01 00 03
17. Disconnect the 2 pipes (T-Fig.14RIWKHDLU¿OWHUSXPSVE\UHPRYLQJWKHLUFODPSV
T1
Fig.14
10
L714 01 00 03
18. Disconnect the brake booster pipe (U-Fig.15WKDWMRLQWVWKHSLSHVRQWKHLQWDNHPDQLIROGVUHPRYLQJWKHFODPSV

(V-Fig.15).
Fig.15
11
L714 01 00 03
7RGLVFRQQHFWWKHIXHOSLSH:)LJIURPWKHHQJLQHORRVHQWKHIXHOSLSH¿[LQJVFUHZRQWKHFKDVVLV

support (X-Fig.16). X
&ORVHWKHVXSSO\SLSHVZLWKWKHVSHFL¿FSOXJVWRSUHYHQWIXHOIURPOHDNLQJDQGGLUWIURPHQWHULQJ
20. Disconnect the canister pipe (Y-Fig.16) by removing its clamp.
Fig.16
12
L714 01 00 03
Remove the engine wiring harness.
• Disassemble the bench (086803).

• Disassemble the right side member cover (086803).
• Disassemble the right B pillar cover (086803).
21. Disconnect the E-gear control unit connectors (A-Fig.17) and loosen the corresponding earth (%)LJ). Only
for vehicles equipped with an E-gear system. %
22. Disconnect the connections of the 4 relays (C-Fig.17) connected to the main electrical system. A
23. Detach the 2 fuse blocks (')LJ) from the corresponding support.
24. Loosen the 2 screws (()LJ) securing the relay support (F-Fig.17) to the chassis.
25. Disconnect the 7 relays on the support (F-Fig.17).

1- Blue 643 main relay.
2- Gray 643 secondary air pump relay.
3- Purple 373 +50 1 relay.
4- Red 373 +50 2 relay.
5- Orange 643 secondary air pump 1 relay.
6- Green 643 engine relay.
7- White 179 E-gear pump relay (only on vehicles equipped with an E-gear system). C
8- Blank.
9- Blank.
26. Disconnect the 3 fuses on the relay support (F-Fig.17). ( '

A- Black - 50A secondary air pump 1.
B- Brown - 40A fuel pump supply.
C- Blank.
D- Red - 50 A secondary air pump 2.
(
Fig.17
13
L714 01 00 03
27. Remove the wiring harness from the clamp (G-Fig.18).
28 7RH[WUDFWWKHZLULQJKDUQHVVIURPWKHLQVLGHRIWKHSDVVHQJHUFRPSDUWPHQWWRWKHHQJLQHFRPSDUWPHQWSDVVLW
through the hole (H-Fig.18).
H
5HPRYHWKHHQJLQHZLULQJKDUQHVVZLWKWKHKHOSRIDVHFRQGRSHUDWRU
3URFHHGZLWKWKHXWPRVWFDXWLRQWRSUHYHQWWKHHQJLQHZLULQJKDUQHVVIURPEHLQJGDPDJHG
Fig.18
14
L714 01 00 03
29. Disconnect the earth cable on the right side of the engine compartment.
I
30. Disconnect the two clamps (L-Fig.19) securing the engine wiring harness to the right secondary air pipe.
L
31. Disconnect the secondary air right pump connector (M-Fig.19).
Fig.19
15
L714 01 00 03
32. 5HOHDVHWKHLQMHFWLRQFRQWUROXQLW1)LJ) on the left side of the passenger compartment by loosening the two
EUDFNHW¿[LQJVFUHZVO-Fig.20).
1
3
33. Loosen the clamp (3)LJ) securing the engine wiring harness to the chassis.
34. Position the control unit (1)LJ) on the engine.
Fig.20
16
L714 01 00 03
35 Disconnect the two earth cables on the left side of the engine compartment (Q-Fig.21).
36. Disconnect the two clamps (R-Fig.21) securing the engine wiring harness to the left secondary air pipe.
37. Disconnect the secondary air left pump connector (S-Fig.21).
Fig.21
17
L714 01 00 03
38. Disconnect the pump connector (T-Fig.22DQGFDQLVWHU¿OWHUU-Fig.22E\UHPRYLQJWKHWKUHH¿[LQJVXSSRUWV

(V-Fig.22). V
V
U
39. Disconnect the ENCS valve connector (:)LJ) in the rear part of the vehicle.
Fig.22
18
L714 01 00 03
Removing the vehicle engine

40. Secure the engine to the lifting device (A-Fig.23) by hooking it onto the relevant anchoring points. A
41. Lift and remove the engine.
Place a protective lid on the manifold to ensure it is not ruined by the lifting device.
3URFHHG VORZO\ ZKHQ OLIWLQJ WKH HQJLQH FKHFNLQJ WKDW WKH HQJLQH GRHV QRW HQFRXQWHU REVWDFOHV
GXULQJUHPRYDO
9HUWLFDOO\H[WUDFWWKHHQJLQHIURPWKHYHKLFOHZLWKRXWWLOWLQJLW
3URWHFWWKHFDUERG\ZLWKUXEEHUJXDUGVVRLWGRHVQRWEHFRPHGDPDJHGGXULQJHQJLQHUHPRYDO
Fig.23
19
L714 01 00 05
(QJLQHSUHSDUDWLRQ
&DUU\RXWWKLVSURFHGXUHZLWKWKHHQJLQHRQDZRUNEHQFK
• install the A/C compressor (026005).

A
• assemble the silencers (025105).
B C
1. Assemble the oil duct (A-Fig.1IDVWHQLQJLWVÀDQJHWRWKHHQJLQHRLOVXPSZLWKWKHVFUHZVB-Fig.1).
2. 6HFXUHWKHRLOGXFWWRWKHHQJLQHZLWKWKHVFUHZC-Fig.1).

1
3. 3RVLWLRQWKHZDWHUSLSHVRQWKHLU¿WWLQJVDQGWLJKWHQWKHPZLWKFODPSVD-Fig.1).
4. 3RVLWLRQWKHLQWDNHSLSHVRQWKHPDQLIROGVDQGUHFRQQHFWWKHGLVFRQQHFWHGUHFRYHU\SLSHV(012905). D
Fig.1
1
L714 01 00 05
5. $VVHPEOHWKHFOXWFKÀ\ZKHHO(014105).
6. Install the gearbox (030105) RQWKHHQJLQHXVLQJDQDSSURSULDWHOLIWLQJGHYLFHFig.2)
Fig.2
$VVHPEOLQJWKHHQJLQHLQWKHYHKLFOH
1. 6HFXUHWKHHQJLQHWRWKHOLIWLQJGHYLFHA-Fig.3E\KRRNLQJLWRQWRWKHUHOHYDQWDQFKRULQJSRLQWV A
2. /LIWLWDQGSRVLWLRQLWLQWKHYHKLFOHLQVLGHWKHHQJLQHFRPSDUWPHQW
3URFHHGVORZO\ZKHQOLIWLQJWKHHQJLQHFKHFNLQJWKDWWKHHQJLQHGRHVQRWHQFRXQWHUREVWDFOHVZKLOH
EHLQJSODFHGLQVLGHWKHYHKLFOH
)LW WKH HQJLQH LQ WKH YHKLFOH YHUWLFDOO\ PDNLQJ VXUH QRW WR WLOW LW 3D\ DWWHQWLRQ WKDW WKH HQJLQH LV
FRUUHFWO\ SRVLWLRQHG VR WKDW WKH SURSHOOHU VKDIW D[OH VKDIWV DQG KROHV IRU WKH ¿[LQJ VFUHZV DUH
matching.
:+(1326,7,21,1*7+((1*,1((1685(7+$77+(3,3(667,//72%(&211(&7('$5(127
&586+('
3URWHFWWKHFDUERG\ZLWKUXEEHUJXDUGVVRLWGRHVQRWEHFRPHGDPDJHGZKLOHWKHHQJLQHLVEHLQJ
put in.
Fig.3
2
L714 01 00 05
3. 6FUHZWKHVFUHZVSHUVLGHB-Fig.4) of the engine support.

6FUHZDWWDFKPHQWWLJKWHQLQJWRUTXHE B
Fig.4
2. 6HFXUHWKHSURSHOOHUVKDIWDQGLWVVSDFHUVE\VFUHZLQJWKH¿[LQJVFUHZV(C-Fig.5).
6FUHZDWWDFKPHQWWLJKWHQLQJWRUTXHF
C
3. )DVWHQWKHSRVLWLYHDOWHUQDWRUFDEOHWRWKHIUDPHE\WLJKWHQLQJWKHVFUHZD-Fig.5).
4. &RQQHFWWKHSRVLWLYHFDEOH()LJ) of the alternator.
5. Fasten the clamps (F-Fig.5).

D
6. 6HFXUHWKHSURWHFWLYHFRYHU*)LJ) of the alternator cables.
( F *
Fig.5
3
L714 01 00 05
7. &RQQHFWWKH$&V\VWHPSLSH+)LJE\¿[LQJWKHÀDQJHZLWKWKHUHOHYDQWVFUHZ
&RQQHFWWKH$&V\VWHPSLSH,)LJWRWKHUHFHLYHUGULHUE\¿[LQJWKHÀDQJHZLWKWKHUHOHYDQWVFUHZ
Fig.6
4
L714 01 00 05
9. &RQQHFWWKHGHOLYHU\SLSHVL-Fig.7) and tighten their clamps.
10. Connect the return pipe (M-Fig.7) and tighten its clamp. L M
)RUPDQXDOJHDUER[FRQQHFWWKHJHDUVKLIWVHOHFWRUFDEOHVE\ORFNLQJWKHFRUUHVSRQGLQJFODPS
Fig.7
11. 7LJKWHQWKHEROWWKDWVHFXUHVWKHJURXQGH\H1)LJ) of the starter.
)LJ
5
L714 01 00 05
12. Connect the engine – radiator return pipe (2)LJE\WLJKWHQLQJWKHVFUHZVVHFXULQJWKHÀDQJH
13. 3RVLWLRQDQGFRQQHFWWKHRLOWDQN±HQJLQHSLSH3)LJE\WLJKWHQLQJWKHVFUHZVVHFXULQJWKHÀDQJH 3 2
3RVLWLRQWKHRLOWDQN±HQJLQHSLSH3)LJLQVXFKDZD\WKDWLWSDVVHVXQGHUWKHD[OHVKDIWWKHRSSRVLWH

HQGZLOOEHFRQQHFWHGWRWKHRLOWDQN.
Fig.9
6
L714 01 00 05
14. &RQQHFWWKHSRZHUVWHHULQJSLSHE\VFUHZLQJLWRQWRLWV¿WWLQJQ-Fig.10).
15. )DVWHQWKHSLSHWRWKHFKDVVLVE\WLJKWHQLQJWKHVFUHZ(5)LJ).
5
Fig.10
7
L714 01 00 05
16. 7LJKWHQWKH¿[LQJVFUHZVRIWKHJHDUER[RLOUDGLDWRU±JHDUER[RLOWDQNSLSHV(S-Fig.11).
Fig.11

L714 01 00 05
17. 5HVWUDLQWKHD[OHVKDIWVRQWKHJHDUER[IROORZLQJWKLVSURFHGXUH:
• insert 5 nuts (T-Fig.12LQWKHZKHHOGLVNWRNHHSWKHGLVNVWHDG\ZKLOHWKHD[OHVKDIW¿[LQJVFUHZVDUHEHLQJ
installed;
'RQRWWLJKWHQWKHQXWVFRPSOHWHO\EXWMXVWDVPXFKDVQHFHVVDU\WRORFNLW. T
8
• VFUHZ RQ WKH D[OH VKDIW ¿[LQJ EROWV 8)LJ ZKLOH NHHSLQJ WKH GLVN VWHDG\ ZLWK WKH KHOS RI WKH QXWV
mounted on it;
EROWDWWDFKPHQWWLJKWHQLQJWRUTXHF
• perform the operations for both axle shafts.

Fig.12
'RQRWXVHRWKHUWRROVRUSURFHGXUHVIRUORFNLQJWKHGLVNVWKHGLVNVFRXOGEHGDPDJHG a
$VVHPEOLQJWKHPDQXDOJHDUER[LQYROYHVVHFXULQJWKHJHDUVHOHFWLRQFDEOHV (a-Fig.13) and the clamp a

b
(b-Fig.13).
Lower the vehicle from the car lift Fig.13
6FUHZRQWKHWZRJHDUER[VXSSRUW¿[LQJEROWVV-Fig. 14).

V V
Fig.14
9
L714 01 00 05
19. &RQQHFWWKHEUDNHERRVWHUSLSH:)LJWKDWMRLQWVWKHSLSHVRQWKHLQWDNHPDQLIROGV
20. Connect the fuel pipe (X-Fig.15).
X
5HPHPEHUWRUHPRYHDQ\SOXJVWKDWPLJKWEHRQWKH¿WWLQJDQGIXHOSLSH
: X
21. Connect the canister pipe (Y-Fig.15E\VHFXULQJLWVFODPS
Fig.15
22. &RQQHFWWKHSLSHVZ-Fig.16RIWKHDLU¿OWHUSXPSVE\VHFXULQJWKHLUFODPSV
Fig.16
10
L714 01 00 05
Laying the engine wiring harness
Keep the battery disconnected while laying the engine wiring harness.
23. &RQQHFWWKH(1&6YDOYHFRQQHFWRUA-Fig.17LQWKHUHDUSDUWRIWKHYHKLFOH A
24. Connect the pump connector (B-Fig.17VHFXUHWKHFDQLVWHU¿OWHUC-Fig.17E\¿[LQJWKHWKUHHVXSSRUWVD- D

D
Fig.17). C
Fig.17
11
L714 01 00 05
25. Connect the earth cable on the right side of the engine compartment (()LJ).
(
26. &RQQHFWWKHWZRFODPSV))LJVHFXULQJWKHHQJLQHZLULQJKDUQHVVWRWKHULJKWVHFRQGDU\DLUSLSH
27. &RQQHFWWKHULJKWVHFRQGDU\DLUSXPSFRQQHFWRU*)LJ).
)LJ
12
L714 01 00 05
&RQQHFWWKHWZRHDUWKFDEOHVRQWKHOHIWVLGHRIWKHHQJLQHFRPSDUWPHQW+)LJ).
29. &RQQHFWWKHWZRFODPSV,)LJVHFXULQJWKHHQJLQHZLULQJKDUQHVVWRWKHOHIWVHFRQGDU\DLUSLSH
30. &RQQHFWWKHOHIWVHFRQGDU\DLUSXPSFRQQHFWRUJ-Fig.19).
Fig.19
13
L714 01 00 05
31. 3RVLWLRQWKHLQMHFWLRQFRQWUROXQLWK-Fig.20RQWKHOHIWVLGHRIWKHSDVVHQJHUFRPSDUWPHQWE\WLJKWHQLQJWKHWZR

EUDFNHW¿[LQJVFUHZVL-Fig.20).
32. Connect the clamp (M-Fig.20VHFXULQJWKHHQJLQHZLULQJKDUQHVVWRWKHFKDVVLV

K
Fig.20
14
L714 01 00 05
33. 7R SRVLWLRQ WKH ZLULQJ KDUQHVV SDVV LW WKURXJK WKH KROH IURP WKH HQJLQH FRPSDUWPHQW WR WKH SDVVHQJHU
compartment (1)LJ).
2
3RVLWLRQWKHHQJLQHZLULQJKDUQHVVZLWKWKHKHOSRIDVHFRQGRSHUDWRU
3URFHHGZLWKWKHXWPRVWFDXWLRQWRSUHYHQWWKHHQJLQHZLULQJKDUQHVVIURPEHLQJGDPDJHG
34. )DVWHQWKHHQJLQHZLULQJKDUQHVVXVLQJWKHFODPS2)LJ).
Fig.21
15
L714 01 00 05
35 &RQQHFWWKHIXVHVRQWKHUHOD\VXSSRUW3)LJ).

Q 5
$%ODFN$VHFRQGDU\DLUSXPS
%%URZQ$IXHOSXPSVXSSO\
&%ODQN
'5HG$VHFRQGDU\DLUSXPS
Q
36 &RQQHFWWKHUHOD\VRQWKHVXSSRUW3)LJ).
%OXHPDLQUHOD\ 3
*UD\VHFRQGDU\DLUSXPSUHOD\
3XUSOHUHOD\
5HGUHOD\
Fig.22
2UDQJHVHFRQGDU\DLUSXPSUHOD\
*UHHQHQJLQHUHOD\
:KLWH(JHDUSXPSUHOD\RQO\RQYHKLFOHVHTXLSSHGZLWK(JHDUV\VWHP
%ODQN
%ODQN
37. 7LJKWHQWKHVFUHZVQ-Fig.22VHFXULQJWKHUHOD\VXSSRUW3)LJ) to the chassis.
)DVWHQWKHIXVHEORFNV5)LJ) to the corresponding support. 8
39. &RQQHFWWKHFRQQHFWLRQVRIWKHUHOD\VS-Fig.23WRWKHPDLQHOHFWULFDOV\VWHP

T
40. &RQQHFWWKH(JHDUFRQWUROXQLWFRQQHFWRUVT-Fig.23) and tighten the corresponding earth (8)LJ). Only for
vehicles equipped with an E-gear system.
• Assemble the bench .

• $VVHPEOHWKHULJKWVLGHPHPEHUFRYHU .
• 6HFXUHWKHULJKW%SLOODUFRYHU.
Fig.23
16
L714 01 00 05
Assembling the engine cross member

• $VVHPEOHWKHHQJLQHRLOWDQN(011505). A B
41. Position the engine cross member (A-Fig. 24).
42. Position the spacers (B-Fig.24LQWKHHQJLQHFURVVPHPEHUVXSSRUWSRLQWVRQWKHFKDVVLV
8VHWKHVDPHVSDFHUVUHPRYHGGXULQJWKHGLVDVVHPEO\VWDJHDQGUHSRVLWLRQWKHPLQWKHVDPHSRVLWLRQ.
Fig.24
43. )DVWHQWKHFURVVPHPEHUE\WLJKWHQLQJWKHODWHUDOVFUHZVSHUVLGH(C-Fig.25).
Fig.25
17
L714 01 00 05
44. &RQQHFWWKHZLULQJKDUQHVVD-Fig.26) to the cross member using its mounting clamps.
D
2QFHWKHHQJLQHFURVVPHPEHULVVHFXUHGLWLVSRVVLEOHWRLQVWDOO:
• SRZHUVWHHULQJRLOWDQNDQGLWVVXSSRUWEUDFNHW(042305).
• YDFXXPWDQNDQGLWVVXSSRUWEUDFNHW(061105).
• Assemble the rear torsion bar (051005).

• Assemble the exhaust silencer (025105).
• $VVHPEOHWKHDLU¿OWHUDVVHPEO\(013305).
Fig.26
• $VVHPEOHWKHFRRODQWWDQNQRXULFH(012105).
• )LOOWKHFRRODQWWDQN.
• )LOOWKHDLUFRQGLWLRQLQJV\VWHPWDQN.
• )LOOWKHHQJLQHRLOWDQN.
• )LOOWKHSRZHUVWHHULQJRLOWDQN.
• Assemble the upper panel .
• $VVHPEOHWKHUHDUZKHHODUFK.
• Assemble the internal panels of the engine compartment.
• Assemble the engine hood .
• Assemble the rear bumper .
• Assemble the rear combination lights (094505).
• $VVHPEOHWKHUHDUZKHHOV(060105).
• $VVHPEOHWKHFDUÀRRUV.
• &RQQHFWWKHEDWWHU\ (091503).
7KH /D5D$6 (109000) EDVLF VHWWLQJ SURFHGXUH KDV WR EH VWDUWHG HYHU\ WLPH DQ HQJLQH RU RQH RU ERWK
LQMHFWLRQFRQWUROXQLWVDUHUHSODFHG
1. EDVLFVHWWLQJRQWKHPDVWHUDQGVODYHFRQWUROXQLWDGDSWVWKHWKURWWOHV
2. EDVLFVHWWLQJDGDSWVWKHWXPEOHYDOYHV
3. EDVLFVHWWLQJDQGDGDSWWKHLQWDNHDQGH[KDXVWFDPVKDIWVROHQRLGYDOYHV

L714 01 03 03
'LVDVVHPEOLQJWKHKHDGV
• Disassemble the engine (010003)

• Disassemble the Exhaust manifold (013103)
• Disassemble the coils (090503)
• Disassemble the variable valve timing mechanisms (011603)
Adopt the safety procedure to reduce the fuel pressure in the supply circuit (012803).
'LVDVVHPEOLQJWKHULJKWDQGOHIWKHDGFRYHUV A
C3 B C9 C15 C10 C4
1. Disconnect the supply circuit pipe (A-Fig.1) from the high pressure pump.
2. Free the 2 head covers (B-Fig.1) from the 2 heads (one cover per head) by removing all 32 screws (16 screws C8 C16
C14 C11 C5
per cover). C2
5HPRYHWKHVFUHZVRIHDFKKHDGIROORZLQJWKHDVFHQGLQJRUGHUIURP&WR&VKRZQLQ)LJ
C1 C7 C13 C12 C6
Fig.1
1
L714 01 03 03
'LVDVVHPEOLQJWKHKHDGVKRHV
3. Disassemble the shoe from each head, removing the 6 screws (')LJ), 12 screws altogether. '
'
Fig.2
4. Remove the shoes (()LJ).
Fig.3
2
L714 01 03 03
'LVDVVHPEOLQJWKHKHDGV
5. Unscrew the access cap (F-Fig.4) for the head bolt.
Fig.4
6. Remove the 5 screws (G-Fig.5) that secure the head to the crankcase on the variable valve timing side (5
screws per head, 10 altogether).
Fig.5
3
L714 01 03 03
7. Remove the heads from the crankcase by means of the 12 screws, following the ascending order from H1 to
H12 shown in Fig.6.
I
H4 H6 H10 H12 H8 H2
2QFHWKHVFUHZVKDYHEHHQUHOHDVHGEHIRUHUHPRYLQJWKHKHDGWLOWWKHHQJLQHWRWRSUHYHQWLW
from slipping.
8. Remove the 2 heads (I-Fig.6) from the respective cylinder banks.
H1 H7 H9 H11 H5 H3
Fig.6
'LVDVVHPEOLQJWKHKHDGJDVNHW
9. Remove the gaskets (L-Fig.7) from the 2 cylinder banks (1 gasket per cylinder bank).
L
Fig.7
4
L714 01 03 05
Assembling the heads
$VVHPEOLQJWKHKHDGJDVNHW
1. Position the gaskets (A-Fig.1) on the 2 cylinder banks (1 gasket per cylinder bank), positioning them correctly
using the centering dowels. A
Assembling the heads Fig.1
2. Position the 2 heads (B-Fig.2) on the respective cylinder banks. B

C11 C5 C3 C1 C7 C9
3. Secure the heads to the crankcase by means of the 12 screws, following the ascending order from C1 to C12
shown in Fig.2.
Use engine oil in advance to lubricate the thread of the screws.
7LJKWHQLQJWRUTXHRIVFUHZVWLJKWHQLQJWRUTXHF.
C10 C8 C2 C4 C6 C12
Fig.2
1
L714 01 03 05
4. Screw the access cap (F-Fig.4) for the head bolt.
'
Fig.3
5. Tighten the 5 screws (()LJ) that secure the head to the crankcase on the variable valve timing side (5 screws
per head, 10 altogether).
7LJKWHQLQJWRUTXHRIVFUHZVWLJKWHQLQJWRUTXHG.
(
Fig.4
2
L714 01 03 05
Assembling the head shoes
1. Secure the 2 shoes (F-Fig.5) onto each head using the 6 screws (G-Fig.6), 12 screws altogether.
Apply System 52A43 medium thread sealant onto the thread of the 12 screws.
6FUHZDWWDFKPHQWWLJKWHQLQJWRUTXHE
Fig.5
2. Position the chains (H-Fig.6DVVKRZQLQWKH¿JXUH

G
G H
Fig.6
3
L714 01 03 05
$VVHPEOLQJWKHULJKWDQGOHIWKHDGFRYHUV
1. Assemble the 2 head covers (L-Fig.7) on the 2 heads (one cover per head). 1
M13 L M7 M2 M8 M14
2. Tighten the 2 covers using the 32 screws (16 screws per cover).
M6 M1 M3 M9 M15
M12
7LJKWHQWKHVFUHZVRIHDFKKHDGIROORZLQJWKHDVFHQGLQJRUGHUIURP0WR0VKRZQLQ)LJ
3ODFHWKHEXVKLQJVDQGVSHFLDOJDVNHWVEHWZHHQWKHVFUHZVZKHQWLJKWHQLQJ
3. Connect the supply circuit pipe to the high pressure pump (1)LJ).
)DVWHQLQJWKHXQLRQWLJKWHQLQJWRUTXHG. M11 M5 M4 M10 M16
Fig.7
• Assemble the variable valve timing mechanisms
• Assemble the coils
• Assemble the exhaust manifolds
• Assemble the engine
4
L714 01 05 03
7KHSUHVHQWVHFWLRQFRQWDLQVWKHIROORZLQJGLVDVVHPEO\VHTXHQFHV
A) &UDQNVKDIWDQGEHDULQJV
%&UDQNVKDIWRLOVHDO
$'LVDVVHPEOLQJWKHFUDQNVKDIWDQGEHDULQJV
• Disassemble the engine (010003).
• Disassemble the exhaust manifold (013103).
• Disassemble the coils (090503)
• Disassemble the variable valve timing mechanisms (011603).
• Disassemble the heads (010303).
• Disassemble the oil pump (011503). C A B
'LVDVVHPEOLQJWKHFUDQNVKDIWDQGEHDULQJV
1. Loosen the 20 screws (A-Fig.1) securing the timing system cover.
2. Loosen the 6 crosshead screws (B-Fig.1) securing the timing system cover.
3. Tighten the 4 screws in the relevant threads (C-Fig.1) so the timing system cover can be raised.
4. Remove the chains that transmit motion to the camshafts.

C
The chain transmitting motion to the right camshafts is shorter than the left chain.
C
Fig.1
1
L714 01 05 03
Completely upturn the engine.
4. /RRVHQWKH¿[LQJVFUHZV')LJ) and remove the alternator support.
'
Fig.2
5. Loosen the 20 crosshead screws (()LJ) securing the oil pan to the crankcase.
Fig.3
2
L714 01 05 03
6. Loosen the 37 screws (F-Fig.4) (18 on the right and 19 on the left) securing the oil pan to the crankcase. '[
6[
Fig.4
3
L714 01 05 03
7. Remove the timing system cover by tightening 4 screws (G-Fig.5) in the relevant threads so it can be raised.
G G
G G Fig.5
8. Loosen the 5 screws (L-Fig.6) securing the shoe and the upper crown gear to remove the oil pump timing chain
(H-Fig.6).
M
9. Loosen the 5 screws (1)LJ) securing the shoes to remove the main camshaft timing chain (M-Fig.6).
1
1 L
Fig.6
4
L714 01 05 03
10. Loosen 6 screws (3)LJ) to remove the oil pump and water drive assembly (O-Fig.7).
O
3
Fig.7
11. To remove the 10 pistons (Q-Fig.8), loosen the screws (R-Fig.8¿[LQJWKHFRQQHFWLQJURGVWRWKHFUDQNVKDIW
Fig.8
5
L714 01 05 03
12. Remove the 26 screws (T-Fig.9) to remove the lower part of the crankcase (S-Fig.9).
Fig.9
13. Remove the crankshaft (Fig.10).
Fig.10
6
L714 01 05 03
% 'LVDVVHPEOLQJWKHFUDQNVKDIWRLOVHDO
• Disassemble the gearbox (030103).
• 'LVDVVHPEOHWKHFOXWFKDQGÀ\ZKHHO(014103).
'LVDVVHPEOLQJWKHRLOVHDO
1. Remove the oil seal (A-Fig.11) using the puller.
Fig.11
7
L714 01 05 05
7KHSUHVHQWVHFWLRQFRQWDLQVWKHIROORZLQJDVVHPEO\VHTXHQFHV
A) &UDQNVKDIWDQGEHDULQJV
%&UDQNVKDIWRLOVHDO
$ $VVHPEOLQJWKHFUDQNVKDIWDQGEHDULQJV
1. Position the crankshaft (A-Fig.1) in its housing.
2. Secure the lower part of the crankcase (B-Fig.1) by tightening the 26 screws (C-Fig.1).
Fig.1
1
L714 01 05 05
3. To secure the 10 pistons (')LJWLJKWHQWKHFRQQHFWLQJURG¿[LQJVFUHZVA-Fig.2) to the crankshaft.

)DVWHQLQJWKHVFUHZVWLJKWHQLQJWRUTXHD
'
Fig.2
4. Tighten 6 screws (G-Fig.3) to secure the oil pump and water drive assembly (F-Fig.3).
)DVWHQLQJWKHVFUHZVWLJKWHQLQJWRUTXHF F
G
Fig.3
2
L714 01 05 05
5. Position the main camshaft timing chain (H-Fig.4) and tighten the 5 screws (L-Fig.4) securing the shoes.
)DVWHQLQJWKHVFUHZVWLJKWHQLQJWRUTXHF
H
Position the oil pump timing chain (M-Fig.4) and tighten the 5 screws (L-Fig.4) securing the shoe and the upper L
crown gear.
L 1
Fig.4
7. Position the timing system cover by tightening the 4 screws (O-Fig.5) in the relevant threads so it can be
raised.
O O
O O Fig.5
3
L714 01 05 05
Tighten the 37 screws (3)LJ) (18 on the right and 19 on the left) securing the oil pan to the crankcase. '[
6[
)LJ
4
L714 01 05 05
Tighten the 20 crosshead screws (Q-Fig.7) securing the oil pan to the crankcase.
Fig.7
Completely upturn the engine.
10. 3RVLWLRQWKHDOWHUQDWRUVXSSRUWDQGWLJKWHQWKH¿[LQJVFUHZV5)LJ).
)LJ
5
L714 01 05 05
11. Position the chains that transmit motion to the camshafts.

S U T
The chain transmitting motion to the right camshafts is shorter than the left chain.
12. Tighten the 4 screws in the relevant threads (6)LJ) so the timing system cover can be raised.
13. 3RVLWLRQWKHWLPLQJV\VWHPFRYHUDQGWLJKWHQWKHFURVVKHDG¿[LQJVFUHZV7)LJ).

)DVWHQLQJWKHVFUHZVWLJKWHQLQJWRUTXHF S
14. Also tighten the 20 screws (8)LJ) securing the timing system cover.
S
S
)LJ
• Assemble the oil pump.
• Assemble the heads .
• Assemble the variable valve timing mechanisms .
• Assemble the coils .
• $VVHPEOHWKHH[KDXVWPDQLIROG.
• Assemble the engine .

L714 01 05 05
% $VVHPEOLQJWKHFUDQNVKDIWRLOVHDO
1. Position the oil seal $)LJXVLQJWKHVSHFL¿FWRROE.
• $VVHPEOHWKHFOXWFKDQGÀ\ZKHHO.
• $VVHPEOHWKHJHDUER[.
Fig.10
7
L714 01 09 00
9$/9(6
Intake valve seat housing diameter (a-Fig.1) 32.85 c c

Exhaust valve seat housing diameter (b-Fig.1) 26.59
Intake and exhaust valve guide housing diameter (c-Fig.1) 11.22
,QWDNHYDOYHVHDWV
Rated inner diameter 31.14
Rated outer diameter 33.85
Contact band angle 45°
([KDXVWYDOYHVHDWV
Rated inner diameter 24.38
Rated outer diameter 28 ± 0.1
Contact band angle 45°
,QWDNHDQGH[KDXVWYDOYHJXLGH
Rated outer diameter 11.059 ÷ 11.048
Inner diameter with pressed and bored guide 6.015
Fig.1
b a
1
L714 01 09 00
,QWDNHYDOYHV
Stem diameter (d-Fig.2) 5.92 ± 0.02
Reduced stem diameter (d1-Fig.2) 4.59 ± 0.05
Valve head diameter (')LJ) 33.85 ± 0.1
Valve seat angle 44°50’ ± 10’
Height (h-Fig.2) 103.97
Tappets support thickness (s-Fig.2) 5.54
([KDXVWYDOYHV
Stem diameter (d-Fig.2) 5.92 ± 0.02
Valve head diameter (')LJ) 28 ± 0.1
Valve seat angle 44°50’ ± 10’
Height (h-Fig.2) 101.87
Tappets support thickness (s-Fig.2) 5.54
Tappets
Diameter 32.974 ÷ 32.990
Washer thickness range 3.25 ÷ 0.70
with intervals of 0.05 Fig.2
9DOYHVWHPJXLGH¿WWLQJ
Intake system assembly clearance 0.025 ÷ 0.055
Exhaust system assembly clearance 0.035 ÷ 0.065
0D[LPXPVKLIWEHWZHHQYDOYHVWHPDQGKHDG
(head-stem concentricity)
Intake 0.03
Exhaust 0.03
Assembly clearance between tappet and its seat (intake-exhaust) 0.025 ÷ 0.071
2
L714 01 15 03
7KLVVHFWLRQH[SODLQVKRZWRGLVDVVHPEOH
$ (QJLQHRLOWDQN
B) Oil-water pump
& 7KHUPRVWDWLFYDOYH
' 2LOWHPSHUDWXUHDQGOHYHOVHQVRU
$ 'LVDVVHPEOLQJWKHHQJLQHRLOWDQN
• 5HPRYHWKHUHDUFDUÀRRU(082503). A
• Empty the engine oil tank (011707).
• Remove the DLU¿OWHUFDUWULGJHV (013303).
• 5HPRYHWKHH[KDXVW(025103).
• 5HOHDVHWKHYDFXXPWDQN(061103).
Disassembling the oil pump

1. /RRVHQWKHODWHUDOVFUHZVSHUVLGHA-Fig.1RIWKHHQJLQHFURVVPHPEHUWRORRVHQLWVRWKDWWKHRLOWDQN
Fig.1
FDQEHUHPRYHGB-Fig.1
2. 'HWDFKWKHORZHUHQJLQHRLOWDQNC-Fig.2E\UHPRYLQJWKHÀDQJHZLWKLWVVFUHZVD-Fig.2.
D C
Fig.2
1
L714 01 15 03
3. 8QVFUHZWKHVFUHZV()LJVHFXULQJWKHHQJLQHRLOWDQNWRWKHFKDVVLV.
Fig.3
4. 8QVFUHZWKHVFUHZVF-Fig.4VHFXULQJWKHHQJLQHRLOWDQNWRWKHFURVVPHPEHU
5. 'LVFRQQHFWWKHRLOEUHDWKHUSLSHVIURPWKHHQJLQHRLOWDQNG-Fig.4
6. 'HWDFKWKHXSSHUHQJLQHRLOWDQNH-Fig.4E\UHPRYLQJWKHÀDQJHZLWKLWVVFUHZVI-Fig.4. G F
H
I
7. )UHHWKHRLOWDQNDOVRE\DFWLQJRQWKHHQJLQHFURVVPHPEHU Fig.4
8. 'LVFRQQHFWWKHRLOWHPSHUDWXUHFRQQHFWRUL-Fig.5
9. Remove the oil tank.
L
Fig.5
2
L714 01 15 03
B) Disassembling the oil-water pump
• Remove the vehicle engine (010003).
• 5HPRYHWKHOHIWH[KDXVWPDQLIROG (013103).
A
Disassembling the pump C

1. 'LVFRQQHFWWKHRLOSLSHA-Fig.6E\XQVFUHZLQJ
• WKHVFUHZVB-Fig.6VHFXULQJWKHÀDQJH
• WKHVFUHZC-Fig.6VHFXULQJWKHSLSHVXSSRUWEUDFNHW
Fig.6
• 5HPRYHWKHDLUFRQGLWLRQLQJSXPS (026003).
2. 'LVFRQQHFWWKHZDWHUSLSHD-Fig.7IURPWKHRLOZDWHUSXPSE\UHPRYLQJLWVFOLS()LJ
D (
Fig.7
3
L714 01 15 03
3. 5HPRYHWKHRLOZDWHUSXPSVXSSRUWEUDFNHWF-Fig.8E\ORRVHQLQJWKHVFUHZVG-Fig.8
4. 5HPRYH WKH RLOZDWHU SXPS VXSSRUW EUDFNHW H-Fig.8 IURP WKH HQJLQH PRXQW E\ ORRVHQLQJ WKH VFUHZV
I-Fig.8
F G
I
H
Fig.8
5. 8QVFUHZWKHPRXQWLQJVFUHZVL-Fig.9
Fig.9
4
L714 01 15 03
6. 5HPRYHWKHRLOZDWHUSXPSM-Fig.10
3RVLWLRQDVXLWDEOHFRQWDLQHUWRFROOHFWRXWSXWÀXLGV
3URFHHGZLWKFDXWLRQGXULQJWKHGLVDVVHPEO\SURFHVV
Fig.10
5
L714 01 15 03
& 'LVDVVHPEOLQJWKHWKHUPRVWDWLFYDOYH
A
• 5HPRYHWKHFHQWUDODQGUHDUFDUÀRRU(082503).
• Empty the engine coolant (012107).
'LVDVVHPEOLQJWKHYDOYH
1. 'LVFRQQHFWWKHSLSHVA-Fig.11
2. /RRVHQWKHVFUHZVB-Fig.11VHFXULQJWKHFRYHUWRWKHRLOZDWHUSXPS.
3. 5HPRYHWKHFRYHUFRPSOHWHZLWKWKHUPRVWDWLFYDOYHC-Fig.11
Fig.11
6
L714 01 15 03
4. /RRVHQWKHVFUHZVD-Fig.12DQGUHPRYHWKHWKHUPRVWDWLFYDOYH()LJ
Fig.12
7
L714 01 15 03
' 'LVDVVHPEOLQJWKHRLOWHPSHUDWXUHDQGOHYHOVHQVRU
3UHOLPLQDU\RSHUDWLRQV B A
• 3XWWKHHQJLQHRLOWDQNRQDZRUNEHQFK3RLQW$.
Disassembling the sensor

1. /RRVHQ WKH ¿[LQJ VFUHZV B-Fig.13 WR UHPRYH WKH KHDWSURRI SDQHO A-Fig.13 VHFXUHG WR WKH HQJLQH RLO
tank.
Fig.13
2. /RRVHQWKHVFUHZVD-Fig.14DQGUHPRYHWKHRLOWHPSHUDWXUHDQGOHYHOVHQVRUC-Fig.14

D C
Fig.14
8
L714 01 15 05
7KLVVHFWLRQH[SODLQVKRZWRDVVHPEOH
$ (QJLQHRLOWDQN
B) Oil-water pump
& 7KHUPRVWDWLFYDOYH
' 2LOWHPSHUDWXUHDQGOHYHOVHQVRU
$ $VVHPEO\LQJWKHHQJLQHRLOWDQN
1. Loosen the 8 lateral screws (4 per side) (A-Fig.1) of the engine cross member to loosen it, so that the engine
oil tank can be installed (B-Fig.1).
2. Put the oil tank (B-Fig.1) inside its housing. A
Fig.1
3. Connect the oil temperature connector (C-Fig.2).
C
Fig.2
1
L714 01 15 05
4. Connect the lower engine oil pipe (')LJ) by screwing on the 2 screws (()LJ).
( '
Fig.3
5. Connect the pipe coming from the oil radiator (H-Fig.4) by tightening the two screws (I-Fig.4).
6. Connect the 2 oil breather pipes from the engine oil tank (G-Fig.4).
G F
7. Secure the engine oil tank to the engine cross member with 2 screws (F-Fig.4).
H
I
8. Secure the engine oil tank to the chassis with 2 screws (L-M-Fig.5).
Fig.4
Final operations
• Secure vacuum tank (061105).
• Assembly of the DLU¿OWHUFDUWULGJHV(013305).
• Assembly of exhaust (025105).
• $VVHPEO\RIWKHUHDUFDUÀRRU(082505). L
Fill the engine oil tank (011708).

M
Fig.5
2
L714 01 15 05
B) Assembling the oil-water pump
1. 3RVLWLRQWKH¿OWHUVA-Fig.6) on the oil-water pump pipelines.
2. Position the oil-water pump (B-Fig.6) in its seat.
%HIRUHDVVHPEO\WKRURXJKO\FOHDQ¿OWHUVLQFDVHRIGDPDJHG¿OWHUVUHSODFHWKHP
B
3URFHHGZLWKFDXWLRQGXULQJWKHDVVHPEO\SURFHVV 2 4 6 8
A
1 3 5 7
Fig.6
3
L714 01 15 05
Be sure to position the pump so that the 2 centring bushes (C-Fig.6) match their couplings.
C C
Fig.7
3. Secure the oil-water pump onto the lower part of the crankcase using the 13 screws (')LJ).
'
Fig.8
4. Secure the oil-water pump support bracket (()LJ) by tightening the 3 screws (F-Fig.9).
6FUHZDWWDFKPHQWWLJKWHQLQJWRUTXHD
5. Secure the oil-water pump support bracket (G-Fig.9) to the engine mount by tightening the 3 screws
(H-Fig.9).
6FUHZDWWDFKPHQWWLJKWHQLQJWRUTXHD ( F
H
G
Fig.9
4
L714 01 15 05
6. Connect the water pipe (I-Fig.10) to the oil-water pump by fastening its clip (L-Fig.10).
I L
• Install the air conditioning pump (026005).
Fig.10
7. Connect the oil pipe (M-Fig.11) by tightening:

• the 2 screws (1)LJVHFXULQJWKHÀDQJH
• the screw (O-Fig.11) securing the pipe support bracket.
• Assemble the left exhaust manifold (013105).

• Assemble the vehicle engine (010005).
1
Fig.11
5
L714 01 15 05
& $VVHPEOLQJWKHWKHUPRVWDWLFYDOYH
1. Put a new gasket (A-Fig.12) inside the cover (B-Fig.12).

A C
2. Position the thermostatic valve (C-Fig.12) inside the cover and secure it using the 3 screws (')LJ).
Fig.12
'
'
Fig.13
6
L714 01 15 05
3. Position the cover on the oil-water pump and secure it using the 5 screws (()LJ).
4. Connect the 2 pipes (F-Fig.14).
• $VVHPEOHWKHFHQWUDODQGUHDUFDUÀRRU(082505).
• Fill the coolant tank (012108). (
Fig.14
7
L714 01 15 05
' $VVHPEOLQJWKHRLOWHPSHUDWXUHDQGOHYHOVHQVRU
1. Position the oil temperature and level sensor (A-Fig.15) and secure using the 2 screws (B-Fig.15).
B A
Fig.15
' C
2. 7LJKWHQWKH¿[LQJVFUHZV')LJ) to secure the heat-proof panel (C-Fig.16) to the engine oil tank.
• Assemble the engine oil tank 3XQWR$.
Fig.16
8
L714 01 16 03
'LVDVVHPEOLQJWKHYDULDEOHYDOYHWLPLQJPHFKDQLVPV
• Disassemble the coils (090503).
• Disassemble the spark plugs (090503).
'LVDVVHPEOLQJWKHYDULDEOHYDOYHWLPLQJPHFKDQLVPV
A
1. Disassemble the valve cover (A-Fig.1). Fig.1
B
2. Loosen eight screws (C-Fig.2) to disassemble the variable timing mechanism cover (B-Fig.2).
3 8QVFUHZRQERWKKHDGVWKHWZR¿[LQJVFUHZV(D-Fig.3) on the two variable valve timing mechanisms.

C
4. Remove the two variable valve timing mechanisms (E-Fig.3).
Fig.2
D
E
Fig.3
1
L714 01 16 05
$VVHPEOLQJWKHYDULDEOHYDOYHWLPLQJPHFKDQLVPV
1. Position the two variable timing mechanisms (A-Fig.1RQERWKKHDGVDQGWLJKWHQWKHWZR¿[LQJVFUHZVB-Fig.1).

Fastening the screws; tightening torque (000800-5c).
2. Tighten eight screws (D-Fig.2) to assemble the variable timing mechanism cover (C-Fig.2).
3. Disassemble the valve cover (E-Fig.1). A

Fig.1
• Assemble the coils (090505). C

• Assemble the spark plugs (090505).
Fig.2
E
Fig.3
1
L714 01 17 03
A) Disassembling the oil radiator
B) Disassembling the engine oil circuit radiator pipes.
A) Disassembling the oil radiator
• Lift the vehicle on a car lift (000000).
• Disassemble the rear left tire (060103).
• Disassemble the front element of the rear wheel arch (082103).
• Drain the engine oil circuit (011707).
B
Disassembling the radiator
Fig.1
1. Loosen the screw (A-Fig.1) securing the pipe to the oil circuit radiator.
2. Loosen the screw (B-Fig.1) securing the pipe to the thermostatic valve. D
/RRVHQWKHWZR¿[LQJVFUHZVD-Fig.2) to remove the conveyor (C-Fig.2) from the radiator.
D
Fig.2
1
L714 01 17 03
4. Loosen the 3 screws (()LJ) securing the radiator to the chassis.
Fig.3
5. Remove the oil radiator (F-Fig.4).
Fig.4
2
L714 01 17 03
B) Disassembling the engine oil circuit radiator pipes
• Lift the vehicle on a car lift (000000).
• Disassemble the rear left tire (060103).
• Disassemble the front element of the rear wheel arch (082103).
• 'LVDVVHPEOHWKHUHDUYHKLFOHÀRRU(082503).
• Drain the engine oil circuit (011707). A
Disassembling the oil pipe

1. Loosen the 2 screws (A-Fig.5) securing the union on the pipe coming from the engine oil tank.
Fig.5
2. Loosen the 6 screws (B-Fig.6)WRUHOHDVHWKHOHIWD[OHVKDIW B
Fig.6
3
L714 01 17 03
3. Disconnect the power steering pipe (C-Fig.7) from the pump.
Before disconnecting the power steering pump, drain the power steering circuit (042307). C
Fig.7
4. Loosen the screw (D-Fig.8) fastening the oil pipe clamp to the chassis.
Fig.8
5. Loosen the 2 screws (E-Fig.9) securing the pipe to the engine oil tank. (
6. Remove the oil pipe.
Fig.9
4
L714 01 17 05
A) Assembling the oil radiator
B) Assembling the engine oil circuit radiator pipes
A) Assembling the oil radiator
1. Position the oil radiator (A-Fig.1) and secure it to the chassis using the 3 screws (B-Fig.1). B
A
B
Fig.1
1
L714 01 17 05
2. 7LJKWHQWKHWZR¿[LQJVFUHZV')LJ to secure the conveyor (C-Fig.2) to the radiator.

'
'
Fig.2
3. Tighten the screw ()LJ to secure the oil pipe to the radiator.
(
4. Tighten the screw (F-Fig.3) to secure the oil pipe to the thermostatic valve.
• Filling the oil tank (011708).

• Assemble the front element of the rear wheel arch (082105).
• Assemble the rear left tire (060105).
F
Fig.3
2
L714 01 17 05
B) Assembling the engine oil circuit radiator pipes.
1. Position the oil pipe and secure it to the engine oil tank using the 2 screws (A-Fig.4).
A
Fig.4
2. Tighten the screw (B-Fig.5) to fasten the oil pipe clamp to the chassis.
Fig.5
3
L714 01 17 05
3. Connect the power steering pipe (C-Fig.6) to the pump.
Fig.6
4. Tighten the 6 screws ')LJWRVHFXUHWKHOHIWD[OHVKDIW
'
Fig.7
5. Secure the pipe union to the engine oil tank using the 2 screws ()LJ.
(
• Filling the power steering oil tank (042308).

• Filling the oil tank (011708).
• $VVHPEOHWKHUHDUYHKLFOHÀRRU(082505).
• Assemble the front element of the rear wheel arch (082105).
• Assemble the rear left tire (060105).
Fig.8
4
L714 01 17 07
Replacing the engine oil
• When the engine is cold (oil temperature > 70°C), lift the vehicle on the car lift (000000).
• 5HPRYHWKHUHDUOHIWDQGFHQWHUFDUÀRRUV (082503). A
• Set up a suitable system for collecting the engine oil (Fig.1).
1. Unscrew the tank plug (A-Fig.1) and allow the oil to drain out of the oil tank drain hole: then clean the plug and
tighten it.
3OXJDWWDFKPHQWWLJKWHQLQJWRUTXHD.
2. Unscrew the plug (B-Fig.2) on the oil pan and allow the oil left in the engine to drain out: then clean the plug Fig.1
and tighten it.
3OXJDWWDFKPHQWWLJKWHQLQJWRUTXHD.
&$87,21
'XULQJWKHVHRSHUDWLRQVEHDZDUHRIKLJKWHPSHUDWXUHV5LVNRIEXUQLQJ B
Dispose of the engine oil according to current laws.
Fig.2
1
L714 01 17 08
),//,1*7+((1*,1(2,/
1. 8QVFUHZWKHHQJLQHRLO¿OOHUFDS1-Fig.1).

2. 7RSXSZLWKDUHFRPPHQGHGW\SHRIRLO(000300).
3. &KHFNWKHRLOOHYHODJDLQ
• (QJLQHRLOOHYHOLQWKH'2127),//VHFWRUD)LJ
'RQRWWRSXSWKHRLO
• (QJLQHRLOOHYHOLQWKH),//VHFWRU (b-Fig.2)
TRSXSWKHRLODERXWOLWUH
7KHRLOOHYHOPXVWWKHQEHLQWKH'2127),// sector.
1
4. ,IQHFHVVDU\WRSXSDJDLQ
5. 6FUHZWKHHQJLQHRLO¿OOHUFDSEDFNRQDQGSXWWKHGLSVWLFNDOOWKHZD\EDFNLQ.
:$51,1* Fig.1
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• ,IWKHHQJLQHRLOFRPHVLQWRFRQWDFWZLWKVNLQZDVKWKHVNLQWKRURXJKO\RQFHWKHMRELV¿QLVKHG. a
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• 1RDGGLWLYHVVKRXOGEHXVHGZLWKHQJLQHRLO$Q\GDPDJHFDXVHGE\WKHXVHRIVXFKVXEVWDQFHVZRXOGQRWEH
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• )ROORZWKHDSSOLFDEOHHPSW\RLOFRQWDLQHUGLVSRVDOVWDQGDUGV.
1
L714 01 21 01
:DWHUFRROLQJFLUFXLWFKHFN
1. Unscrew the cap of the water cooling circuit’s tank (A-Fig.1).

2. Make sure that the coolant level matches the mark visible through the plug. If necessary, top up with the
prescribed coolant.
3. Retighten the cap of the water cooling circuit’s tank.
A
&22/$177<3(
Fig.1
80-90mm
1
L714 01 21 03
$ :DWHUFRROLQJFLUFXLWWDQNQRXULFH
B) Cooling circuit radiator
C) Radiator fan
' :DWHUSLSHV
$ 'LVDVVHPEOLQJWKHZDWHUFRROLQJFLUFXLWWDQNQRXULFH
• Empty the engine coolant circuit .
• Disassemble the rear hood support piston .
• Disassemble the right side bulkhead .
• Release the right engine injection control unit (MASTER) . C
'LVDVVHPEOLQJWKHWDQN
1. Disconnect the coolant level connector (A-Fig.1).
2. Disconnect the 4 pipes (B-Fig.1) connected to the tank (C-Fig.1).
A B
Fig.1
1
L714 01 21 03
3. Remove the tank mounting bracket (')LJ) by loosening the 2 screws (()LJ).
'
Fig.2
4. Detach the water cooling circuit tank from the mounting bracket (F-Fig.3) and pull it out towards the vehicle
passenger compartment.
5. Remove the tank. G
To remove the bracket (F-Fig.3), loosen the 2 screws (G-Fig.3).
Fig.3
2
L714 01 21 03
% 'LVDVVHPEOLQJWKHFRROLQJFLUFXLWUDGLDWRU
5,*+75$',$725
• Empty the coolant tank ).
• Remove the front bumper .
'LVDVVHPEOLQJWKHUDGLDWRU
1. Remove the waterproof panel (A-Fig.4) taking the 5 screws (B-Fig.4) away.
Fig.4
2. Disassemble the right front air conveyor (C-Fig.5) by loosening the 4 screws (')LJ).
'
' C
Fig.5
3
L714 01 21 03
3. Remove the water delivery pipe (()LJ) after loosening their clamp.
F (
4. Remove the breather pipe (F-Fig.6) after loosening the corresponding clamp.
When removing the pipes, some coolant may still come out. Recover the coolant in a special container.
Fig.6
5. Remove the return water pipe (G-Fig.7) after loosening their clamp.
Fig.7
6. Disconnect the fan connector (+)LJ).
7. Disengage the wiring harness from the chassis removing the 3 clamps (,)LJ).
H
I
)LJ
4
L714 01 21 03
/RRVHQWKHFRUUHVSRQGLQJ¿[LQJVFUHZV to release the air conditioner radiator.
Attach the air conditioner radiator to the chassis with a hook to prevent damaging the pipes still connected
to the radiator.
Loosen the 4 screws (/)LJ) securing the radiator to the chassis.
10. Remove the radiator, complete with fan. L
)LJ
5
L714 01 21 03
/()75$',$725
1. Disassemble the left front air conveyor (A-Fig.10) by loosening the 4 screws (B-Fig.10).
A B B
Fig.10
2. Remove the water delivery pipe (C-Fig.11) after loosening their clamp.
C
3. Remove the breather pipe (')LJ) after loosening the corresponding clamp.
When removing the pipes, some coolant may still come out. Recover the coolant in a special container. '
Fig.11
6
L714 01 21 03
4. Remove the return water pipe (()LJ) after loosening their clamp.
(
Fig.12
5. Disconnect the fan connector (F-Fig.13).

F
6. Disengage the wiring harness from the chassis removing the 2 clamps (G-Fig.13).
Fig.13
7. Loosen the 4 screws (H-Fig.14) securing the radiator to the chassis.
Remove the radiator, complete with fan.

H
Fig.14
7
L714 01 21 03
& 'LVDVVHPEOLQJWKHUDGLDWRUIDQULJKWOHIW
• Disassemble the luggage compartment .
• Disassemble the upholstery covers .
'LVDVVHPEOLQJWKHUDGLDWRUIDQ
1. Remove the waterproof panel (A-Fig.15) taking the 5 screws (B-Fig.15) away.
Fig.15
2. Disconnect the fan connector (C-Fig. 16).
3. Disengage the wiring harness from the chassis removing the 3 clamps (')LJ).
C
'
Fig.16

L714 01 21 03
4. 5HPRYHWKHUDGLDWRU¿[LQJIUDPH()LJ) removing the 5 screws (F-Fig.17).

F (
Fig.17
5. 'LVDVVHPEOHWKHIDQVXSSRUWE\ORRVHQLQJWKH¿[LQJVFUHZV*)LJ).
)LJ

L714 01 21 03
6. Remove the fan, complete with support (+)LJ), from the radiator.
I H
7. Loosen the 4 screws (,)LJ) and remove the fan.
)LJ
10
L714 01 21 03
' 'LVDVVHPEOLQJWKHZDWHUSLSHV
',6$66(0%/,1*7+(:$7(5'(/,9(5<$/80,1803,3(6
• Raise the car on the car lift .
• Disassemble the front FDUÀRRUV .
'LVDVVHPEOLQJWKHSLSHV
1. Remove the clamps (A-Fig.20) connecting the rubber sleeves to the water delivery aluminum pipes. 6[ '[
A A
2. Remove the water delivery pipes (B-Fig.20).
B B
A A
Fig.20
11
L714 01 21 03
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• Raise the car on the car lift .
• Disassemble the FDUÀRRUV .
• Disassemble the propeller shaft .
• Disassemble the front differential .
A
1. Disconnect the cooling pipes (A-Fig.21) from the sleeves originating from the engine and remove the
corresponding clamps.
Fig.21
2. Release the air conditioner pipe clamp (B-Fig.22).
B
Fig.22
12
L714 01 21 03
3. Disconnect the sleeve (C-Fig.23) originating from the hot water pump and remove the corresponding clamp.
4. Loosen the two screws (')LJ) securing the pipes to the rear bracket. ' C
Fig.23
5. Loosen the two central brackets (()LJ) that fasten the cooling circuit pipes to the chassis.
( (
Fig.24
6. Loosen the front bracket (F-Fig.25) that fastens the cooling circuit pipes to the chassis.
7. Disconnect the sleeves (G-Fig.25) from the front part cooling circuit pipes and remove the corresponding G F G
clamps.
When disassembling the pipes, some coolant may still come out. Recover the coolant using the relevant
container.
Fig.25
13
L714 01 21 03
Loosen the clamp securing the brake pipes to the chassis bracket.
Remove the central part cooling circuit pipes (H-Fig.26).
Fig.26
14
L714 01 21 03
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• Disassemble the front and center FDUÀRRUV .
• Disassemble the front differential .
'LVDVVHPEOLQJWKHSLSH
1. Remove the clamps securing the pipe (A-Fig.27) to the T-union.
2. Remove the bracket secured to the chassis by the screw (B-Fig.27).
B A
Fig.27
15
L714 01 21 03
3. Loosen the two screws (&)LJ) securing the central pipes of the water cooling system to the front section of
the chassis. C '
4. Loosen the clamp (')LJ) securing the 2 central pipes of the air conditioning system.
)LJ
5. Loosen the 7 screws (()LJ) securing the 2 mounting brackets of the pipes on the right part of the center
console.
( (
)LJ
F
6. Loosen the two screws (F-Fig.30) securing the hot water pump.
Fig.30
16
L714 01 21 03
7. Disconnect the breather pipe (G-Fig.31) connection from the water cooling circuit.
G
Remove the breather pipe.
Fig.31
17
L714 01 21 03
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'LVDVVHPEOLQJWKHSLSHVEHKLQGWKHHQJLQH
• Remove the engine from the vehicle .
A B
1. Open the clamps (A-Fig.32DQGH[WUDFWWKHSLSHB-Fig.32).
Fig.32
2. Open the clamps (C-Fig.33DQGH[WUDFWWKHSLSHV')LJ) behind the engine.
' C
C '
Fig.33

L714 01 21 03
'LVDVVHPEOLQJWKHFRRODQWWDQNNourice) connection pipe

(
• 'LVDVVHPEOHWKHUHDUDQGFHQWUHYHKLFOHÀRRUV.
F
G
'LVDVVHPEOLQJWKHFRRODQWWDQNNourice) connection pipe
1. Disconnect the cooling circuit pipes behind the engine (A-Fig.34) ORRVHQLQJWKHVSHFL¿FFODPSV.
2. /RRVHQWKHVSHFL¿FFODPSWRGLVFRQQHFWWKHSLSH (B-Fig.34) originating from the engine cooling circuit pump.
3. Disconnect the union (C-Fig.34) to the hot water pump connection pipe.
4. Disconnect the union (')LJ) to the heating system pipe.

B
5. Disconnect the joint (()LJ) to the pipe originating from the coolant tank (NouriceORRVHQLQJWKHVSHFL¿F A A
clamp.
6. Loosen the four screws securing the pipe (F-Fig.34).
7. ([WUDFW the coolant tank (Nourice) connection pipe (G-Fig.34).

G
F C
' G
Fig.34

L714 01 21 05
$ :DWHUFRROLQJFLUFXLWWDQNQRXULFH
B) Cooling circuit radiator
C) Radiator fan
' :DWHUSLSHV
B
$ $VVHPEOLQJWKHZDWHUFRROLQJFLUFXLWWDQNQRXULFH
Secure the radiator expansion tank support bracket (A-Fig.1) by tightening the 2 screws (B-Fig.1).
1. Put the water cooling circuit tank on the support bracket, making the coupling (C-Fig.1) match up with the C A D
relevant guide (D-Fig.1).
Fig.1
2. Position and fasten the tank mounting bracket (E-Fig.2) by tightening on the 2 screws (F-Fig.2).
Fig.2
1
L714 01 21 05
3. Connect the 4 pipes (G-Fig.3) to the tank (H-Fig.3).
4. Connect the coolant level connector (I-Fig.3).
• Fill the engine coolant circuit .

• Secure the right engine injection control unit (MASTER) .
• Assemble the right side bulkhead .
• Assemble the rear hood support piston .
H
I G
Fig.3
2
L714 01 21 05
A
B) Assembling the cooling circuit radiator
RIGHT RADIATOR
1. )DVWHQWKHUDGLDWRUWRWKHFKDVVLVE\PHDQVRIWKH¿[LQJVFUHZVA-Fig.4).

6FUHZDWWDFKPHQWWLJKWHQLQJWRUTXHG
2. 6HFXUHWKHDLUFRQGLWLRQHUUDGLDWRUDQGWLJKWHQWKHFRUUHVSRQGLQJ¿[LQJVFUHZV.
Fig.4
3. Connect the fan connector (B-Fig.5).
4. Secure the wiring harness to the chassis using the 3 clamps (C-Fig.5). B
C
Fig.5
3
L714 01 21 05
5. Insert the return water pipe (')LJ) and secure it using the clamp.
)LJ
Insert the water delivery pipe (E-Fig.7) and secure it using the clamp.
F E
7. Insert the breather pipe (F-Fig.7) and secure it using the clamp.
Fig.7
Assemble the right front air conveyor (*)LJ) E\PHDQVRIWKH¿[LQJVFUHZV (+)LJ).
H G
)LJ
4
L714 01 21 05
Install the waterproof panel (,)LJ) by tightening on the 5 screws (/)LJ).
• Install the front bumper .

• Fill the coolant tank .
)LJ
5
L714 01 21 05
LEFT RADIATOR
1. )DVWHQWKHUDGLDWRUWRWKHFKDVVLVE\PHDQVRIWKH¿[LQJVFUHZVA-Fig.10).

A
Fig.10
2. Connect the fan connector (B-Fig.11). B

3. Secure the wiring harness to the chassis using the 3 clamps (C-Fig.11).
Fig.11
4. Insert the return water pipe (D-Fig.12) and secure it using the clamp.
D
Fig.12

L714 01 21 05
5. Insert the water delivery pipe (E-Fig.13) and secure it using the clamp.
Insert the breather pipe (F-Fig.13) and secure it using the clamp. E
Fig.13
7. Assemble the left front air conveyor (G-Fig.14) E\PHDQVRIWKH¿[LQJVFUHZV (H-Fig.14).
G H H
Fig.14
7
L714 01 21 05
C) Assembling the radiator fan

C A
1. Put the fan (A-Fig.15) on the fan support (B-Fig.15).
B
2. Secure the fan to the fan support by means of the 4 screws (C-Fig.15).
Fig.15
3. Install the fan with its support above the radiator, then secure it by means of the 2 screws (&)LJ).
)LJ

L714 01 21 05
4. $VVHPEOHWKHUDGLDWRU¿[LQJIUDPHD-Fig.17), tightening the 5 screws (E-Fig.17).

E D
Fig.17
5. Connect the fan connector ())LJ).
Secure the fan wiring harness to the vehicle chassis using the clamps (*)LJ).
F
G
)LJ

L714 01 21 05
7. Install the waterproof panel (+)LJ), tightening the 5 screws (,)LJ).
• Assemble the luggage compartment .

• Assemble the upholstery covers .
• Install the front bumper .
)LJ
10
L714 01 21 05
D) Assembling the water pipes
$66(0%/,1*7+(:$7(5'(/,9(5<$/80,1803,3(6
6[ '[
1. Connect the water delivery pipes (A-Fig.20) to the rubber sleeves and secure them using the corresponding
clamps (B-Fig.20). B B

• Assemble the front FDUÀRRUV .
A A
B B
Fig.20
$66(0%/,1*7+(:$7(5&22/,1*&,5&8,73,3(6±&(175$/3$57
1. Position the central section cooling circuit pipes (A-Fig.21).
2. Secure the clamp securing the brake pipes to the chassis bracket.
Fig.21
11
L714 01 21 05
3. Connect the sleeves (B-Fig.22) to the front part cooling circuit pipes and secure the corresponding clamps.
B C B
4. Tighten the front bracket (C-Fig.22) that fastens the cooling circuit pipes to the chassis.
Fig.22
5. Tighten the two central brackets (D-Fig.23) that fasten the cooling circuit pipes to the chassis.
D D
Fig.23
Tighten the two screws (E-Fig.24) securing the pipes to the rear bracket.
E F
7. Connect the sleeve (F-Fig.24) originating from the hot water pump and fasten the corresponding clamp.
Fig.24
12
L714 01 21 05
Secure the air conditioner pipe clamp (G-Fig.25).

G
Fig.25
Connect the cooling pipes (+)LJ) to the sleeves originating from the engine and secure the corresponding
H
clamps.

• Assemble the front differential .
• Assemble the propeller shaft .
• Disassemble the FDUÀRRUV .
)LJ
13
L714 01 21 05
$66(0%/,1*7+(:$7(5&22/,1*&,5&8,7%5($7+(53,3(
1. Connect the breather pipe (A-Fig.27) to the water cooling circuit.

A
Fig.27
B
2. Tighten the two screws (%)LJ) securing the hot water pump.
)LJ
3. Tighten the 7 screws (&)LJ) securing the 2 mounting brackets of the pipes on the right part of the center
console.
C C
)LJ
14
L714 01 21 05
4. Secure the 2 central pipes of the air conditioning system using the clamp (D-Fig.30).
E D
5. Tighten the two screws (E-Fig.30) securing the central pipes of the water cooling system to the front section of
the chassis.
Fig.30
Secure the support bracket to the chassis by tightening the screw (F-Fig.31).
7. Secure the pipe (G-Fig.31) to the T-union using the corresponding clamps.

• Disassemble the front and center FDUÀRRUV .
F G
Fig.31
15
L714 01 21 05
$66(0%/,1*7+(:$7(5&22/,1*&,5&8,73,3(6±5($53$57
A B
Assembling the pipes behind the engine
1. Connect the pipe (A-Fig.32) behind the engine and secure the clamp (B-Fig.32).
B A
Fig.32
2. Connect the pipe (C-Fig.33) and then and secure the clamps (C-Fig.33).
D C

• Assemble the engine on the vehicle .
Fig.33

L714 01 21 05
$VVHPEOLQJWKHFRRODQWWDQNNourice) connection pipe

E
1. Position the coolant tank (Nourice) connection pipe (A-Fig.34).
2. )DVWHQWKHVSHFL¿FFODPSWRFRQQHFWWKHSLSHB-Fig.34) originating from the engine cooling circuit pump.
F
3. Connect the union (C-Fig.34) to the hot water pump connection pipe. A
4. Connect the union (D-Fig.34) to the heating system pipe.
5. )DVWHQ WKH VSHFL¿F FODPS WR FRQQHFW WKH MRLQW E-Fig.34) to the pipe originating from the coolant tank
(Nourice).
Tighten the four screws securing the pipe (F-Fig.34).
7. )DVWHQWKHVSHFL¿FFODPSVWRFRQQHFWWKHFRROLQJFLUFXLWSLSHVEHKLQGWKHHQJLQHG-Fig.34).

B
G G

• $VVHPEOHWKHUHDUDQGFHQWUHYHKLFOHÀRRUV.
F C
D A
Fig.34
17
L714 01 21 07
Replacing the engine coolant
:$51,1*
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Fig.1
• Open the radiator expansion tank plug (A-Fig.1). B C
• Raise the car on the car lift (000000).
• 5HPRYHWKHFHQWHUDQGUHDUFDUÀRRU (082503).
Replacing the engine coolant

1. Place a container under the vehicle in order to collect all the engine coolant.
2. Remove the 2 delivery pipes (B-Fig.2) by loosening the clamps and let the coolant drain out.
3. Remove the return pipe (C-Fig.2) by loosening its clamp and let the coolant drain out.
5HVSHFWWKHHQYLURQPHQWDQGGLVSRVHRIHQJLQHFRRODQWDFFRUGLQJWRFXUUHQWODZV
C
Fig.2
1
L714 01 21 08
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)LOO WKH FRRODQW WDQN ZLWK WKH HQJLQH RII DQG ZDLW IRU WKH HQJLQH WR FRPSOHWHO\ FRRO GRZQ 7KH
FRROLQJFLUFXLWLVXQGHUSUHVVXUH'RQRWRSHQWKHFRRODQWWDQNFDSZLWKWKHHQJLQHERLOLQJKRWULVN
of burns!
1. Unscrew the plug (A-Fig.1) of the expansion tank and top up with the prescribed type of coolant (000300) up to
50 ÷ 60 mm from the base of the cap.
A
2. Start the engine and run it at idle speed for some minutes leaving the radiator expansion tank plug open.
3. Adjust the air conditioner control to maximum heat and maximum fan speed (B-Fig.2); stop the engine and
check the coolant level through the radiator expansion tank plug; top up with coolant if necessary.
Fig.1
4. Close the cap
5. Wait for the engine to cool down (to below 80°C) and top up the coolant tank (Nourice) with the missing
coolant.
6. Then tighten the radiator expansion tank plug.
Fig.2
1
L714 01 27 03
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A
$ ÀRDWVDQGIXHOSXPSGLVDVVHPEO\
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3UHOLPLQDU\RSHUDWLRQV B B
• Disassemble the control unit plate (098103).
• Empty the fuel tank (020107).
Floats disassembly
Fig.1
1. Detach the plate (A-Fig.1E\XQVFUHZLQJWKH¿[LQJVFUHZVB-Fig.1).
2. Disconnect the tubes (C-Fig.2) and the connector (D-Fig.2).

C D F
3. Unscrew the ring nut (E-Fig.2) that secures the cover.
4. Remove the cover (F-Fig.2) and the gasket (G-Fig.2).
E G
Fig.2
1
L714 01 27 03
5. Disconnect the fuel tubes (H-Fig.3) and the connectors (I-Fig.3).

H
6. 'LVFRQQHFWWKHÀRDWL-Fig.3) from its seat inside the tank.
7. Disconnect the fuel level sensor connector (M-Fig.3IURPWKHÀRDWDQGUHPRYHWKHÀRDW

M
8. 5HPRYHWKHÀRDW1)LJ) by disconnecting it from its seat inside the tank while keeping the teeth 1 and 2
pressed (Fig.3).
I
1 1 1
L
2 2
Fig.3
5,*+77$1.
• Disassemble the control unit plate (098103). B B
• Empty the fuel tank (020107).
Floats and fuel pump disassembly

A
1. Detach the plate (A-Fig.4E\XQVFUHZLQJWKH¿[LQJVFUHZVB-Fig.4).
Fig.4
2
L714 01 27 03
2. Disconnect the tubes (C-Fig.5) and the connector (D-Fig.5).

C
3. Unscrew the ring nut (E-Fig.5) that secures the cover.
D E
Fig.5
4. Remove the cover (F-Fig.6) and the gasket (G-Fig.6).
5. Disconnect the tube (H-Fig.6) and the connectors (I-Fig.6). F H I
6. Disconnect the connector (L-Fig.6) from the fuel pump.
G L
Fig.6
3
L714 01 27 03
7. Disconnect the tube (M-Fig.7) from the fuel pump.
8. Disengage the fuel pump (1)LJ) by turning the two clamps (O-Fig.7). O O
9. Remove the fuel pump. 1
M
Fig.7
10. 'LVFRQQHFWWKHÀRDW3)LJ) from its seat inside the tank.
11. Disconnect the fuel level sensor connector (Q-Fig.8IURPWKHÀRDWDQGUHPRYHWKHODWWHU
12. 5HPRYHWKHÀRDWR-Fig.8) by disconnecting it from its seat inside the tank, while keeping the teeth 1 and 2
pressed (Fig.8).
Q
R
1 2
3 1 2
Fig.8
4
L714 01 27 03
%IXHO¿OWHUGLVDVVHPEO\
• Disassemble the left side bulkhead (081303).
Filter disassembly
1. Unscrew the screw (A-Fig.9WKDWWLJKWHQVWKHFODPSVHFXULQJWKH¿OWHU
2. )UHHWKH¿OWHUB-Fig.9) from the pipes (C-Fig.9) to which it is connected.
3. 5HPRYHWKH¿OWHU
C Fig.9
5
L714 01 27 05
A. Floats and fuel pump assembly
% IXHO¿OWHUDVVHPEO\
A. Floats and fuel pump assembly D
/()77$1.
A
1. Connect the fuel level sensor connector (A-Fig.1WRWKHÀRDWB-Fig.1).
2. 3XWWKHÀRDWV%&)LJLQVLGHWKHLUJXLGHVLQWKHIXHOWDQNDQGSUHVVWKHPGRZQZDUGVXQWLO\RXKHDUDFOLFN

E
3. Connect the fuel tubes (D-Fig.1DQGWKHFRQQHFWRUVE-Fig.1).
Fig.1
1
L714 01 27 05
4. 3RVLWLRQWKHJDVNHWF-Fig.2DQGFRYHUG-Fig.2RQWKHWDQNLQOHW
5. Connect the tubes (H-Fig.2DQGWKHFRQQHFWRUI-Fig.2).

G H I
6. 6FUHZRQWKHULQJQXWL-Fig.2) to secure the cover.
F L
Fig.2
7. 6HFXUHWKHSODWHM-Fig.3E\WLJKWHQLQJWKH¿[LQJVFUHZV1)LJ).
M
• $VVHPEOHWKHFRQWUROXQLWSODWH(098105).
• $VVHPEOHWKHEHQFK(086805).
• 5H¿OOWKHIXHOWDQN
1 1
Fig.3
2
L714 01 27 05
5,*+77$1.
1. Connect the fuel level sensor connector (A-Fig.4WRWKHÀRDWB-Fig.4).
2. 3XWWKHÀRDWV%&)LJLQVLGHWKHLUJXLGHVLQWKHIXHOWDQNDQGSUHVVWKHPGRZQZDUGVXQWLO\RXKHDUDFOLFN
Fig.4
3. 3RVLWLRQWKHIXHOSXPSD-Fig.5LQVLGHWKHWDQN
4. 6HFXUHWKHSXPSE\WXUQLQJWKHWZRFODPSVE-Fig.5). E E
5. Connect the tube (F-Fig.5WRWKHIXHOSXPS D
F
Fig.5
3
L714 01 27 05
6. Connet the connector (G-Fig.6WRWKHIXHOSXPS

I M H
7. Connect the fuel tube (H-Fig.6DQGWKHFRQQHFWRUVI-Fig.6).
8. 3RVLWLRQWKHJDVNHWL-Fig.6DQGFRYHUM-Fig.6RQWKHWDQNLQOHW
Fig.6
9. Connect the tubes (1)LJDQGWKHFRQQHFWRUO-Fig.7).
1
10. 6FUHZRQWKHULQJQXW3)LJ) to secure the cover.
Fig.7
11. 6HFXUHWKHSODWHQ-Fig.8E\WLJKWHQLQJWKH¿[LQJVFUHZVR-Fig.8).
• $VVHPEOHWKHFRQWUROXQLWSODWH(098105).
• $VVHPEOHWKHEHQFK(086805).
R R
• 5H¿OOWKHIXHOWDQN
Fig.8
4
L714 01 27 05
% )XHO¿OWHUDVVHPEO\
1. &RQQHFWWKHSLSHVA-Fig.9WRWKH¿OWHUB-Fig.9).
2. 7LJKWHQWKHVFUHZC-Fig.9WKDWWLJKWHQVWKHFODPSVHFXULQJWKH¿OWHU
• $VVHPEOHWKHOHIWVLGHEXONKHDG(081305).
C Fig.9
5
L714 01 28 00
/HSURFHGXUHHOHLQIRUPD]LRQLSXEEOLFDWHGLVHJXLWRVRQRVWUHWWDPHQWHFRQ¿GHQ]LDOLHULYROWHHVFOXVLYDPHQWHDOOD5HWH'HDOHUH6HUYLFH3RLQW$XWRUL]]DWL/DPERUJKLQL7XWWLLGLULWWLG¶DXWRUHVRQRSURSULHWj
GL$XWRPRELOL/DPERUJKLQL6S$LQEDVHDOODOHJJHVXLGLULWWLG¶DXWRUH7XWWLLFDSLWROL3')GLFXLVLFRPSRQJRQRLPDQXDOLRI¿FLQD:(%GHVFULWWLGLVHJXLWRVLEDVDQRVXOOHLQIRUPD]LRQLGLVSRQLELOLDO
PRPHQWRGHOODSXEEOLFD]LRQH&RQULVHUYDGLDJJLRUQDPHQWRHPRGL¿FKH6RQRYLHWDWHODULVWDPSDODULSURGX]LRQHO¶LQROWURDSHUVRQHQRQDXWRUL]]DWHHRDWHU]HSHUVRQHODWUDGX]LRQHDQFKHSDU]LDOH
VHQ]DO¶DXWRUL]]D]LRQHVFULWWDGDSDUWHGL$XWRPRELOL/DPERUJKLQL6S$
*HQHUDOGHVFULSWLRQRIWKHGLUHFWLQMHFWLRQV\VWHP',6
The GLUHFWLQMHFWLRQV\VWHP',6is comparable to the running of an indirect injection engine. The basic difference
is that in this case, the fuel is injected directly into the cylinder.
This system better optimizes the amount of fuel to be injected, so consumption – and consequently emissions – are
reduced.
Characteristics of the system

• A low pressure pump having an operation range between 6 and 4 bar,
• 7ZRLQWDNHPDQLIROGVHTXLSSHGZLWKWZRDLUÀRZPHWHUVWKDWPHDVXUHWKHÀRZDQGWHPSHUDWXUHRIWKHDVSLUDWHG
air (one per manifold),
• Two high pressure pumps mechanically driven by the motion of the engine can reach a pressure varying
between EDU0,1DQGEDU0$;.
• High pressure injectors that directly inject the fuel into the cylinder crown.
• A special piston that allows a vortex to be created, inside of which the fuel vaporized at high pressure is
sprayed.
The system is designed for the following types of operation:

• VWRLFKLRPHWULFVWUDWL¿HGPL[WXUH
• homogeneous mixture,
• homogeneous and rich mixture.
,QRXUVSHFL¿FFDVHhomogeneous operation is used:
IURPWRUSPLQVWRLFKLRPHWULFVWUDWL¿HGPL[WXUHHVSHFLDOO\DWORZVSHHGVDQGGXULQJWKHLJQLWLRQSKDVHVWR
help with emissions.
A
Homogenous and rich running is used only when there is a demand for torque.
When running at low speeds, the injection system is further aided by a tumble system inside the intake manifold that
helps the vortex created by the design of the piston, ensuring that the quantity of injected fuel goes directly beneath
the spark plug. In this way the mixture is optimized with a lower quantity of fuel.
The injection of fuel during the compression phase of the cylinder is managed electronically by two injection control
A
units, of which one works as the MASTER and the other as the SLAVE .
The injection system is controlled by two linear oxygen sensors that alter the amount of fuel according to the demand
of torque and engine rpm. There are also two latest generation three-way pre-catalytic converters (A-Fig.1) (with two
oxygen sensors for their control) and two post-catalytic converters incorporated inside the silencer (B-Fig.1). B
Fig.1
1
L714 01 28 00
Funzionction
,QWDNH
The tumble throttle (A-Fig.2) is opened depending on the position of the accelerator pedal.
To switch over intake (B-Fig.2), the tumble throttle is open or closed depending on the point of operation:
• The intake switchover tumbleWKURWWOHLVFORVHGLQWKHPLGGOHORDGUDQJHDQGUSPVRWKHDVSLUDWHGDLUÀRZV

inside the cylinder with a rotary movement, which has a positive effect on carburetion. A B
C '
• As the load and rpm gradually rise, the air that can be aspirated only through the upper duct (C-Fig.2) would no
ORQJHUVXI¿FH6RWKHQWKH tumble throttle opens the lower duct as well (')LJ).
Fig.2
,QMHFWLRQ
The fuel is injected directly into the cylinder by the high pressure injector (()LJ) during intake.
1RWH
The energy necessary for evaporating the fuel is taken from the air contained inside the combustion chamber
that cools down. Thanks to this, it is possible to increase the compression ratio compared to that of an
indirect injection engine.
Fig.3
2
L714 01 28 00
Carburetion
A relatively long time remains for carburetion with the injection of fuel during the intake phase.
Therefore, in the cylinder there is a homogeneous distribution of the mixture of injected fuel and aspirated air (F-
Fig.4).
7KHDLUWRIXHOUDWLRLQWKHFRPEXVWLRQFKDPEHULVȜ
Fig.4
Combustion
,Q KRPRJHQHRXV RSHUDWLRQ WKH ¿UH SRLQW G-Fig.5) has a determining effect on torque, consumption and
emissions.
Fig.5
3
L714 01 28 00
5SPOLPLWLQJGHYLFH
In normal operating conditions with operative temperatures TH2O 90°C and Toil 90°C, the limiting device is structured
as follows:
in neutral engine limited to 7800 rpm (3500 rpm only for JP and Korea)
st gear USP
2nd gear 8550 rpm
3rd gear 8650 rpm
4th gear 8500 rpm
5th gear 8500 rpm
6ty gear USP
Reverse gear 6000 rpm
The values stated above are indicative and subject to changes introduced in the Factory.
1RWH
It must however be remembered that when the vehicle is hot, idle speed is 680 rpm and it goes up to 820
rpm with the A/C on.
Control and power limitation strategies
The ECU controls rpm limitation using different maps, depending on the environmental conditions at the time:
• with engine cold (Water temperature < 60°C) and with low Toil (Oil temperature < 40°C), the rpm are limited
• with engine hot (Water temperature >&WKHUSPDUHOLPLWHG
4
L714 01 28 00
Fuel pump
There is only one electric fuel pump (A-Fig.6) and it is in the right tank. This pump is controlled by an ECU (B-Fig.6)
which in turn is controlled by the master control unit.
A B
The pump has an operating pressure ranging between 4 and 6 bar, depending on the various operating conditions
of the vehicle.
The pump sends the fuel to the two high pressure pumps (which are mechanical) that compress the fuel and take
the pressure to a value varying from 120 to 140 bar, according to vehicle operation.
Both the high and low pressure pumps are monitored by two sensors installed on the respective lines to prevent
overpressure problems.
Fig.6
Linear phase transformers
Linear phase transformers allow the engine phase to vary according to the torque required in order to always have B
optimum phasing.
A
In this version they are always enabled, and the phasing follows different maps according to the load and the
atmospheric conditions.
Piloting is performed by a solenoid valve (A-Fig.7), which makes the oil pass inside the phase-changing gear.
This operation is managed by the injection control units that also receive the position of the camshaft through the
Hall effect sensors (B-Fig.7) mounted on the camshafts:
• two sensors for the exhaust (one per cylinder bank)
• two sensors for the intake (one per cylinder bank) A
B
Fig.7
5
L714 01 28 00
0LV¿ULQJ
7RSURFHVVGDWDWKHPLV¿ULQJV\VWHPQRORQJHUXVHVWKHSUHVVXUHVHQVRUVOLNH0<
• WKHV\VWHPGLUHFWO\GHWHFWVPLV¿ULQJE\PHDQVRIWKHÀ\ZKHHOVHQVRUVLJQDO&$/&8/$7,1*WKHWRUTXHGHOLYHUHG
WR WKH FDPVKDIW ZH VD\ WKHUH LV D PLV¿UH LI WKH DFFHOHUDWLRQ± KHQFH WRUTXH ± FKDQJHV IURP RQH VHFWLRQ RI
phonic wheel to the next are different than expected.
There is no map of the expected torque, but the changes of delivered torque are analysed.
Accelerator pedal
The accelerator pedal arrives already factory-set. Once installed, it is the software that adapts it to the range of
operation.
When it is replaced, the total assembly is supplied.
The pedal consists of two sensors that read the position:

• WKH¿UVWVHQGVWKHGDWDUHDGWRWKHPDVWHUFRQWUROXQLW
• WKHVHFRQGFKHFNVRSHUDWLRQRIWKH¿UVWRQH.
Fig.8
6
L714 01 28 00
Sensor
A Speed sensor ' C G H , 3 O

B *HDUVSRVLWLRQVHQVRUV
C Secondary air pressure sensors
(
' Low fuel pressure sensor output
( Wiv pressure sensor output 5
F Oil pressure sensor output M
A
G CAM sensors output
H Exhaust phase sensors output
, Intake phase sensors output B
L Coolant temperature sensor output F
M Air temperature sensor 1
1 A/C sensor
O Clutch pump sensor
3 $,5%$*VHQVRUV
Q Coolant level sensor C G H Q L 3 Fig.7
5 Oil level and temperature sensor
7
L714 01 28 03
A) Injectors
% )XHOSXPS
C) 'LVDVVHPEO\fuel pump
1
L714 01 28 03
6$)(7<352&('85(
It is compulsory to carry out the safety procedure before disassembling the injection system
components.
%HIRUH GLVDVVHPEOLQJ DQ\ FRPSRQHQWV EHORQJLQJ WR WKH KLJK SUHVVXUH V\VWHP VXFK DV WKH KLJK
SUHVVXUHSHWUROSXPSIXHOGLVWULEXWRULQMHFWRUVIXHOFLUFXLWSLSHVHWFLWLVQHFHVVDU\WRUHGXFHWKH
fuel pressure.
Strictly comply with the safety procedure to reduce the fuel pressure in the injection system.
5HGXFLQJWKHIXHOSUHVVXUH
1. Switch on the engine and leave it to idle for a few minutes. The pressure in the engine will fall to below 25 bar.
It is fundamental that the engine is allowed to idle during this phase.
2. Switch the engine off and remove the key from the ignition.
%HIRUHFDUU\LQJRXWDQ\RIWKHVWHSVLQWKHIROORZLQJSURFHGXUHLWLVQHFHVVDU\WRHQVXUHWKDW
ERWKEDWWHU\WHUPLQDOVDUHGLVFRQQHFWHGWRSUHYHQWWKHORZSUHVVXUHSXPSIURPEHLQJDFWLYDWHGLI
RQHRIWKHYHKLFOHGRRUVLVRSHQHG
WKHHQJLQHLVFROGWRDYRLGWKHULVNVRIEXUQV
:$51,1*
)LUH KD]DUG '2 127 23(5$7( ,1 7+( 35(6(1&( 2) 1$.(' )/$0(6 25 722/6 7+$7 &$1
67$57),5(6
2
L714 01 28 03
$ 'LVDVVHPEOLQJWKHLQMHFWRUV
• Disassemble the engine hood (082703) ' ' ' ' ' '
• Remove the engine aesthetic panels (Engine Bay) (081303) ) ) )
• Remove the air intake manifold (012903).
'LVDVVHPEOLQJWKHLQMHFWRUV
It is compulsory to carry out the fuel pressure reduction safety procedure before disassembling the
( ( ( ( (
injectors.
1. Disconnect the connector ($)LJ). % A
2. Disconnect the fuel pipe (%)LJ).
3. Unscrew the screws that secure the stop (&)LJ) to the engine:
• 6 screws (')LJ).
• 5 nuts (()LJ).
• 6 screws ())LJ). C
)LJ
4. Remove the stop (&)LJ).
5. Disconnect the phase transformer actuator connector (*)LJ).
)LJ
3
L714 01 28 03
6. Remove the injectors and tumble valves assembly ()LJ).
7. Disconnect the 5 injector wiring connectors (+)LJ).
1 2 3 4 5
)LJ
8. Remove the 5 injectors (,)LJ).

I
'LVDVVHPEOHWKHLQMHFWRUVWRUHSODFHWKHVHDOV
)LJ
4
L714 01 28 03
% 'LVDVVHPEOLQJWKHKLJKSUHVVXUHIXHOSXPS
• Remove the Engine Bay (081303).
A
+LJKSUHVVXUHSXPSVDUHIXOORIIXHO
:KHQ\RXRSHQWKHIXHOIHHGLQJV\VWHPLWLVDGYLVDEOHWRZHDUSURWHFWLYHFORWKHVDQGJODVVHVWR
DYRLGGLUHFWFRQWDFWRULQMXULHV
%HIRUHRSHQLQJDVHFWLRQRIWKHKLJKSUHVVXUHLQMHFWLRQV\VWHPLWLVQHFHVVDU\WRSXWVRPHFORWKV
around the union.
'LVDVVHPEOLQJWKHKLJKSUHVVXUHIXHOSXPS
1. Remove the two low and high pressure pipes mounting screws ($)LJ).
)LJ
2. Put a cloth below the area connecting pipes and pump (%)LJ) .
%
)LJ
5
L714 01 28 03
3. Unscrew the high pressure pipe union (&)LJ) while holding the nipple ')LJ.
4. Pull the union away from the nipple (&)LJ) paying attention not to bend the pipe.
'
,IWKHSLSHVDUHEHQWWKH\PXVWEHUHSODFHG3D\DWWHQWLRQQRWWRGDPDJHWKHP
C
)LJ
6
L714 01 28 03
5. Unscrew the low pressure pipe union (()LJ) while holding the nipple ))LJ.
6. Pull the union away from the nipple (()LJ) paying attention not to bend the pipe.
)
(
,IWKHSLSHVDUHEHQWWKH\PXVWEHUHSODFHG3D\DWWHQWLRQQRWWRGDPDJHWKHP
)LJ
7
L714 01 28 03
7. Loosen the screws ())LJ E\ WXUQLQJ WUZLFH ¿UVW RQH VFUHZ DQG WKHQ WKH RWKHU VR DV WR WDNH WKHP RXW
symmetrically. Continue in this way until the two screws are completely removed.
)
,I\RXUHPRYHWKHWZRVFUHZVDV\PPHWULFDOO\\RXFDQGDPDJHWKHVHDWRIWKHSXPSVWHP
)LJ
8. Disconnect the connector (*)LJ).
9. Remove the pump (+)LJ).
Disassemble the pump located on the left side of the engine as described in the procedure, starting from *
point 1.
+
)LJ
8
L714 01 28 03
& 'LVDVVHPEO\KLJKSUHVVXUHIXHOSXPS
• Remove the Engine Bay (081303).
• Remove high pressure fuel pump 38172%.
)LJ
'LVDVVHPEO\KLJKSUHVVXUHIXHOSXPS
1. Softly screw the two nipples ($)LJ) on the pump
8VHDQHZQLSSOHVDIWHUHYHU\UHPRYDO %
2. Softly screw the purge screw (%)LJ) on the pump.
8VHDQHZSXUJHVFUHZDIWHUHYHU\UHPRYDO
3. Disassemble the pump ()LJ) )LJ
1. High pressure pump

2. Nipple
3. Nipple
4. Purge Screw
1 2 3 4
)LJ
9
L714 01 28 05
A) Injectors
% Reassembly fuel pump
& )XHOSXPS
1
L714 01 28 05
A) Assembling the injectors

A
1. Assemble the 5 injectors ($)LJ).
Use new seals for each one of the 5 injectors.
)LJ
2. Fix the injectors inside their seats ()LJ).
3. Connect the 5 injector wiring connectors (%)LJ).
1 2 3 4 5
)LJ
2
L714 01 28 05
4. Position the injectors and tumble valves assembly on the engine ()LJ).
5. Screw the screws that secure the stop (&)LJ) to the engine:
• 6 screws (')LJ). ' ' ' ' ' '
• 5 nuts (()LJ). ) ) )
• 6 screws ())LJ).
6. Connect the fuel pipe (*)LJ).
7. Connect the connector (+)LJ).

( ( ( ( (
G H
C
)LJ
8. Connect the phase transformer actuator connector (,)LJ). I
• Assemble the air intake manifold (012905).

• Assemble the engine aesthetic panels (Engine Bay) (081305).
• Assemble the engine hood (082705).
)LJ
3
L714 01 28 05
% 5HDVVHPEO\KLJKSUHVVXUHIXHOSXPS
1. Reassemble the various parts of the high pressure pump ()LJ).
1. High pressure pump

2. Nipple
1 2 3 4
3. Nipple )LJ
4. Purge Screw
2. Manually screw the purge screw ($)LJ) on the pump.
Use a new purge screw. A
3. Mannualy screw the two nipples ($)LJ) on the pump.
Use new nipples.

)LJ
• Assemble the high pressure fuel pump (Step C).

• Assemble the air intake manifold (012905). %
• Assemble the Engine Bay (081305).
)LJ
4
L714 01 28 05
C) Assembling high pressure fuel pump

A
It is necessary to use new spare parts for the assembly procedure. Using worn parts can damage
WKHFDUVHYHUHO\
1. Spread a thin layer of oil on the grommet ($)LJ)
)LJ
2. Assemble the pump and screw the mounting screws (%)LJE\WXUQLQJWZLFH¿UVWRQHVFUHZDQGWKHQWKH
other so as to tighten them symmetrically. Continue until the two screws are completely tightened.
6FUHZLQJWKHVFUHZVWLJKWHQLQJWRUTXHE %
Screwing the screws asymettrically can cause damage to the seat or the stem of the pump.
)LJ
5
L714 01 28 05
3. Tighten the nipple (&)LJ).

7LJKWHQLQJWRUTXHF
)LJ
4. Tighten the nipple (')LJ).

7LJKWHQLQJWRUTXHF
'
)LJ
6
L714 01 28 05
5. Screw the union (()LJ) on the nipple ())LJ).

7LJKWHQLQJWRUTXHRIWKHXQLRQRQWKHQLSSOHG
)LJ
6. Screw the union (*)LJ) on the nipple (+)LJ). H G

7LJKWHQLQJWRUTXHRIWKHXQLRQRQWKHQLSSOHG
)LJ
7
L714 01 28 05
7. Tighten the purge screw (,)LJ).

7LJKWHQLQJWRUTXHD
)LJ
8. Screw the high and low pressure pipes mounting crews (/)LJ).
• Assemble the air intake manifold (012905).

• Assemble the Engine Bay (081305).
)LJ
8
L714 01 29 00
$LULQWDNHPDQLIROG
The air intake manifold consists of:

• An air cleaner with a connecting sleeve to the relevant DBW
• An intake manifold on which two DBW are installed A B D C
,QWDNHPDQLIROGVSQHXPDWLFFRQQHFWLRQV)LJ
A. $LU¿OWHUV
6-10
B. Sleeve
C. Intake manifold 1-5
D. DBW
B D
Fig.1
1
L714 01 29 00
Tumble system
The tumble system is made up of diaphragms commanded according to the characteristic diagram of the engine,
and are used to restrict emissions. The diaphragms are closed (so the valve is disabled) at low speed and low
load.
There are two operation speeds depending on the water temperature.
7KHPDVVRIDVSLUDWHGDLUÀRZVWKURXJKWKHXSSHUVHFWLRQRIWKHLQWDNHGXFWFUHDWLQJDURWDU\PRYHPHQWLQWKH
cylinder.
The intake manifold diaphragms are opened, releasing the entire section of the duct when power is demanded of
the engine. All diaphragms of a cylinder bank are fastened to a common camshaft.
The position of the intake manifold diaphragms for each cylinder bank is checked by the Hall sensors which, in the
event of incorrect reading, send the information to the ECU that turns on the engine malfunction warning light. This
information can be seen using the LaRa-AS.
The intake manifold diaphragms are enabled by a cylinder bank vacuum positioner in the engine for high rotation
speeds. Feedback of the position of the diaphragms is provided in this case as well, through the Hall sensors. In
the case of malfunctioning, they send the information to the ECU. Also in this case the errors can be read using
the LaRa-AS.
The system is in stand-by (therefore enabled) with the engine cold, TH2O < 60°C, and with a torque demand
< 40% beneath 2000 rpm.
The system is operating (therefore disabled) with the engine hot, TH2O > 60°C, and with a torque demand < 40%
beneath 3000 rpm.
The activation solenoid valve for the vacuum system is underneath the intake manifold:
• it is enabled when the intake manifold is closed
• it is disabled when the intake manifold is open
Fig.2
6ROHQRLGYDOYH Tumble rpm Torque TH2O
Off On 0÷2000 rpm < 40% < 60°C
Off On 0÷3000 rpm < 40% > 60°C
On Off over 2000 rpm > 40% < 60°C
On Off over 3000 rpm > 40% > 60°C
Malfunctioning is detected by the LaRa-AS system and can be caused by a lack of vacuum
(therefore, leakage in the circuit) or in the two position detection sensors.
2
L714 01 29 00
6HOIOHDUQLQJWKURWWOHSRVLWLRQ
6HOIOHDUQLQJLVGHWHUPLQHGE\WKHWRUTXHGHPDQGDQGE\WKHÀRZRIDLUHVWDEOLVKHGE\WKHDLUÀRZPHWHU
Self-learning is part of the calibration.
$LUÀRZPHWHU$)LJ
7KHDLUÀRZPHWHUFDOFXODWHVWKHDPRXQWRIDLUHQWHULQJWKHLQWDNHPDQLIROGDVWKHPDQLIROGLVGLYLGHGLQWRWZR
sections.
7KHUHDUHWZRDLUÀRZPHWHUVDQGDUHORFDWHGRQWKHDLU¿OWHUV,IWKH¿OWHUVDUHUHSODFHGWKH\PXVWEHGLVDVVHPEOHG
DQGLQVWDOOHGRQWKHQHZ¿OWHUV
A
7KHDLUÀRZPHWHUVDUHKRWZLUH7RNHHSWKHPFOHDQWKHV\VWHPWDNHVWKHZLUHWRKLJKWHPSHUDWXUHVZKHQWKH
vehicle is switched off, in order to be able to burn any grime that has deposited on the wire.
%RWKDLUÀRZPHWHUVJRLQVLGHWKHUHOHYDQWLQMHFWLRQFRQWUROXQLWVWKHRQHRQWKHOHIWRQWKH6/$9(FRQWUROXQLWWKH
one on the right on the MASTER control unit. Fig.3
Basic settings are not required for their replacement.
3
L714 01 29 01
Inspecting the throttle bodies
Use the LaRa-AS system (109000) to inspect the throttle bodies every time a throttle body is cleaned or replaced.
Settings are made using special basic setting 60 (throttle body adaptation) on both the MASTER injection and
SLAVE control units.
To check the throttle bodies, use diagnostic function 33 and special group 07 (Throttle body control) on both the
MASTER injection and SLAVE control units. 2
1
Fig.1
1
L714 01 29 03
A) Disassembling the throttle bodies

B) 'LVDVVHPEOLQJWKHDLULQWDNHPDQLIROGV
A) Disassembling the throttle bodies
1. Detach the clamp (A-Fig.1) connecting the air intake pipe (B-Fig.1) to the throttle body (C-Fig.1).
2. Disconnect the throttle body from the engine by unscrewing the 4 screws (D-Fig.1) and detaching the connector
(E-Fig.1).
C
2QFHWKHWKURWWOHERG\KDVEHHQGLVDVVHPEOHGLWLVDGYLVDEOHWRUHSODFHWKHJDVNHWRQWKHHQJLQH 2
EHIRUHUHDVVHPEOLQJWKHWKURWWOHERG\7KHUHIRUHGRQRWUHDVVHPEOHWKHWKURWWOHERG\RQWKHVDPH
1
A
JDVNHW
B
E D
Fig.1
1
L714 01 29 03
% 'LVDVVHPEOLQJWKHDLULQWDNHPDQLIROGV
• Disconnect the vehicle battery. (091503).
• Disassemble the engine hood (082703).
• Remove the engine aesthetic panels (Engine Bay) (081303). B A
'LVDVVHPEOLQJWKHDLULQWDNHPDQLIROGV
1. Unscrew the 5 screws (A-Fig.2) and remove the cover (B-Fig.2).
2. Unscrew the 12 screws (C-Fig.2) securing the manifolds (4 side screws and 8 center screws).
Fig.2
2
L714 01 29 03
3. Disconnect the breather pipe (D-Fig.3).
4. Remove the fuel pipe support bracket (E-Fig.3) by unscrewing the 2 screws.
D E
Fig.3
3
L714 01 29 03
5. Disconnect the 2 purge valve vacuum pipes (F-Fig.4).
6. Disconnect the vacuum tank vacuum pipe (G-Fig.4). F G H H F
7. Disconnect the 2 oil vapor pipes (H-Fig.4).
F G H H F
Fig.4
4
L714 01 29 03
8. Disconnect the breather pipe (I-Fig.5).
9. Disconnect the expansion tank pipe stop (L-Fig.5) from the intake manifold.
10. Remove the air intake manifold.
I L
Fig.5
5
L714 01 29 05
A) Assembling the throttle bodies

B) $VVHPEOLQJWKHDLULQWDNHPDQLIROGV
A) Assembling the throttle bodies
1. Connect the throttle body to the engine by tightening the 4 screws (A-Fig.1) and connecting the connector (B-
Fig.1).
2. Connect the air intake pipe (C-Fig.1) to the throttle body (D-Fig.1) using the clamp (E-Fig.1). B A
%HIRUHDVVHPEOLQJWKHWKURWWOHERG\HQVXUHWKHJDVNHWLQFRQWDFWZLWKWKHHQJLQHLVXQGDPDJHGDQG
WKDWLWKDVQHYHUEHHQXVHGEHIRUH
$IWHUWKHWKURWWOHERGLHVKDYHEHHQDVVHPEOHGVHWWKHPFRQQHFWLQJWR/D5D$6(&8

EDVLFVHWWLQJQRERWK0$67(5DQG6/$9(
D
1 2
E
Fig.1
1
L714 01 29 05
B) $VVHPEOLQJWKHDLULQWDNHPDQLIROGV
1. Position the air intake manifolds and tighten the 12 mounting screws (A-Fig.2) (4 side screws and 8 center
screws).
Fig.2
2
L714 01 29 05
2. Connect the breather pipe (%)LJ).
Secure the fuel pipe support bracket (&)LJ) by tightening the 2 screws.
B C
)LJ

L714 01 29 05
4. Connect the 2 purge valve vacuum pipes (D-Fig.4).
5. Connect the vacuum tank vacuum pipe (E-Fig.4). D E F F D
6. Connect the 2 oil vapor pipes (F-Fig.4).
D E F F D
Fig.4
4
L714 01 29 05
7. Connect the breather pipe (G-Fig.5).
Secure the expansion tank pipe stop (H-Fig.5) to the intake manifold.
G H
Fig.5
9. Tighten the 5 screws (I-Fig.6) securing the cover (L-Fig.6).
• Connect the vehicle battery . L I

• Assemble the engine aesthetic panels (Engine Bay) .
• Assemble the engine hood .
Fig.6
5
L714 01 30 03
'LVDVVHPEOLQJWKHRLO¿OWHU
Important!
&DUU\RXWWKLVSURFHGXUHZKHQWKHHQJLQHLVDWDPELHQWWHPSHUDWXUHWRDYRLGWKHULVNRIEXUQV
A
1. 8QVFUHZWKHRLO¿OWHUFDSA-Fig.1DQGUHPRYHWKHHQJLQHRLO¿OWHU
Fig.1
1
L714 01 30 05
$VVHPEOLQJWKHRLO¿OWHU
1. 3RVLWLRQWKHRLO¿OWHUDQGWLJKWHQWKHFDSA-Fig.1).
Fig.1
1
L714 01 31 01
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7KHWHPSHUDWXUHRIWKHFDWDO\WLFFRQYHUWHUVLVHVWLPDWHGWKURXJKFDOLEUDWLRQZLWKWKH0LV¿ULQJV\VWHPWKHUHDUH12
more sensors that measure their temperature.
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GHSHQGLQJRQRQHRUPRUHPLV¿ULQJVKRZPXFKWKHWHPSHUDWXUHYDULHVLV&$/&8/$7('
,QWKLVZD\WKHWHPSHUDWXUHRIWKHFDWDO\WLFFRQYHUWHULVGHWHUPLQHGGHSHQGLQJRQWKHSUREOHP
,W PXVW LQ DQ\ FDVH EH UHPHPEHUHG WKDW WKLV WHPSHUDWXUH LV QRW WKH UHDO RQH EXW RQO\ WKH HVWLPDWHG
one.
7KLVYDOXHFDQEHVHHQE\PHDQVRI/D5D$6(109000).
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L714 01 31 03
'LVDVVHPEOLQJWKHFDWDO\WLFFRQYHUWHUVDQGH[KDXVWPDQLIROG
• Remove the vehicle engine (010003).
C
A
'LVDVVHPEOLQJWKHFDWDO\WLFFRQYHUWHUVDQGH[KDXVWPDQLIROG
1. Remove the supports from their couplings and disconnect the connectors (A-Fig.1) of the 4 oxygen sensors (2
per side).
2. Unscrew and remove the oxygen sensors (B-Fig.1). B

Fig.1
3. Loosen the screw (C-Fig.1) securing the exhaust manifold to the vibration dampers. RIGHT
4. Loosen the 12 nuts (6 per side) (D-Fig.2WKDW¿[WKHPDQLIROGVE-Fig.2) to the engine.
E D
LEFT
D E
Fig.2
1
L714 01 31 03
7RXQVFUHZWKH¿IWKQXWJRLQWRWKHKROHRQWKHPDQLIROGVZLWKWKHZUHQFK (F-Fig.3).
F
5. Remove the manifolds.
Fig.3
6. Remove the gaskets (G-Fig.4).
Fig.4
Disassembling the heat-proof panel
7. Loosen the screws (H-Fig.5) that secure the heat-proof panel (2 screws on left and 3 screws on right).
8. Remove the heat-proof panel (I-Fig.5)
H I H
Fig.5
2
L714 01 31 05
$VVHPEOLQJWKHH[KDXVWPDQLIROGV
Assembling the heat-proof panel

1. Position the heat-proof panel (A-Fig.1DQGWLJKWHQWKH¿[LQJVFUHZVB-Fig.1VFUHZVOHIWVLGHDQGVFUHZV
right side).
B A B
Fig.1
Assembling the manifolds
2. Position the gaskets (C-Fig.2).
Fig.2
1
L714 01 31 05
3. Position the manifolds (')LJDQGVFUHZRQWKHQXWVSHUVLGH (()LJ). RIGHT
' (
/()7
( '
Fig.3
7RVFUHZRQWKH¿IWKQXWJRLQWRWKHKROHRQWKHPDQLIROGVZLWKWKHZUHQFK (F-Fig.4).
F
Fig.4
2
L714 01 31 05
4. /RRVHQWKHVFUHZG-Fig.5VHFXULQJWKHH[KDXVWPDQLIROGWRWKHYLEUDWLRQGDPSHUV
Fig.5
4. 6FUHZRQWKHR[\JHQVHQVRUVSHUVLGHH-Fig.6).
5. &RQQHFWWKHFRQQHFWRUVI-Fig.6RIWKHR[\JHQVHQVRUVDQGORFNWKHPLQWRWKHLU¿[LQJVXSSRUWV I
7KH212))R[\JHQVHQVRUVSRVWFDWDO\WLFFRQYHUWHUDUHLQVWDOOHGLQEDFNZKHUHDVWKH/,1($5R[\JHQ

sensors (front) are installed in front. H
Fig.6
• $VVHPEOHWKHHQJLQHRQWKHYHKLFOH(010005).
3
L714 01 33 03
A) 'LVDVVHPEOLQJWKHDLU¿OWHUFDUWULGJH
B) 'LVDVVHPEOLQJWKH¿OWHURIWKHDLU¿OWHUXQLW
C) 'LVDVVHPEOLQJWKHDLU¿OWHUXQLW
A) 'LVDVVHPEOLQJWKHDLU¿OWHUFDUWULGJH
B A
• Remove the engine compartment side and rear panels (081303).
'LVDVVHPEOLQJWKHDLU¿OWHUFDUWULGJH
1. Unscrew the 10 screws (A-Fig.1) that secure the cover (B-Fig.1RIWKH¿OWHUER[H
Fig.1
1
L714 01 33 03
2. Release the air pipes (C-Fig.2) from the engine, removing the clamps (')LJ) that hold them in place.
3. 5HPRYHWKHDLU¿OWHUFDUWULGJHV()LJ).
( ' C
Fig.2
4. Disconnect the connector (F-Fig. 3) of the DB gauge.
5. Loosen the 2 screws (G-Fig.3) and remove the DB gauge (H-Fig.4).
6HWDVLGHWKH'%JDXJHDQGUHDVVHPEOHLWRQWKHQHZ¿OWHUFDUWULGJH.
F G
Fig.3
H
Fig.4
2
L714 01 33 03
B) 'LVDVVHPEOLQJWKH¿OWHURIWKHDLU¿OWHUXQLW
• Remove the DLU¿OWHUULJKWFDUWULGJH 3RLQW$.
'LVDVVHPEOLQJWKH¿OWHU
1. Unscrew the screw (A-Fig.5) WKDWVHFXUHVWKH¿OWHUWRWKH¿OWHUER[
2. 5HPRYHWKH¿OWHU(B-Fig.5).
Fig.5
3
L714 01 33 03
C) 'LVDVVHPEOLQJWKHDLU¿OWHUXQLW
• Remove the DLU¿OWHUFDUWULGJHV 3RLQW$.
'LVDVVHPEOLQJWKHDLU¿OWHUXQLW
1. Unscrew all 4 screws (A-Fig.6WKDWVHFXUHWKHDLU¿OWHUXQLWB-Fig.7) to the car (2 screws per side).
2. Disconnect the 2 conveyors (C-Fig.6).
3. ([WUDFWWKHHQWLUHDLU¿OWHUXQLW
C A A C
Fig.6
B Fig.7
4
L714 01 33 05
A) AVVHPEOLQJWKHDLU¿OWHUFDUWULGJH
B) AVVHPEOLQJWKH¿OWHURIWKHDLU¿OWHUXQLW
C) AVVHPEOLQJWKHDLU¿OWHUXQLW
$ $VVHPEOLQJWKHDLU¿OWHUFDUWULGJH
1. Place the DB gauge (A-Fig.1RQWKHDLU¿OWHUFDUWULGJH.
,QVWDOOWKH'%JDXJHUHPRYHGIURPWKHROGDLU¿OWHUFDUWULGJH.
2. Tighten the 2 screws (B-Fig.1).

A
3. Connect the connector (C-Fig.1RIWKH'%JDXJH.
B C
Fig.1
1
L714 01 33 05
4. ,QVHUWWKHDLU¿OWHUFDUWULGJH')LJLQVLGHWKHFRUUHVSRQGLQJ¿OWHUER[
5. &RQQHFWWKHDLUSLSHV(-Fig.2WRWKHHQJLQHXVLQJWKHFODPSVF-Fig.2).
' F (
Fig.2
6. Secure the cover (G-Fig.3) using the 10 screws (H-Fig.3). G H
Fig.3
2
L714 01 33 05
B) AVVHPEOLQJWKH¿OWHURIWKHDLU¿OWHUXQLW
1. ,QVHUWWKH¿OWHUA-Fig.5).
2. Tighten the screw (B-Fig.5DQGVHFXUHWKH¿OWHUWRWKH¿OWHUER[.
• Secure the DLU¿OWHUULJKWFDUWULGJH 3RLQW$.
Fig.5
3
L714 01 33 05
& $VVHPEOLQJWKHDLU¿OWHUXQLW
1. 3RVLWLRQWKHHQWLUHDLU¿OWHUXQLWA-Fig.6LQVLGHWKHKRXVLQJLQWKHHQJLQHFRPSDUWPHQW
2. Secure the 4 screws (B-Fig.7WKDWVHFXUHWKHDLU¿OWHUXQLWWRWKHFDUVFUHZVSHUVLGH
3. Connect the 2 conveyors (C-Fig.7).
A Fig.6
• Secure the DLU¿OWHUFDUWULGJHV 3RLQW$.
C B B C
Fig.7
4
L714 01 41 00
Clutch technical data

• 7ZRSODWHGU\FOXWFKZLWKÀH[LEOHFRXSOLQJDQGGLDSKUDJPVSULQJ
• 7KUXVWLQJPHFKDQLVP
• 6HOIDGMXVWLQJK\GUDXOLFGLVHQJDJHPHQWGLVHQJDJHPHQWWDNHVSODFHE\DWKUXVWEHDULQJK\GUDXOLFDOO\FRQWUROOHG
E\DGHYLFHLQVLGHWKHFOXWFKEHOO
Clutch technical data

*DVNHWRXWHUGLDPHWHU
*DVNHWLQQHUGLDPHWHU PP
&OXWFKGLVNWKLFNQHVVZLWK1ORDG ·
0D[GLVNZHDU
7KUXVWEHDULQJPD[VWURNH
Clutch pump technical data

3LVWRQERUH
7RWDOVWURNH
A B C E
Clutch (Fig.1)
A. Flywheel
B. &OXWFKGLVNDQGSUHVVXUHSODWHDVVHPEO\
C. &OXWFKVOHHYHDQGWKUXVWEHDULQJDVVHPEO\
D. &OXWFKSXPS
E. &OXWFKEOHHGHU
F. &OXWFKFRQWUROSLSHV
D F
Fig.1
1
L714 01 41 02
Adjusting the clutch pedal

B
• Adjust the brake pedal (092702).
Adjusting the pedal

1. Place the clutch pedal (A-Fig.1) at the same height as the brake pedal (B-Fig.1).
2. Using the adjustment screw (C-Fig.2), raise the clutch pedal approximately 2-3 mm higher than the brake A
pedal.
Fig.1
Fig.2
1
L714 01 41 03
$FOXWFKDQGÀ\ZKHHOGLVDVVHPEO\
B. clutch thrust bearing disassembly
$&/87&+$1')/<:+((/',6$66(0%/<
B
D
F
Clutch (Fig.1)
A. crankshaft
G H
B. À\ZKHHO
C. VFUHZVVHFXULQJWKHÀ\ZKHHOWRWKHFUDQNVKDIW
D. FOXWFKXQLW A
E. VFUHZVVHFXULQJWKHFOXWFKWRWKHÀ\ZKHHO
F. SKRQLFZKHHO
G. FOXWFKWKUXVWEHDULQJDVVHPEO\ C
H. JHDUER[ E
Fig.1
• 5HPRYHWKHJHDUER[(030103).
Clutch disassembly
1. 5HPRYHWKHVFUHZVE-Fig.1DQGWKHFOXWFKXQLWIURPWKHÀ\ZKHHO
2. 5HPRYHWKHVFUHZV&)LJDQGWKHÀ\ZKHHOFRPSOHWHZLWKWKHSKRQLFZKHHOIURPWKHFUDQNVKDIW
1
L714 01 41 03
5HPRYHWKHVFUHZVIROORZLQJWKHRUGHUIURP&WR&VKRZQLQ)LJ
7KHUHPRYHGVFUHZVFDQQRORQJHUEHUHXVHGIRUVXEVHTXHQWDVVHPEO\1HZVFUHZVZLOOQHHGWR
EHXVHGZKHQUHDVVHPEOLQJWKHÀ\ZKHHO
C1
C10 C3
C8 C5
C6 C7
C4 C9
C2
Fig.2
1. )UHHWKHSKRQLFZKHHO))LJIURPWKHÀ\ZKHHOE\XQVFUHZLQJWKHPRXQWLQJVFUHZV,)LJ).
5HPRYHWKHVFUHZVIROORZLQJWKHDVFHQGLQJRUGHUIURP,WR,VKRZQLQ)LJ ,
, ,
Fig.3
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L714 01 41 03
%&/87&+7+5867%($5,1*',6$66(0%/< manual e-gear
1RWH B1
B1
7RUHSODFHWKHFOXWFKWKUXVWEHDULQJWKHHQWLUHFOXWFKVOHHYHXQLWPXVWEHUHSODFHG
B B1
• 5HPRYHWKHJHDUER[(030103). B B1
A B1 A1
Bearing disassembly B
1. 5HPRYHWKHVOHHYHXQLWZLWKWKHFOXWFKWKUXVWEHDULQJA-Fig.4XQVFUHZLQJWKHWKUHHSLQVB-Fig.4).
1RWH(JHDU
5HPRYH WKH VOHHYH XQLW ZLWK WKH e-gear FOXWFK WKUXVW EHDULQJ A1-Fig.4 XQVFUHZLQJ WKH ¿YH VFUHZV Fig.4
B1-Fig.4).
([WUDFWWKHVOHHYHXQLWZLWKWKHWKUXVWEHDULQJVOLGLQJLWDORQJWKHVKDIW%HFDUHIXOQRWWRORVHWKHVSULQJV
2. 5HPRYHWKHWZR2ULQJVC-Fig.5IURPWKHLUVHDWVRQWKHFOXWFKEHOO
Fig.5
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L714 01 41 05
$FOXWFKDQGÀ\ZKHHODVVHPEO\
B. clutch thrust bearing assembly
$&/87&+$1')/<:+((/$66(0%/<
B
D
F
Clutch (Fig.1) G
A. crankshaft
G H
B. À\ZKHHO
C. VFUHZVVHFXULQJWKHÀ\ZKHHOWRWKHFUDQNVKDIW
D. FOXWFKXQLW A
E. VFUHZVVHFXULQJWKHFOXWFKWRWKHÀ\ZKHHO
F. SKRQLFZKHHO
G. FOXWFKWKUXVWEHDULQJDVVHPEO\ C
H. JHDUER[ E Fig.1
Fig.1
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7KHQHZÀ\ZKHHOFOXWFKXQLWLVVXSSOLHGEDODQFHG7KHFRUUHFWDVVHPEO\SRVLWLRQLVLQGLFDWHGE\UHIHUHQFH
FRGHV
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3UHDVVHPEOLQJWKHSKRQLFZKHHORQWKHÀ\ZKHHO
1. $VVHPEOHWKHSKRQLFZKHHO))LJRQWKHÀ\ZKHHO%)LJXVLQJWKHPRXQWLQJVFUHZVI-Fig.2)

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F
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phonic wheel and that there are always 3 holes between each mounting screw. B
I1 I2
Fig.3
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$VVHPEOLQJWKHÀ\ZKHHORQWRWKHFUDQNVKDIW
1. 3RVLWLRQWKHÀ\ZKHHORQWKHFUDQNVKDIWVRWKDWWKHFHQWHULQJGRZHORQWKHÀ\ZKHHOFRLQFLGHVZLWKWKHFHQWHULQJ
GRZHORQWKHFUDQNVKDIWL-Fig.3
2. &KHFNWKDWWKHÀ\ZKHHOPRXQWLQJVFUHZVRQWKHFUDQNVKDIWDUHFOHDQ
3. &OHDQWKHWKUHDGHGKROHVRQWKHFUDQNVKDIWZLWK/2&7,7(DQGWKHQFRPSUHVVHGDLU
Fig.3
4. 6HFXUHWKHÀ\ZKHHORQWRWKHFUDQNVKDIWXVLQJWKHPRXQWLQJVFUHZV&)LJ)

$SSO\6\VWHP$PHGLXPWKUHDGVHDODQWRQWRWKHWKUHDGRIWKHVFUHZV
6FUHZDWWDFKPHQWWLJKWHQLQJWRUTXHE C1
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& C7
C4 C9
C2
Fig.4
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L714 01 41 05
Assembling the clutch

0
2. $VVHPEOH WKH FOXWFK XQLW RQ WKH À\ZKHHO XVLQJ WKH VSHFLDO FHQWHULQJ WRRO (000200-19c) DQG FKHFN WKDW WKH
UHIHUHQFHFRGHVFRLQFLGH0)LJ
Apply System 52A43 medium thread sealant and tighten the 9 screws E-Fig.1) LQWKHFORFNZLVHRUGHU
LQGLFDWHGE\WKHQXPEHUVLQ)LJ
7LJKWHQLQJWRUTXHE
• 5HDVVHPEOHWKHJHDUER[(030105)
Fig.5
2 1
3 3
1
2
2
1
3
)LJ
4
L714 01 41 05
%&/87&+7+5867%($5,1*$66(0%/<
Important! B
.HHSHYHU\WKLQJDVFOHDQDVSRVVLEOHGXULQJDVVHPEO\
A
1. &OHDQWKHLQVLGHRIWKHFOXWFKEHOODQGWKHULEEHGVKDIW
2. 7KRURXJKO\FOHDQWKHPDFKLQHGDUHDA-Fig.7RIWKHFOXWFKVOHHYHKRXVLQJRQWKHFOXWFKEHOODQGWKHVHDWVRI

WKH2ULQJVB-Fig.7 B
Fig.7
D
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4. $VVHPEOHWKH2ULQJ&)LJRQWKHFOXWFKVOHHYHZLWKKuril K2DQGOLJKWO\JUHDVHWKHLQWHUQDOHGJHRIWKHVHDO

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5. $VVHPEOHWKHWZR2ULQJVF-Fig.9RQWKHFOXWFKEHOOVHDWZLWK.XULO.
%HIRUHLQVHUWLQJWKHFOXWFKVOHHYHXQLWRQWKHJHDUER[FRPSOHWHO\SURWHFWWKHJURRYHGSUR¿OHRIWKHVKDIWZLWK
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Fig.9
7. ,QVHUW WKH FOXWFK VOHHYH XQLW H-Fig.10 VOLGLQJ LW DORQJ WKH ULEEHG VKDIW ZUDSSHG ZLWK WDSH SUHVVLQJ RQ WKH manual e-gear
VOHHYH
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L1
1RWH(JHDU
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L L1
L L1
9. 3XVKWKHEHDULQJWRZDUGWKHJHDUER[DQGUHPRYHWKHSURWHFWLYHWDSH
H L1 H1
Important!
5HPHPEHUWRUHPRYHWKHSURWHFWLYHWDSH
Fig.10
• 5HDVVHPEOHWKHJHDUER[(030105)
• %OHHGWKHFOXWFK

L714 01 41 06
Clutch bleeding
• 5HPRYHWKHHQJLQH¿QLVKLQJFRYHU(081303).
• Remove WKHDLU¿OWHUXQLW (013303).
1. %ULQJWKHEUDNHRLOOHYHOWR0$;
2. 5HPRYHWKHFDSWKDWSURWHFWVWKHEOHHGVFUHZA-Fig.1).
3. 3UHVVDQGKROGGRZQWKHFOXWFKSHGDO2SHQWKHEOHHGHUDQGUHOHDVHDVPDOOTXDQWLW\RIFOXWFKK\GUDXOLFRLO
&ORVHWKHEOHHGVFUHZ A
4. 5HSHDWWKHSUHYLRXVRSHUDWLRQXQWLOWKHFOXWFKQRORQJHUVSULQJVEDFN
Fig.1
5. 5HSRVLWLRQWKHFDSRQWKHEOHHGVFUHZ
6. &KHFNWKHEUDNHRLOOHYHOLQWKHWDQN,IQHFHVVDU\WRSXSZLWKWKHVSHFL¿HGW\SHRIEUDNHRLO(061108).
• 5HDVVHPEOHWKHDLU¿OWHUXQLW (013305).
• 5HDVVHPEOHWKHHQJLQH¿QLVKLQJFRYHU (081305).
1
L714 01 41 12
Running-in procedure on roads at dealer
1. Carry out 5 standing starts from 0 to 50 km/h. During pickup, ensure the engine is running at 2,800 rpm ±
300 rpm.
2. At the end of every pickup, once 50 km/h have been reached, put into second gear (without loading the
accelerator pedal) and continue at a constant speed for 30 seconds.
3. After the 5 starts, continue at a constant speed of about 50 km/h for 60 seconds.
4. Repeat points 1, 2, 3, twice again (for a total 15 starts).
1RWH
The present procedure also applies to clutches using the new Valeo F510 material, which can create a little
smoke and odor during running-in. Such conditions are to be considered normal and are caused by the
friction material.
1
L714 01 42 00
(*($56<67(0
System description
• The Selespeed System is a system developed by Magneti Marelli to control a standard mechanic transmission
by operating the clutch Actuator and the command shaft of the conventional gear box.
• The Selespeed System also interfaces with the engine controller in order to adapt the engine torque and speed
during the gear shifting phases.
• 7KH6HOHVSHHGFRPSRQHQWVFRQVWLWXWHDQDGGRQNLWWKDWQRUPDOO\GRHVQ¶WUHTXHVWLPSRUWDQWPRGL¿FDWLRQVWR
the vehicle/transmission .
• The ³(*HDUV\VWHP´ constitutes the Selespeed application for mechanical gearboxes.
Layout
A. Valve Group and Gear Actuetor

B. Gearbox
C. Power unit
A
B
C
1
L714 01 42 00
7+(+<'5$8/,&&20321(176/$<287$5281'7+(*($5%2;
A B C '
( ) * H
A. Gear sensor
B. Gear actuator
C. Low pressure pipe
' Gear and clutch valves
( High pressure pipe
) Oil tank
* Accumulator
I
H. Pressure sensor
I. DC motor/Hydraulic pump )LJ
2
L714 01 42 00
*HDUDFWXHWRU
A. Sensor
A
)LJ
3RZHU8QLW
A. DC Motor/Hydraulic pump
B. Tank
C. Accumulator
)LJ
3
L714 01 42 00
• Minimal and maximal hydraulic Pressure dependent on Hydraulic Temperature Model
Hydraulic Temperature -30 °C -20 °C 0 °C 20 °C 40 °C 70 °C 100 °C 130 °C 140 °C

Minimal Hydraulic Pressure [bar] 37 37,5 39 40 40 40 41,5 43 43
Maximal Hydraulic Pressure [bar] 42 43 45 50 50 50 50,5 51 51
• Tank Capacity: 1 liter
• Accumulator Preload pressure: 27 bar
• Pump Activation:
• in stand-still (engine on, no gearshift in progress): time >20 seconds between two pump activation.
• Key on and engine off (no gearshift in progress): time >60 seconds between two pump activation.
9DOYHJURXS
2 3
1. EV2 (Even Gear Actuetor)
2. Pressure Sensor
4
3. EV1 (Odd Gear Actuetor)
4. EV0 (Clutch Valve)
1
5. EV3 (brake valve actuator) (ON/OFF)
)LJ
4
L714 01 42 00
6&$0
6
1. Brake 7
8
2. S-CAM
3. Pin 9
4. Engaging 5/6 10
1
5. Querrastierung
2
6. Gearing/Shifting
3
7. Sleeve Collar 11
8. Engaging fork 3/4

9. Engaging pin
10. Engaging fork 1/2
5
11. Central engaging shaft 4
)LJ
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L714 01 42 00
6(16256
*HDUDQGVKLIWSRVLWLRQVHQVRU
• Active Hall Effect Sensor
• Supplier Wabash
• Output range 0 – 5V
• Working range 0.5 – 4.5 V
• Diagnosis range < 0.5 V and >4.5 V
• Supply voltage 5V (must not be supply at 12V)
)LJ
3UHVVXUH6HQVRU
• Active analog Sensor
• Supplier T.I.
• Output range 0,5 – 4.8 V
• Diagnosis range < 0.25 V and > 4.8 V
• Supply voltage 5V (must not be supply at 12V) )LJ
6
L714 01 42 00
&OXWFK3RVLWLRQ6HQVRU
• Sensor LVDT
• Supplier Tyco
• Output range 0 – 5 V
• Diagnosis range < 0.293 V and > 4.398 V
Clutch wear
The reading of the clutch position sensor also determines the state of wear of the clutch.
The values that determine deterioration are read with the LaRa-AS (109000) in the 0HDVXUHPHQWYDOXHV for the )LJ
E-GEAR system, channel 10 ()LJ):
• Line 3 indicates the real clutch position

• Line 4 indicates the initial clutch position
clutch wear index default = 4000 ,
The difference between the 2 values determines the thickness of the clutch, which is deteriorated when less than default max = 15000
5.6 mm.
clutch kiss point default = 480
0:% Clutch status clutch closed position default min = 1050 ,
7KHYDOXHVDUHH[SUHVVHGLQELWVVRLWLVQHFHVVDU\WRFRQYHUWWKHPLQWRPPGLYLGHWKH¿JXUHE\WR default max = 2000
determine the clutch thickness measurement. clutch closed position default min = 1050 ,
(learned) default max = 2000
In addition to the value calculated by the difference of lines 3 and 4, also the other data establish the state of clutch
wear: )LJ
• Line 1 indicates the degree of deterioration of the clutch (the clutch is deteriorated when the value is higher
than 15000)
• Line 2 indicates the Kiss Point of the clutch (the clutch is deteriorated when the value is higher than 800)
7
L714 01 42 00
,13876$1'2873876
Snssply 1 5V External Sensor Power Supply

Clutch EV0
Snssply 2 K130 and KL15
Input EV1
From EV2
Can
EV3
5V Power
Supply
Pump Relay
Gear pos
Input Cranking relay
Shift pos From
Hyd pos Analog TCU Can
Clutch pos Input
Key pos
Brake
Tachin
Frequency PWT
Clutch Speed
Inputs CAN
Handbrake
External Temp Input
paddels From
Can
MMI Switch
8
L714 01 42 00
:LUHVLJQDOV
)RUWKHRSHUDWLRQWKH(*HDUV\VWHPQHHGVWKHIROORZLQJVLJQDOVFRPLQJIURPVSHFL¿FVHQVRURUIURPRWKHUYHKLFOH
system.
• 6SHFL¿FVHQVRUVIRU6HOHVSHHG
• Clutch speed sensor:
• Position sensors: clutch , gear and shift actuators
• Pressure sensor of the Selespeed hydraulic circuit
• Single Signals coming from other vehicle system.
• Engine speed (wired frequency signal, coming from engine ECU or from the dashboard )
• Brake pedal switch
• wake-up line
• Ignition key (cranking position KL_50).
&$1VLJQDOV
Other signals coming from vehicle systems via CAN network

• Engine speed
• Engine Torque
• Water/Oil Engine Temperature
• Brake pedal switch
• Handbrake
• Wheels Speeds
• Sport Switch
• Accelerator Pedal (real and virtual)
• External Temperature
• Lateral Acceleration
• Steering wheel angol
• ...
9
L714 01 42 00
&/87&+$1'75$160,66,21$'$37$7,21
&/87&+$'$37$7,21
$ &OXWFK&ORVHG3RVLWLRQ
% .LVV3RLQW
& 7UDVPLVVLYLW\LQGH[
' &OXWFKYDOYHPDLQFKDUDWWHULVWLF
$ &OXWFK&ORVHG3RVLWLRQ
The clutch closed position is self tuned when the clutch valve is off, including engine off.
The clutch closed position must be in the range 1050bit and 2000 bit.
% .LVV3RLQWWXQLQJ
The kiss point is self tuned at each cranking when the gearbox is in neutral. The engine is colder than 70C and the
clutch estimated temperature is colder than 70C.
The average of each calculated kiss point value is used and stored in the TCU memory.
7KH.LVVSRLQWLVSHUIRUPHGGXULQJWKHYHKLFOHOLIHDQGLVKLJKO\¿OWHUHG
For a fast adaptation of kiss point an LaRa-AS (109000) service is implemented.
The range is 300bit < Kisspoint < 800bit (the frequent value is between 350 and 550 bit).
The routine is activated if the following condition are true:

• The engine is ON
• No gear is engaged
• The clutch kiss point self tuning has never been performed or a special service is asked by the tested
and it is suspended if one of the following condition is true:
• a new cranking is requested during the self tuning
• the clutch is not able to open
• the clutch closure phase is completed and no clutch rotation is detected
• a gear is requested
• a failure is detected on the clutch position sensor or on the gear valves
10
L714 01 42 00
& 7KHFOXWFKWUDVPLVVLYLW\LQGH[
The routine is activated during pickup with:

In medium/low gas pedal 30%
In warm Clutch (70 – 110 °C)
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The Range is 4000 < Transm. index < 15000
' &OXWFKYDOYHPDLQFKDUDWWHULVWLF
7KH,=HUR)ORZ&XUUHQWDQGWKHOHDNDJHDUHVHOIWXQHGLQ6WDQG6WLOOLQQHXWUDORULQ¿UVWJHDUDWHQJLQH2Q
The maneuver for self-tuning is to leave the vehicle on neutral with the Engine On for 3-4 minutes.
11
L714 01 42 00
*5,'781,1*
The grid self tuning is composed in four phases:
• Stable neutral position research

• Engaging of all gear from Reverse to Sixth
• Stable Neutral engaging
• Plausibility Check
6RIWZDUHGHIDXOWSRVLWLRQVGHSHQGLQJRQJHDUELW
0 1 2 3 4 5 6 7
Valve ON Position 400 316 705 319 701 319 700 708
Valve OFF Position 409 325 696 328 692 328 691 699
Shift Position 366 475 579 685
When it is necessary to perform the selftuning grid?
• Vehicle End of Line
• after every substitution of:

• Gearbox
• Kit
• T.C.U
• Gear and Shift Position Sensors
12
L714 01 42 00
&$5¶6)81&7,21$/,7<
:DNHXS
When the driver door is opened and the car is sleeping starts the ZDNHXS phase. In this phase the TCU is partially
switched on, and if the hydraulic pressure is lower than a limit the pump is activated for maximum 4 seconds.
&UDQNLQJ
In the car there’s a relay that releases the cranking. This relay is controlled by E-Gear TCU.
The cranking is only released if the brake is pushed and not paddles an R switch pushed.
The cranking can be done also with a gear engaged. The system will engage the neutral before release the
cranking.
3LFNXS
The pick up is related to the gas pedal position and how it’s pushed.
To perform good pick up is important to keep constant the gas pedal.
During pick up is calculated the clutch wear index, if the engine and clutch temperatures are in a range.
7R$YRLGSLFNXSZLWKEUDNHSXVKHGWKHV\VWHPFRQWUROVWKH&OXWFKWRUTXHWRD¿[HGYDOXH
'ULYDELOLW\0RGHV
• Normal Mode , Sport Mode, Corsa Mode: the gearshifts are performed by the driver, with steering paddles,
better keeping constant the gas pedal. The gearshift speed and comfort quality depend on the gas pedal posi-
tion and engine speed.
• Automatic Mode and Automatic Sport Mode: the gearshift are performed directly from the E-Gear TCU, that
decides when to perform them according to the gas pedal position and vehicle speed.
• Underspeed: in order to avoid engine stalling if the driver doesn’t require any DW, E-Gear TCU perform itself
them when the engine speed becomes too low.
• Overspeed: in order to avoid engine limiter intervention the automatic gearshift is done when the maximum
engine speed is reached. This Function is not available in CORSA Mode.
13
L714 01 42 00
'ULYDELOLW\0RGHV
• The drivability modes can be selected by tunnel switches. There are the switches for Automatic, Sport and Cor-
sa Mode
• The paddles can be used for manual gearshift
Comfort 3HUIRUPDQFH
NORMAL •••• •
SPORT ••• •••
CORSA • ••••
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/0< /6&$0
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S S 2
3 3 5
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(performance) 1 5 (performance) 1 5 A
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(63 N S N (63 N S S
14
L714 01 42 00
• The Automatic mode is available only for Normal and Sport mode.
• The ESP program (Normal and Sport) is connected to the E-Gear driving program.
(3621 (362))
*HDUER[ Thrust (63 *HDUER[ Thrust (63

.20%, 8SVKLIW .20%, 8SVKLIW
map 0RGH Status map 0RGH Status
1250$/ OFF
NORMAL NORMAL
(Default at 1 2 3 4 5 6 YES NO NORMAL YES NO (panic
MANUAL MANUAL
key on) 1 2 3 4 5 6 mode)
OFF
1250$/ NORMAL NORMAL
R N A YES NO NORMAL YES NO (panic
$872 AUTO AUTO
R N A mode)
OFF
SPORT SPORT
63257 1 2 3 4 5 6 S YES NO SPORT YES NO (panic
MANUAL MANUAL
1 2 3 4 5 6 S mode)
OFF
63257 SPORT SPORT
R N A S YES NO SPORT YES NO (panic
$872 AUTO AUTO
R N A S mode)
CORSA CORSA
&256$ 1 2 3 4 5 6 C NO NO SPORT NO YES1 OFF
MANUAL MANUAL
1 2 3 4 5 6 C
OFF
0$18$/
n.a. n.a. n.a. n.a. n.a. NORMAL n.a. n.a. n.a. (panic
*($5%2;
mode)
15
L714 01 42 00
7LS,Q)XQFWLRQ
When the driver requests a gear shift via shift paddles on steering wheel while driving in Automatic mode, the system
switched to manual mode and the gearshift is executed. After 8 seconds the system goes back to Automatic mode
if there is no addition manual gear request.
The E-Gear SW siplays on dashboard always the mode it is currently using. Tip-In mode is displayed like Manual
mode.
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In Automatic mode (normal and sport) a curve detection function is active. This function prevent an automatic upshift
when the steering wheel is turned over a threshold (at low speed) or the lateral acceleration is higher than a thre-
shold (at medium – high speed).
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7ZRWHPSHUDWXUHOLPLWDUHGH¿QHG
• A warning limit which means, when the clutch temperature is higher, the clutch is loosing its capacity of torque
transmission and it is near to the damage limit
• A damage limit, which means, when the clutch temperature is higher, the clutch is no more able to transmit the
UHTXHVWHGWRUTXHDQGFDQEHGH¿QLWHO\GDPDJHG
When the clutch temperature is higher than the warning limit:

• Anticipation of the automatic underspeed 2nd --> 1st (the clutch speed threshold for starting the underspeed
gear shift is higher than the normal case), in order to avoid pickup in 2nd gear.
8VHRIDVSHFL¿FSLFNXSWDEOHLQRUGHUWRUHGXFHWKHFOXWFKVOLSSKDVH
When the clutch temperature is higher than the damage limit:

• Switch on the warning lamp and the message “Clutch overheated” to the driver.
• Store a DTC error code in the TCU memory if the clutch temperature remains over this limit.
16
L714 01 42 00
Launch Control
The mode “Launch Control” realises the max. possible acceleration during pick up.
The activation is done if the following condition are true:

• Brake pressed
• CORSA mode activated
• ESP deactivated
When the “launch control” is activated the engine speed is reasing according to the gas pedal position.
The Pick-UP starts immediately when the Brake pedal is Released.
&OXWFK7HPSHUDWXUH:DUQLQJ
A Special buzzer is used by the dashboard, that indicate that the clutch is too hot (c,a 200°), is switched on by Gear-
box ECU.
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A Driver Warning Message in the dashboard display, that indicate that the car need workshop attention, is switched
on by Gearbox ECU.
The Symbol ($)LJ) is displayed permanently.
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17
L714 01 42 00
7KUXVW0RGHODXQFKFRQWURO
The “Thrust Mode” function is an extreme procedure whose purpose is to fully exploit all of the vehicle’s potentials
when starting the car in a standstill position with the maximum acceleration possible. In this way we will get the
maximum performance in terms of acceleration.
The conditions necessary for enabling the function are:
1. twater temperature > 60°C (otherwise the engine is limited by default and it is impossible to get the required
high performance start)
2. &256$EXWWRQHQDEOHGYHUL¿HGZKHQWKH&256$OLJKWLVRQ
3. disable the (63E\SUHVVLQJWKHEXWWRQRQWKHLQVWUXPHQWFOXVWHU%-$YHUL¿HGZKHQWKH(632))OLJKWLV
on)
4. press the brake pedal
5. HQJDJH¿UVWJHDU
6. press the accelerator all the way down (the engine will automatically run at around 5500-6000 rpm)
7. release the brake pedal
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7KLVIXQFWLRQFKDQJHVJHDUIURP¿UVWWRVL[WKDXWRPDWLFDOO\WRRSWLPL]HWKHSRZHUWKHYHKLFOHGHOLYHUVEvery
choking of the accelerator pedal makes the system leave the launch control strategy VR \RX PLJKW ¿QG
yourself no longer with the automatic gearshift, but with the manual gearshift.
Important!
The Thrust Mode procedure entails enormous stress on all mechanical parts regarding the engine-gearbox-
transmission.
18
L714 01 42 01
&KHFNLQJWKHK\GUDXOLFRLOOHYHO
Note
Before checking the S-CAM hydraulic oil level, use LaRa-AS “Basic Setting” (109000) to perform the basik A
“5” that discharges the circuit pressure.
3UHOLPLQDU\RSHUDWLRQV MAX
• Remove the right rear wheel (060103).
MIN
&KHFNLQJWKHRLO
1. Visually check the tank level (A-Fig.1) and check that the oil level is between the MIN and MAX marks
(Fig.2).
2. If necessary, top up exclusively using the recommended type of hydraulic oil (014208).
Fig.1
7\SHRIUHFRPPHQGHGK\GUDXOLFRLO(000300)
1
L714 01 42 06
%OHHGLQJWKHHJHDUFOXWFK
%OHHGLQJWKHHJHDUFOXWFK only if the 7+5867%($5,1*+$6%((15(3/$&('RULQDQ\FDVHLI

the +<'5$8/,&&,5&8,7+$623(1('83.
• Remove the engine compartment rear panel (081303).
• Remove the DLU¿OWHUFDUWULGJHV (013303). A
%OHHGLQJWKHFOXWFK
1. 5HPRYHWKHFDSWKDWSURWHFWVWKHEOHHGVFUHZ$)LJRQWKHJHDUER[
2. $IWHUWKHFOXWFKKDVEHHQDVVHPEOHGLQLWLDOL]HWKHHJHDUXVLQJWKH/D5D$6³%DVLFVHWWLQJ´(109000):
$ EDVLN³´
DXWRPDWLFEOHHGDSSUR[LPDWHO\RSHQLQJVFORVLQJV
% EDVLN³´
HPSWLHVWKHFLUFXLWDQGFKHFNVWKHOHYHO
3. &KHFNWKH6&$0RLOOHYHO (014201). Fig.1
1
L714 01 42 08
),//,1*7+(6&$0+<'5$8/,&2,/
1RWH B
%HIRUH¿OOLQJWKH6&$0K\GUDXOLFRLOXVH/D5D$6³%DVLF6HWWLQJ´(109000)WRSHUIRUPWKHEDVLN“5”WKDW
GLVFKDUJHVWKHFLUFXLWSUHVVXUH
• 5HPRYHWKHHQJLQHFRPSDUWPHQWUHDUSDQHO (081303)
• 5HPRYHWKHDLU¿OWHUFDUWULGJHV (013303)
B A
Filling the oil
1. 5HPRYHWKHVDIHW\SDQHO$)LJRQWKH6&$0DVVHPEO\WDQNE\ORRVHQLQJWKHVFUHZV %)LJ
Fig.1
2. 8QVFUHZWKHFDS&)LJ
3. 7RSXSZLWKDUHFRPPHQGHGW\SHRIRLO
7\SHRIUHFRPPHQGHGK\GUDXOLFRLO(000300)
4. &KHFNWKHRLOOHYHODJDLQ(014201)
,IQHFHVVDU\WRSXSDJDLQ C
5. 6FUHZWKHFDSDQGUHSODFHWKHSDQHOVHFXULQJLWZLWKWKHVFUHZV
• $VVHPEOHWKHDLU¿OWHUFDUWULGJHV (013305)
• $VVHPEOHWKHHQJLQHFRPSDUWPHQWUHDUSDQHO (081305)
Fig.2
1
L714 01 42 12
&/87&+5811,1,*,1
$IWHULQVWDOOLQJDQHZFOXWFKGLVNÀ\ZKHHODVVHPEO\WKHFOXWFKPXVWEHUXQLQDVIROORZV
6WHSRQH
1. Do not activate the AUTOMATIC, SPORT or LOW GRIP functions.
2. 6WDUWWLPHVLQ¿UVWJHDU6WRSDQG*R
1RWH
$IWHUVWDUWLQJHDFKWLPHLQ¿UVWJHDUWUDYHODPLQLPXPRIPEHIRUHFDUU\LQJRXWWKHRSHUDWLRQDJDLQ
6WHSWZR
3. 6WDUWLQ¿UVWJHDUDQGOHWVHFRQGJHDUHQJDJHDWDSSUR[LPDWHO\USP
4. 6ORZWRDSSUR[LPDWHO\NPK)LUVWJHDUHQJDJHVDXWRPDWLFDOO\5HSHDWWKHSURFHGXUHWLPHV
6WHSWKUHH
5. $FFHOHUDWHLQ¿UVWJHDUWRUSPDQGWKHQUHOHDVHWKHDFFHOHUDWRUXQWLOUSP
,PSRUWDQW
$YRLG³MXPSVWDUWV´DQGXSKLOOVWDUWVGXULQJWKH¿UVWNP
1RWH
$IWHUUXQQLQJLQXVHWKH/D5D$6V\VWHPWRFKHFNFOXWFKZHDUUHDGFOXWFKVQDSVKRWVDYH$SULQWRXWRI
WKHGDWDPXVWEHSUHVHQWHGWR/DPERUJKLQL7HFKQLFDO$VVLVWDQFHXSRQUHTXHVW
1
L714 02 01 00
7DQNWHFKQLFDOGDWD
• Capacity of both tanks 90 l

• Total reserve approx. 20 l
1
L714 02 01 03
7KLVVHFWLRQH[SODLQVKRZWRGLVDVVHPEOHWKH
$ /HIWIXHOWDQN
% 5LJKWIXHOWDQN
& )XHOWDQNFRQQHFWLRQSLSHV
' &RQQHFWLRQSLSHEHWZHHQWKHOHIWDQGULJKWWDQNVDQGWKHDFWLYHFDUERQ¿OWHU&DQLVWHU
( )XHO¿OOHUÀDSDFWXDWRU
) )XHOWDQN¿OOHU
1
L714 02 01 03
$ 'LVDVVHPEOLQJWKHOHIWIXHOWDQN
• Empty the fuel tank
• Disassemble the engine unit . C
• Disassemble the control unit plate .
'LVDVVHPEOLQJWKHOHIWIXHOWDQN
%
1. Disconnect the following pipes by removing the corresponding clamps A
• Rear air conditioner pipe ($)LJ).
• Power steering circuit pipes (%)LJ).
• Brake vacuum pump pipe (&)LJ).
)LJ
2. Disassemble the bulkhead (')LJ), removing the corresponding mounting screws (()LJ).
( '
)LJ
2
L714 02 01 03
3. Loosen the 3 screws ())LJ) and remove the LIE control unit support bracket (*)LJ).
) G
)LJ
4. Loosen the 5 screws (,)LJ) to remove the chassis support bar (+)LJ). H
)LJ
3
L714 02 01 03
/RRVHQWKHVSHFL¿FVFUHZV.)LJ) to release the 2 clamps (-)LJ¿[LQJWKHWDQNWRWKHFKDVVLV
K
K
J
K J
)LJ
Disconnect the 2 fuel pick-up pipes (/)LJ) and the connection pipe (0)LJ) between the left tank and the
3 O
DFWLYHFDUERQ¿OWHU&DQLVWHU
7. Disconnect the earth connector (1)LJ), loosen the clamp (2)LJDQGUHPRYHWKHIXHO¿OWHU3)LJ).
M L
)LJ
4
L714 02 01 03
Disconnect the connection pipe (4)LJ) between the left and right tanks.
Loosen the 2 screws (6)LJ) to remove the support bracket (5)LJ) of the power steering circuit pipes.
5 S
)LJ
10. Loosen the 3 screws (8)LJWRUHPRYHWKHGHK\GUDWRU¿OWHU7)LJ)
T
11. Disconnect the pipe connecting the oil radiator to the engine (9)LJ)
V
U
)LJ

L714 02 01 03
12. Loosen the 4 screws (;)LJ) to remove the plate (:)LJ). X
Z
13. Disconnect the connection pipes between the left and right tanks (<)LJ) and the connector (=)LJ).
:
)LJ
14. Remove the left fuel tank.
)LJ

L714 02 01 03
% 'LVDVVHPEOLQJWKHULJKWIXHOWDQN
• Empty the fuel tank .
• Disassemble the engine unit .
• Disassemble the control unit plate . A
'LVDVVHPEOLQJWKHULJKWIXHOWDQN %
1. Loosen the 2 screws (%)LJ) to remove the rear water pipe ($)LJ).
)LJ
2. Disassemble the bulkhead (&)LJ), removing the corresponding mounting screws (')LJ).
' C
)LJ
7
L714 02 01 03
3. /RRVHQWKHVSHFL¿FVFUHZV))LJ) to release the 2 clamps (()LJ¿[LQJWKHWDQNWRWKHFKDVVLV
( )
)LJ
4. 'LVFRQQHFWWKHDFWLYHFDUERQ¿OWHUSLSH&DQLVWHU*)LJ) to allow free access to all the bracket screws.
Loosen the 3 screws (+)LJ) and remove the LIE control unit support bracket (,)LJ). I K
H
5. Loosen the 2 screws (-)LJVHFXULQJWKHDFWLYHFDUERQ¿OWHU&DQLVWHU.)LJ) to the chassis support H
bar.
H
G
J
)LJ

L714 02 01 03
Loosen the 5 screws (0)LJ) to remove the chassis support bar (/)LJ).
)LJ
7. Loosen the remaining screw (1)LJWRUHPRYHWKHDFWLYHFDUERQ¿OWHU&DQLVWHU.)LJ) and disconnect
the connection pipe to the fuel tank (2)LJ). O 1 K Q
8. Disconnect the 2 fuel tank pipes (3)LJ) and the fuel tank earth connector (4)LJ).
)LJ

L714 02 01 03
/RRVHQWKHVSHFL¿FFODPS6)LJ) to disconnect the connection pipe (5)LJ) between the fuel tank and
WKHIXHO¿OOHU
5
)LJ
10. Disconnect the connection pipe (7)LJ) between the left and right tanks.
)LJ
10
L714 02 01 03
11. /RRVHQWKHVSHFL¿FVFUHZV9)LJ) to release the cooling circuit pipe (8)LJ).
V
)LJ
12. Loosen the 4 screws (;)LJ) to remove the plate (:)LJ0). X

Z
Y
13. Disconnect the connection pipes between the left and right tanks (<)LJ) and the connector (=)LJ).
:
)LJ
14 . Remove the right fuel tank.
)LJ
11
L714 02 01 03
& 'LVFRQQHFWLQJWKHIXHOWDQNFRQQHFWLRQSLSHV C
• Disassemble the engine unit . %
• Disassemble the control unit plate . A
'LVFRQQHFWLQJWKHIXHOWDQNFRQQHFWLRQSLSHV
1. On the left side, disconnect the following pipes by removing the corresponding clamps:
• Rear air conditioner pipe ($)LJ)
• Power steering circuit pipes (%)LJ).
• Brake vacuum pump pipe (&)LJ).
)LJ
2. Loosen the 2 screws (()LJ) to remove the rear water pipe (')LJ) on the right side.
'
)LJ
12
L714 02 01 03
3. 2QWKHOHIWVLGHORRVHQWKHVSHFL¿FPRXQWLQJVFUHZV*)LJ) to disassemble the guard panel ())LJ).
G )
)LJ
4. 2QWKHULJKWVLGHORRVHQWKHVSHFL¿FPRXQWLQJVFUHZV,)LJ) to disassemble the bulkhead (+)LJ).
I H
)LJ
13
L714 02 01 03
On both the left and right sides, loosen the 4 screws (.)LJ) to remove the plate (-)LJ). K
L
On both the left and right sides, disconnect the tank connection pipes (/)LJ).
J
)LJ
7. /RRVHQWKHVSHFL¿FVFUHZV1)LJ) to release the cooling circuit pipe (0)LJ).
1
)LJ
Remove the fuel tank connection pipes.
)LJ
14
L714 02 01 03
' 'LVDVVHPEOLQJWKHFRQQHFWLRQSLSHEHWZHHQWKHIXHOWDQNVDQGWKHDFWLYHFDUERQ¿OWHU&DQLVWHU

A
• Remove the engine aesthetic panels (Engine Bay) .
• Remove the coolant tank (Nourice) (012103).
'LVDVVHPEOLQJWKHFRQQHFWLRQSLSHEHWZHHQWKHIXHOWDQNVDQGWKHDFWLYHFDUERQ¿OWHU&DQLVWHU
1. Disconnect the 2 connections ($)LJRQWKHSLSHIURPWKHDFWLYHFDUERQ¿OWHU&DQLVWHUDQGRQH%)LJ)

from the right fuel tank.
%
)LJ
2. 'HWDFKWKHSLSHIURPWKH¿[LQJFODPSV&)LJ).
)LJ

L714 02 01 03
3. Disconnect the pipe (')LJ) from the left fuel tank.
'
)LJ
4. Remove the connection pipe.
)LJ

L714 02 01 03
( 'LVDVVHPEOLQJWKHIXHOWDQNÀDSRSHQLQJDFWXDWRU
%
3UHOLPLQDU\RSHUDWLRQV %
• Disassemble the right rear wheel ().
• Disassemble the right rear wheel arch ().
'LVDVVHPEOLQJWKHIXHOWDQNÀDSRSHQLQJDFWXDWRU
A
1. Loosen the 2 screws (%)LJ) to disassemble the right front air conveyor ($)LJ)
)LJ
2. Loosen the 2 screws(&)LJVHFXULQJWKHIXHOWDQNÀDSRSHQLQJDFWXDWRUWRWKHEUDFNHW
3. Disconnect the stem (')LJIURPWKHIXHOWDQNÀDSRSHQLQJDFWXDWRU
4. Disconnect the connector (()LJ) and remove the actuator ())LJ). C '
(
)LJ
17
L714 02 01 03
) 'LVDVVHPEOLQJWKHIXHOWDQN¿OOHU
• Disassemble the right rear wheel ().
• Disassemble the right rear wheel arch ().
'LVDVVHPEOLQJWKHIXHOWDQN¿OOHU
1. Loosen the screw (%)LJ VHFXULQJ WKH FODPS WR GLVFRQQHFW WKH ¿OOHU SLSH $)LJ) from the fuel tank
¿OOHU
2. Disconnect the fuel recovery pipe (&)LJIURPWKHIXHO¿OOHU
% A C
)LJ

L714 02 01 03
3. Loosen the cap (')LJ) and the 4 screws (()LJVHFXULQJWKH¿OOHUWRWKHFRUUHVSRQGLQJSDQ

(
'
)LJ
4. Remove the pan ())LJDQGWKHIXHOWDQN¿OOHU*)LJ).

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L714 02 01 05
$ /HIWIXHOWDQN
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( )XHO¿OOHUÀDSDFWXDWRU
) )XHOWDQN¿OOHU
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L714 02 01 05
$ $VVHPEOLQJWKHOHIWIXHOWDQN
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ensure the welds and joins are sound.
1. Insert the left fuel tank into the housing inside the vehicle. %
%
2. 7R¿[WKHOHIWIXHOWDQNIDVWHQWKHFODPSV$)LJDQGWLJKWHQWKHFRUUHVSRQGLQJVFUHZV%)LJ).
A
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)LJ
3. &RQQHFWWKHFRQQHFWLRQSLSHVEHWZHHQWKHOHIWDQGULJKWWDQNV&)LJDQGWKHFRQQHFWRU')LJ) )
'
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4. 3RVLWLRQDQGIDVWHQWKHSODWH()LJXVLQJWKHVFUHZV))LJ).
• $VVHPEOHWKHFRQWUROXQLWSODWH).
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5. 5HSRVLWLRQWKHSLSHFRQQHFWLQJWKHRLOUDGLDWRUWRWKHHQJLQH*)LJ).
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• Turn off the engine and remove the ignition key from the instrument cluster.
• Disassemble the control unit plate (098103)
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1. Loosen 4 screws on each plate (B-Fig.1) to remove the 2 fuel tank plates on either side (A-Fig.1).
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2. Disconnect the fuel pump connector on the right (C-Fig.1DQGWKHÀRDWFRQQHFWRURQWKHOHIWC-Fig.1).
3. Disconnect the pipe with the smallest diameter (D-Fig.1) from the connection pipes on the two tanks and
connect an extractor pump.
It is advisable to connect the extractor pump to the pipe with the smallest diameter because this allows the D
fuel to be extracted directly from the bottom of the tank.
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The anti-evaporation system prevents the fuel vapors, which consist of the lightest fractions of the hydrocarbons that
form in the tank, from discharging into the atmosphere and being suctioned again to be burned.
The system operates especially when the outside temperature is high and the fuel temperature rises, thus increasing
the tendency to evaporate.
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absorb them when the engine is off.
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• It prevents the fuel from reaching the canister in the case of hard acceleration/deceleration when the car has a
full tank, or from spilling from the tank, in case the car rolls over;
• It allows the vapors to pass from the tank to the canister;
• It enables to discharge into the atmosphere any excess pressure inside the tank (electrovalve malfunctioning,
clogged pipe).
The canister is connected, by means of two solenoid valves, to two pipes that convey the vapors to the engine intake
manifolds. With the engine running, each solenoid valve is piloted in duty-cycle by the engine control unit according
to engine speed and load, thus putting the canister into communication with the intake manifold and allowing the A C D
suction of the vapors inside the canister. At high engine speed, a venting valve, connecting the canister to the
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vacuum.
Fuel anti-evaporation system layout (Fig.1)

A. Fuel pump
B. Left fuel tank
C. Right fuel tank
D. Filter Canister
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E. Diagnosis pump
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The purge valves (A-Fig.2) empty the canister (that holds back the fuel gases that form inside the tank) positioned
on the right side of the engine compartment. A A
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The purge valves are driven by the injection control units according to a strategy set by their calibration software.
In the circuit is a pump positioned under the canister that controls the system’s seal; this pump is driven according
to the operating time.
The control unit receives the information if the circuit is sealed, so the more time spent loading the pressure into the
tank, the greater the possibility is that the system turns on the pilot lamp.
Fig.2
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A) Canister disassembly
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• Disassemble the rear hood support piston .
• Disassemble the right side bulkhead .
• Disassemble the water cooling circuit tank (nourice) with its support frame .
• Disassemble the vacuum tank .
• Disassemble the pannel upper .
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1. Disconnect and remove the third brake light connection from its supports ($)LJ) and the rear view camera
connection (%)LJ).
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2. Loosen the 3 screws (&)LJ) and remove the engine injection control unit support bracket (')LJ). Disconnect
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procedure (()LJ).
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3. To release the water cooling circuit tank (Nourice) ())LJ), disconnect the connector (*)LJ) and loosen the
2 screws (+)LJ) securing the mounting bracket. G H
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4. Disconnect the 2 remaining pipes (()LJ) connected to the canister.

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L714 02 03 03
Disengage the cross member (*)LJ) so that the canister can be removed:
• Loosen the 2 screws (+)LJ). 1 K 1
• Loosen the 3 screws (,)LJ).
• Disengage the canister pump from the cross member 3XQWR%
7. Loosen the 2 screws (/)LJ) and detach the heat-proof panel from the cross member.
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Remove the canister (0)LJ).
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• Lift the vehicle on the car lift .
• Remove the rear wheel arch .
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2. Disconnect the canister pipe (%)LJ).
3. Disconnect the air pipe (&)LJ) by removing its clamp.
4. Loosen the 3 screws (')LJ) that secure the bracket supporting the pump to the cross member.
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5. Disconnect the vacuum tank pipe (()LJ).
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Remove the pump.
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• Raise the vehicle on the car lift .
• Disassemble the right rear wheel .
• Disassemble the right rear wheel arch .
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1. Disconnect the connection pipe ($)LJEHWZHHQWKHDFWLYHFDUERQ¿OWHU&DQLVWHUDQGWKHSXPSE\GHWDFKLQJ

the corresponding clamp.
2. Disconnect the air inlet pipe (%)LJ) by detaching the corresponding clamp.
3. Loosen the screw (&)LJVHFXULQJWKHFODPSWRWKHDFWLYHFDUERQ¿OWHUSXPS&DQLVWHUVXSSRUWEUDFNHW

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1. 'LVFRQQHFWWKHIXHO¿OWHUFRQQHFWLRQSLSH$)LJ) to the engine.
2. Disconnect the 2 pick-up pipes (%)LJ) on the left fuel tank.
3. Loosen the screw on the clamp (&)LJDQGUHPRYHWKHIXHO¿OWHU')LJ).
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L714 02 03 03
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1. Disconnect the delivery pipe ($)LJWRHQJLQHIURPWKHIXHO¿OWHU
2 8QVFUHZWKH¿[LQJVFUHZV%)LJ) on the 2 clamps fastening the pipe to the chassis (&)LJ). '
3. Disconnect the delivery pipe (')LJ) from the engine.
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A) Assembling the canister
Assembling the canister

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1. Put the canister ($)LJ) into its seat.
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2. Secure the cross member (%)LJ):

• Tighten the 2 screws (&)LJ). ( % (
• Tighten the 3 screws (')LJ).
• Secure the canister pump to the cross member 3XQWR%
3. Fasten the heat-proof panel onto the cross member by tightening the 2 screws (()LJ).
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6. To secure the engine injection control unit support bracket (+)LJ), use 3 screws (,)LJ). Then connect the
remaining pipe (-)LJZKLFKFRQQHFWVWKHDFWLYHFDUERQ¿OWHUCanister) to its pump. H J
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• Insert the cylinder bank 1-5 engine injection control unit .
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L714 02 03 05
7. To fasten the water cooling circuit tank (Nourice) (.)LJ), connect the connector (/)LJ) and tighten the 2
screws (0)LJ) securing the mounting bracket. L M
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Connect the third brake light connection (1)LJ) and the rear view camera connection (2)LJ).
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• Assemble the right side bulkhead .
• Assemble the upper panel .
• Assemble the rear engine hood support piston .
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1. Tighten the 3 screws ($)LJ) that secure the pump supporting bracket to the cross member.
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4. Connect the connection (')LJ).
5. Connect the vacuum tank pipe (()LJ).
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• Assemble the right rear wheel arch .
• Assemble the right rear wheel . )LJ
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1. 3RVLWLRQWKH&DQLVWHUSXPS¿OWHU$)LJ) inside its housing.
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3. Connect the connection pipe (&)LJEHWZHHQWKHDFWLYHFDUERQ¿OWHUCanister) and the pump by fastening
the corresponding clamp.
4. Connect the air inlet pipe (')LJ) by connecting the corresponding clamp. C
• Assemble the right rear wheel arch .

• Assemble the right rear wheel .
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4 7LJKWHQWKH¿[LQJVFUHZV')LJ) on the 2 clamps fastening the pipe to the chassis (()LJ).
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• Remove rear wheel arch elements (082103).
• Remove the engine compartment side panels (081303).
• Remove the pannel upper (081303). )LJ )LJ
• Remove the light support bracket with the heat-proof guard (094503).
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2. Remove the clip (%)LJ) that secures the hood opening wiring harness to the cross member.
3. 5HPRYHWKHUHDUIRJOLJKWFDEOHE\GLVFRQQHFWLQJLWVIDVWHQHUV&)LJ) on the cross member.
4. Loosen the 8 screws (')LJ) securing the cross member (()LJ) to the chassis. ' (
5. Loosen the 3 screws ())LJ) securing the heat-proof panel (*)LJ) to the cross member.

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2
L714 02 51 03
Disassembling the upper rear cross member

7. Disconnect the hood opening cable (+)LJ).
8. Disconnect the connector (,)LJ).
H ,
9. Withdraw the ECS pipe (/)LJ) from the 3 clips (0)LJ) on the cross member. )LJ
10. Loosen the 2 screws (1)LJ) securing the heat-proof panel (2)LJ) to the cross member. 1 M L O O 1 M
11. Extract the sensor (3)LJ) from its bracket on the cross member.
3
)LJ
3
L714 02 51 03
12. Loosen the 5 screws (4)LJ) that secure the cross member to the chassis.
b
Repeat the operation (point 13) for both sides (DE)LJ) (remove all the 10 screws to disengage the cross
member).
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Q
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4
L714 02 51 03
14. /RRVHQWKH¿[LQJVFUHZV5)LJDQGUHPRYHWKHVLGHIUDPH6)LJ).
Repeat the operation (point 15) for both sides, removing the right and left side frames.
5
5
)LJ
15. Disengage the heat-proof panel (7)LJIURPWKHFKDVVLVE\UHPRYLQJWKHVFUHZV8)LJ).
)LJ
5
L714 02 51 03
16. Remove the 4 bolts (9)LJWKDWVHFXUHWKHVLOHQFHUWRWKHÀH[LEOHVXSSRUWV
V V
V V
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)LJ).
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)LJ
18. Extract the silencer (;)LJ).
X )LJ
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L714 02 51 03
% 'LVDVVHPEOLQJWKHVLOHQFHUKHDWSURRISDQHOV
• Remove the silencer (3RLQW$).
'LVDVVHPEOLQJWKHSDQHOV
1. /RRVHQWKHVSHFL¿FVFUHZVWRUHPRYHWKHKHDWSURRISDQHOVLQWKHIROORZLQJRUGHU (
• Side panels ($)LJ) %1
• Side panels (%)LJ)
• Side panels (&)LJ) %2
• )URQWFHQWUHSDQHO')LJ)
• Rear centre panel (()LJ)
C1 C2
To remove the panel (()LJ¿UVWGLVDVVHPEOHWKHIROORZLQJFRPSRQHQWV

5HPRYHWKHVDIHW\ZDVKHU))LJDQGH[WUDFWWKH¿[LQJGLVN*)LJ) with the corresponding spring
(+)LJ) so that the heat-proof panel can be replaced.
' A2
A1
)LJ
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L714 02 51 03
& 'LVDVVHPEOLQJWKHH[KDXVWWHUPLQDOV
:$51,1*
'LVDVVHPEOHWKHH[KDXVWWHUPLQDOVZKHQWKH\DUHFROG:KHQWKHYHKLFOHLVKRWWKH\UHDFKH[WUHPHO\ %
KLJKWHPSHUDWXUHVZLWKWKHULVNRIVHULRXVEXUQV
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1. /RRVHQWKHVSHFL¿F¿[LQJVFUHZV%)LJ) to remove the heat-proof panel ($)LJ).
A
)LJ
2. Loosen the 6 screws (&)LJ) securing the exhaust terminal to the rear bumper. C
3. Remove the exhaust terminal.
&DUU\RXWWKHVDPHSURFHGXUHRQERWKH[KDXVWWHUPLQDOV C C
)LJ
8
L714 02 51 03
' 'LVDVVHPEOLQJWKHVHFRQGDU\DLUSXPS
• Remove the rear element of the rear stone guard (082103).
• Remove the rear lights and the heat-proof panels (094503).
1. Disconnect the electric connector ($)LJRQWKHVHFRQGDU\DLUSXPS
2. Loosen the 3 screws (%)LJVHFXULQJWKHVHFRQGDU\DLUPRXQWLQJEUDFNHWWRWKHFKDVVLV
3. Disconnect the pipe (&)LJ) which goes from the pump to the exhaust manifold.
% A
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9
L714 02 51 05
A) Silencer heat-proof panels
% Silencer
C) ([KDXVWWHUPLQDOV
' Secondary air pump
1
L714 02 51 05
A) Assembling the silencer heat-proof panels
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Assembling the upper rear cross member

3XWWKHFURVVPHPEHULQVLGHLWVVHDW b
7. 7LJKWHQWKHVFUHZV+)LJDQGVHFXUHWKHFURVVPHPEHUWRWKHFKDVVLV
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Assembling the lower rear cross member

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L714 02 53 00
2[\JHQVHQVRUV
The oxygen sensors are the sensors generating an electric signal according to the ratio between the oxygen inside
the exhaust gas and the oxygen inside the outside air. By means of these sensors it is possible to measure the
deviation from the stoichiometric ratio (lambda ratio) of the air – fuel mixture sent to the cylinders.
A C B
A. Pre-catalyst oxygen sensor (LINEAR)
B. Post-catalyst oxygen sensor (ON-OFF)
C. Catalyst
Fig.1
212))R[\JHQVHQVRURSHUDWLRQGLDJUDPSRVWFDWDO\WLFFRQYHUWHU
Sensor voltage
• The main element is a ceramic body coated on both sides (Nernst cell). External air
• The coatings act as electrodes.
• One layer of electrodes is in contact with external air, the other with the exhaust gases.
• The difference between the oxygen contained in the outside air and that in the exhaust gases generates the
sensor’s voltage.
Use LaRa-AS on both the MASTER and SLAVE engine injection control units to check the POST-
catalytic converter oxygen sensors.
Electrodes
Exhaust gases Engine control unit
Fig.2
1
L714 02 53 00
/,1($5R[\JHQVHQVRURSHUDWLRQGLDJUDPSUHFDWDO\WLFFRQYHUWHU
Oxygen sensor adjustment with broadband oxygen sensor:

• The pumping effect of the pump cell is a purely physical process.
• No mechanical component.
• The positive voltage of the pump cell attracts negative oxygen ions through the oxygen-permeable ceramic.
Use LaRa-AS on both the MASTER and SLAVE engine injection control units to check the PRE-
catalytic converter oxygen sensors.
Fig.3
2
L714 02 53 03
'LVDVVHPEOLQJWKHFRQYHUWHUR[\JHQVHQVRU
&DUU\RXWWKLVSURFHGXUHZKHQWKHHQJLQHLVFROGWRDYRLGWKHULVNRIEXUQV
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7KHUHDUHR[\JHQVHQVRUVRQHDFKFDWDO\WLFFRQYHUWHU
• DOLQHDUSUHFDWDO\WLFFRQYHUWHUVHQVRUWRPDLQWDLQWKHULJKWVWRLFKLRPHWULFDOUDWLR
• DQ212))SRVWFDWDO\WLFFRQYHUWHUVHQVRUWRFKHFNZKHWKHUWKHFDWDO\WLFFRQYHUWHUIXQFWLRQV
$ 'LVDVVHPEOLQJWKHIURQWULJKWDQGOHIWR[\JHQVHQVRUV
B A
D
• Raise the vehicle on the car lift (000000).
• Disassemble the engine aesthetic panels (Engine Bay) (081303).
• 'LVDVVHPEOHWKHDLU¿OWHUXQLW(013303).
• Disassemble the rear tyres (060103).
• Disassemble the rear wheel arches (082103).
• 'LVDVVHPEOHWKHYDFXXPWDQN(061103).
'LVDVVHPEOLQJWKHIURQWULJKWDQGOHIWR[\JHQVHQVRUV
Fig.1
1. Loosen the three screws (B-Fig.1WRUHOHDVHWKHSRZHUVWHHULQJRLOWDQNA-Fig.1).
2. Loosen eight screws (D-Fig.1) to remove the central cross member (C-Fig.1). E
35HPRYHWKHVXSSRUWVIURPWKHLUFRXSOLQJVDQGGLVFRQQHFWWKHFRQQHFWRUVE-Fig.2) of the 2 front oxygen sensors

RQHSHUVLGH F
48QVFUHZDQGUHPRYHWKHR[\JHQVHQVRUVF-Fig.2).
Fig.2
1
L714 02 53 03
% 'LVDVVHPEOLQJWKHUHDUULJKWDQGOHIWR[\JHQVHQVRUV
A
• Disassemble the engine aesthetic panels (engine bay) (081303).
• 5HPRYHWKHDLU¿OWHUXQLW(013303).
B
Disassembling WKHUHDUULJKWDQGOHIWR[\JHQVHQVRUV
1. 5HPRYHWKHVXSSRUWVIURPWKHLUFRXSOLQJVDQGGLVFRQQHFWWKHFRQQHFWRUVA-Fig.1) of the 2 oxygen sensors

SHUVLGH
2. 8QVFUHZDQGUHPRYHWKHR[\JHQVHQVRUV(B-Fig.1).
Fig.3
2
L714 02 53 05
$VVHPEOLQJWKHFRQYHUWHUR[\JHQVHQVRU A
7KHUHDUHR[\JHQVHQVRUVRQHDFKFDWDO\WLFFRQYHUWHU
• DOLQHDUSUHFDWDO\WLFFRQYHUWHUVHQVRUWRPDLQWDLQWKHULJKWVWRLFKLRPHWULFDOUDWLR
• DQ212))SRVWFDWDO\WLFFRQYHUWHUVHQVRUWRFKHFNZKHWKHUWKHFDWDO\WLFFRQYHUWHUIXQFWLRQV
properly.
$ $VVHPEOLQJWKHIURQWULJKWDQGOHIWR[\JHQVHQVRUV Fig.1
1. Tighten the 2 front oxygen sensors (one each side) (A-Fig.1). C
2. Connect the connectors (B-Fig.1RIWKHR[\JHQVHQVRUVDQGORFNWKHPLQWRWKHLU¿[LQJVXSSRUWV
3. Position the central cross member (C-Fig.2) and fasten with eight screws (D-Fig.2).
4 )DVWHQWKHSRZHUVWHHULQJRLOWDQNE-Fig.2XVLQJWKHWKUHHVFUHZVF-Fig.2).

D
• $VVHPEOHWKHYDFXXPWDQN(061105).
• Assemble the rear wheel arches (082105).
• Assemble the rear tyres (060105).
• $VVHPEOHWKHDLU¿OWHUXQLW(013305).
• $VVHPEOHWKHHQJLQHDHVWKHWLFSDQHOVEngine Bay) (081305). F E
D
Fig.2
1
L714 02 53 05
% $VVHPEOLQJWKHUHDUULJKWDQGOHIWR[\JHQVHQVRUV
1. 6FUHZRQWKHR[\JHQVHQVRUVRQHSHUVLGHA-Fig.1). B
2. Connect the connectors (B-Fig.1RIWKHR[\JHQVHQVRUVDQGORFNWKHPLQWRWKHLU¿[LQJVXSSRUWV

A
• $VVHPEOHWKHDLU¿OWHUXQLW(013305).
• $VVHPEOHWKHHQJLQHDHVWKHWLFSDQHOVEngine Bay) (081303).
Fig.3
2
L714 02 60 00
Air conditioning system
7KHDLUFRQGLWLRQLQJV\VWHPSURYLGHGZLWKWKHYHKLFOHKROGVWKHWHPSHUDWXUHDQGDLUÀRZLQWKHSDVVHQJHUFRPSDUWPHQW
to the values set by the driver and the passenger.
The air conditioning system has the following features:
• automatic temperature-ventilation-air distribution control
• recirculation
• DLUÀRZGLVWULEXWLRQ
The system’s operation is controlled by a special electronic control unit set by the driver and passenger on the
control unit’s push-button panel.
The system has an air conditioning unit (B-Fig.1WKDWPRGL¿HVWKHWHPSHUDWXUHDQGKXPLGLW\RIWKHDLUHQWHULQJWKH
vehicle by means of two radiators (driver and passenger side) connected to a heating system that receives heat from
the engine (green lines) and an evaporator, part of an air conditioning system (red and blue lines).
F
G
Air conditioner diagram (Fig.1)
A. Air conditioner control unit
B. Air conditioning unit B A C D
C. Engine coolant pump
D. Engine E
E. Air conditioner compressor
F. Air conditioner pressure sensor
Fig.1
G. Condenser
1
L714 02 60 00
The air conditioning unit has two parts:
• ventilation unit outside the passenger compartment in the luggage compartment, equipped with an air
conveyor
• heating, cooling, and air distribution unit inside the passenger compartment under the dashboard
Air conditioning unit (Fig.2)

A. Heating, cooling, and air distribution unit
B. Ventilation unit
B
The ventilation unit takes in external air through the conveyor by means of a fan and sends it to the heating, cooling
and distribution unit. The fan is also used to recirculate the air inside the passenger compartment.
The fan has: A
• an intake air temperature sensor
• WKUHHÀDSVIRUWKHLQFRPLQJH[WHUQDODLUPRYHGE\DVLQJOHDFWXDWRUIUHVKÀDSDQGRQHIRULQWHUQDODLUPRYHG
E\DQRWKHUDFWXDWRUUHFLUFXODWLRQÀDS Fig.2
The unit has a drain pipe for draining rain water that enters the unit. G
F H
E I
Ventilation unit (Fig.3)
A. Fan
B. Intake air temperature sensor
C. 5HFLUFXODWLRQÀDSDFWXDWRU
D. )UHVKÀDSVDFWXDWRU
E. )UHVKÀDSV B
F. Cover A C
G. Intake conveyor
H. 5HFLUFXODWLRQÀDS D
I. Conveyor that sends air to heating, air conditioning and air distribution unit
Fig.3
2
L714 02 60 00
The heating, air conditioning and air distribution unit is “dual zone” with: RIGHT SIDE
A B
• a heater battery (A-Fig.4) divided into two zones, each supplied by the engine coolant by means of an
independent valve
• an evaporator (B-Fig.4) for air conditioning connected to the air conditioning system
LEFT SIDE
A B
Fig.4
3
L714 02 60 00
The heating, air conditioning and air distribution unit includes:

• PRWRUL]HGÀDSVIRUYHQWLODWLRQDQGGLVWULEXWLRQFRQWURO
• internal and outside temperature sensors for temperature control
• SROOHQ¿OWHUVIRUDLUHQWHULQJWKHSDVVHQJHUFRPSDUWPHQW
+HDWLQJDLUFRQGLWLRQLQJDQGDLUGLVWULEXWLRQXQLWFRPSRQHQWV)LJ B C
A
D
A. 8SSHUYHQWVÀDSDFWXDWRU E
B. 8SSHUYHQWVÀDS F
C. 'HIURVWLQJYHQWVÀDSDFWXDWRU
T G
D. RH radiator temperature sensor
E. Evaporator temperature sensor (deicer) H
F. &HQWHUYHQWVÀDS S
I
G. Cold air actuator for center vents
H. &ROGDLUÀDSIRUFHQWHUYHQWV L
I. 5+ORZHUYHQWÀDS R
L. /RZHUÀDSVDFWXDWRU
M. Evaporator expansion valve Q
M
1 RH radiator inlet
O. LH radiator inlet 3 O 1
3 Radiator outlet Fig.5
R. Center vents actuator

S. /+ORZHUYHQWÀDS
T. )ODSIRU/+SROOHQ¿OWHU
U. LH radiator temperature sensor
4
L714 02 60 00
Air conditioning system
The evaporator inside the air conditioning unit is powered by a compressor located next to the engine. The system’s
condenser is installed in front of the right front radiator of the engine’s cooling system.
The coolant used by the air conditioning system is R134a. C B
Air conditioning system (Fig.6) F

A. Air conditioning unit
B. Compressor
C. Condenser
D. Receiver-drier
E. &RRODQW¿OOLQJGUDLQLQJYDOYH
F. Coolant pressure sensor
Fig.6
A E D
5
L714 02 60 00
The outside air (or recirculation air) enters the heating, ventilation and air distribution unit where it is treated with
KHDWLQWHUFHSWHGDQGWHPSHUHGE\DVHULHVRIPRWRUL]HGÀDSVWKDWGLUHFWWKHÀRZWRZDUGFKDQQHOVFRQQHFWHGWR
various passenger compartment vents.
Fig.7
6
L714 02 60 00
7KHDLUH[LWLQJWKHÀDSVLVVHQWWRWKHYHQWVRQWKHGDVKERDUGDQGFRQVROHWKURXJKDVHULHVRIGXFWV A
A A
A
B
$LUÀRZIURPWKHSDVVHQJHUFRPSDUWPHQWYHQWV)LJ
A. Upper vents
B. Upper side vents C
C. Front vents
B D
D. Lower vents
C
C
C D C
A A A
B
B
C C C C
C
D
D
Fig.8
7
L714 02 60 00
Air conditioner control unit
The automatic dual zone control unit is built into the push-button panel on the console. It separately controls the
following parameters on the LH and RH sides of the passenger compartment:
3DVVHQJHUFRPSDUWPHQWWHPSHUDWXUH
Seat temperature (if function is present)

A B B A
'LVWULEXWLRQRIWKHDLUÀRZ
$LUÀRZ)DQ
Fig.9
These parameters, except for the temperature, are manually controlled by pressing the relative buttons (an LED
comes on) and using the knobs (A-Fig.9). The display (B-Fig.9) shows the value.
1RWH
7KHWHPSHUDWXUHFDQEHDGMXVWHGEHWZHHQ&DQG&,IWKHSURJUDPPHGYDOXHH[FHHGVWKHVHOLPLWV
on the display, LO or HI appears and the temperature is no longer adjusted.
The button completely blocks air from entering the passenger compartment.
The EXWWRQDFWLYDWHVWKHÀDSVIDQVSHHGDLUUHFLUFXODWLRQDQGWHPSHUDWXUHWRGHIURVWWKHZLQGVFUHHQDQGWKH
side windows as quickly as possible.
The button excludes the air conditioner. As a result, the passenger compartment temperature cannot be
ORZHUWKDQWKHRXWVLGHWHPSHUDWXUH7KHGHKXPLGL¿HULVDOVRH[FOXGHG7KHZLQGRZVFRXOGWKHUHIRUHVWHDPXS
The button activates automatic operation. The temperature, the amount and distribution of the air are
automatically controlled to achieve the desired passenger compartment temperature as quickly as possible and to
maintain it.
Ventilation is possible in the passenger compartment even when the engine key is on OFF by simply keeping the
FRQWUROXQLWRQRIIEXWWRQSUHVVHG
8
L714 02 60 00
The control unit continuously adjusts the system according to driver and passenger requests (RH and LH). In
particular: F
• It acquires information on internal (RH and LH) and outside temperature and on solar irradiation intensity by B
means of special sensors. G
• It sets the speed of the air entering the passenger compartment by means of the fan. C
• ,WFRQWUROVWKHRSHQLQJFORVLQJRIWKHDLUGLVWULEXWLRQÀDSV
• It controls air recirculation by means of an actuator. A H
• It controls the incoming hot air temperature by means of two solenoid valves (RH and LH) and a circulation D
pump. I
• It controls compressor activation.
• ,WFRQWUROVULJKWIDQRSHUDWLRQRQWKHFRQGHQVHUUDGLDWRU E M L
The control unit (A-Fig.10) implements the heat regulating strategies according to input received from the following
Fig.10
sensors:
• outside air temperature (B-Fig.10)
• internal air temperature (RH and LH) (C-Fig.10)
• Vent outlet air temperature (D-Fig.10)
• Solar irradiation (E-Fig.10)
The control unit memory contains a resident program, composed of a set of strategies, each of which manages a
VSHFL¿FIXQFWLRQRIWKHFRQWUROV\VWHP
The strategies process a set of parameters by means of the above inputs and memorized data maps. These
parameters control the system actuators (outputs), that is those devices causing the system to reach and hold a
comfortable temperature inside the passenger compartment.
The devices are the following:
• Air distribution actuator (F-Fig.10)
• Motor fan (G-Fig.10)
• Recirculation actuator (H-Fig.10)
• (QJLQHFRRODQWÀRZUDWHVROHQRLGYDOYHVI-Fig.10)
• Engine coolant pump (L-Fig.10)
• Compressor (M-Fig.10)
9
L714 02 60 01
&KHFNDQGUHSODFLQJWKHSROOHQ¿OWHUV
3UHOiminary operations
A A
• Remove the passenger side footboard (080103).
• Disassemble the passenger side lower dashboard assembly (086803).
• Remove the main fuse box (098103).
• Remove the ZKE control unit (098103). B
1RWH
Ensure that the ignition key is in the OFF position and disconnect the battery (091500).
5HSODFLQJWKH¿OWHUV
1. Remove the 4 relays (A-Fig.1¿WWHGRQWKH,/0FRQWUROXQLW
2. 'LVFRQQHFWWKH,/0FRQWUROXQLWFRQQHFWLRQVB-Fig.1). C
3. Unscrew the 3 bolts (C-Fig.1) securing the support bracket (D-Fig.1).
4. 5HPRYHWKHHQWLUHVXSSRUWLQFOXGLQJEUDFNHWDQG,/0FRQWUROXQLW
C C
Fig.1
1
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5. 2SHQWKHDLUFRQGLWLRQHUSROOHQ¿OWHUÀDS()LJDQGUHPRYHWKHORZHUSROOHQ¿OWHUDQGWKHQWKHXSSHUSROOHQ

¿OWHUF-Fig.3).
6. ,QVHUWRQH¿OWHUDQGWKHQOLIWLWDQGKROGLWZLWK\RXU¿QJHUWRLQVHUWWKHRWKHURQH
(
7. &ORVHWKHDLUFRQGLWLRQHUÀDS
8. Fasten the entire support, including bracket and control unit, on the chassis.
9. Connect the 3 connectors (B-Fig.1) to the control unit.
10. Put the 4 relays (A-Fig.1) on the control unit.
Fig.2
1RWH
8VHWKH/D5D$6³%DVLFVHWWLQJ´V\VWHP (109000) for the software checks and settings (set up the control
XQLWVE\PHDQVRIWKH³DXWRPDWLFPRGH´
• Reconnect the ZKE control unit (098105).

• Reconnect the main fuse box (098105).
• $VVHPEOHWKHSDVVHQJHUVLGHORZHUGDVKERDUGDVVHPEO\(086805). F
• $VVHPEOHWKHSDVVHQJHUVLGHIRRWERDUG(080105).
• Reconnect the battery (091505).
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% 6\VWHPSUHVVXUHVHQVRUGLVDVVHPEO\
C) Ventilation unit disassembly
' /HIWWHPSHUDWXUHVHQVRUDQGFHQWHUDLUÀDSDFWXDWRUGLVDVVHPEO\
( 5LJKWWHPSHUDWXUHVHQVRUDQGFHQWHUFROGDLUÀDSDFWXDWRUGLVDVVHPEO\
) 9HQWLODWLRQXQLWVHQVRUDQGDFWXDWRUVGLVDVVHPEO\
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H) 3ROOHQ¿OWHUV disassembly
, 'LVDVVHPEOLQJWKHDLUFRQGLWLRQHUUDGLDWRU
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A
• Place the ignition key (steering wheel column) in the OFF position.
• Remove the battery from inside the front hood by unscrewing the unit.
• Remove the dashboard (086803).
'LVDVVHPEOLQJWKHDFWXDWRUV
1. Disconnect the connector from the actuators.
• 8SSHUYHQWVÀDSDFWXDWRU$)LJ)
• 'HIURVWYHQWVÀDSDFWXDWRU%)LJ)
2. Unscrew the 3 screws on the actuator and remove it.
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A
The air conditioning system’s pressure sensor is located at the front of the car on the right.
• 5HPRYHWKHIURQWFDUÀRRU(082503).
'LVDVVHPEOLQJWKHVHQVRU
1. Remove the connector from the sensor ($)LJ).
Important! )LJ
7KHXQLRQKDVDFKHFNYDOYHWKDWDOORZVWKHVHQVRUWREHUHPRYHGZLWKRXWGUDLQLQJWKHDLUFRQGLWLRQLQJ
system.
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2. Unscrew the sensor (%)LJ) and remove it.
)LJ
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C) Ventilation unit disassembly
• Remove the luggage compartment tray (080603). A
• Remove the lock covers (080603).
• Remove Windshield wiper harms (095503).
A A
'LVDVVHPEOLQJWKHYHQWLODWLRQXQLW
1. Remove the plastic sides of the luggage compartment tray, unscrewing the three screws that secure it to the
chassis ($)LJ).
)LJ
2. Disconnect the connector on the ventilation unit (%)LJ).
)LJ
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L714 02 60 03
3. Unscrew the air conveyor screws:

• Front and top (&)LJ)
• Side (')LJ)
Important! C
7KLVRSHUDWLRQGRHVQRWUHPRYHWKHFRQYH\RUEXWUDWKHUDOORZVLWWREHPRYHGWRWKHOHIW
4. Move the conveyor to the left for unscrewing the screw (()LJ) that secures the fan to the chassis.
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5. Remove the 3 remaining screws that secure the fan to the chassis ())LJ). Remove the fan.
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To disassemble the following sensors on the driver side:

• LH radiator temperature sensor
• Center vents actuator
A
proceed as described:
1. Disassemble the driver side panel of the center console ($)LJ) secured to the chassis using the pins.
)LJ
2. Disassembling the instrument cluster dashboard cover
• Disassemble the Kombi ornament. The ornament is pressed in without screws.
• Disassemble the Kombi instrument cluster using the fasteners (%)LJ). %
• Disassemble the dashboard cover by removing the two screws (&)LJ) on the sides of the dashboard
cover.
)LJ
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L714 02 60 03
3. Disassemble the driver side lower dashboard assembly.

• Remove the dashboard side cover left cap (')LJ).
• 'LVDVVHPEOHWKHGULYHUVLGHORZHUGDVKERDUGDVVHPEO\¿QLVKLQJHOHPHQW
• 2 screws (()LJ) are inside the dashboard cover
• 2 screws are near the side member cover
• one screw is near the center console
4. Disassembling the actuators of the center vents ())LJ)
• Remove the connector from the actuator.
• Unscrew the three screws on the actuator. Remove the actuator. ' (
)LJ
5. Disassembling the LH radiator temperature sensor (*)LJ)
• Disconnect the sensor connector by pressing on the sides.
• Turn the sensor 90° to extract it from the air conditioning unit.
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To disassemble the following sensors on the passenger side air conditioner:

• RH radiator temperature sensor
• Cold air actuator for center vents A
Proceed as follows:
1. Disassemble the passenger side panel of the center console secured to the chassis using the pins ($)LJ).
)LJ
2. Disassemble the passenger side footrest panel (%)LJ).
3. Disassemble the passenger side lower dashboard assembly (including the glove box):
• Open the glove box and remove the two screws (&)LJ) that secure it to the upper dashboard ('
)LJ). %
)LJ
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L714 02 60 03
• Remove the dashboard side cover right cap (()LJ) and the screw ())LJ).
• Remove the lower left mounting screw of the dashboard lower cover (*)LJ).
)
• Remove the lower right mounting screw of the dashboard lower cover (+)LJ).
• Remove the rear screw of the glove box (,)LJ).
• Lower the glove box and disconnect the glove box light and passenger side AIRBAG deactivation block
(/)LJ). (
• Remove the passenger side lower dashboard assembly complete with the glove box.
)LJ
C
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L714 02 60 03
4. Disassembling the cold air actuators of the center vents (0)LJ)
• Remove the actuator’s connector.
• Unscrew the three screws on the actuator. Remove the actuator.
5. Disassembling the RH radiator temperature sensor (1)LJ)

• Disconnect the sensor connector by pressing on the sides.
• Turn the sensor 90° to extract it from the air conditioning unit.
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• Remove the ventilation unit from the car (081603).
• Remove the ventilation unit cover screws to access the sensor and the actuators.
'
'LVDVVHPEOLQJWKHWHPSHUDWXUHVHQVRU$)LJ
1. Disconnect the sensor connector by pressing on the sides (%)LJ).
2. Turn the sensor 90° to extract it from the ventilation unit.
A
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3. Disconnect the actuator connector (()LJ).
4. Unscrew the three screws on the actuator. Remove the actuator ())LJ).
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:KHQUHSODFLQJWKHDLUUHFLUFXODWLRQÀDSDFWXDWRU&)LJ), do not damage the part that connects it to the
ÀDS
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• Remove the vehicle engine (010003). (
• Remove the left exhaust manifold (013103).
'LVDVVHPEOLQJWKHFRPSUHVVRU %
1. Disconnect the delivery pipes ($)LJ) and the intake pipes (%)LJ) from the compressor by removing the
screws (&)LJ). C
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2. Disconnect the connector (')LJ). )
3. Remove the 3 screws (()LJ) that secure the compressor to the engine.
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:KHQUHPRYLQJWKH¿[LQJVFUHZVEHVXUHWRDOVRUHPRYHWKHFRQQHFWRUVXSSRUWEUDFNHW ())LJ).
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4. Remove the clamp (*)LJ), releasing its rubber covering (+)LJ).
5. Extract the compressor complete with the control shaft toward the front part of the car.
6. Disassemble the shaft, loosening the lock nut (,)LJ) and unscrewing the shaft from the compressor’s
housing.
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H) 3ROOHQ¿OWHUV disassembly
A A
• Remove the passenger side footboard (080103).
• Disassemble the passenger side lower dashboard assembly (086803).
• Remove the main fuse box (098103).
• Remove the ZKE control unit (098103). %
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Ensure that the ignition key is in the OFF position and disconnect the battery (091500).
'LVDVVHPEOLQJWKH¿OWHUV
1. Remove the 4 relays ($)LJ¿WWHGRQWKH,/0FRQWUROXQLW
2. Disconnect the 3 ILM control unit connections (%)LJ). C

3. Unscrew the 3 bolts (&)LJ) securing the support bracket (')LJ).
4. Remove the entire support, including bracket and ILM control unit.
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6. 5HPRYH¿UVWWKHORZHUSROOHQ¿OWHUDQGWKHQWKHXSSHURQH))LJ).

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• (PSW\WKHDLUFRQGLWLRQHUÀXLG (026007).
• Remove the front bumper (080703).
1. Disassemble the right front air conveyor ($)LJ) by loosening the 4 screws (%)LJ).
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2. Release the air conditioner radiator by loosening the 4 screws (&)LJ).

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3. Disconnect the 2 air conditioner pipes by loosening the 2 screws (')LJ).
4. Remove the air conditioner radiator.

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A A
• Empty the air conditioning system (026007).
• Disassemble the right rear wheel (060103).
• Disassemble the right rear wheel arch (082103).
'LVDVVHPEOLQJWKHGHK\GUDWLRQ¿OWHU C
1. Loosen one screw ($)LJ) for each union on the air conditioning system delivery pipes.
2 /RRVHQWKH¿[LQJVFUHZV&)LJRQWKHVXSSRUWEUDFNHWWRUHPRYHWKHGHK\GUDWLRQ¿OWHU%)LJ). %
3. Loosen the 3 screws (')LJVHFXULQJWKHGHK\GUDWLRQ¿OWHUVXSSRUWEUDFNHWWRWKHFKDVVLV
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The air conditioning system is grouped as follows ()LJ):
A1. Front delivery pipe A2
A2. Front return pipe

I2
I1. Internal delivery pipe
3
I2. Internal delivery pipe
C1. Central delivery pipe C2

A1
C2. Central return pipe
I1
3 Rear delivery pipe
3 Rear return pipe
3
C1
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• 'LVDVVHPEOHWKHIURQWDQGFHQWUHÀDWÀRRUV(082503). '
• Disassemble the propeller shaft (030703). A
• Disassemble the front differential (040903).
• Disassemble the luggage compartment tray (080603).
A2
'LVDVVHPEOLQJSLSH$
A1
1. Disconnect pipe A1 on the radiator and loosen the screw ($)LJ).
2 8QIDVWHQWKHVSHFL¿FVFUHZ&)LJWRORRVHQWKH¿[LQJFOLS%)LJ).
3. Disconnect the union (')LJRQSLSH$VRWKH¿UVWSDUWRIWKHSLSHFDQEHUHPRYHGH[WUDFWIURPWKHIURQW

of the vehicle.
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4. 1HDUWKHUDFNORRVHQWKHVSHFL¿FVFUHZ))LJWRORRVHQWKH¿[LQJFOLS()LJ).

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5. Loosen the screw fastening the union and remove pipe A1 (*)LJ) from internal pipe I1. G
A1
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1. Loosen the screw ($)LJ) to disconnect pipe A2 from the radiator.

A
2. /RRVHQWKHVSHFL¿FVFUHZ&)LJWRORRVHQWKH¿[LQJFOLS%)LJ).
A2
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3. 1HDUWKHUDFNXQIDVWHQWKHVSHFL¿FVFUHZ()LJWRORRVHQWKH¿[LQJFOLS')LJ).
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4. Loosen the screw ())LJ) fastening the union to pipe C2 and remove pipe A2.
A2
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A2
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• 'LVDVVHPEOHWKHIURQWFHQWUHDQGUHDUÀDWÀRRUV(082503).
• Disassemble the propeller shaft (030703).
'LVDVVHPEOLQJSLSH&
C1
1. Loosen the screw fastening the union ($)LJ) to internal pipe I2 and release pipe C1.
A
)LJ
2. Loosen the 5 screws (%)LJ) securing the clamp to the propeller shaft tunnel.
)LJ
23
L714 02 60 03
3. Loosen 2 screws (')LJ) to release the hot water pump (&)LJ).

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)LJ
4. Loosen the screws (()LJ) securing the clamps on the nearby pipes.
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5. Loosen the screw ())LJ) securing pipe C1 to rear pipe 3.
C1
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C1
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1. Loosen the screw ($)LJ) fastening the union to pipe A2 and release pipe C2. A2
A
C2
)LJ
2. Loosen the screws and then cut the clamps (&)LJ) to remove the support brackets (%)LJ).
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3. Loosen 2 screws (()LJ) to release the hot water pump (')LJ). ( (
'
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L714 02 60 03
4. /RRVHQWKHVSHFL¿FVFUHZWRUHPRYHWKHFODPS))LJ) and ease removal of pipe C2. )
)LJ
5. Loosen the screw (*)LJ) securing pipe C2 to rear pipe 3
)LJ
C2
)LJ
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• Remove the entire engine (010003).
• 'LVDVVHPEOHWKHIURQWFHQWUHDQGUHDUÀDWÀRRUV(082503).
'LVDVVHPEOLQJSLSH3
1. Loosen the screw ($)LJ) securing the union on pipe 3 to pipe C1.
2. Loosen the screws (%)LJ) securing the pipe fastening clamps to the chassis.
3
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3. Loosen the screw (&)LJ) securing pipe 3WRWKHGHK\GUDWRU¿OWHU
)LJ
3
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• Place the engine on a workbench (010003).

3
1. Loosen the screw ($)LJ) securing pipe 3 to the compressor, remove the clamps and the pipe.
)LJ
3
)LJ
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• Engine on a workbench (010003).
1. Loosen the screw ($)LJ) securing pipe 3 to the compressor and then remove the pipe. 3
)LJ
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• 'LVDVVHPEOLQJWKHUHDUDQGFHQWUHYHKLFOHÀRRUV(082503).
• Disassembling the propeller shaft (030703).
• Empty the coolant circuit (012107).
• Disassembling the center console end panels (086303). I2 A
• Disassembling the center console ornament (086303).
• Disassembling the BJA push-button panel (086803).
• Disassembling the air conditioner grille (081603).
• Disassembling the air conditioner control unit (081603).
• Disassembling the multimedia system (097503).
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To disassemble the air conditioning system pipes it is necessary to simultaneously disassemble the heating I1
system pipes. condizionamento deve essere realizzato con il contestuale smontaggio dei tubi dell’impianto
di riscaldameto.
)LJ
'LVDVVHPEOLQJSLSHV,DQG,LQVLGHWKHSDVVHQJHUFRPSDUWPHQW
1. 2QWKHULJKWVLGHRIWKHSDVVHQJHUFRPSDUWPHQWORRVHQWKH¿[LQJVFUHZ$)LJ) to disconnect the two air

conditioning system pipes I1 and I2.
2QWKHOHIWVLGHRIWKHSDVVHQJHUFRPSDUWPHQWORRVHQWKHVSHFL¿FFODPSV&)LJ) to remove the 3 sleeves

(%)LJ) on the heating system. %
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3. /RRVHQWKHVSHFL¿FVFUHZVWRGLVFRQQHFWWKHWZRDLUFRQGLWLRQLQJV\VWHPSLSHVI1 and I2 and the three heating

system pipes (')LJ).
I2 I1
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)LJ
4. Working inside the passenger compartment, remove the pipe assembly (()LJ) by applying enough force ) (
towards the inside.
5. Remove the 2 air conditioning system pipes I1 and I2 from the seal ())LJ).
I2 I1
)LJ
I1 I2
)LJ
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% $VVHPEOLQJWKHV\VWHPSUHVVXUHVHQVRU
& $VVHPEOLQJWKHYHQWLODWLRQXQLW
' $VVHPEOLQJWKHOHIWWHPSHUDWXUHVHQVRUDQGFHQWUHDLUÀDSDFWXDWRU
( $VVHPEOLQJWKHULJKWWHPSHUDWXUHVHQVRUDQGFHQWUHFROGDLUÀDSDFWXDWRU
) $VVHPEOLQJWKHYHQWLODWLRQXQLWVHQVRUDQGDFWXDWRUV
* $VVHPEOLQJWKH$&,FRPSUHVVRU
H) Assembling the pROOHQ¿OWHUV
, $VVHPEOLQJWKHDLUFRQGLWLRQHUUDGLDWRU
- $VVHPEOLQJWKHGHK\GUDWLRQ¿OWHU
K) Assembling the air conditioning system pipes
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1. Reposition the actuators:
• 8SSHUYHQWVÀDSDFWXDWRU$)LJ).
• 'HIURVWYHQWVÀDSDFWXDWRU%)LJ).
/LQHXSWKHFRQQHFWLRQHOHPHQWVDQGWLJKWHQWKHWKUHH¿[LQJVFUHZV
,PSRUWDQW
7KHDFWXDWRUFRQQHFWLRQHOHPHQW&)LJPXVWPDWFKXSZLWKWKHFRQQHFWLRQHOHPHQW')LJRQ
WKHÀDSPRWLRQOHYHUVLIWKLVLVQRWWKHFDVHDSSO\YROWDJHWRSLQVDQGRIWKHDFWXDWRUXVLQJD
A fuse connected to a 12 V battery and realign the connection elements. The rotation direction can
EHUHYHUVHGE\VZLWFKLQJWKHSRVLWLYHDQGQHJDWLYHSROHV
2. Connect the actuator connectors.
• Re-assemble the dashboard (086805). )LJ
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The air conditioning system pressure sensor is located at the front of the car on the right.
1. 3RVLWLRQWKHVHQVRU$)LJDQGVFUHZRQ$OZD\VDVVHPEOHZLWKDQHZJDVNHW

6HQVRUDWWDFKPHQWWLJKWHQLQJWRUTXHF.
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7KH XQLRQ KDV D FKHFN YDOYH WKDW DOORZV WKH VHQVRU WR EH UHSRVLWLRQHG ZLWKRXW GUDLQLQJ WKH DLU
conditioning system.
2. 5HFRQQHFWWKHFRQQHFWRURQWKHVHQVRU%)LJ). )LJ
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• $VVHPEOHWKHOXJJDJHFRPSDUWPHQWWUD\(080605).
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2. 3RVLWLRQWKHIDQE\FRQQHFWLQJWKHDLUÀRZGXFWWRWKHDLUFRQGLWLRQHUDLULQOHW%)LJ). '
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9. Reconnect the fan connector.
• Reassemble the plastic parts on the sides of the tray.

• Reassemble the tray (080605). %
• Reassemble, if present, the satellite navigation system (097505).
• Reassemble the luggage compartment light.
• Reassemble the four pins inside the tray.
• 5HDVVHPEOHWKHWUD\VHDOLIQHFHVVDU\PRLVWHQZLWK9DVHOLQHWRHDVHSRVLWLRQLQJ
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1. 5HSRVLWLRQWKHDFWXDWRUIRUWKHFHQWUDODLUYHQWV$)LJ) by lining up the connection elements and tighten the
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A fuse connected to a 12 V battery and realign the connection elements. The rotation direction can
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2. Connect the actuator connector.
3. $VVHPEOLQJWKHOHIWUDGLDWRUWHPSHUDWXUHVHQVRU%)LJ):

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• Insert the sensor and turn 90° to secure to the air conditioning unit
• Connect the sensor connector.
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• DVVHPEOHWKHORZHUGDVKERDUGDVVHPEO\¿QLVKLQJHOHPHQWGULYHUVLGH
• VFUHZV()LJ) are inside the dashboard cover
• VFUHZVDUHQHDUWKHVLGHPHPEHUFRYHU
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• SRVLWLRQWKHGDVKERDUGVLGHFRYHUOHIWFDS')LJ)
5. 5HDVVHPEOHWKHGDVKERDUGFRYHUZLWKWKHLQVWUXPHQWFOXVWHUE\UHYHUVLQJWKHGLVDVVHPEO\SURFHGXUH ) (
• DVVHPEOH WKH GDVKERDUG FRYHU E\ WLJKWHQLQJ WKH WZR VFUHZV *)LJ) on the sides of the dashboard )LJ
cover.
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• DVVHPEOHWKH.RPELRUQDPHQW7KHRUQDPHQWLVSUHVVHGLQZLWKRXWVFUHZV
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WLJKWHQWKHWKUHH¿[LQJVFUHZV
Important!
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3. $VVHPEOLQJWKHVHQVRU%)LJ).
• Insert the sensor and turn 90° to secure to the air conditioning unit
• Connect the sensor connector.
4. Reassemble the foot rest panel passenger side.
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• &RQQHFWWKHJORYHER[OLJKWDQGWKH$,5%$*GHDFWLYDWLRQEORFNSDVVHQJHUVLGH()LJ).
• 7LJKWHQWKHUHDUVFUHZRIWKHJORYHER[))LJ).
• 7LJKWHQWKHORZHUULJKW¿[LQJVFUHZRQWKHGDVKERDUGORZHUFRYHU*)LJ). L
• 7LJKWHQWKHORZHUOHIW¿[LQJVFUHZRQWKHGDVKERDUGORZHUFRYHU+)LJ). L
• 5HSRVLWLRQWKHGDVKERDUGVLGHFRYHUULJKWFDSDQGWLJKWHQWKHVFUHZ,)LJ).
• 6FUHZWKHWZR¿[LQJVFUHZV/)LJ) to the upper dashboard and close the compartment. (
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1. 5HSRVLWLRQWKHYHQWLODWLRQXQLWDFWXDWRU$)LJ) by lining up the connection elements and tighten the three
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the actuator using a 5 A fuse connected to a 12 V battery and realign the connection elements.
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3. ,QVHUWWKHDLUWHPSHUDWXUHVHQVRU%)LJ) and turn 90° to secure to the ventilation unit )LJ
4. Connect the sensor connector.
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• Reassemble the ventilation unit on the car (081605).
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*$VVHPEOLQJWKH$&FRPSUHVVRU
1. ,QVWDOOWKHVKDIWE\ORRVHQLQJWKHORFNQXW$)LJ) and tightening the shaft on the compressor seat. G
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2. ,QVHUWWKHFRPSUHVVRUFRPSOHWHZLWKWKHFRQWUROVKDIWWRZDUGWKHIURQWSDUWRIWKHYHKLFOH
3. ,QVHUWLWVUXEEHUFRYHULQJ%)LJDQGVHFXUHLWZLWKWKHFODPS&)LJ).

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:KHQVHFXULQJWKHVFUHZVPDNHVXUHWRDOVRLQVHUWWKHFRQQHFWRUVXSSRUWEUDFNHW ')LJ). ,
,
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4. 7LJKWHQWKHVFUHZV()LJ) that secure the compressor to the engine.
5. &RQQHFWWKHFRQQHFWRU))LJ).
6. &RQQHFW WKH GHOLYHU\ SLSHV *)LJ DQG WKH LQWDNH SLSHV +)LJ) to the compressor by tightening the
VFUHZV,)LJ).
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• $VVHPEOHWKHOHIWH[KDXVWPDQLIROG(013105).
• $VVHPEOHWKHYHKLFOHHQJLQH (010005).
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H) Assembling the pROOHQ¿OWHUV
1. ,QWURGXFHD¿OWHU$)LJ)OLIWLWDQGKROGLWLQWKDWSRVLWLRQZLWKD¿QJHUDQGLQWURGXFHWKHRWKHURQH

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2. Close the air conditioner lid %)LJ).
8. )DVWHQWKHHQWLUHVXSSRUWLQFOXGLQJEUDFNHWDQGFRQWUROXQLWRQWKHFKDVVLV
9. &RQQHFWWKHFRQQHFWRUV&)LJ) to the ILM control unit.

A
10. 3XWWKHUHOD\V')LJ) on the ILM control unit.
)LJ
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8VHWKH/D5D$6³%DVLFVHWWLQJ´V\VWHP (109000)IRUWKHVRIWZDUHFKHFNVDQGVHWWLQJVVHWXSWKHFRQWURO
XQLWVE\PHDQVRIWKH³DXWRPDWLFPRGH´
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• Reconnect the ZKE control unit (098105).

• 5HFRQQHFWWKHPDLQIXVHER[(098105).
• $VVHPEOHWKHSDVVHQJHUVLGHORZHUGDVKERDUGDVVHPEO\(086805).
• $VVHPEOHWKHSDVVHQJHUVLGHIRRWERDUG(080105).
• Reconnect the battery (091505).
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, $VVHPEOLQJWKHDLUFRQGLWLRQHUUDGLDWRU
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1.&RQQHFWWKHDLUFRQGLWLRQHUUDGLDWRUE\WLJKWHQLQJWKHVFUHZV$)LJ).
2.&RQQHFWWKHDLUFRQGLWLRQHUSLSHVE\WLJKWHQLQJWKHVFUHZV%)LJ).
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3. $VVHPEOHWKHULJKWIURQWDLUFRQYH\RU&)LJE\WLJKWHQLQJWKHVFUHZV')LJ).
• Install the front bumper (080705).

• Restore the air conditioner gas (026008).
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- $VVHPEOLQJWKHGHK\GUDWLRQ¿OWHU
$VVHPEOLQJWKHGHK\GUDWLRQ¿OWHU A
1. 7LJKWHQWKHVFUHZV$)LJVHFXULQJWKHGHK\GUDWRU¿OWHUVXSSRUWEUDFNHWWRWKHFKDVVLV
2 3RVLWLRQDQGIDVWHQWKHGHK\GUDWLRQ¿OWHU%)LJXVLQJ¿[LQJVFUHZV&)LJRQWKHVXSSRUWEUDFNHW
3 7LJKWHQRQHVFUHZ')LJ) for each union on the air conditioning system delivery pipes.
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• $VVHPEOHWKHULJKWUHDUZKHHODUFK(082105).
• $VVHPEOHWKHULJKWZKHHO(060105).
• Fill the air conditioning system (026008).
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L714 02 60 05
K) Assembling the air conditioning system pipes
7KHDLUFRQGLWLRQLQJV\VWHPLVJURXSHGDVIROORZV)LJ):
A1. Front delivery pipe A2

,
, Internal delivery pipe
3
, Internal delivery pipe
C1. Central delivery pipe C2

A1
C2. Central return pipe
,
3 Rear return pipe
3
C1
3 )LJ
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Assembling pipe A1
1. 3RVLWLRQSLSH$RQWKHUDGLDWRUDQGWLJKWHQWKH¿[LQJVFUHZ%)LJ).
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A1
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2. 8VLQJDVFUHZFRQQHFWWKHXQLRQEHWZHHQSLSHA1DQGLQWHUQDOSLSHO%)LJ).

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A1
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3. )DVWHQWKH¿[LQJFOLS&)LJE\WLJKWHQLQJWKHFRUUHVSRQGLQJVFUHZ')LJ).
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L714 02 60 05
Montaggio tubo A2
1. Position pipe A2RQWKHUDGLDWRUDQGWLJKWHQWKH¿[LQJVFUHZ$)LJ).
A2
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A2
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L714 02 60 05
2. 8VLQJDVFUHZFRQQHFWWKHXQLRQEHWZHHQSLSHA2 and central pipe C2%)LJ).
A2
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3. )DVWHQWKH¿[LQJFOLS&)LJE\WLJKWHQLQJWKHFRUUHVSRQGLQJVFUHZ')LJ).
4. 1HDUWKHUDFNIDVWHQWKH¿[LQJFOLS()LJE\WLJKWHQLQJWKHFRUUHVSRQGLQJVFUHZ))LJ).
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• $VVHPEOHWKHIURQWDQGFHQWUHÀDWÀRRUV(082505). )
• $VVHPEOHWKHSURSHOOHUVKDIW(030705). C
• $VVHPEOHWKHIURQWGLIIHUHQWLDO(040905).
• Fill the air conditioning system (026008). '
• $VVHPEOHWKHOXJJDJHFRPSDUWPHQWWUD\(080605).
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L714 02 60 05
&(175$/3$57
Assembling pipe C1
1. 7LJKWHQWKHVFUHZIDVWHQLQJWKHXQLRQ$)LJEHWZHHQSLSHC1 and internal pipe l2. C1
)LJ
C1
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2. 7LJKWHQWKHVFUHZIDVWHQLQJWKHXQLRQ%)LJEHWZHHQSLSHC1 and rear pipe 3.
C1
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L714 02 60 05
3. )DVWHQWKHKRWZDWHUSXPS&)LJE\WLJKWHQLQJVFUHZV')LJ).

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4. 7LJKWHQWKHVFUHZV()LJ) securing the clamp to the propeller shaft tunnel.
5. 7LJKWHQWKHVFUHZV))LJ) securing the clamps on the nearby pipes. )LJ
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L714 02 60 05
Assembling pipe C2
1. 7LJKWHQWKHVFUHZIDVWHQLQJWKHXQLRQ$)LJEHWZHHQSLSHA2 and pipe C2.
C2
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A2
A
C2
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2. 7LJKWHQWKHVFUHZIDVWHQLQJWKHXQLRQ%)LJEHWZHHQSLSHC2 and rear pipe 3.
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3. )DVWHQWKHKRWZDWHUSXPS&)LJE\WLJKWHQLQJVFUHZV')LJ).
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4. 3RVLWLRQDQGIDVWHQWKHVXSSRUWEUDFNHWV()LJE\WLJKWHQLQJWKHFRUUHVSRQGLQJVFUHZVDQGWKHQUHSRVLWLRQ
WKHFODPSV))LJ).
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• $VVHPEOHWKHSURSHOOHUVKDIW(030705).
• $VVHPEOHWKHIURQWFHQWUHDQGUHDUÀDWÀRRUV(082505).
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5($53$57
$VVHPEOLQJSLSH3
1. 7LJKWHQWKHVFUHZIDVWHQLQJWKHXQLRQ$)LJEHWZHHQSLSH3 and pipe C1.
3
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2. 7LJKWHQWKHVFUHZV%)LJ) securing the pipe fastening clamps to the chassis.
3
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3. 7LJKWHQWKHVFUHZ&)LJ) securing pipe 3WRWKHGHK\GUDWRU¿OWHU
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1. 7LJKWHQWKHVFUHZ$)LJ) securing pipe 3 to the compressor and reposition the clamps.
3
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$VVHPEOLQJSLSH3
1. Position and secure pipe 3E\WLJKWHQLQJWKHVFUHZ$)LJ¿[LQJLWWRWKHFRPSUHVVRU

3
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• $VVHPEOHWKHHQWLUHHQJLQH(010005).
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necessary to simultaneously assemble the heating system pipes.
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1. Position pipes , and ,LQVLGHWKHVHDO$)LJZLWKWKHKHDWLQJV\VWHPSLSHV%)LJ).
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2. Position the pipe assembly in its housing inside the passenger compartment and pull the tabs to adjust the
VHDOXQGHUQHDWKWKHYHKLFOH&)LJ).
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3. 7LJKWHQ WKH VSHFL¿F VFUHZV WR FRQQHFW WKH WZR DLU FRQGLWLRQLQJ V\VWHP SLSHV , and , and the three heating
V\VWHPSLSHV')LJ).
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4. 2Q WKH ULJKW VLGH RI WKH SDVVHQJHU FRPSDUWPHQW WLJKWHQ WKH ¿[LQJ VFUHZ ()LJ WR FRQQHFW WKH WZR DLU
conditioning system pipes , and ,.
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RQWKHKHDWLQJV\VWHP&)LJ).
• $VVHPEOLQJWKHSURSHOOHUVKDIW(030705).
• $VVHPEOLQJWKHUHDUDQGFHQWUHYHKLFOHÀRRUV(082505).
• Filling the air conditioning system (026008). )
• Filling the coolant circuit (012108).
• $VVHPEOLQJWKHFHQWHUFRQVROHHQGSDQHOV(086305).
• $VVHPEOLQJWKHFHQWHUFRQVROHRUQDPHQW(086305).
• $VVHPEOLQJWKH%-$SXVKEXWWRQSDQHO(086805).
• $VVHPEOLQJWKHDLUFRQGLWLRQHUJULOOH(081605).
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• $VVHPEOLQJWKHDLUFRQGLWLRQHUFRQWUROXQLW(081605).
• $VVHPEOLQJWKHPXOWLPHGLDV\VWHP(097505).
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Air conditioning system emptying
7KLVV\VWHPHPSOR\V5DFRRODQWWHWUDÀXRULGHHWKDQHZKLFKLVFODVVL¿HGDVDQHQYLURQPHQWDO

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)RUUHDVRQVRILQFRPSDWLELOLW\EHWZHHQFRPSUHVVRURLODQGFRRODQW5FDQQRWEHXVHGLQV\VWHPV
designed to run on R134a.
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:$51,1*
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L714 02 60 07
• Start the engine at idle speed with the hood closed for approximately 15 min. and with the A/C system fan
on maximum speed. This operation facilitates the movement of oil mixed with coolant and heats the system,
preventing freezing during collection.
• Turn off the engine.
• Disassemble the engine compartment left side panels and remove the LIE control unit.
• Connect the LP pipe (BLUE) ($)LJRIWKHGUDLQHTXLSPHQWDQGUH¿OOWKHV\VWHPDWWKHRXWOHW%)LJ) on the
compressor’s intake pipe.
• Connect the HP pipe (RED) (&)LJRIWKHGUDLQHTXLSPHQWDQGUH¿OOWKHV\VWHPDWWKHRXWOHW')LJ) on the
compressor’s delivery pipe.
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1. Activate the equipment’s coolant collection phase. )LJ
2. Drain the system slowly to prevent the formation of ice inside the expansion valve and oil leakage from the
compressor.
3. Check the amount of oil collected in the equipment’s container.
&UHDWLQJWKHYDFXXP '
1. After draining the system completely, bleed the air from the coolant charging cylinder and system.
A vacuum of approximately LP=-0.98 (bar) and HP=-0.2 (bar) in the system is required according to the device
used.
Check system tightness for at least 15 minutes after eliminating all the air from the system.
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L714 02 60 08
Air conditioning system ¿OOLQJ
7KLVV\VWHPHPSOR\V5DFRRODQWWHWUDÀXRULGHHWKDQHZKLFKLVFODVVL¿HGDVDQHQYLURQPHQWDO

IULHQGO\VXEVWDQFHE\WKHOHJLVODWLRQLQIRUFH1HYHUXVHWKLVFRRODQWLQV\VWHPVRSHUDWLQJZLWKWKH
SUHYLRXV5ÀXLG)UHRQ
)RUUHDVRQVRILQFRPSDWLELOLW\EHWZHHQFRPSUHVVRURLODQGFRRODQW5FDQQRWEHXVHGLQV\VWHPV
designed to run on R134a.
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:$51,1*
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L714 02 60 08
• Disassemble the engine compartment left side panels .
• Connect the LP pipe (BLUE) ($)LJRIWKHGUDLQHTXLSPHQWDQGUH¿OOWKHV\VWHPDWWKHRXWOHW%)LJ) on the
compressor’s intake pipe.
• Connect the HP pipe (RED) (&)LJRIWKHGUDLQHTXLSPHQWDQGUH¿OOWKHV\VWHPDWWKHRXWOHW')LJ) on the
FRPSUHVVRU¶VGHOLYHU\SLSH
,QWURGXFLQJRLODQGOHDNGHWHFWRUG\H
:$51,1*
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2LOPXVWQRWEHDGGHGWRDQHZ$&V\VWHP
)RUDOUHDG\XVHGV\VWHPVWKLVDPRXQWHTXDOVWKHDPRXQWRIFRRODQWWKDWZDVFROOHFWHG.HHSLQPLQG )LJ
the amount of oil collected from any replaced components.
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1. ,QVHUWWKHOHDNGHWHFWRUG\HWRLGHQWLI\DQ\OHDNV
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1. Introduce 550 gr of R134a coolant.
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1. Start the engine with the air conditioner on LOZLWKWKHHQJLQHDWDSSUR[LPDWHO\USPIRUDSSUR[LPDWHO\

PLQXWHVWRDOORZFRPSUHVVRURLOGLVWULEXWLRQLQWKHFLUFXLW9HULI\SURSHURSHUDWLRQRIWKHV\VWHP
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• Disconnect the LP-HP pipes.

• Assemble the engine compartment left side panels .
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L714 02 65 03
$ +HDWLQJVROHQRLGYDOYHGLVDVVHPEO\
% +HDWLQJZDWHUSXPSGLVDVVHPEO\
C) Heating system pipes
1
L714 02 65 03
$+HDWLQJVROHQRLGYDOYHGLVDVVHPEO\
The solenoid valve of the heating system is located under the car tunnel.
• Remove the central and rear FDUÀRRUV (082503). A %
• Remove the propeller shaft (030703).
• DrainWKHZDWHUFRROLQJÀXLGV(012107).
'LVDVVHPEOLQJWKHVROHQRLGYDOYHV
1RWH
Prepare a suitable container for collecting the liquid that leaks when the solenoid valve pipes are )LJ
disconnected.
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1. Disconnect the lower pipe ($)LJ) coming from the water pump using the clamp (%)LJ) and plug it.
2. Disconnect the other two pipes pressed onto the unions (&)LJ) and plug them.
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3. Unscrew the nut (')LJ) that secures the solenoid valve bracket (()LJ) to the chassis.
'
)
4. Lower the solenoid valve, disconnect the connector ())LJ) and then remove the solenoid valve complete with
the bracket.
5. Remove the bracket (()LJ) from the solenoid valve, unscrewing the nut (*)LJ) and removing the screw
(+)LJ).
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L714 02 65 03
%+HDWLQJZDWHUSXPSGLVDVVHPEO\
7KHKHDWLQJV\VWHPORZÀRZSXPS$)LJ) is located under the car tunnel.
• Turn the air conditioner to “ON” at the minimum temperature (LO) to close the two solenoid valves that shut off
engine coolant to the air conditioner radiators (left and right).
• Raise the car on the car lift (000000). A
• Remove the central and rear FDUÀRRUV (082503).
• Remove the propeller shaft (030703). %
• DrainWKHZDWHUFRROLQJÀXLGV(012107).
'LVDVVHPEOLQJWKHSXPS '
)LJ
1RWH
Prepare a suitable container for collecting the liquid that leaks when the pump’s pipes are disconnected.
1. Disconnect the connector ($)LJ)LJ). A
2. Disconnect the pump’s pipes (%)LJ) using the clamps (&)LJ) and plug the pipes.
3. Unscrew the 2 bolts of the 2 clamps that secures the pump to the bracket (')LJ)LJ).
4. Remove the heating system pump.
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L714 02 65 03
C) 'LVDVVHPEOLQJWKHKHDWLQJV\VWHPSLSHV
Important!
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engine cooling circuit are at ambient temperature.
The air conditioning system is grouped as follows ()LJ):

C4
C1. Right heating delivery pipe
C2. Left heating delivery pipe
C3. Engine cooling return pipe
Central connection pipe between the engine heating system and C3
C4.
cooling system.
I1. Right heating delivery pipe I2
I4
I2. Left heating delivery pipe C1
C2
I3. Engine cooling return pipe
I4 Connection pipe between the central pipes and the internal pipes.
I1
I3
)LJ
4
L714 02 65 03
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• 'LVDVVHPEOHWKHUHDUDQGFHQWUHYHKLFOHÀRRUV(082503).
'LVDVVHPEOLQJSLSH&
1. 5HOHDVHWKHVSHFL¿FFODPS$)LJ) to disconnect pipe C1 from the union with pipe l4.
A
C1
)LJ
2. Loosen the screw (%)LJ) fastening the pipe mounting bracket to the center console.
)LJ
5
L714 02 65 03
3. Disconnect pipe C1 from the heating system solenoid valves (&)LJ) by loosening the corresponding clamp
(')LJ).
C1
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)LJ
4. Extract and remove pipe C1 ()LJ).
C1
)LJ
6
L714 02 65 03
'LVDVVHPEOLQJSLSH&
C2 A
I4
)LJ
2. Loosen the screw (%)LJ) fastening the pipe mounting bracket to the center console.
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7
L714 02 65 03
3. Release the heating system solenoid valves (&)LJ) from the center console.
C
4. /RRVHQWKHVSHFL¿FFODPSWRGLVFRQQHFWSLSHC2 from the heating system solenoid valves (&)LJ). C2
)LJ
5. Remove pipe C2 ()LJ).
C2
)LJ
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L714 02 65 03
'LVDVVHPEOLQJSLSH&
C3 A I4
)LJ
2. Loosen the screw (B-Fig.15) fastening the pipe mounting bracket to the center console. %
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L714 02 65 03
3. Release the heating system solenoid valves (&)LJ) from the center console.
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)LJ
4. Release the pipe (')LJ) connecting the heating water pump to the cooling system.
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)LJ
10
L714 02 65 03
5. /RRVHQWKH¿[LQJVFUHZV))LJ) to release the cooling system pipes (()LJ).
( (
)LJ
6. /RRVHQ WKH VSHFL¿F FODPS *)LJ) to disconnect connection pipe C4 between the water pump and the
heating system solenoid valves.
C4
)LJ
11
L714 02 65 03
7. /RRVHQWKHVSHFL¿FFODPSWRGLVFRQQHFWSLSHC3 from the piping branch (+)LJ).
C3
8. Extract and remove pipe C3 ()LJ). )LJ
C3
)LJ
12
L714 02 65 03
'LVDVVHPEOLQJSLSH&
1. /RRVHQWKHVSHFL¿FFODPS%)LJ) to disconnect pipe C4 from the heating system solenoid valves
($)LJ).
C4 %
2. /RRVHQWKHVSHFL¿FFODPS')LJ) to disconnect pipe C4 from the heating system pump (&)LJ).
C
'
C4
)LJ
13
L714 02 65 03
3. /RRVHQWKHVSHFL¿FFODPS()LJ) to disconnect pipe C4 from the union with pipe C3.
1RWH
If the fastening clamp (()LJ) of pipe C4LVGLI¿FXOWWRDFFHVV¿UVWUHOHDVHWKHKHDWLQJV\VWHPVROHQRLG C3
valves.
C4
)LJ
4. Extract and remove pipe C4 ()LJ).
C4
)LJ
14
L714 02 65 03
3,3(6,16,'(7+(3$66(1*(5&203$570(17
• Disassemble the central console end panels (086303). A %
• Disassemble the central console ornament (086303).
• Disassemble the BJA push-button panel unit (086803).
• Remove the air conditioner grille (081603).
• Remove the air conditioner control unit (081603).
• Disassemble the multimedia system .
1RWH
A
To disassemble the heating system pipes it is necessary to simultaneously disassemble the air conditioning
system pipes.
)LJ
'LVDVVHPEOLQJSLSHVOOODQGOLQVLGHWKHSDVVHQJHUFRPSDUWPHQW
1. 2QWKHULJKWVLGHRIWKHSDVVHQJHUFRPSDUWPHQWORRVHQWKH¿[LQJVFUHZV%)LJ) to disconnect the two air

conditioning system pipes ($)LJ).
2. 2QWKHOHIWVLGHRIWKHSDVVHQJHUFRPSDUWPHQWORRVHQWKHVSHFL¿FFODPSV&)LJ) to disconnect the three

heating system pipes (OODQGO). I2
I1
I3
)LJ
15
L714 02 65 03
3. 2Q WKH XQGHUQHDWK RI WKH YHKLFOH ORRVHQ WKH VSHFL¿F VFUHZV WR GLVFRQQHFW WKH WZR DLU FRQGLWLRQLQJ V\VWHP
pipes (')LJ) and disconnect the three heating system pipes (&&DQG&) from connection pipe C4. '
C3
C2
I4
C1
)LJ
4. Working inside the passenger compartment, remove the pipe assembly (()LJ) by applying enough force
G I4
towards the inside.
(
5. Remove the two air conditioning system pipes ())LJ) and the heating system pipes (OOODQGO) from
the gasket (*)LJ).
I3
I1
) I2
)LJ
6. Take the assembly apart and remove the individual pipes (OOODQGO) ()LJ).
I4
I3
I1
I2
)LJ
16
L714 02 65 05
$ +HDWLQJVROHQRLGYDOYHDVVHPEO\
% +HDWLQJZDWHUSXPSDVVHPEO\
C) Heating system pipes
1
L714 02 65 05
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) A
The heating system solenoid valve is located under the car tunnel.
1. Assemble the bracket ($)LJ; $)LJ) on the solenoid valve using the screw (%)LJ) and the self-locking
nut (&)LJ; &)LJ). Place new seals in between (')LJ).
G
2. Insert the connector (()LJ) and then assemble the solenoid valve using the nut ())LJ; ))LJ) to secure
it to the chassis. H
3. Unplug and reconnect the pipes (*)LJ; *)LJ) and secure the clamp (+)LJ; +)LJ).
)LJ
• Assemble the propeller shaft (030705). %
• Bleed the engine cooling system .

' A
• Start the engine and check that while the A/C system is on HI, hot air issues from the air conditioning system air
(
vents. )
• Assemble the central and rear FDUÀRRUV .
'
H
)LJ
2
L714 02 65 05
% $VVHPEOLQJWKHKHDWLQJZDWHUSXPS
A
1. 3RVLWLRQWKHKHDWLQJV\VWHPORZÀRZSXPS($)LJ) under the car tunnel.
2. Connect the pump pipes (%)LJ) acting on the clamps (&)LJ).
3. Connect the connector (')LJ; ')LJ).

'
4. Tighten the bolts of the two clamps securing the pump to the chassis (()LJ; ()LJ). %
(
• Assemble the propeller shaft (030705). )LJ
• Fill the circuit and then bleed the engine cooling circuit (012106).
'
• Start the engine and check that while the A/C system is on HI, hot air issues from the air conditioning system
air vents.
• Assemble the central and rear FDUÀRRUV .
)LJ
3
L714 02 65 05
C) Assembling the heating system pipes
The heating system is grouped as follows ()LJ):

C4
C1. Right heating delivery pipe
C2. Left heating delivery pipe
C3. Engine cooling return pipe
Central connection pipe between the engine heating system and C3
C4.
cooling system.
I1. Right heating delivery pipe I2
I4
I2. Left heating delivery pipe C1
C2
I3. Engine cooling return pipe
I4 Connection pipe between the central pipes and the internal pipes.
I1
I3
)LJ
4
L714 02 65 05
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Assembling pipe C1
1. Position pipe C1 ()LJ) in its housing.
C1
)LJ
2. )DVWHQWKHVSHFL¿FFODPS$)LJ) to connect pipe C1 to the union with pipe l4.
A
C1
)LJ
5
L714 02 65 05
3. )DVWHQWKHVSHFL¿FFODPS&)LJ) to connect pipe C1 to the heating system solenoid valves (%)LJ).
C1
)LJ
4. Tighten the screw (')LJ) to fasten the pipe mounting bracket to the center console.
1RWH
Direct the pipe fastening clamp openings so that they are easy to access the next time they need to be
disassembled.
'
)LJ
6
L714 02 65 05
Assembling pipe C2
1. Position pipe C2 in its housing ()LJ).
C2
)LJ
C2 A
I4
)LJ
7
L714 02 65 05
3. )DVWHQWKHVSHFL¿FFODPSWRFRQQHFWSLSHC2 to the heating system solenoid valves (&)LJ).
4. Fasten the heating system solenoid valves (&)LJ) to the center console.
C
C2
)LJ
5. Tighten the screw (')LJ) to fasten the pipe mounting bracket to the center console.
'
1RWH
disassembled.
)LJ

L714 02 65 05
Assembling pipe C3
C3
)LJ
C3 A I4
)LJ

L714 02 65 05
3. )DVWHQWKHVSHFL¿FFODPS%)LJ) to connect connection pipe C4 between the water pump and the heating
system solenoid valves.
C4
)LJ
4. Connect pipe C3 to the piping branch and tighten the corresponding clamp (&)LJ).
C3
)LJ
10
L714 02 65 05
5. Fasten the pipe (')LJ) connecting the heating water pump to the cooling system.
'
)LJ
6. Fasten the heating system solenoid valves (()LJ) to the center console. (
)LJ
)
7. Tighten the screw ())LJ) to fasten the pipe mounting bracket to the center console.
)LJ
11
L714 02 65 05
7LJKWHQWKH¿[LQJVFUHZV+)LJ) to fasten the cooling system pipes (*)LJ).
G G
1RWH
disassembled.
)LJ
12
L714 02 65 05
Assembling pipe C4
C4
)LJ
2. )DVWHQWKHVSHFL¿FFODPS%)LJ) to connect pipe C4 to the heating system solenoid valves ($)LJ).
C4 %
3. )DVWHQWKHVSHFL¿FFODPS')LJ) to connect pipe C4 to the heating system pump (&)LJ.
C
'
C4
)LJ
13
L714 02 65 05
4. )DVWHQWKHVSHFL¿FFODPS()LJ) to connect pipe C4 to the union with pipe C3.
1RWH
Direct the pipe fastening clamp openings so that they are easy to access the next time they need to be C3
disassembled.
• Assemble the propeller shaft (030705). (
• Fill the circuit and then bleed the engine cooling system (012106).
vents. C4
• $VVHPEOHWKHUHDUDQGFHQWUHYHKLFOHÀRRUV. )LJ
14
L714 02 65 05
3,3(6,16,'(7+(3$66(1*(5&203$570(17
I4
1RWH
As mentioned already in the disassembly procedure, to assemble the heating system pipes it is necessary
to simultaneously assemble the air conditioning system pipes. I3
I1
I2
$VVHPEOLQJSLSHVOOODQGOLQVLGHWKHSDVVHQJHUFRPSDUWPHQW
)LJ
1. Position the individual pipes (OOODQGO) to piece together the assembly ()LJ).
%
A
2. Position the pipe assembly in its housing inside the passenger compartment and pull the tabs to adjust the
gasket underneath the vehicle ($)LJ). C3
3. 7LJKWHQWKHVSHFL¿FVFUHZVWRFRQQHFWWKHWZRDLUFRQGLWLRQLQJV\VWHPSLSHV%)LJ) and the three heating

system pipes (OODQGO) to connection pipe l4.
C1 I4
C2
)LJ
4. 2Q WKH ULJKW VLGH RI WKH SDVVHQJHU FRPSDUWPHQW WLJKWHQ WKH ¿[LQJ VFUHZV ')LJ) to connect the two air
conditioning system pipes (&)LJ).
C '
)LJ
15
L714 02 65 05
5. 2Q WKH OHIW VLGH RI WKH SDVVHQJHU FRPSDUWPHQW WLJKWHQ WKH VSHFL¿F FODPSV ()LJ) to connect the three
heating system pipes (OODQGO).
1RWH I2
I1
disassembled.
I3
• Assemble the propeller shaft (030705).

)LVVDJJLRYLWLFRSSLDGLVHUUDJJLRF
(
• Fill the circuit and then bleed the engine cooling system (012106).
vents. )LJ
• $VVHPEOHWKHUHDUDQGFHQWUHYHKLFOHÀRRUV.
• Assemble the center console end panels .
• Assemble the center console ornament .
• Assemble the BJA push-button panel unit .
• Assemble the air conditioner grille .
• Assemble the air conditioner control unit .
• Assemble the multimedia system .
16
L714 03 01 00
*HDUER[WHFKQLFDOGDWD
• Fast engagement 6 gear ratios + reverse gear

• 6\QFKURQLVHUVZLWKÀRDWLQJULQJV
• Meshing clearance (all gears) 0.11 ÷ 0.03 mm
• Lubrication with gear pump
• Net Weight: 80 Kg
• Oil quantity: 4 Lt
• Number teeth: 25
• Gearbox ratios:
67' &20)257
(Comfort Package)
1st gear 1 : 3,313 1 : 2,563
2nd gear 1 : 2,053 1 : 1,850
3rd gear 1 : 1,458 1 : 1,423
4th gear 1 : 1,138 1 : 1,138
5th gear 1 : 0,939 1 : 0,939
6th gear 1 : 0,784 1 : 0,806
Reverse 1 : 2,813 1 : 2,813
countershaft/front differential input shaft 1 : 1,409
countershaft/rear differential input shaft 1 : 1,240
• 0DQXDOW\SH with cable control
• (*HDU W\SH robotised with electronically managed electro-hydraulic control and 4 function modes: normal,
automatic, sport and low adherence.
Hydraulic circuit pressure: approx. 40 – 50 bar
Valve trigger pressure approx. 90 bar
System capacity (000300)
Fig.1
1
L714 03 01 00
*HDUER[GHVFULSWLRQ
1 Clutch Housing 38 Roller Cage
2 Ball Bearing 39 Retaining Ring
3 Clutch Shaft 40 1st-2nd Speed Triple Cone Synchroniser
4 Drive Shaft 41 Complete 2nd Speed Gear
5 Main Shaft Front Ring Nut 42 Roller Cage
6 Ball Bearing 43 Spacer Ring
7 Thrust Washer 44 Ring
8 Roller Cage 45 Lay Shaft
9 Complete 4th Speed Gear 46 Bearings Retaining Plate
10 Retaining Ring 47 Intermediate Plate
11 3rd-4th Speed Double/Triple Cone Synchroniser 48 Pinion Driving Gear
12 Complete 3rd Speed Gear 49 Drive Driving Gear
13 Roller Cage 50 Drive Driven Gear
14 Complete 6th Speed Gear 51 Roller Bearing
15 6th Speed Gear Spacer 52 Radial Shaft Seal
16 Retaining Ring 53 Roller Bearing
17 5th-6th Speed Double Cone Synchroniser 54 Ring Nut
18 Complete 5 Th Speed Gear 55 Drive Shaft
19 Roller Cage 56 Ball Bearing
20 Complete 3rd-4th Speed Shaft 57 Drive Shaft Cover
21 Complete 3rd-4th Speed Selector Fork 58 Pinion Adjusting Washer
22 Complete 1st-2nd Speed Selector Fork 59 Tapered Roller Bearing
23 Complete Reverse Gear Shift Shaft 60 Preload Adjusting Washer
24 O-ring 61 Pinion Driven Gear
25 Ball Bushing 62 Tapered Roller Bearing
26 Roller Bearing 63 Ring Nut
27 Complete 5th-6th Speed Selector Fork 64 Manual Gearbox Gear Shift Mechanism
28 Reverse Drive Gear 65 Complete Oil Pump
29 Ring Nut 66 Roller Casing
30 Complete Reverse Fork 67 Idle Gear Shoulder Ring
31 Rear Cover 68 Idle Gear - Reverse
32 Complete Reverse Synchroniser 69 Driving Dowels
33 Roller Cage 70 Driving Pin
34 Complete Reverse Idle Gear 71 Pinion
35 Reverse Gear Bushing 72 Gearbox Housing
36 Thrust Washer 73 Washer
37 Complete 1st Speed Gear 74 Retaining Ring
2
L714 03 01 00
General instructions
Prior to starting work on the dismantling or assembing of the Gearbox and Differential assy, bear in mind the following
points:
• When working on the gearbox assy observe high standards of cleanliness. All parts should be cleaned throughly
prior to assembly.
• The location where the work is to be carried out should be dust-free clean.
• 0DNHVXUHWKDWDOOWKHQHFHVVDU\WRROVDUHDYDLODEOHSDUWLFXODUO\WKRVHPHQWLRQHGLQWKLVPDQXDO3DUWV¿WWHG
incorrectly can cause serious damage, in the same way as metal chips or foreign bodies.
• During the differential assy overhaul, you are advised tu substitute the following with new parts: oil sealing rings,
gaskets, retaining rings and any parts damaged during dismantling.
• If breakage occurs inside the planetary gears side or differential, all lines, casing and should be cleaned thor-
oughl to prevent damage caused by residues left inside the system.
SHIMS
All adjustments shall be carried out after all adjustment shims have been selected measuring them one by one with
a micrometer gauge and, then, summing up all values measured; do not trust incorrect measurement of pack as a
unit or sum of nominal value printed on each shim.
SEALS FOR REVOLVING SHAFTS
3URFHHGDVIROORZVIRUSURSHU¿WWLQJRIRLOVHDOV
• prior assembly, seals should be soared, for at least half an hour, in a bath with the same oil to be sealed;
• FOHDQWKRURXJKO\VKDIWDQGPDNHVXUHWKDWZRUNLQJVXUIDFHLVQRWGDPDJHGSRVLWLRQVHDOLQJOLSDJDLQVWWKHÀXLG
to be sealed; in case of hydrodynamic lip lines should be oriented so as that, considering direction of revolving
VKDIWWKH\OHDGÀXLGLQVLGHRIVHDOLQJPHDQV
• VPHDUVHDOLQJOLSZLWKD¿OPRIOXEULFDQWRLOLVEHWWHUWKDQJUHDVHDQG¿OOXSZLWKJUHDVHWKHVSDFHEHWZHHQ
sealing lip and dust shield lip, if using double sealing lip type seals;
• SUHVVVHDOLQUHOHYDQWSRVLWLRQRUXVHDSURSHU¿WWHUZLWKÀDWFRQWDFWVXUIDFHQHYHUXVHKDPPHURUPDOOHWWR
mount seal;
• ZKHQSUHVV¿WWLQJVHDOPDNHVXUHWKDWLWEHFRUUHFWO\GULYHQLQUHOHYDQWSRVLWLRQLHVTXDUHZLWKUHVSHFWWRLWV
SRVLWLRQDV¿WWLQJLVFRPSOHWHGPDNHVXUHLIUHTXLUHGWKDWVHDOLWVHOIEHLQFRQWDFWZLWKUHOHYDQWVKRXOGHU
• to prevent damage of seal lip when inserting shaft, duly protect component during assembly.
3
L714 03 01 00
O-RING SEALS
Lubricate O-RING seals at assembly to prevent twisting that would impair correct sealing.
SEALING COMPOUNDS
)RUPDWFKLQJVXUIDFHVLGHQWL¿HGE\;XVHFRPSRXQG/2&7,7(RUVLPLODURQH
Clean matching surface as follows prior, smearing compound:
• remove old deposits using a metal brush;
• degrease surfaces by one the following cleaners: trichloroethylene, kerosene or a warm water and soda solu-
tion.
BEARINGS
When assembling them it is advisable to proceed as follows:

• KHDWWKHPDWWR½&EHIRUH¿WWLQJRQUHOHYDQWVKDIWV
• cool them before inserting in relevant external position.
SPRING PINS
When using spring pins be sure that lengthwise slot be positioned toward stress on pin.
&RLOSLQVGRQIWUHTXLUHVSHFL¿FSRVLWLRQ
(QYLURQPHQWVDIHJXDUGV
Dispose of worn and replaced materials according to local regulation.
4
L714 03 01 00
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In order to assure the right condition, handling and utilization of the product, perform the following instruction:
• TEMPERATURE CONDITIONS
• Storage - 40 + 70° C
• Working - 30 + 60° C
• During the handling of the product avoid any collision in order not to damage the external and internal
components.
• In case of long inactivity of the product, before installing or starting, beware that the product has not suffered
any damage.
• Do not energize the electrical components with incompatible voltage.
• 1HYHUXVHSHWUROVROYHQWVRURWKHULQÀDPPDEOHÀXLGVXVHRQO\DSSURYHGFRPPHUFLDOVROYHQWVWKDWDUHERWK
QRQLQÀDPPDEOHDQGQRWWR[LF
• In case of stopping and before living the vehicle, make sure the parking brake is engaged.
&$87,21
Failing to follow these instructions or an unproper use of the product may result in harm to persons and
objects damages.
1RWH
,QWURGXFWLRQWRWKH(JHDUV\VWHP
5
L714 03 01 03
'LVDVVHPEOLQJWKHJHDUER[PDQXDOJHDUER[

• Drain the engine oil circuit .
• Disassemble the rear tires .
• Disassemble the rear wheel arches .
• 'LVDVVHPEOHWKHUHDUYHKLFOHÀRRU.
• Disassemble the engine hood .
• Remove the engine internal panels (Engine Bay) .
• Disassemble the rear lights .
• Disassemble the upper panel . A
• Remove the rear bumper .
• Remove the stabiliser bar .
• 5HPRYHWKHDLU¿OWHUDVVHPEO\.
• Remove the exhaust terminal .
• Remove the oil tank. A
'LVDVVHPEOLQJWKHJHDUER[
1. Loosen the clamps on both sides (A-Fig.1) securing the rear hood opening pipe to the chassis. Fig.1
2. Disconnect the cable connector (B-Fig.2) originating from the gearshift selector (reverse gear).
B
3. Disconnect the cable connector (C-Fig.2) originating from the starter.
4. Disconnect the speed sensor connector (D-Fig.2).
Fig.2
1
L714 03 01 03
Loosen the nut (()LJ) on both sides securing the gearbox to the chassis.
Loosen the screw (F-Fig.3) securing the mounting bracket of the gearbox oil circuit pipes.
7. Disconnect the oil circuit delivery and return pipes (G-Fig.3) from the gearbox.
( (
&ORVHWKHJHDUER[K\GUDXOLFFRQQHFWLRQVXVLQJWKHVSHFL¿FSOXJVWRSUHYHQWGLUWIURPHQWHULQJ G
G
3RVLWLRQDVXLWDEOHFRQWDLQHUWRFROOHFWDQ\UXQRIIJHDUER[RLO
Fig.3
Disconnect the positive cable connector (H-Fig.4) from the starter.
Disconnect the earth cable (I-Fig.4) from the starter.
H I
Fig.4
2
L714 03 01 03
10. Cut three clamps (-)LJ). 1
11. Loosen three screws (.)LJ) on the left side and remove the joint bulkhead (/)LJ) between the axle shaft
and the differential to release the gearbox.
J
M
12. Loosen the rear differential gearbox assembly support screw (0)LJ) and remove the bracket (1)LJ). J
K
J
)LJ
13. Loosen three screws (2)LJ) on the right side and remove the joint bulkhead (3)LJ) between the axle shaft Q
and the differential.
14. Loosen the rear differential gearbox assembly support screw (4)LJ) and remove the bracket (5)LJ).
R
O 3
)LJ
Disconnect the two gear selection cables (S-Fig.7). T

S
Loosen three screws to remove the gear selection cable support bracket (T-Fig.7).
Fig.7
3
L714 03 01 03
17. Loosen the six screws on both sides (8)LJ) securing the axle shaft to the rear differential.
)LJ
V
Disconnect the speed sensor cable connector (9)LJ).
)LJ
Disconnect the power steering circuit pipe (:)LJ) from the corresponding pump.
3RVLWLRQDVXLWDEOHFRQWDLQHUWRFROOHFWDQ\UXQRIISRZHUVWHHULQJRLO
Fig.10
4
L714 03 01 03
20. Loosen the four screws (X-Fig.11) securing the engine to the chassis.
X X
Fig.11
21. Loosen the nine screws (Y-Fig.12) securing the gearbox housing to the engine.
Fig.12
22. Lift the engine slightly and remove the gearbox rear differential assembly (Z-Fig.13) using a suitable lifting Z
device.
Fig.13

L714 03 01 05
$VVHPEOLQJWKHJHDUER[PDQXDOJHDUER[
1. Lift the engine (A-Fig.1VOLJKWO\XVLQJDVSHFL¿FOLIWLQJGHYLFHWRIDFLOLWDWHWKHFRQQHFWLRQEHWZHHQWKHHQJLQH

DQGWKHJHDUER[UHDUGLIIHUHQWLDODVVHPEO\ A
Fig.1
2. 3RVLWLRQWKHJHDUER[UHDUGLIIHUHQWLDODVVHPEO\RQWKHHQJLQHB-Fig.2

D a B
Important!
(QVXUH WKH JHDU VKDIW (a-Fig.2) DQG 372 VKDIW (b-Fig.2) DUH DOLJQHG ZLWK WKHLU UHVSHFWLYH HQJLQH
connections.
Lubricate the gear shaft (a-Fig.2) DQG372VKDIW(b-Fig.2) junctures. b
3. 7LJKWHQDVFUHZC-Fig.2WRVHFXUHWKHJHDUER[UHDUGLIIHUHQWLDODVVHPEO\WRWKHHQJLQH

4. 7LJKWHQWKHUHPDLQLQJHLJKWVFUHZVD-Fig.2VHFXULQJWKHJHDUER[KRXVLQJWRWKHHQJLQH

Fig.2
1
L714 03 01 05
5. 7LJKWHQIRXUVFUHZV()LJWRVHFXUHWKHHQJLQHWRWKHFKDVVLV

6FUHZDWWDFKPHQWWLJKWHQLQJWRUTXHE ( (
Fig.3
&RQQHFWWKHSRZHUVWHHULQJFLUFXLWSLSHF-Fig.4WRWKHFRUUHVSRQGLQJSXPS
Fig.4
7. &RQQHFWWKHVSHHGVHQVRUFDEOHFRQQHFWRUG-Fig.5
G
Fig.5
2
L714 03 01 05
7LJKWHQWKHVL[VFUHZVRQERWKVLGHV+)LJVHFXULQJWKHD[OHVKDIWWRWKHUHDUGLIIHUHQWLDO

)LJ
3RVLWLRQWKHJHDUVHOHFWLRQFDEOHVXSSRUWEUDFNHWI-Fig.7E\WLJKWHQLQJWKUHHVFUHZV I

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10. &RQQHFWWKHWZRJHDUVHOHFWLRQFDEOHVJ-Fig.7
Fig.7
11. 3RVLWLRQWKHMRLQWEXONKHDG.)LJRQWKHULJKWVLGHEHWZHHQWKHD[OHVKDIWDQGWKHGLIIHUHQWLDOE\WLJKWHQLQJ 1

WKUHHVFUHZV/)LJ
12. 3RVLWLRQWKHEUDFNHW0)LJDQGWLJKWHQWKHUHDUGLIIHUHQWLDOJHDUER[DVVHPEO\VXSSRUWVFUHZ1)LJ M
L K
)LJ
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13. 3RVLWLRQWKHMRLQWEXONKHDG2)LJRQWKHOHIWVLGHEHWZHHQWKHD[OHVKDIWDQGWKHGLIIHUHQWLDOE\WLJKWHQLQJ Q

WKUHHVFUHZV3)LJ
14. 3RVLWLRQWKHEUDFNHW4)LJDQGWLJKWHQWKHUHDUGLIIHUHQWLDOJHDUER[DVVHPEO\VXSSRUWVFUHZ5)LJ

S
15. 6HFXUHWKUHHFODPSV6)LJ R
S
3
S
)LJ
&RQQHFWWKHRLOFLUFXLWGHOLYHU\DQGUHWXUQSLSHVT-Fig.10WRWKHJHDUER[
17. 7LJKWHQWKHVFUHZU-Fig.10VHFXULQJWKHPRXQWLQJEUDFNHWRIWKHJHDUER[RLOFLUFXLWSLSHV
7LJKWHQWKHQXWV-Fig.10RQERWKVLGHVVHFXULQJWKHJHDUER[WRWKHFKDVVLV

%ROWDWWDFKPHQWWLJKWHQLQJWRUTXHF
V V
Fig.10
4
L714 03 01 05
&RQQHFWWKHSRVLWLYHFDEOHFRQQHFWRU:)LJWRWKHVWDUWHU
20. &RQQHFWWKHHDUWKFDEOHX-Fig.11WRWKHVWDUWHU
: X
Fig.11
21. &RQQHFWWKHVSHHGVHQVRUFRQQHFWRUY-Fig.12

A1
22. &RQQHFWWKHFDEOHFRQQHFWRUZ-Fig.12RULJLQDWLQJIURPWKHVWDUWHU
23. &RQQHFWWKHFDEOHFRQQHFWRUA1-Fig.12RULJLQDWLQJIURPWKHJHDUVHOHFWRUUHYHUVHJHDU
Fig.12
24. 6HFXUHWKHFODPSVRQERWKVLGHVB -Fig.13VHFXULQJWKHUHDUKRRGRSHQLQJSLSHWRWKHFKDVVLV

1
B1
3ODFHWKHJHDUVHOHFWLRQOHYHULQQHXWUDODQGPDNHDQ\QHFHVVDU\DGMXVWPHQWVWRWKHJHDUER[

B1
Fig.13
5
L714 03 01 05
• $VVHPEOHWKHRLOWDQN
• $VVHPEOHWKHH[KDXVWWHUPLQDO
• $VVHPEOHWKHDLU¿OWHUDVVHPEO\
• $VVHPEOHWKHVWDELOLVHUEDU
• $VVHPEOHWKHUHDUEXPSHU
• $VVHPEOHWKHXSSHUSDQHO5
• $VVHPEOHWKHUHDUOLJKWV
• $VVHPEOHWKHHQJLQHLQWHUQDOSDQHOV(QJLQH%D\
• $VVHPEOHWKHHQJLQHKRRG
• $VVHPEOHWKHUHDUYHKLFOHÀRRU
• $VVHPEOHWKHUHDUZKHHODUFKHV
• $VVHPEOHWKHUHDUWLUHV
• )LOOWKHHQJLQHRLOFLUFXLW

L714 03 07 03
'LVDVVHPEOLQJWKHSURSHOOHUVKDIW
A
A
• Raise the vehicle on the car lift (000000). A
• 'LVDVVHPEOHWKHUHDUDQGFHQWUHYHKLFOHÀRRUV(082503). A
A
'LVDVVHPEOLQJWKHSURSHOOHUVKDIW
A
1. Loosen the 6 screws (A-Fig.1) securing the propeller shaft to the front differential.
Fig.1
2. Loosen the 6 screws securing the propeller shaft to the PTO shaft (B-Fig.2).
B
B
B B
B
B
Fig.2
3. Loosen the 2 screws (C-Fig.3) that secure the propeller shaft bracket to the chassis.
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4. Remove the propeller shaft.
C C
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L714 03 07 05
Assembling the propeller shaft

A
A
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1. Fit the propeller shaft into place.
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2. Tighten the 6 screws (A-Fig.1) securing the propeller shaft to the front differential.
Screw attachment: tightening torque (000800-24c).
Fig.1
3. Tighten the 2 screws (B-Fig.2) that secure the propeller shaft bracket to the chassis.
Screw attachment: tightening torque (000800-24d).
B B
Fig.2
4. Tighten the 6 screws securing the propeller shaft to the PTO shaft (C-Fig.3).
C
Screw attachment: tightening torque (000800-23a).
C
C C
C
C
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1. Loosen the 4 screws ($)LJ) securing the two radiator mounting brackets (%)LJ) to the chassis.
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Position a suitable container to collect the gearbox oil.
2. After releasing the radiator, disconnect the two gearbox oil circuit pipes (&)LJ).
3. Remove the radiator including the air conveyors (')LJ).
)LJ
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L714 03 17 03
4. /RRVHQ WKH VSHFL¿F VFUHZV *)LJ) to remove the front conveyor (()LJ) and the rear conveyor ()
)LJ).
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5. Remove the gearbox oil radiator (+)LJ).
)LJ
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L714 03 17 03
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The gearbox oil circuit is grouped as follows ()LJ):

A1
A1. Front delivery pipe
3 Rear return pipe 3
A2
3
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1. Unscrew the nuts ($)LJ) and disconnect the front A1 and A2 pipes from the gearbox oil radiator.
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2. Loosen the screw (%)LJ) fastening the gearbox oil radiator mounting bracket (&)LJ) to the chassis.
A1
C
A1
A
A2
A2
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3. Unscrew the nuts (')LJ) and disconnect the front A1 and A2 pipes from the temperature regulator.
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4. Remove and extract the front A1 and A2 gearbox oil circuit pipes ()LJ).
A1
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• SRaise the vehicle on the car lift (000000).
• Remove the right wheel (060103).
• Disassemble the right rear wheel arch (082103).
• Remove the exhaust (025103). 3
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1. /RRVHQWKH¿[LQJVFUHZV$)LJ) and disconnect the rear 3 and 3 pipes from the temperature regulator.
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)LJ
2. Loosen the screws (%)LJ) fastening the rear 3 and 3 pipe mounting brackets to the gearbox support.
3
3
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L714 03 17 03
3. Unscrew the nuts (&)LJ) and disconnect the rear 3 and 3 pipes from the gearbox.
3
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4. Remove and extract the rear 3 and 3 gearbox oil circuit pipes ()LJ)
3
3
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1. Unscrew the nuts ($)LJ) and disconnect the front A1 and A2 pipes from the temperature regulator.
2. /RRVHQWKH¿[LQJVFUHZ%)LJ) and disconnect the rear 3 and 3 pipes from the temperature regulator. A A2
3
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3. Loosen the screw (&)LJ¿[LQJWKHWHPSHUDWXUHUHJXODWRUWRWKHFKDVVLV
4. Remove and extract the temperature regulator (')LJ')LJ).
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C) Assembling the temperature regulator
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1. Tighten 5 screws on the gearbox oil radiator (&)LJ) to assemble the front conveyor ($)LJ) and the rear
conveyor (%)LJ).
)LJ
2. Position the radiator including the air conveyors (')LJ).
A C % A
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L714 03 17 05
3. Connect the two gearbox oil circuit pipes (()LJ).

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4. Tighten the 4 screws ())LJ) securing the two radiator mounting brackets (*)LJ) to the chassis.
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• Fill with gearbox oil (032108)
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• Check the gearbox oil level (032101).
• Assemble the rear wheel arch (082105).
• Assemble the right rear wheel (060105).

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1. Position the front A1 and A2 gearbox oil circuit pipes ()LJ).
A2
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2. Tighten the nuts ($)LJ) to connect the front A1 and A2 pipes to the temperature regulator.
A1
A A2
)LJ
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L714 03 17 05
3. Tighten the nuts (%)LJ) to connect the front A1 and A2 pipes to the gearbox oil radiator.
4. Tighten the screw (&)LJ) fastening the gearbox oil pipe mounting bracket (')LJ) to the chassis.

A1
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• Assemble the rear wheel arch (082105). A1
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A2
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1. Position the rear 3 and 3 gearbox oil circuit pipes ()LJ).
3
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3
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3. Tighten the nuts (%)LJ) to connect the rear 3 and 3 pipes to the gearbox.
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4. Tighten the screws (&)LJ) fastening the rear 3 and 3 pipe mounting brackets to the gearbox support.
C
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• Assemble the exhaust (025103).
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C) Assembling the temperature regulator
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1. Unscrew the oil level inspection nut (A-Fig.1) on the side of the gearbox.
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Every time the gearbox oil level inspection nut is disassembled, replace the copper gasket.
2. Once the nut has been removed, check that the gearbox oil level reaches the hole: If this is not the case, top up
using an appropriate tool.
A
Fig.1
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• Raise the vehicle on the car lift . A
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• Disassemble the rear lights. %
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• Remove the rear bumper . (
• Remove the stabiliser bar . ( '
• Remove the exhaust terminal .
• Remove the oil tank .
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discharge (Routine 5) I
1. Loosen the clamps on both sides ($)LJ) securing the rear hood opening pipe to the chassis.
2. Loosen four screws (&)LJ) to remove the E-Gear actuator heat-proof panel (%)LJ).
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3. Loosen four screws (()LJ) to remove the E-Gear actuator oil tank heat-proof panel (')LJ).
4. Cut three clamps ())LJ). *
Disconnect the connectors (*)LJ) of the two potentiometers. H
Disconnect the speed sensor connector (+)LJ) and the earth cable (,)LJ). )LJ
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L714 03 21 03
7. Disconnect the cable connector (-)LJ) originating from the starter.
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Disconnect the earth cable (/)LJ) from the starter. M
10. Loosen the nut (0)LJ) on both sides securing the gearbox to the chassis.
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11. Disconnect the clutch connector (1)LJ). 1

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12. Disconnect the S-Cam valve connectors (2)LJ).
)LJ
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L714 03 21 03
13. Loosen a screw (4)LJ) on the right side to disconnect the delivery and return pipes (3)LJ) from the
gearbox oil circuit temperature regulator.
3
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14. Disconnect the E-Gear pump connector (5)LJ).
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Disconnect the speed sensor connector (6)LJ) on the left side.
)LJ
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L714 03 21 03
Loosen three screws (7)LJ) on both sides of the vehicle and remove the joint bulkhead (8)LJ) between U T
the axle shaft and the differential to release the gearbox. V :
17. Loosen the rear differential gearbox assembly support screw (9)LJ) on both sides of the vehicle and remove
the bracket (:)LJ).
Loosen the six screws (;)LJ) on both sides of the vehicle securing the axle shaft to the rear differential.
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Disconnect the power steering circuit pipe (<)LJ) from the corresponding pump.
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20. Loosen the four screws (=)LJ) securing the engine to the chassis.
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L714 03 21 03
21. Loosen the nine screws (A1)LJ) securing the gearbox housing to the engine.
%1 A1
22. Lift the engine slightly and remove the gearbox rear differential assembly including the E-Gear actuator (%1
)LJ) using a suitable lifting device.
)LJ

L714 03 21 03
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• Remove the engine internal panels (Engine Bay).
• Disassemble the rear lights. %
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• Disassemble the upper panel .
• Remove the rear bumper .
• Remove the stabiliser bar .
• Remove the exhaust terminal . %
• Remove the oil tank .
• Disassemble the gearbox 32,17$.
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1. Position the handle ($)LJ) by tightening four fastening screws (%)LJ) to remove the E-Gear actuator.
'
2. Loosen three screws (&)LJ) securing the oil pan and the E-Gear actuator accumulator (')LJ) to the
gearbox rear differential assembly.
C
)LJ
7
L714 03 21 03
3. Loosen the three screws (()LJ) on the left side securing the S-Cam valve assembly mounting bracket.
)LJ
4. Loosen the three screws ())LJ) on the right side securing the S-Cam valve assembly mounting bracket.
)LJ
Disconnect the hydraulic pipe (*)LJ).
)LJ

L714 03 21 03
Loosen the eight screws (+)LJ) securing the E-Gear actuator to the gearbox rear differential assembly.
H
)LJ
7. Remove the E-Gear actuator, including the oil pan and accumulator (,)LJ) .
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1. Disconnect the connectors ($)LJ) connected to the S-Cam system valves. )LJ
2. /RRVHQWKHWZR¿[LQJVFUHZV%)LJ) for each valve.
C
Use a 24 wrench to loosen and release the pressure sensor (&)LJ).
)LJ
3. Remove the valves ()LJ).
)LJ
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L714 03 21 03
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discharge (Routine 5)
1. 8VHWKHVSHFL¿FZUHQFKH to loosen the accumulator ($)LJ).
2. Remove the accumulator.
)LJ
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1. /RRVHQWKHIRXUFRUUHVSRQGLQJ¿[LQJVFUHZV%)LJ) to remove the safety guard ($)LJ).
2. Loosen the three screws (&)LJ) securing the oil pump. )LJ
3. Remove the pump (')LJ). C
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• Disassemble the E-gear actuator 32,17%.
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1. Cut the low pressure pipe ($)LJ).
2. Loosen the four screws (%)LJ) securing the oil pan.

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3. Remove the pan (&)LJ).
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2. 3RVLWLRQWKHRLOSDQ%)LJLQLWVKRXVLQJDQGVHFXUHLWE\WLJKWHQLQJWKHIRXUVFUHZV&)LJ
3. &RQQHFWWKHORZSUHVVXUHSLSH')LJ %
Important!
)LOOWKHRLOSDQ )LJ
• $VVHPEOHWKH(JHDUDFWXDWRU32,17%
C
)LJ
'
)LJ
13
L714 03 21 07
&KDQJLQJWKHJHDUER[RLO
1. Unscrew the gearbox oil drainage nut (A-Fig.1ORFDWHGRQWKHERWWRPRIWKHJHDUER[DQGDOORZWKHÀXLGWRGUDLQ

away.
1RWH
A
1RWH
Every time the gearbox oil level inspection nut is disassembled, replace the copper gasket.
:$51,1*
Fig.1
'XULQJWKHVHRSHUDWLRQVEHDZDUHRIKLJKWHPSHUDWXUHVULVNRIEXUQV
3URWHFWLQJWKHHQYLURQPHQW
Dispose of the engine oil according to the laws in effect.
1
L714 03 21 08
)LOOLQJXSZLWKJHDUER[RLO
• 'LVDVVHPEOHWKHDLU¿OWHUER[(013303).
1. 8QVFUHZWKHJHDUER[RLO¿OOHUQXWA-Fig.1ORFDWHGRQWRSRIWKHER[DQGSRXULQWKHRLOXVLQJDQDSSURSULDWH

tool.
VW)LOO OLWUHV
QGDQGVXEVHTXHQW¿OOV OLWUHV
1RWH
(YHU\WLPHWKHJHDUER[RLOOHYHOLQVSHFWLRQQXWLVGLVDVVHPEOHGUHSODFHWKHFRSSHUJDVNHW
Fig.1
1
L714 04 00 00
Front suspension (Fig.1)

A. Hub L E
B. Rim plastic cap
C
C. Hub housing
D. Bearing F D
E. Articulated joint B
H
F. Upper arm
G. Lower arm M N
H. Anti-roll bar I A
I. Anti-roll bar tie rod
G E
L. Shock absorber
M. Axle shaft
Fig.1
N. Driveshaft screw
• Independant wheel suspension in forged aluminium.

• The suspension is double-triangle.
• FSD type shock absorbers with frequency control.
• ³$QWLGLYH´FRQ¿JXUDWLRQLQWKHIURQWGXHWRWKHLQFOLQDWLRQRIWKHXSSHUDUPVWRDYRLGSLWFKLQJZKHQEUDNLQJ
• Coaxial springs with shock absorbers, one for each wheel.
• Rims in alloy.
• Anti-roll bars.
• Shock absorber rubber bumpers.
1
L714 04 01 03
'LVDVVHPEOLQJWKHIURQWD[OHVKDIW
• Remove the front wheel (060103).
A
'LVDVVHPEOLQJWKHIURQWD[OHVKDIW
This procedure is the same for the right and left axle shafts.
1. Release the rack joint head (A-Fig.1) from the hub housing.
B
2. Release the lower suspension arm (B-Fig.1) from the hub housing.
%HFDUHIXOQRWWRVSRLORUEUHDNWKHORZHUVXVSHQVLRQDUPMRLQWJXDUGVZLWKWKHKXEKRXVLQJ
Fig.1
3. Release the connecting rod of the stabilizer bar (C-Fig.2) from the lower suspension arm.
Fig.2
1
L714 04 01 03
4. Loosen the centre screw (')LJ) securing the front axle shaft to the wheel hub.
'
Fig.3
5. Loosen the six screws (()LJ) securing the axle shaft (F-Fig.4) to the front differential.
( (
6. To remove the front axle shaft (F-Fig.4¿UVWUHOHDVHLWIURPWKHZKHHOKXEDQGWKHQIURPWKHIURQWGLIIHUHQWLDO
(
( ( F
Fig.4
2
L714 04 01 05
$VVHPEOLQJWKHIURQWD[OHVKDIW
This procedure is the same for the right and left axle shafts.
B
1. 7RLQVHUWWKHD[OHVKDIW¿UVWSRVLWLRQWKHGLIIHUHQWLDOVLGHDQGWKHQWKHKXEKRXVLQJVLGH
&KHFNWKHVKRFNDEVRUEHULVFRPSOHWHO\GLODWHGWRHQVXUHWKHD[OHVKDIWHQWHUVWKHKRXVLQJRQWKH
wheel hub.
2. Fasten the lower suspension arm (B-Fig.1WRWKHKXEKRXVLQJ

Bolt attachment: tightening torque (000800-31a). A
3. Fasten the rack joint head (A-Fig.1WRWKHKXEKRXVLQJ

Bolt attachment: tightening torque (000800-40d).
Fig.1
4. )DVWHQWKHFRQQHFWLQJURGRIWKHVWDELOL]HUEDUC-Fig.2) to the lower suspension arm.

Screw attachment: tightening torque (000800-29d).
Fig.2
1
L714 04 01 05
5. Tighten the centre screw (')LJVHFXULQJWKHIURQWD[OHVKDIWWRWKHZKHHOKXE

Screw attachment: tightening torque (000800-22b).
'
Fig.3
6. Tighten the 6 screws (()LJ) securing the axle shaft (F-Fig.4) to the front differential.
( (
7KHUHPXVWEHDVHFRQGRSHUDWRULQWKHSDVVHQJHUFRPSDUWPHQWWRNHHSWKHIURQWGLVNEUDNHGWR (
ensure the screws are tightened at the correct torque.
• $VVHPEOHWKHIURQWZKHHO(060105).
(
( ( F
Fig.4
2
L714 04 03 00
Lifting System
This is an hydraulic device enabling to lift the front part of the vehicle when driving at low speed, to allow access to
areas with uneven surfaces.
The system is composed of the following components:
• Front shock absorbers;
• Electronic control unit (GFA);
• Ascent or descent control button;
• Connecting hoses and electric wires.
A
C
Lifting system layout (Fig.1) B
A
A. Front shock absorbers
D
B. Electronic control unit (GFA)
C. Ascent or descent control button
D. Lifting System
The system can be activated up to the maximum speed of 70 Km/h (30 Km/h for Japan); when it reaches this speed
threshold the system will automatically go to the DOWN position.
The system is activated:
• with engine on only by means of LDAS-32 (109100) to perform diagnosis and operational tests. Fig.1
• with a speed lower than 70 km/h (30 km/h for Japan).

• when the thrust mode function is not activated.
The system is deactivated:
• when there is a problem on the ABS ESP system.
• when there is a problem concerning the UP or DOWN sensor.
• when the electric pump absorption is too high.
• when an incorrect vehicle speed signal is read.
The warning light on the dashboard will blink quickly to signal errors (it blinks slowing during raising/lowering).
'DWDLV]HURHGXVLQJWKH/'$6UHVHWWLQJWKHHUURUVSUHVHQW
1
L714 04 03 00
If an error occurs, the ECU places the system in the DOWN position and the warning light will simultaneously blink
quickly on the dashboard.
/LIWLQJV\VWHPFRQWUROGLDJUDP)LJ G
A. GFA control unit
B. Vehicle speed signal
C. Lifting system button A F
D. Lifting system solenoid valves D
B
( Lifting system pressure switches C (
F. Lifting system warning light
G. +12 V power supply )LJ

L714 04 03 00
Lifting system hydraulic connections (Fig.3)

1
1. Solenoid valve
Pressure switch
A
3. Shock absorber lower chamber
A. Lifting System

O. (pipe) to front shock absorbers
3
Fig.3
3
L714 04 03 03
$'LVDVVHPEOHWKHOLIWLQJV\VWHP
%'LVDVVHPEOHWKHOLIWLQJV\VWHPFLUFXLWSLSH
1
L714 04 03 03
$'LVDVVHPEOLQJWKH/LIWLQJ6\VWHP
7KH/LIWLQJ6\VWHP¶VWDQNLVORFDWHGRQOHIWIURQWSDUWRIWKHYHKLFOH
7KH/LIWLQJ6\VWHPWDQNDQGSXPSDUHRQHVROHFRPSRQHQW
'LVDVVHPEOLQJWKH/LIWLQJ6\VWHP
1. Disconnect the valve connector ($)LJ) from the Lifting System.
2. Disconnect the pump connector (%)LJ) from the Lifting System.

A
3. Remove the Lifting System fast coupling pipe (&)LJ). )LJ
)LJ
2
L714 04 03 03
4. 'LVHQJDJHWKH/LIWLQJ6\VWHPE\ORRVHQLQJWKHWKUHH¿[LQJVFUHZV')LJ).
5. Remove the clamp (()LJ) that secures the pipes to the Lifting System frame.
'
'
'
)LJ
6. Remove the Lifting System ())LJ)
)LJ
3
L714 04 03 03
/HIWKDQGGULYH
%
%'LVDVVHPEOLQJWKHOLIWLQJV\VWHPFLUFXLWSLSH A C
• Remove the side and rear upholstery covers (080603).
• 'LVDVVHPEOHWKHIURQWDQGFHQWUHYHKLFOHÀRRUV(082503).
5LJKWKDQGGULYH
'LVDVVHPEOLQJWKHOLIWLQJV\VWHPFLUFXLWSLSH %
A
1. Remove the bulkhead ($)LJE\ORRVHQLQJD¿[LQJVFUHZ%)LJ) and cutting a clamp (&)LJ). C
)LJ
2. /RRVHQWKHVFUHZRQERWKVLGHV')LJ) connecting the lifting system circuit pipe to the shock absorber.
'
)LJ
4
L714 04 03 03
3. /RRVHQWKHWZRFODPSV()LJ) securing the lifting system circuit pipe to the front part of the chassis.
(
)LJ
4. Release the front part of the engine cooling system central pipes ())LJE\ORRVHQLQJWZRVFUHZV*)LJ). )
G
)LJ
5. Remove the lifting system circuit pipe (+)LJ) and disconnect it from the control unit ,)LJ). /HIWKDQGGULYH 5LJKWKDQGGULYH
H I
)LJ
5
L714 04 03 05
A) Assemble the lifting system

%$VVHPEOHWKHOLIWLQJV\VWHPFLUFXLWSLSH
1
L714 04 03 05
A) Assembling the Lifting System
7KH/LIWLQJ6\VWHP¶VWDQNLVORFDWHGRQOHIWIURQWSDUWRIWKHYHKLFOH A
7KH/LIWLQJ6\VWHPWDQNDQGSXPSDUHRQHVROHFRPSRQHQW
1. Position the Lifting System ($)LJ) in the right space.

)LJ
2. Secure the Lifting System to the vehicle chassis by tightening the three screws (%)LJ).
%
3. Close the clamp (&)LJ) that secures the pipes to the Lifting System frame.
)LJ
2
L714 04 03 05
4. Connect the Lifting System fast coupling pipe (')LJ).
'
)LJ
5. Connect the valve connector to the Lifting System (()LJ). )
6. Connect the pump connector to the Lifting System ())LJ
• Assemble the luggage compartment tray (080605). (
)LJ
2QFHDVVHPEO\LVFRPSOHWHEOHHGWKHOLIWLQJV\VWHPFLUFXLW
3
L714 04 03 05
/HIWKDQGGULYH 5LJKWKDQGGULYH
A %
%$VVHPEOLQJWKHOLIWLQJV\VWHPFLUFXLWSLSH %
1. Position the lifting system circuit pipe ($)LJ) and connect it to the control unit (%)LJ).
A
)LJ
2. Fasten the two clamps (&)LJ) securing the lifting system circuit pipe to the front part of the chassis.
C
)LJ
3. Fasten the front part of the engine cooling system pipes (')LJ) by fastening two screws (()LJ). '
(
)LJ
4
L714 04 03 05
4. Tighten the screw on both sides ())LJ) connecting the lifting system circuit pipe to the shock absorber.
)LJ
/HIWKDQGGULYH
5. Position the bulkhead (*)LJE\WLJKWHQLQJD¿[LQJVFUHZ+)LJDQGFXWWLQJD¿[LQJFODPS,)LJ).
H
• Assemble the front differential . G I

• $VVHPEOHWKHIURQWDQGFHQWUHYHKLFOHÀRRUV(082505).
• Assemble the side and rear upholstery covers (080605).
• Assemble the luggage compartment tray (080605).
2QFHDVVHPEO\LVFRPSOHWHEOHHGWKHOLIWLQJV\VWHPFLUFXLW
5LJKWKDQGGULYH
H
G
I
)LJ
5
L714 04 03 06
/HIWKDQGGULYH
Bleeding the lifting system
• Remove the front wheels (060103). A
)RUULJKWKDQGGULYHYHKLFOHVRQO\
5LJKWKDQGGULYH
Bleeding the lifting system
1. Open the lifting system pump cap (A-Fig.1) and check the oil level.
A
Fig.1
2. 6WDUWXSWKHHQJLQHDQGFRQQHFWDVXLWDEOHFRQWDLQHUWRFROOHFWWKHRLOWRWKHVSHFL¿FQR]]OHWLSRIHDFKVKRFN
absorber (B-Fig.2).
Bleeding of the lifting system must be performed by two operators.

B
Fig.2
1
L714 04 03 06
3. Activate the shock-absorber extension switch (C-Fig.3) in the passenger compartment.
Fig.3
4. Activate the switch again to compress the shock absorber while the second operator opens and closes the
VSHFL¿FQR]]OHWLS')LJ) to force any air bubbles out before total compression.
'
Fig.4
5. Check the oil level in the lifting system pump (A-Fig.1) when the shock absorbers are completely
compressed.
5HSHDWWKHSURFHGXUHIRUHDFKIURQWVKRFNDEVRUEHU
2
L714 04 03 08
Filling or topping up the lifting system oil
1. Remove the cover (A-Fig.1).

A
2. Remove the cap (B-Fig.1) of the power steering oil tank (C-Fig.1).
3. Top up the oil level.
7KHRLOOHYHOPXVWDOZD\VEHEHWZHHQWKH0,1')LJDQG0$;()LJZKHQWKHOLIWLQJV\VWHPLV

C
off.
B E D
Fig.1
1
L714 04 04 02
Front height from ground
Important!
%HIRUHFKHFNLQJ
• &KHFNIRUSURSHULQÀDWLRQRIWKHIURQWWLUHVEDU
• (QVXUHWKDWWKHFDULVDGMXVWHGFDUU\RXWDSSUR[LPDWHO\PEUDNLQJV'RQRWUDLVHWKHZKHHOV
ZLWKUHVSHFWWRWKHFKDVVLVXVHRQO\DUXQQLQJERDUGOLIWWROLIWWKHYHKLFOH
&KHFNWKHIURQWKHLJKWIURPWKHJURXQGZLWKUHVSHFWWRWKHFKDVVLVXVLQJWKHGDWDLQ¿JXUH(Fig.1).
1RWH
Carry out the check and adjustment on both sides of the vehicle.
Hf= 130±3 mm
Fig.1
(TXLSPHQWDVVHPEO\RQWKHZKHHOV
8VHDYDLODEOHFRPPHUFLDOHTXLSPHQW7KHRQHVKRZQLQ¿JXUHLVIRULOOXVWUDWLYHSXUSRVHVRQO\
Set the wheel rim value at 482.6 mm.
Important!
7DNHFDUHQRWWRGDPDJHWKHZKHHOULP
Fig.2
1
L714 04 04 02
&DPEHUIURQWZKHHOV D ¶+/-¶ D

Important!
7KHPHDVXUHPHQWPXVWEHWDNHQDIWHUFKHFNLQJDQGDGMXVWLQJLIQHFHVVDU\WKHIURQWKHLJKWIURP
the ground.
&KHFNWKHFDPEHUXVLQJWKHGDWDUHSRUWHGLQ¿JXUH(Fig.3).
Adjust operating on cam pins ($)LJ).

%ROWVDWWDFKPHQWWLJKWHQLQJWRUTXHF.
A
&DUU\RXWWKHFKHFNDQGDGMXVWPHQWRQERWKVLGHVRIWKHYHKLFOH
Fig.3
)URQWZKHHOWRHLQ
% $¶¶
&KHFNWKHWRHLQXVLQJWKHGDWDUHSRUWHGLQ¿JXUH(Fig.4).
A
1RWH
The indicated values are related to one wheel only.
Adjust operating on the steering tie rod after loosening the lock nut (%)LJ).
1XWDWWDFKPHQWWLJKWHQLQJWRUTXHF.
1RWH
• Carry out the check and adjustment on both sides of the vehicle. %
• The total must be ¶¶. %
Fig.4
2
L714 04 04 02
Front wheel caster angle

J ¶+/- 0°15¶
Important!
7KHPHDVXUHPHQWPXVWEHWDNHQDIWHUFKHFNLQJDQGDGMXVWLQJLIQHFHVVDU\WKHFDPEHURIWKHIURQW
wheels.
&KHFNWKHFDVWHUXVLQJWKHGDWDUHSRUWHGLQ¿JXUH()LJ).
Adjust operating on cam pins ($)LJ).

%ROWVDWWDFKPHQWWLJKWHQLQJWRUTXHF.
Important! A A
,I WKH FDVWHU H[FHHGV WKH VSHFL¿FDWLRQV ZKHQ WKH FDPEHU LV DW WKH OLPLW WKH VXVSHQVLRQ RU WKH
chassis are damaged and must be repaired.
)LJ
3
L714 04 07 03
7KLVVHFWLRQH[SODLQVWKHIROORZLQJGLVDVVHPEO\SURFHGXUHV
$'LVDVVHPEOLQJWKHIURQWKXEKRXVLQJ
%'LVDVVHPEOLQJWKHIURQWEHDULQJ
%'LVDVVHPEOLQJWKHIURQWZKHHOKXE
1
L714 04 07 03
$'LVDVVHPEOLQJWKHIURQWKXEKRXVLQJ
A
• Remove the front wheel (060103). C
'LVDVVHPEOLQJWKHIURQWKXEKRXVLQJ
1. Release the front brake calliper ($)LJ) without disconnecting it from the hydraulic circuit.
3ODFHWKHIURQWEUDNHFDOOLSHULQDVDIHSRVLWLRQVRWKDWLWGRHVQRWJHWLQWKHZD\GXULQJWKHGLVDVVHPEO\
procedure.
• Remove the front brake disk (061503).
2. Disconnect the ABS sensor (%)LJ).
,WLVLPSRUWDQWWRGLVFRQQHFWWKH$%6VHQVRUEHIRUHFRPSOHWHO\UHOHDVLQJWKHKXEKRXVLQJ
3. Loosen the screw (&)LJ) securing the axle shaft to the front hub housing.
%
,IQHFHVVDU\XVHDSQHXPDWLFVFUHZGULYHU
)LJ
2
L714 04 07 03
4. Unscrew the nut (')LJ) securing the rack joint head to the hub housing.
H
5. Loosen the screw (()LJ) securing the connecting rod to the lower suspension arm.
)
G '
6. Unscrew the nut ())LJ) securing the lower front suspension arm to the hub housing.
7. Release the front axle shaft (*)LJ) from the hub housing.
8. Unscrew the nut (+)LJ) securing the upper front suspension arm and remove the hub housing (,)LJ).
)LJ
3
L714 04 07 03
%'LVDVVHPEOLQJWKHIURQWEHDULQJ
A A
• Disassemble the front hub housing 32,17$.
'LVDVVHPEOLQJWKHUHDUZKHHOKXE
%
1. Loosen the 4 screws ($)LJ) securing the front bearing to the hub housing.
2. Knock gently from behind to extract the wheel hub together with the front wheel bearing (%)LJ). A A
)LJ
3. To remove the hub housing bulkhead (&)LJ), loosen 3 screws (')LJ).
' C
'
'
)LJ
4
L714 04 07 03
&'LVDVVHPEOLQJWKHIURQWZKHHOKXE
C
• Remove the front wheel (060103). A
• Remove the front hub housing and the wheel hub (040703).
'LVDVVHPEOLQJWKHIURQWZKHHOEHDULQJ
1. Place the bearing ($)LJ) and the front wheel hub (%)LJ) under a press (&)LJ) and exercise enough %
pressure to detach the two components. )LJ
8VLQJDSUHVVGXULQJWKHGLVDVVHPEO\SURFHVVZLOOEUHDNWKHIURQWZKHHOEHDULQJPDNLQJLWLPSRVVLEOH
to reuse. '
2. Manually remove the remains of the wheel bearing (')LJ).
)LJ
3. Using an appropriate tool (()LJ) exercise enough pressure to remove the remaining residues of the wheel
bearing. (
)LJ
5
L714 04 07 05
%$VVHPEOLQJWKHIURQWZKHHOKXE
%$VVHPEOLQJWKHIURQWZKHHOEHDULQJ
&$VVHPEOLQJWKHIURQWKXEKRXVLQJ
1
L714 04 07 05
$$VVHPEOLQJWKHIURQWZKHHOKXE
7KHIURQWZKHHOEHDULQJPXVWEHUHSODFHGDIWHUHYHU\GLVDVVHPEO\SURFHGXUH
%
1. Join the wheel hub ($)LJ) to the front wheel bearing (%)LJ) applying enough pressure with a press.
%HZDUHRIWKHDVVHPEO\GLUHFWLRQRIWKHZKHHOKXEDQGWKHIURQWZKHHOEHDULQJ$UURZV)LJ
A
)LJ
2
L714 04 07 05
%$VVHPEOLQJWKHIURQWZKHHOEHDULQJ
1. Tighten 3 screws (%)LJ) to secure the bulkhead ($)LJ) to the front hub housing.
% A
7KHEXONKHDGPXVWEHLQVWDOOHG¿UVWEHFDXVHRQFHWKHIURQWZKHHOEHDULQJKDVEHHQSODFHGLQLWV
KRXVLQJLWLVQRORQJHUSRVVLEOHWRLQVWDOOWKHEXONKHDG
%
)LJ
2. Knock gently to insert the front wheel hub together with the bearing (&)LJ) on the hub housing (')LJ).
7LJKWHQWKH¿[LQJVFUHZV()LJ) on the front wheel hub to the hub housing using medium thread sealant. ( (
C
Screw attachment: WLJKWHQLQJWRUTXHG
'
( (
)LJ
3
L714 04 07 05
&$VVHPEOLQJWKHIURQWKXEKRXVLQJ
A
1. ,QVHUWWKHXSSHUDUPRIWKHIURQWVKRFNDEVRUEHURQWKHKXEKRXVLQJDQGWLJKWHQWKH¿[LQJQXW$)LJ).
Bolt attachment: WLJKWHQLQJWRUTXHD
2. ,QVHUWWKHIURQWD[OHVKDIW%)LJDQGWLJKWHQWKH¿[LQJVFUHZ

Screw attachment: WLJKWHQLQJWRUTXHE
3. ,QVHUWWKHORZHUDUPRIWKHIURQWVKRFNDEVRUEHURQWKHKXEKRXVLQJDQGWLJKWHQWKH¿[LQJQXW&)LJ).

Bolt attachment: WLJKWHQLQJWRUTXHD.
C
% (
4. ,QVHUWWKHFRQQHFWLQJURGRQWKHORZHUDUPRIWKHIURQWVKRFNDEVRUEHUDQGWLJKWHQWKH¿[LQJVFUHZ')LJ).
5. ,QVHUWWKHUDFNMRLQWKHDGRQWKHKXEKRXVLQJDQGWLJKWHQWKH¿[LQJQXW()LJ). '

Bolt attachment: WLJKWHQLQJWRUTXHG
)LJ
4
L714 04 07 05
6. Connect the ABS sensor ())LJ).

G
• Assemble the front brake disk (061505)
7. Tighten 2 screws to secure the front brake calliper (*)LJ).

Screw attachment: WLJKWHQLQJWRUTXHE.
$IWHUDVVHPEOLQJWKHKXEKRXVLQJWKHZKHHOVPXVWEHDOLJQHGFDPSRVLWLRQPRGL¿FDWLRQVRWKDW

the correct toe-in and caster are restored.
• Assemble the front wheel .
)LJ
5
L714 04 09 03
'LVDVVHPEOLQJWKHIURQWGLIIHUHQWLDO A
A
• Remove both front wheels (060103). A
• 'LVDVVHPEOHWKHIURQWFHQWUHDQGUHDUYHKLFOHÀRRUV(082503).
• Disassemble the propeller shaft (030703). A
A
'LVDVVHPEOLQJWKHIURQWGLIIHUHQWLDO A
Fig.1
1. Loosen the 6 screws on both sides (A-Fig.1) securing the front differential to the axle shafts.
B B B
Important!
3ODFHDSLOODUMDFNEHORZWKHIURQWGLIIHUHQWLDOWRSUHYHQWLWIURPIDOOLQJGXULQJGLVDVVHPEO\
2. Loosen the 6 screws securing the front differential to the chassis (B-Fig.2).
Important! B B B
3URFHHGZLWKWKHXWPRVWFDXWLRQZKHQUHOHDVLQJWKHIURQWGLIIHUHQWLDOIURPWKHFKDVVLV
Fig.2
3. Release and remove the front differential (C-Fig.3).
C
Fig.3
1
L714 04 09 05
Assembling the front differential

C C C
Important!
3URFHHGZLWKWKHXWPRVWFDXWLRQZKHQDVVHPEOLQJWKHIURQWGLIIHUHQWLDO
1. Position the front differential (A-Fig.1) using a pillar jack (B-Fig.1). A
2. Tighten the 6 screws (C-Fig.1) securing the front differential to the chassis. C C
C
Screw attachment: tightening torque (000800-20b).
B
Fig.1
3. Tighten the 6 screws on both sides (D-Fig.1) securing the front differential to the axle shafts. D
D
D
D
Fig.2
• $VVHPEOHWKHIURQWFHQWUHDQGUHDUYHKLFOHÀRRUV(082505).
• Assemble both front wheels (060105).
1
L714 04 10 03
Disassembling the front anti-roll bar
• Remove both front wheels (060103).
• Disassemble the front suspension upper arm (041103).
• Disassemble the battery (091503).
Disassembling the anti-roll bar
1. Remove the screw (A-Fig.1) and disassemble the connecting rod.
2. Remove the two mounting srew (B-Fig.1).
3. Release the rack joint head from the hub housing (C-Fig.1).
5HSHDWWKHVWHSVDERYHRQERWKVLGHVULJKWOHIWRIWKHDQWLUROOEDU
A B
4. Remove the anti-roll bar (D-Fig.1).
%HFDXVHWKHIURQWVXVSHQVLRQXSSHUDUPKDVEHHQGLVDVVHPEOHGWKHZKHHOVPXVWEHDOLJQHGFDP
SRVLWLRQPRGL¿FDWLRQVRWKDWWKHFRUUHFWWRHLQDQGFDVWHUDUHUHVWRUHG
D
C
Fig.1
1
L714 04 10 05
Assembling the front anti-roll bar
1. Position the anti-roll bar (A-Fig.1) and tighten the two mounting screws (B-Fig.1) using medium thread
sealant.
6FUHZVDWWDFKPHQWWLJKWHQLQJWRUTXH-29c).
&KHFNWKHDVVHPEO\GLUHFWLRQRIWKHWLHURGV)LJ
2. Assemble the connecting rod and tighten the screw (C-Fig.1).

3. Fasten the rack joint head to the hub housing (D-Fig.1).

Bolt attachment: WLJKWHQLQJWRUTXHG.
5HSHDWWKHVWHSVDERYHRQERWKVLGHVULJKWOHIWRIWKHDQWLUROOEDU
• Assemble the battery . C B

• Assemble the front suspension upper arm .
• Assemble the front wheels ).
After assembling the front anti-roll barWKHZKHHOVPXVWEHDOLJQHGFDPSRVLWLRQPRGL¿FDWLRQVR

that the correct toe-in and caster is restored
A
D
Fig.1
1
L714 04 11 03
A) 7KH)URQW6XVSHQVLRQ8SSHU$UP
% 7KH)URQW6XVSHQVLRQ/RZHU$UP
C) Stabiliser bar connecting rod.
1
L714 04 11 03
$)URQW6XVSHQVLRQ8SSHU$UP
• Remove the wheel (060103).
• Release the shock absorber from the upper front suspension (041303). C
• SDisassemble the front stone-guard on the front wheel (082103).
%
)LJ
'LVDVVHPEOLQJWKHVXVSHQVLRQV
1. Free the shock absorber ($)LJ) on the wheel by unscrewing the 2 bolts (%)LJ): one upper and one
lower.
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3ODFHWKHVKRFNDEVRUEHULQDVDIHSRVLWLRQVRWKDWLWGRHVQRWJHWLQWKHZD\GXULQJWKHGLVDVVHPEO\ '
procedure.
2. Loosen the screw (')LJ) securing the stabiliser bar to the arm.
)LJ
3. Unscrew the 4 screws (()LJ) securing the upper arm of the front suspension to the chassis. (
( )
4. Unscrew the screw ())LJ) securing the upper front suspension (*)LJ) to the hub carrier.
7KHYHKLFOH¶VZKHHODOLJQPHQWPXVWDOZD\VEHFKHFNHGDIWHUUHSODFLQJDVXVSHQVLRQ (040402).
)LJ
2
L714 04 11 03
A
%)URQW6XVSHQVLRQ/RZHU$UP
• Disassemble the front stone-guard on the front wheel (082103).
'LVDVVHPEOLQJWKHVXVSHQVLRQV )LJ
1. Loosen the screw ($)LJ) securing the stabiliser bar to the arm.
C
2. Unscrew the screw (%)LJ) securing the lower front suspension (&)LJ&)LJ) to the hub carrier.
)LJ
3. Unscrew the 2 screws (')LJ) securing the lower arm of the front suspension (&)LJ &)LJ) to the
chassis’ mount.
C
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' '
)LJ
3
L714 04 11 03
&'LVDVVHPEOLQJWKHFRQQHFWLQJURGRQWKHIURQWVWDELOLVHUEDU
'LVDVVHPEOLQJWKHVWDELOLVHUEDUFRQQHFWLQJURG
1. Loosen the two screws ($)LJ) securing the connecting rod (%)LJ) to the front stabiliser bar (&)LJ) and
'
the lower suspension arm (')LJ).
2. Remove and extract the stabiliser bar connecting rod (%)LJ)
C
A
%
)LJ
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L714 04 11 05
A) 7KH)URQW6XVSHQVLRQ8SSHU$UP
% 7KH)URQW6XVSHQVLRQ/RZHU$UP
C) Stabiliser bar connecting rod.
1
L714 04 11 05
$ $VVHPEOLQJWKH)URQW6XVSHQVLRQV8SSHU$UP
% %
1. Secure the front suspension upper arm ($)LJ) to the chassis using the 4 nuts (%)LJ).
ScrewsDWWDFKPHQWWLJKWHQLQJWRUTXHG
)LJ
2. Secure the front suspension upper arm ($)LJ) to the hub carrier using the nut (&)LJ).
1XWDWWDFKPHQWWLJKWHQLQJWRUTXHD C
)LJ
7LJKWHQWKHWZR¿[LQJEROWV()LJ) to fasten the shock absorber (')LJRQHXSSHUDQGRQHORZHU
%ROWDWWDFKPHQWWLJKWHQLQJWRUTXHE.
(
4. Tighten the screw ())LJVHFXULQJWKHVWDELOLVHUEDUWRWKHFRQQHFWLQJURG
6FUHZDWWDFKPHQWWLJKWHQLQJWRUTXHG.
'
• Attach the shock absorber to the upper front suspension .
• $VVHPEOHWKHZKHHO.
)
$IWHUDVVHPEOLQJWKHVXVSHQVLRQVWKHZKHHOVPXVWEHDOLJQHGFDPSRVLWLRQPRGL¿FDWLRQVRWKDW (

the correct toe-in and caster is restored. )LJ
2
L714 04 11 05
A
% $VVHPEOLQJWKH)URQW6XVSHQVLRQV/RZHU$UP
1. Secure the front suspension ORZHUarm ($)LJ$)LJ) to the chassis’ mount using the 2 nuts (%)LJ).
ScrewsDWWDFKPHQWWLJKWHQLQJWRUTXHF
% %
2. 6HFXUHWKHORZHUIURQWVXVSHQVLRQ($)LJ$)LJ) to the hub carrier using the nut (&)LJ). )LJ
1XWDWWDFKPHQWWLJKWHQLQJWRUTXHD
Tighten the screw (')LJVHFXULQJWKHVWDELOLVHUEDUFRQQHFWLQJURGWRWKHORZHUVXVSHQVLRQDUP A

C
:KHQIDVWHQLQJWKHORZHUVXVSHQVLRQDUPWRWKHKXEKRXVLQJDSSO\HQRXJKSUHVVXUHIURPEHORZ
to ease tightening.
• $VVHPEOHWKHZKHHO.
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WKHFRUUHFWWRHLQDQGFDVWHULVUHVWRUHG
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:$51,1*
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L714 04 11 05
C) Assembling the connecting rod on the front stabiliser bar.
1. 3RVLWLRQWKHVWDELOLVHUEDUFRQQHFWLQJURG$)LJ).
'
2. Tighten the two screws (%)LJ) securing the connecting rod ($)LJWRWKHIURQWVWDELOLVHUEDU&)LJ) and
WKHORZHUVXVSHQVLRQDUP
C
• $VVHPEOHWKHZKHHO. %
)LJ
4
L714 04 13 03
'LVDVVHPEOLQJWKHVKRFNDEVRUEHU
• Remove the wheel (060103). B
• Disassemble the stone guard (082103). A
1. Disconnect the lifting system’s pipe (A-Fig.1) from the shock absorber.
3ODFHDFRQWDLQHUXQGHUWKHFRXSOLQJDQGZDLWIRUWKHRLOWRGUDLQRXW A
C
2. Free the shock absorber (B-Fig.1) on the wheel by unscrewing the 2 bolts (C-Fig.1) (one upper and one Fig.1
lower).
3. Loosen the screw (D-Fig.2) securing the connecting rod to the front suspension lower arm.
Fig.2
1
L714 04 13 03
4. Loosen the 2 screws (()LJ) securing the upper bracket of the suspensions and loosen the screw (F-Fig.3)
that supports the suspension to create just enough play as to allow the shock absorber to be disengaged.
F
(
Fig.3
5. Remove the shock absorber (Fig.4).
7KHYHKLFOHKDVVKRFNDEVRUEHUIRUHDFKUHDUZKHHODQGRQHIRUHDFKIURQWZKHHO
Fig.4
2
L714 04 13 05
$VVHPEOLQJWKHVKRFNDEVRUEHU
Assemble the shock absorber with the vehicle raised on the car lift, using the following procedure: B
1. Assemble the shock absorber (A-Fig.1), locking it into place with the 2 special bolts (B-Fig.1) (one upper and A
one lower). C
6HFXULQJWKHVKRFNDEVRUEHUWLJKWHQLQJWRUTXHE
7RLQVWDOOWKHVKRFNDEVRUEHULQLWVKRXVLQJ¿UVWLQVHUWWKHERWWRPSDUWDQGWKHQWKHWRSSDUW
2. Connect the lifting system’s pipe (C-Fig.1) onto the shock absorber.
C
7RSXSWKHOLIWLQJV\VWHPWDQN B
Fig.1
$IWHUWRSSLQJXSWKHWDQNEOHHGWKH/LIWLQJ6\VWHPFLUFXLW
3. Screw the 2 bolts (D-Fig.2) that secure the upper bracket of the suspensions back on and tighten the screw E
(E-Fig.2) that supports the suspension.
D
)L[LQJWKHVXVSHQVLRQWLJKWHQLQJWRUTXHG
Fig.2
1
L714 04 13 05
4. Tighten the screw (F-Fig.3) securing the connecting rod to the front suspension lower arm.
• Assemble the stone guard .

• Assemble the wheel .
F
7KHYHKLFOHKDVRQHVKRFNDEVRUEHUIRUHDFKUHDUZKHHODQGRQHIRUHDFKIURQWZKHHO
$IWHUDVVHPEOLQJWKHVKRFNDEVRUEHUWKHZKHHOVPXVWEHDOLJQHGFDPSRVLWLRQPRGL¿FDWLRQVR

that the correct toe-in and caster is restored.
Fig.3
2
L714 04 19 00
Steering gear technical data
• Collapsing steering column

• Steering rack with hydraulic power steering
• Turns of the steering wheel for full travel 2 ± 2/3
• Steering diameter 11.5 m
1
L714 04 19 01
6WHHULQJFKHFN
&KHFN UHJXODUO\ WKH WLJKWHQLQJ WRUTXHV WKH LQWHJULW\ RI WKH VWHHULQJ SDUWV MRLQW JXDUGV
VWHHULQJUDFNERRWVVWHHULQJOHYHUERRWVDQGD[OHVKDIWERRWV
Check that the nut (A-Fig.1) that adjusts the striking surface of the steering gear arm’s ball joint is positioned
approximately 20 mm from the beginning of the internal thread (B-Fig.1).
B
A
Fig.1
1
L714 04 19 02
Steering wheel position (Fig.1)
STEP 1:
right side rotation + left side rotation

2
STEP 2:
Check that the steering wheel is in central position;

LILWLVQRWUHPRYHDQGUH¿WLQWKHFRUUHFWSRVLWLRQ
Fig.1
1
L714 04 19 03
$ 6WHHULQJUDFNGLVDVVHPEO\
B) Steering column disassembly
A) 'LVDVVHPEOLQJWKHVWHHULQJUDFN A
B
• Lift the vehicle on the car lift (000000). Fig.1
• Remove the front wheels (060103).
• 5HPRYHWKHIURQWFDUÀRRU(082503). F
E
'LVDVVHPEOLQJWKHVWHHULQJUDFN
1. Unscrew the joint heads (A-Fig.1) on both front wheels (one ball joint for each wheel).
2. Release the stabilizer bar (B-Fig.1; B-Fig.3).

C
3. Disconnect the oil delivery pipe (C-Fig.2) and the oil return pipe (D-Fig.2). D
3RVLWLRQDFRQWDLQHUWRFROOHFWDQ\RLOOHDNDJH
Fig.2
4. Disconnect the steering box from the steering wheel (or sleeve) using the screw (E-Fig.2) After removing the B
guard (F-Fig.2), disconnect. H
5. On the right side disassemble the U-bolt (G-Fig.3) unscrewing 2 screws (H-Fig.3) and on the left side unscrew
2 screws securing the steering rack on the chassis.
6. Extract the steering rack. I
Fig.3
1
L714 04 19 03
B) Disassembling the steering column

A
• Disassemble the instrument cluster grille (086803).
• Disassemble the instrument cluster (086803).
• Disassemble the driver side dashboard assembly (086803).
• Disassemble the driver side airbag (088003).
• Disassemble the steering wheel (087503).
• Disassemble the steering wheel cover (087503). B
• Disassemble the combination switch (087503).
• Disassemble the ignition key assembly (090103).
Fig.4
Disassembling the steering column
1. Unscrew the 4 screws ($)LJ) securing the steering column to the car.
2. Unscrew the screw (B-Fig. 4) securing the steering column coupling.
3. Remove the steering column (C-Fig.6). A
Fig.5
Fig.6
2
L714 04 19 05
$ 6WHHULQJUDFNDVVHPEO\ A
B) Steering column assembly
$ $VVHPEOLQJWKHVWHHULQJUDFN B
1. Insert the steering rack (A-Fig.1). I
2. Tighten the joint heads (B-Fig.1) on both front wheels (one ball joint for each wheel). Fig.1
Bolt attachment: tightening torque (000800-40d).
I
3. On the right side secure the U-bolt (C-Fig.2) using the 2 screws (D-Fig.2) and on the left side secure the D
steering rack using other 2 screws.
5LJKWVFUHZDWWDFKPHQWWLJKWHQLQJWRUTXHG
/HIWVFUHZDWWDFKPHQWWLJKWHQLQJWRUTXHF
4. Tighten the screw (E-Fig.3) that secures the steering box and the steering wheel (or sleeve) and reposition the
guard (F-Fig.1).
/HIWVFUHZDWWDFKPHQWWLJKWHQLQJWRUTXHE
C
5. Connect the oil delivery pipe (G-Fig.3) and the oil return pipe (H-Fig.3).
/HIWVFUHZDWWDFKPHQWWLJKWHQLQJWRUTXHE Fig.2
6. Secure the stabilizer bar (I-Fig.1; I-Fig.2). F
• $VVHPEOHWKHIURQWÀDWERWWRP(082105).. E
• Assemble the front wheels (060105).
Top up with oil (042308) and bleed the power steering system by turning the wheels left and right.
The car must undergo a toe-in test before returning to road use (040002). G
H
Fig.3
1
L714 04 19 05
B) Assembling the steering column

C
1. Secure the screw (A-Fig.4) of the steering column coupling (B-Fig.5).
2. Tighten the 4 screws (&)LJ) securing the steering column to the car.
• Assemble the ignition key assembly (090105).

• Assemble the combination switch (085705).
• Assemble the steering wheel cover (087505). A
• Assemble the steering wheel (087505).
• Assemble the driver side airbag (088005).
• Assemble the driver side dashboard assembly (086805).
• Assemble the instrument cluster (086805). Fig.4
• Assemble the instrument cluster grille (086805).
The steering wheel needs to be centered before the car can return to road use (041902).
B
Fig.5
Fig.6
2
L714 04 22 03
$ 3RZHUVWHHULQJWDQN
% 3RZHUVWHHULQJUDGLDWRU
& 3RZHUVWHHULQJV\VWHPSLSHV
1
L714 04 22 03
A) 'LVDVVHPEOLQJ7KH3RZHU6WHHULQJ7DQN
• Remove the left side panel in the engine compartment (081303).
Empty the power steering oil tank (042307).
1. Loosen the 3 screws ($)LJ) that secure the bracket to the chassis. A
2. Remove the 2 clamps (%)LJ) and disconnect the relevant oil pipes.
3. Remove the power steering tank (&)LJ).
)LJ
2
L714 04 22 03
% 'LVDVVHPEOLQJ7KH3RZHU6WHHULQJ5DGLDWRU

• Disassemble the front stone guards (082103).
• Disassemble the front lock cover (080603).
A
'LVDVVHPEOLQJWKHUDGLDWRU )LJ
Place a container underneath the radiator to recover the power steering oil.
1. Remove the 2 clamps from the power steering oil radiator pipes ($)LJ) and remove the pipes.
Wait for the oil in the power steering radiator to empty.

C % C
)LJ
2. Disengage the radiator (%)LJIURPWKHIUDPHE\ORRVHQLQJWKH¿[LQJVFUHZV&)LJ).
3
L714 04 22 03
To remove the air conveyor panel, loosen the 2 screws (')LJ).
' '
)LJ
To remove the 2 mounting brackets (()LJ) of the conveyor, unscrew the 4 screws ())LJ) (2 screws per
bracket).
)LJ
4
L714 04 22 03
C) 'LVDVVHPEOLQJWKHSRZHUVWHHULQJFLUFXLWSLSHV 3
7KHJHDUER[RLOFLUFXLWLVJURXSHGDVIROORZV)LJ):
/HIWKDQGGULYH
A1
C2
C1 Central delivery pipe
3
C2 Central return pipe
3
C1
3 Rear return pipe
A2
5LJKWKDQGGULYH
A1
C2
3
3
C1
A2
)LJ
5
L714 04 22 03
',6$66(0%/,1*7+()52173,3(6
• Disassemble the front tyres (060103).
• Disassemble the front wheel arches (082103).
• 'LVDVVHPEOHWKHIURQWDQGFHQWUHYHKLFOHÀRRUV(082503).
• Empty the power steering circuit (042307)..
'LVDVVHPEOLQJWKH$DQG$SRZHUVWHHULQJFLUFXLWSLSHV
Position a suitable container to collect any residual power steering oil.
1. Loosen the 2 screws ($)LJ) securing the air conveyor to the left cooling circuit radiator.
2. Loosen the 2 top screws (%)LJ) to release the left cooling circuit radiator; if necessary, also loosen the 2
A
bottom screws.
%
)LJ
3. Cut the two clamps (&)LJ) to disconnect the power steering circuit pipes A1 and A2 from the radiator.
A1
A2
C
C
)LJ
6
L714 04 22 03
4. /RRVHQ WKH VSHFL¿F VFUHZV ()LJ WR UHOHDVH WKH FODPSV ¿[LQJ WKH SRZHU VWHHULQJ FLUFXLW SLSHV WR WKH
chassis (')LJ).
'
'
(
)LJ
5. Release the two front water cooling system pipes ())LJ).
)LJ
7
L714 04 22 03
6. 5LJKWKDQGGULYHRQO\
Loosen the screw (+)LJ) to release the clamp (*)LJ) located on the bracket securing the A1 front
delivery pipe and C1 central delivery pipe.
*
C1
A1 +
)LJ
7. Disconnect the A1 front delivery pipe connection from the rack (,)LJ).
A1
A1 ,
,
)LJ
8. Disconnect the A2 front return pipe connection from the C2 power steering circuit central return pipe (J-
)LJ).
C2
A2
)LJ
8
L714 04 22 03
9. 5HPRYHDQGH[WUDFWWKHIURQWA1 and A2 power steering circuit pipes ()LJ).

/HIWKDQGGULYH
A1
5LJKWKDQGGULYH
A1
/HIW5LJKWKDQGGULYH
A2
)LJ
9
L714 04 22 03
',6$66(0%/,1*7+(&(175$/3,3(6
• Disassemble the front and central cooling circuit pipes (012103).
• Empty the power steering circuit (042307)
.
'LVDVVHPEOLQJWKH&DQG&SRZHUVWHHULQJFLUFXLWSLSHV

A
C2
1. Unscrew the nut ($)LJ) to disconnect the A2 front return pipe connection from the C2 power steering circuit
central return pipe.
A2
)LJ
2. Loosen the screw (&)LJ) to release the clamp (%)LJ) securing the C2 power steering circuit central %
return pipe and the brake vacuum pump pipe to the chassis.
C
C2
)LJ
10
L714 04 22 03
3. Disconnect the C1 power steering circuit central delivery pipe from the rack (')LJ). /HIWKDQGGULYH 5LJKWKDQGGULYH
C1
'
C1 '
)LJ
4. 5LJKWKDQGGULYHRQO\
Loosen the screw ())LJ) to release the clamp (()LJ) located on the bracket securing the A1 front
delivery pipe and C1 rear delivery pipe.
(
C1
A1 )
)LJ
5. Release the 3 clamps (*)LJ) securing the C1 central delivery pipes, C2 central return pipes and the brake
vacuum pump pipe to the chassis.
* * C2 *
C1
)LJ
11
L714 04 22 03
6. To disconnect the C1 central delivery pipe connections and the C2 central return pipe connections from the 3
rear delivery pipes and 3 rear return pipes, unscrew the respective nuts (+)LJ).
+ C2
3
3 + C1
)LJ
/HIWKDQGGULYH
7. 5HPRYHDQGH[WUDFWWKHC1 and C2 power steering circuit pipes ()LJ).
C1
5LJKWKDQGGULYH
C1
/HIW5LJKWKDQGGULYH
C2
)LJ
12
L714 04 22 03
',6$66(0%/,1*7+(5($53,3(6
'LVDVVHPEOLQJWKH3DQG3SRZHUVWHHULQJFLUFXLWSLSHV
C2
3UHOLPLQDU\RSHUDWLRQV 3
A
• Disassemble the engine cooling system rear pipe (012103).
• Empty the power steering circuit (042307).
3 A C1
'LVDVVHPEOLQJWKH3DQG3SRZHUVWHHULQJFLUFXLWSLSHV )LJ
1. To disconnect the C1 central delivery pipe connections and the C2 central return pipe connections from the 3
rear delivery pipes and 3 rear return pipes, unscrew the respective nuts ($)LJ).
3
2. Release the front part of the 3 return pipe from the clamp (%)LJ) securing it to the brake booster pipe. %
)LJ
3. Disconnect the front part from the rear part of the 3 return pipe (&)LJ).
3
)LJ
13
L714 04 22 03
4. Loosen the screw (')LJ) securing the rear part of the 3 return pipe to the support bracket.
'
3
)LJ
5. Loosen the 3 screws ())LJ) to release the power steering tank (()LJ) and loosen the clamp (*)LJ)
to disconnect the rear part of the 3 return pipe.
(
) *
3
6. Remove both parts of the 3 return pipe ()LJ) )LJ
3
)LJ
14
L714 04 22 03
7. Loosen the screw (+)LJ) fastening the mounting bracket on the front part of the 3 delivery pipe to the
chassis.
3 +
)LJ
8. Loosen the connection nut (,)LJ) to disconnect the front part from the rear part of the 3 delivery pipe.
3
9. Loosen the screw (-)LJIDVWHQLQJWKH¿[LQJFODPSRIWKH3 delivery pipe rear part to the chassis. Then )LJ
disconnect the connection to the power steering circuit pump (.)LJ).
3 K
)LJ
15
L714 04 22 03
10. Remove both parts of the 3 delivery pipe ()LJ).
3
)LJ
16
L714 04 22 03
'LVDVVHPEOLQJWKH3SRZHUVWHHULQJFLUFXLWSLSH
• Disassemble the left and rear aesthetic panels (081303).
• 'LVDVVHPEOHWKHDLU¿OWHUER[(013303).
• Empty the power steering circuit (042307).
3
%
'LVDVVHPEOLQJWKH3SRZHUVWHHULQJFLUFXLWSLSH
A 3
)LJ
1. Cut the clamp ($)LJ) to disconnect pipe 3 from the power steering pump
2. Release the clamp (%)LJ) securing the pipe to the engine. C

' (
3. Loosen the three screws (')LJ) to release the power steering oil tank (&)LJ).
4. Release the clamp (()LJ) to disconnect pipe 3 from the power steering oil tank.
3
5. To remove pipe 3 ()LJH[WUDFWLWIURPEHORZWKHYHKLFOH )LJ
3
)LJ
17
L714 04 22 05
A) 3RZHUVWHHULQJWDQN
% 3RZHUVWHHULQJUDGLDWRU
& 3RZHUVWHHULQJV\VWHPSLSHV
1
L714 04 22 05
A) $VVHPEOLQJWKH3RZHU6WHHULQJTDQN
1. Position the power steering tank ($)LJ).
2. Tighten the 3 screws (%)LJ) that secure the bracket to the chassis.
C
3. Connect the 2 oil pipe and tighten the clamps (&)LJ).
Fill the power steering oil tank (042308).
A
• $VVHPEOHWKHHQJLQHFRPSDUWPHQWVLGH¿QLVKLQJHOHPHQW(081305).
)LJ
)LJ
2
L714 04 22 05
% $VVHPEOLQJWKH3RZHU6WHHULQJ5DGLDWRU
If removed:
• Assemble the 2 mounting brackets ($)LJ) of the conveyor by means of the 4 screws (%)LJ) (2
screws per bracket).
• Assemble the air conveyor panel by means of the 2 screws (&)LJ).
A
)LJ
C C
)LJ
3
L714 04 22 05
1. Secure the power steering oil radiator (')LJ) to the cross member of the chassis using the 2 screws
(()LJ).
( ' (
)LJ
2. Connect the two oil delivery and return pipes ())LJ), securing them using the relevant clamps (*)LJ).
• Install the front bumper (080705).
Start the vehicle and perform the following operations:

• Move the steering wheel all the way to the right and to the left. Repeat this operation several times.
• Top up the power steering oil tank (042308).
G )
)LJ
4
L714 04 22 05
C) Assembling the power steering circuit pipes 3

/HIWKDQGGULYH
A1
C2
C1 Central delivery pipe
3
C2 Central return pipe
3
C1
3 Rear return pipe
A2
5LJKWKDQGGULYH
A1
C2
3
3
C1
A2
)LJ
5
L714 04 22 05
$66(0%/,1*7+()52173,3(6
/HIWKDQGGULYH
Assembling the A1 and A2 power steering circuit pipes
1. Position and arrange power steering circuit pipes A1 and A2 ()LJ). A1
5LJKWKDQGGULYH
A1
/HIW5LJKWKDQGGULYH
A2
)LJ

L714 04 22 05
2. Secure the two clamps ($)LJ) to connect power steering circuit pipes A1 and A2 to the radiator.
A1
A2
A
A
)LJ
3. Connect the front delivery pipe connection A1 to the rack (%)LJ).
A1
A1 %
%
)LJ
4. Connect the front return pipe connection A2 to the C2 power steering circuit central return pipe (&)LJ).
C2
A2
)LJ
7
L714 04 22 05
5. /RRVHQWKHVSHFL¿FVFUHZV()LJWRVHFXUHWKHFODPSV¿[LQJWKHSRZHUVWHHULQJFLUFXLWSLSHVWRWKH

chassis (')LJ).
'
'
(
)LJ
5LJKWKDQGGULYHRQO\
Tighten the screw (*)LJ) to secure the clamp ())LJ) located on the bracket securing the A1 front
delivery pipe and C1 central delivery pipe. )
C1
A1 G
)LJ
8
L714 04 22 05
7. Fasten the two front water cooling system pipes (+)LJ).
)LJ
8. Fasten the 2 top screws (,)LJ); if loosened beforehand, to secure the left cooling circuit radiator also tighten
the 2 bottom screws.
Tighten the 2 screws (-)LJ) securing the air conveyor to the left cooling circuit radiator.

• Assemble the front bumper (080705). J
• Assemble the battery .
• Assemble the luggage compartment tray . ,
$VVHPEOHWKHIURQWDQGFHQWUHYHKLFOHÀRRUV(082505).
)LJ
• Assemble the front wheel arches (082105).
• Assemble the front tyres .
• Fill the power steering oil circuit (042308).

L714 04 22 05
$66(0%/,1*7+(&(175$/3,3(6 /HIWKDQGGULYH
Assembling C1 and C2 power steering circuit pipes
1. Position and arrange the C1 and C2 power steering circuit pipes ()LJ).
C1
5LJKWKDQGGULYH
C1
/HIW5LJKWKDQGGULYH
C2
)LJ
2. Tighten the nut ($)LJ) to connect the A2 front return pipe connection to the C2 power steering circuit central
return pipe.
C2
A2
)LJ
10
L714 04 22 05
3. Connect the C1 power steering circuit central delivery pipe to the rack (%)LJ). /HIWKDQGGULYH 5LJKWKDQGGULYH
C1
%
C1 %
)LJ
4. To connect the C1 central delivery pipe connections and C2 central return pipe connections to the 3 rear
delivery pipes and 3 rear return pipes, tighten the respective nuts (&)LJ).
C C2
3
3 C C1
5. Tighten the screw (()LJ) to fasten the clamp (')LJ) securing the C2 power steering circuit central return )LJ
pipe and the brake vacuum pump pipe to the chassis.
'
C2
)LJ
11
L714 04 22 05
5LJKWKDQGGULYHRQO\
Tighten the screw (*)LJ) to secure the clamp ())LJ) located on the bracket securing the A1 front
delivery pipe and the C1 rear delivery pipe.
C1
A1 G
)LJ
7. Tighten the 3 clamps (+)LJ) securing the C1 central delivery pipes, C2 central return pipes and the brake
vacuum pump pipe to the chassis. + + +
C2
• Assemble the front and central cooling circuit pipes (012105).

• Assemble the front bumper (080705).
• Assemble the battery . C1
• Assemble the luggage compartment tray .
• $VVHPEOHWKHIURQWDQGFHQWUHYHKLFOHÀRRUV(082505).
• Assemble the front wheel arches (082105). )LJ
• Assemble the front tyres .
12
L714 04 22 05
$66(0%/,1*7+(5($53,3(6
$VVHPEOLQJ3DQG3SRZHUVWHHULQJFLUFXLWSLSHV
A
Before reassembling the power steering circuit pipes 3 and 3, remove the pipe support bracket (A-
)LJ)
)LJ
1. Position both parts of the 3 return pipe ()LJ).
3
)LJ
2. )DVWHQWKHVSHFL¿FFODPS%)LJ) to connect the 3 return pipe. Then tighten the three screws (')LJ) to
fasten the tank.
C
' %
3
)LJ
13
L714 04 22 05
3. Connect the front part to the rear part of the 3 return pipe (()LJ).
3
)LJ
4. Fasten the front part of the 3 return pipe to the clamp ())LJ) to secure it to the brake booster pipe.
3
)
)LJ
5. Tighten the screw (*)LJ) securing the rear part of the 3 return pipe to the support bracket.
G
3
)LJ
14
L714 04 22 05
Position both parts of the 3 return pipe ()LJ).
3
)LJ
7. Connect pipe 3 to the power steering circuit pump (+)LJ) and tighten the screw (,)LJ) fastening the
¿[LQJFODPSRIWKHUHDUSDUWRIWKH3 delivery pipe to the chassis.
,
3 +
)LJ
8. Tighten the connection nut (-)LJ) to connect the front part to the rear part of the 3 delivery pipe.
J
3
)LJ
15
L714 04 22 05
Tighten the screw (.)LJ) fastening the mounting bracket on the front part of the 3 delivery pipe to the
chassis.
3 K
)LJ
10. To connect the C1 central delivery pipe connections and C2 central return pipe connections to the 3 rear
delivery pipes and 3 rear return pipes, tighten the respective nuts (/)LJ).
• Assemble the entire engine (010003).

C2
• Assemble the engine cooling system rear pipe (012103). 3
L
3 L C1
)LJ

L714 04 22 05
$VVHPEOLQJ3SRZHUVWHHULQJFLUFXLWSLSH
1. Insert pipe 3 ()LJ) passing underneath the rear cross member ()LJ) and place it in its housing.
3
)LJ
)LJ
2. Secure the clamp ($)LJ) to connect pipe 3 to the power steering oil tank.
%
3. Tighten the three screws (&)LJ) to fasten the power steering oil tank (%)LJ). C A
3
)LJ
17
L714 04 22 05
4. Secure the clamp (')LJ) to connect pipe 3 to the power steering pump
5. Fasten the clamp (()LJ) to secure the pipe to the engine.
• Assemble the left and rear aesthetic panels (081305).
3
• $VVHPEOHWKHDLU¿OWHUER[(013305).
• Fill the power steering oil circuit (042308). (
' 3
)LJ
18
L714 04 23 03
Disassembling the power steering pump
• Remove the rear left wheel (060103).
• 5HPRYHWKHUHDUÀDWERWWRP(082503).
Disassembling the power steering pump
1RWH A
SRVL]LRQDUHXQDGHJXDWRUHFLSLHQWHSHUODUDFFROWDGLOLTXLGLLQGHÀXVVR
1. Loosen the screw (A-Fig.1) fastening the power steering circuit delivery pipe clamp to the chassis.
Fig.1
2. Loosen the screw (B-Fig.2) and extract the delivery pipe (C-Fig.2) from the power steering pump.
F
3. Cut the clamp (D-Fig.2) and extract the power steering oil return pipe (E-Fig.2) from the pump.
4 /RRVHQWKH¿[LQJVFUHZVF-Fig.2) securing the pump to the engine. G
5. Remove the power steering pump (G-Fig.2).

C
B
E
D
F
Fig.2
1
L714 04 23 03
1RWH H
$IWHU GLVDVVHPEOLQJ WKH SRZHU VWHHULQJ SXPS UHPRYH WKH7KUHH %RQG % VLOLFRQH H-Fig.3) applied
GXULQJDVVHPEO\IURPWKHVXSSRUW
Disassembling the power steering pump parts
6. 'LVDVVHPEOHWKHSXPSIURPWKHVXSSRUWI-Fig.4UHPRYLQJWKHVFUHZVJ-Fig.3).
J
Fig.3
Fig.4
2
L714 04 23 05
Assembling the power steering pump

A
Assembling the power steering pump parts
1. Position the components of the power steering pump on the special preassembly tool (A-Fig.1).
2. Assemble the pump (B-Fig.1) on the support (C-Fig.1), securing it with the 3 screws (D-Fig.2). C
Apply System 52A43 medium thread sealant onto the thread of the 3 screws.
6FUHZDWWDFKPHQWWLJKWHQLQJWRUTXHF. E
B
3RVLWLRQWKHVKDIW()LJFRUUHFWO\LQSDUWLFXODUFKHFNLWVD[LDOLW\ZLWKWKHUHVWRIWKHDVVHPEO\
1RWH
Apply Three Bond 1207 B silicone as indicated (F-Fig.2). Fig.1
F
Meticulously apply the silicone as indicated.
D
Fig 2
1
L714 04 23 05
Assembling the power steering pump
1. Position the power steering pump (G-Fig.3) in its housing. H
2. 7LJKWHQWKH¿[LQJVFUHZVH-Fig.3) securing the pump to the engine.

Screw attachment: tightening torque (E). G
1RWH
If worn, replace the gasket on the delivery pipe. I
J
3. Position the delivery pipe (I-Fig.3) on the power steering pump and tighten the corresponding screw (J-Fig.3).
L
4. Install a new clamp (K-Fig.3) on the power steering circuit return pipe (L-Fig.3) and tighten the clamp to fasten K
the pipe to the pump. H
Fig.3
5. Tighten the screw (M-Fig.4) fastening the power steering circuit delivery pipe clamp to the chassis.
$IWHUDVVHPEOLQJ¿OOFRPSOHWHO\ZLWKRLOVWDUWWKHHQJLQHDQGPRYHWKHVWHHULQJZKHHO

times to the right and left to drain the system.
• Assemble the rear left wheel .

M
• $VVHPEOHWKHUHDUYHKLFOHÀRRU.
Fig.4
2
L714 04 23 07
Replacing the power steering oil

• 5HPRYHWKHOHIWUHDUFDUÀRRU (082503).
• Set up a suitable system for collecting the engine oil (Fig.1).
A
1. 5HPRYHWKHGHOLYHU\SLSH¿[LQJFODPSDQGGLVFRQQHFWWKHSLSHA-Fig.1OHWDOORIWKHRLOÀRZRXWDQGWKHQ

reconnect the pipe after having cleaned it.
2. Loosen the coupling (B-Fig.2RIWKHSRZHUVWHHULQJSXPSWDQNOHWDOORIWKHRLOÀRZRXWDQGWKHQUHWLJKWHQWKH

coupling after having cleaned it.
&$87,21
Fig.1
'XULQJWKHVHRSHUDWLRQVEHDZDUHRIKLJKWHPSHUDWXUHV5LVNRIEXUQLQJ
'LVSRVHRIWKHHQJLQHRLODFFRUGLQJWRFXUUHQWODZV
B
Fig.2
1
L714 04 23 08
Filling or topping up the power steering oil

B A
• Remove the cap (A-Fig.1) of the power steering oil tank (B-Fig.1).
• Top up the oil level.
• Start the vehicle so that the liquid inside the power steering system circulates.
• Move the steering wheel as far as it will go both right and left.
• Check the power steering tank level, and top up if necessary.
7KHRLOOHYHOPXVWDOZD\VEHEHWZHHQWKH0,1DQG0$;)LJ
MIN
MAX Fig.1
1
L714 05 00 00
Rear suspension (Fig.1)

A. Brake disk
B. Lower arm F H
C. Anti-roll bar I
D. Axle shaft
G L
E. Anti-roll bar tie rod
F. Shock absorber E M
G. Upper arm
D N
H. Hub housing
C A
I. Bearing
L. Hub B
M. Rim lens
N. Driveshaft screw Fig.1
• Independant wheel suspension in forged aluminium.

• The suspension is double-triangle.
• FSD type shock absorbers with frequency control.
• ³$QWLVTXDW´FRQ¿JXUDWLRQWRUHGXFHSLWFKLQJLQDFFHOHUDWLRQ
• Coaxial springs with shock absorbers, one for each wheel.
• Rims in alloy.
• Anti-roll bars.
• Shock absorber rubber bumpers.
1
L714 05 04 00
Camber
This is the wheel’s camber with respect to a plane perpendicular to the ground (Fig.1). The camber may be positive
(the vehicle’s wheels are “open” toward the top) or negative (the wheels appear open toward the bottom). The
camber affects roadholding and driving comfort. The adjustment values were designed to obtain the best compromise
between roadholding and comfort.
Fig.1
Strut caster
This is the angle that forms the steering axis of the wheel projected on the longitudinal vertical plane with respect to
the transversal vertical plane passing through the wheel axle (Fig.2). When this angle is positive the steering axis
meets the ground in front of the vertical axis; momentum is therefore created that tends to realign the wheels.
Fig.2
Toe-in
This is the angle formed between the equatorial planes of the wheels of an axle and the vertical-longitudinal plane
passing through the middle of the vehicle (Fig.3). The angle is positive when the directions of the two wheels
converge at a point in front of the vehicle. It is negative when the point of convergence is behind the vehicle. In order
to improve vehicle stability, the toe-in of the wheels is kept positive.
Fig.3
1
L714 05 04 02
Rear height from ground
Important!
&KHFNIRUSURSHULQÀDWLRQRIWKHUHDUWLUHVEDU
&KHFNWKHUHDUKHLJKWIURPWKHJURXQGZLWKUHVSHFWWRWKHFKDVVLVXVLQJWKHGDWDLQ¿JXUH(Fig.1).
1RWH
Carry out the check and adjustment on both sides of the vehicle.
Hr= 140±3 mm
Fig.1
&DPEHUUHDUZKHHOV E
E = -1° 20’ ÷ -1° 30’
Important!
7KHPHDVXUHPHQWPXVWEHWDNHQDIWHUFKHFNLQJDQGDGMXVWLQJLIQHFHVVDU\WKHUHDUKHLJKWIURP
the ground.
&KHFNWKHFDPEHUXVLQJWKHGDWDUHSRUWHGLQ¿JXUH(Fig.2).
Adjust operating on cam pins (A-Fig.2).

%ROWVDWWDFKPHQWWLJKWHQLQJWRUTXHG.
A
Fig.2
1
L714 05 04 02
Rear wheel toe-in
Important! ' &¶¶

7KHPHDVXUHPHQWPXVWEHWDNHQDIWHUFKHFNLQJDQGDGMXVWLQJLIQHFHVVDU\WKHFDPEHURIWKHUHDU
wheels.
Adjust operating on the cam pins (A-Fig.3WRUHDFKWKHVSHFL¿HG'PHDVXUH C

%ROWVDWWDFKPHQWWLJKWHQLQJWRUTXHG. A
The indicated values are related to one wheel only.
&DUU\RXWWKHFKHFNDQGDGMXVWPHQWRQERWKVLGHVRIWKHYHKLFOH '
The total toe-in must be ¶¶. A
Important!
,I WKH WRHLQ H[FHHGV WKH VSHFL¿FDWLRQV ZKHQ WKH FDPEHU LV DW WKH OLPLW WKH VXVSHQVLRQ RU WKH A
chassis are damaged and must be repaired.
Fig.3
2
L714 05 05 03
Disassembling the rear D[OHVKDIW B
• Remove the rear wheel (060103).
A
Fig.1
Disassembling the D[OHVKDIW
1. Release the brake calliper (A-Fig.1) from the hub housing by loosening the two corresponding screws (B-Fig.1)
without disconnecting it from the hydraulic system. C
2. Release the parking brake calliper (C-Fig.2) from the hub housing by loosening the two corresponding screws
(D-Fig.2) without disconnecting it from the hydraulic system.
D
3RVLWLRQ WKH EUDNH FDOOLSHUV ZLWKRXW FRPSURPLVLQJ WKH LQWHJULW\ RI WKH EUDNH FLUFXLW SLSHV DQG
REVWUXFWLQJZRUNGXULQJWKHGLVDVVHPEO\SURFHGXUH
• Remove the rear brake disk (061503).

Fig.2
3. Loosen the screw (E-Fig.3) securing the rear shock absorber to the hub housing and the connecting rod to the
hub housing simultaneously.
Fig.3
1
L714 05 05 03
4. Loosen the six screws (F-Fig.4) securing the rear axle shaft (G-Fig.4) to the differential.
Fig.4
5. Loosen the eight screws (H-Fig.5) securing the rear suspension lower arm.
H
H H H
Fig.5
6. Loosen the six screws (I-Fig.6) securing the rear suspension upper arm to the chassis.
I I I I
Fig.6
2
L714 05 05 03
7. Remove the rear suspension assembly, hub housing and rear axle shaft (J-Fig.7) by placing it on a
J
workbench.
%HFDUHIXOZKHQGLVDVVHPEOLQJWKHUHDUVXVSHQVLRQDVVHPEO\KXEKRXVLQJDQGUHDUD[OHVKDIW
K
8. Release the rear axle shaft (K-Fig.7) from the hub housing.
,IWKHUHDUD[OHVKDIWLVGLI¿FXOWWRUHPRYHOXEULFDWHWKHMXQFWXUHDQGWDSUHSHDWHGO\
Fig.7
3
L714 05 05 05
Assembling WKHUHDUD[OHVKDIW A
1. Position the rear axle shaft (A-Fig.1) on the hub housing by tightening the corresponding nut (B-Fig.1).
%ROWDWWDFKPHQWWLJKWHQLQJWRUTXHG
2. Using a pillar jack, position the rear suspension assembly, hub housing and rear axle shaft (C-Fig.1), by placing
it into its housing in the chassis. C
Fig.1
$VVHPEOHWKHUHDUVXVSHQVLRQDVVHPEO\KXEKRXVLQJDQGUHDUD[OHVKDIWZLWKWKHKHOSRIDVHFRQG
operator.
D D D D
3. Tighten the six screws (D-Fig.2) securing the rear suspension upper arm to the chassis.
)DVWHQLQJWKHVFUHZVWLJKWHQLQJWRUTXHE
Fig.2
4. Tighten the eight screws (E-Fig.3) securing the rear suspension lower arm.
E
E E E
Fig.3
1
L714 05 05 05
5. Tighten the six screws (F-Fig.4) securing the rear axle shaft (A-Fig.4) to the differential.
A
Fig.4
6. Tighten the screw (G-Fig.5) securing the rear shock absorber to the hub housing and the connecting rod to the
%ROWDWWDFKPHQWWLJKWHQLQJWRUTXHE
• Assemble the rear brake disk .
Fig.5
7. Fasten the parking brake calliper (H-Fig.6) to the hub housing by tightening the two corresponding screws (I-
Fig.6). H
Fig.6
2
L714 05 05 05
Fasten the brake calliper (J-Fig.7) to the hub housing by tightening the two corresponding screws (K-Fig.7).
3RVLWLRQWKHEUDNHFDOOLSHUVDQGHQVXUHWKHLQWHJULW\RIWKHEUDNHFLUFXLWSLSHVLVQRWFRPSURPLVHG
K
• Assemble the wheel.

• Assemble the rear wheel arch .

WKHFRUUHFWWRHLQDQGFDVWHUDUHUHVWRUHG J
Fig.7
3
L714 05 07 03
$'LVDVVHPEOLQJWKHUHDUKXEKRXVLQJ
%'LVDVVHPEOLQJthe rear wheel bearing
&'LVDVVHPEOLQJthe rear wheel hub
1
L714 05 07 03
$'LVDVVHPEOLQJWKHUHDUKXEKRXVLQJ
• Raise the vehicle on the car lift (000000). A
• Remove the rear suspension (051103).
'LVDVVHPEOLQJWKHUHDUKXEKRXVLQJ
1. 8QVFUHZWKH¿[LQJQXW$)LJDQGH[WUDFWWKHUHDUVXVSHQVLRQXSSHUDUPIURPWKHKXEKRXVLQJ
8QVFUHZWKH¿[LQJQXW%)LJDQGH[WUDFWWKHUHDUVXVSHQVLRQORZHUDUPIURPWKHKXEKRXVLQJ
8QVFUHZWKH¿[LQJQXW&)LJDQGH[WUDFWWKHFRQQHFWLQJURGIURPWKHKXEKRXVLQJ
)LJ
% C
2
L714 05 07 03
4. 8QVFUHZWKH¿[LQJQXW')LJDQGH[WUDFWWKHUHDUD[OHVKDIWIURPWKHKXEKRXVLQJ
'
) )
5. 7RUHPRYHWKHKXEKRXVLQJEXONKHDG()LJORRVHQWKHIRXUVFUHZV))LJ).
) )
(
)LJ
3
L714 05 07 03
%'LVDVVHPEOLQJthe rear wheel bearing

A A
• 5HPRYHWKHUHDUKXEKRXVLQJ(050703).
'LVDVVHPEOLQJWKHUHDUZKHHOKXE %
1. /RRVHQWKHVFUHZV$)LJVHFXULQJWKHZKHHOEHDULQJWRWKHKXEKRXVLQJ
2. .QRFNJHQWO\IURPEHKLQGWRH[WUDFWWKHZKHHOKXEWRJHWKHUZLWKWKHUHDUZKHHOEHDULQJ%)LJ).

A A
)LJ
4
L714 05 07 03
&'LVDVVHPEOLQJthe rear wheel hub

C
• Remove the rear wheel (060103). A
• 'LVDVVHPEOHWKHKXEKRXVLQJDQGWKHUHDUZKHHOKXE(050703).
'LVDVVHPEOLQJWKHUHDUZKHHOEHDULQJ %
)LJ
1. 3ODFHWKHEHDULQJ$)LJDQGWKHUHDUZKHHOKXE%)LJXQGHUDSUHVV&)LJDQGH[HUFLVHHQRXJK
pressure to detach the two components.
'
8VLQJDSUHVVGXULQJWKHGLVDVVHPEO\SURFHVVZLOOEUHDNWKHUHDUZKHHOEHDULQJPDNLQJLWLPSRVVLEOH
to reuse.
2. 0DQXDOO\UHPRYHWKHUHPDLQVRIWKHZKHHOEHDULQJ')LJ).
)LJ
3. 8VLQJDQDSSURSULDWHWRRO()LJH[HUFLVHHQRXJKSUHVVXUHWRUHPRYHWKHUHPDLQLQJUHVLGXHVRIWKHZKHHO
EHDULQJ (
)LJ
5
L714 05 07 05
A) Assembling the rear wheel hub

%$VVHPEOLQJthe rear wheel bearing
C) Assembling the rear hub housing
1
L714 05 07 05
A) Assembling the rear wheel hub
7KHUHDUZKHHOEHDULQJPXVWEHUHSODFHGDIWHUHYHU\GLVDVVHPEO\SURFHGXUH
%
1. Join the wheel hub ($)LJ) to the rear wheel bearing (%)LJ) applying enough pressure with a press.
%HZDUHRIWKHDVVHPEO\GLUHFWLRQRIWKHZKHHOKXEDQGWKHUHDUZKHHOEHDULQJ$UURZV)LJ
A
)LJ
2
L714 05 07 05
%$VVHPEOLQJthe rear wheel bearing

%
1. Knock gently to insert the rear wheel hub together with the bearing ($)LJ) on the hub housing (%)LJ).
2 7LJKWHQ WKH ¿[LQJ VFUHZV &)LJ) on the rear wheel bearing to the hub housing using medium thread
sealant.
Screw attachment: WLJKWHQLQJWRUTXHD.
C C
C C
)LJ
3
L714 05 07 05
C) Assembling the rear hub housing A
1. ,QVHUWWKHUHDUVXVSHQVLRQXSSHUDUPRQWKHKXEKRXVLQJDQGWLJKWHQWKH¿[LQJQXW$)LJ).

,QVHUWWKHFRQQHFWLQJURGRQWKHKXEKRXVLQJDQGWLJKWHQWKH¿[LQJQXW%)LJ).

Bolt attachment: WLJKWHQLQJWRUTXHF.
,QVHUWWKHUHDUVXVSHQVLRQORZHUDUPRQWKHKXEKRXVLQJDQGWLJKWHQWKH¿[LQJQXW&)LJ).

Bolt attachment: WLJKWHQLQJWRUTXHD
C %
)LJ
4
L714 05 07 05
4. ,QVHUWWKHUHDUD[OHVKDIWRQWKHKXEKRXVLQJDQGWLJKWHQWKH¿[LQJQXW')LJ).
'
) )
5. Position the hub housing bulkhead in its housing (()LJDQGWLJKWHQWKHIRXUVFUHZV))LJ).
) )
(
)LJ
• Assemble the rear suspension .

the correct toe-in and caster are restored.
• Assemble the rear wheel .
5
L714 05 10 03
'LVDVVHPEOLQJWKHUHDUVWDELOL]HUEDU
• Remove rear wheel arch elements (082103).
• Remove the engine compartment side panels (081303).
• Remove the pannel upper (081303). B
• Remove the headlight mounting bracket with the heat-proof guard (094503).
• Remove the silencer (025103). A
'LVDVVHPEOLQJWKHVWDELOL]HUEDU
1. 7RHDVHDFFHVVWRWKHVWDELOL]HUEDUIDVWHQLQJVKLIWWKHÀH[LEOHVXSSRUWA-Fig.1) after loosening a screw to

UHOHDVHLWB-Fig.1). D E C
2. 5HPRYHWKHWZRPRXQWLQJEROWVC-Fig.1).
3. 5HPRYHWKHEROWD-Fig.1) and disassemble the connecting rod.
5HSHDWWKHWZRVWHSVDERYHRQERWKVLGHVULJKWOHIWRIWKHVWDELOL]HUEDU
Fig.1
4. Remove the stabilizer bar E-Fig.1).
1
L714 05 10 05
$VVHPEOLQJWKHUHDUVWDELOL]HUEDU
1. Position the stabilizer bar (A-Fig.1) and tighten the two mounting bolts (B-Fig.1) using medium thread
sealant.
Fastening the bolt: tightening torque (000800-30a).
2. Assemble the connecting rod and tighten the bolt (C-Fig.1).

Fastening the bolt: tightening torque (000800-30b).
E
3. )DVWHQWKHÀH[LEOHVXSSRUWD-Fig.1E\WLJKWHQLQJWKHFRUUHVSRQGLQJVFUHZE-Fig.1).
&KHFNWKHDVVHPEO\GLUHFWLRQRIWKHVWDELOL]HUEDU.
C A B
5HSHDWWKHWZRVWHSVDERYHRQERWKVLGHVULJKWOHIWRIWKHVWDELOL]HUEDU
• Assemble the silencer (025105).

• $VVHPEOHWKHDLU¿OWHUDVVHPEO\(013305)
• $VVHPEOHWKHKHDGOLJKWVXSSRUWEUDFNHWZLWKWKHKHDWSURRIJXDUG(094505).
• $VVHPEOHWKHSDQQHOXSSHU(081305).
• Assemble WKHUHDUEXPSHU(080705).
• Assemble WKHHQJLQHFRPSDUWPHQWVLGHSDQHOV(081305).
• Assemble rear wheel arch elements (082105).
Fig.1
• Assemble the rear wheels (060105).
1
L714 05 11 01
5HDUVSULQJVFKHFN
&KHFNWKHWLJKWHQLQJWRUTXHVDQGWKHLQWHJULW\RIWKHVXVSHQVLRQDUPVUHJXODUO\
1
L714 05 11 03
Disassembling rear suspensions (upper and lower) B
A
Disassembling suspensions
Fig.1
1. Release the brake calliper (A-Fig.1) from the hub housing by loosening the two corresponding screws (B-Fig.1)
without disconnecting it from the hydraulic system.
C
2. Release the parking brake calliper (C-Fig.2) from the hub housing by loosening the two corresponding screws
(D-Fig.2) without disconnecting it from the hydraulic system.
3RVLWLRQ WKH EUDNH FDOOLSHUV ZLWKRXW FRPSURPLVLQJ WKH LQWHJULW\ RI WKH EUDNH FLUFXLW SLSHV DQG D
REVWUXFWLQJZRUNGXULQJWKHGLVDVVHPEO\SURFHGXUH
• Remove the rear brake disk (061503).
Fig.2
3. Loosen the screw (E-Fig.3) securing the rear shock absorber to the hub housing and the connecting rod to the
Fig.3
1
L714 05 11 03
4. Loosen the six screws (F-Fig.4) securing the rear axle shaft (G-Fig.4) to the differential.
Fig.4
5. Loosen the eight screws (H-Fig.5) securing the rear suspension lower arm.
H
H H H
Fig.5
6. Loosen the six screws (I-Fig.6) securing the rear suspension upper arm to the chassis.
I I I I
Fig.6
2
L714 05 11 03
7. Remove the rear suspension assembly, hub housing and rear axle shaft (J-Fig.7) by placing it on a
J
workbench.
%HFDUHIXOZKHQGLVDVVHPEOLQJWKHUHDUVXVSHQVLRQDVVHPEO\KXEKRXVLQJDQGUHDUD[OHVKDIW
K
8. Release the rear axle shaft (K-Fig.7) from the hub housing.
,IWKHUHDUD[OHVKDIWLVGLI¿FXOWWRUHPRYHOXEULFDWHWKHMXQFWXUHDQGWDSUHSHDWHGO\
Fig.7
L
9. Remove the rear suspension upper arm (L-Fig.8) by loosening the screw (M-Fig.8) securing it to the hub
housing and the two bolts securing the supports.
M
Fig.8
10. Remove the rear suspension lower arm (1)LJ) by loosening the screw (O-Fig.9) securing it to the hub
housing and the two bolts (3)LJ) securing the supports.
O
11. Remove the lower connecting rod by loosening the bolt (Q-Fig.9) securing it to the rear hub housing.
Q
3
1
7KHYHKLFOH¶VZKHHODOLJQPHQWPXVWDOZD\VEHFKHFNHGDIWHUUHSODFLQJDVXVSHQVLRQ 3
Fig.9
3
L714 05 11 05
D
Assembling rear suspensions (upper and lower) B
E
1. Position the lower connecting rod (A-Fig.1RQWKHUHDUKXEKRXVLQJE\WLJKWHQLQJWKH¿[LQJQXWB-Fig.1). C
2. Position the rear suspension lower arm (C-Fig.1) by tightening the screw (D-Fig.1) securing it to the hub E
housing and the two bolts (E-Fig.1) securing the supports.
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Fig.1
3. Position the rear suspension upper arm (F-Fig.2) by tightening the screw (G-Fig.2) securing it to the hub F
housing and the two bolts securing the supports.
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Fig.2
4. 3RVLWLRQWKHUHDUD[OHVKDIWH-Fig.3) on the hub housing by tightening the corresponding nut (I-Fig.3). I
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it into its housing in the chassis. H
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operator.
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7LJKWHQWKHVL[VFUHZVK-Fig.4) securing the rear suspension upper arm to the chassis.
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Fig.4
7. Tighten the eight screws (L-Fig.5) securing the rear suspension lower arm.
L
L L L
Fig.5
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L714 05 11 05
Tighten the screw (O-Fig.7) securing the rear shock absorber to the hub housing and the connecting rod to the
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• Assemble the rear brake disk ).
Fig.7
10. Fasten the parking brake calliper (3)LJ) to the hub housing by tightening the two corresponding screws (Q-
)LJ). 3
)LJ
11. Fasten the brake calliper (5)LJ) to the hub housing by tightening the two corresponding screws (6)LJ).
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the correct toe-in and caster are restored (050402).
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• Disassemble the stone guard (082103).
• Disassemble the air intake (081303).
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1. Free the shock absorber ($)LJ) on the wheel by unscrewing the 2 bolts (%)LJ) (one upper and one
lower).
2. Remove the shock absorber.
)LJ
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• Place the shock absorber on a workbench .
%
1. Position the shock absorber ($)LJ) and the tool on the vice (%)LJ). )LJ
2. Compress the shock absorber spring by tightening the screw (&)LJRQWKHVSHFL¿FWRROWRIRUFHWKHLQWHUQDO
rod out.
3. Position the second part of the tool (')LJ) and then act on the pump to lock it and fasten the internal rod.
. Unscrew the top part of the shock absorber (()LJ). (
'
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5. After removing the tool, disassemble the shock absorber ()LJ).
1. Shock absorber
)LJ
2. Lower seal
1 6 8
3. Lower spacer ring
Upper seal
5. Dust guard
6. Spring
7. Upper spacer ring
8. Head 2 3 5 7
)LJ
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Proceed by assembling the shock absorbers with the vehicle raised on the car lift, using the following procedure:
1. Assemble the shock absorber ($)LJ), locking it into place with the 2 special bolts (%)LJ) (one upper and
one lower).
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• Assemble the side cover . A

• Assemble the stone guard .
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L714 05 13 05
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1. Reassemble the shock absorber without screwing the head on, following the order indicated below ()LJ).
1. Shock absorber
2. Lower seal
3. Lower spacer ring 2 3 4 5 7
4. Upper seal )LJ
5. Dust guard
Spring
7. Upper spacer ring
Head
2. Place the shock absorber on the tool ($)LJ) and compress it to force the rod out.
3. Position the second part of the tool (%)LJ) and then act on the pump to lock it and fasten the internal rod.
4. Tighten the shock absorber head (&)LJ).

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Diameter (Standard) 365 356
Diameter (Carbon Ceramic) 380 356
Nominal thickness (Standard) 34 32
Nominal thickness (Carbon Ceramic) 38 32
Minimum allowed thickness after grinding (Standard) 32,4 30,4
Parallelism tolerance of the two disk faces (Standard) 0.015
Parallelism tolerance of the two disk faces (Carbon Ceramic) 0.020
Max. surface roughness (Standard) 1.6 P
Max. surface roughness (Carbon Ceramic) RK 4,0 RpK 2,0 max
%UHPEREUDNHFDOLSHUV(Standard) 8 wheel cylinders 4 wheel cylinders

Wheel cylinder bore 32-28/32-28 mm 44-38 mm
%UHPEREUDNHFDOLSHUV(Carbon Ceramic) 6 wheel cylinders 4 wheel cylinders

Wheel cylinder bore 32 / 36 / 38 mm 44-38 mm
%UDNHSDGV3DJLGW\SH /LQLQJ +3

Thickness when new (Standard) 17.2 18
Thickness when new (Carbon Ceramic) 17.75 17.75
Minimum allowed thickness (Standard) 7 7
Minimum allowed thickness (Carbon Ceramic) 7 7
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L714 06 00 00
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Type vacuum
Wheel cylinder bore HZØ26.99 CF/CF, HUB 18/18, i=7 LSC 115 T HEF
3XPS
Type Tandem
Wheel cylinder bore 26.99 mm
Front wheel cylinder stroke 18 + 18
3DUNLQJEUDNH
Type disk brake on rear wheels
Mechanically-operated
by hand lever
Caliper cylinder bore (Standard) 36
Caliper cylinder bore (Carbon Ceramic) 36
Pads (Standard) Frendo 222
Pads (Carbon Ceramic) MD 558
Thickness when new (Standard) 10
Thickness when new (Carbon Ceramic) 9
Minimum thickness allowed (Standard) 5.5
Minimum thickness allowed (Carbon Ceramic) 4.5
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Type BOSCH ESP 5.7_X1.34
Channels Four
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L714 06 00 00
Aluminium alloy wheels

Front 8,5” x 19”
Rear 11” x 19”
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Rear P Zero 295/30 ZR 19 PUNTO
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Front 2.4 bar
Rear 2.2 bar
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Radial ply Asymmetrical tubeless:
PIRELLI P ZERO tyres Size Cold tyre inflation pressure Cold tyre inflation pressure Aluminum alloy rims
(regolar use) (permanent use at speed > 260 Km/h
Front 235/35 ZR 19 91Y XL 2,4 bar 3,0 bar 8,5” x 19”

Rear 295/30 ZR 19 100Y XL 2,2 bar 3,0 bar 11” x 19”
PIRELLI Winter 240 Sottozero Cold tyre inflation pressure Cold tyre inflation pressure
Size Aluminum alloy rims
tyres (regolar use) (permanent use at speed > 260 Km/h
Front 235/35 R19 87V M+S 2,4 bar -- 8,5” x 19”

Rear 295/30 R19 100V M+S 2,2 bar -- 11” x 19”
PIRELLI PZERO CORSA tyres Size Cold tyre inflation pressure Cold tyre inflation pressure Aluminum alloy rims
(regolar use) (permanent use at speed > 260 Km/h
Front 235/35 ZR 19 91Y XL 2,4 bar 3,0 bar 8,5” x 19”

Rear 295/30 ZR 19 100Y XL 2,2 bar 3,0 bar 11” x 19”
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A
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WKH\DUHFRUUHFWO\DVVHPEOHGWKHZRUG³(67(512´PXVWDSSHDURQWKHH[WHUQDOO\YLVLEOHVLGHRIWKH
tire.
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General information and safety notes
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• LIWKHZKHHOULPKDVEHHQGDPDJHG (%)LJ)
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• Vehicle handling could be impaired.
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7KHUHIRUHSOHDVHGULYHFDUHIXOO\WRWKHQH[WDYDLODEOHTXDOL¿HGZRUNVKRS
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• on cuts and punctures larger than 4 mm
• if the wheel rim has been damaged
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• ,I\RXGRFRPHLQWRFRQWDFWZLWKWKHVHDODQWLPPHGLDWHO\ULQVHWKHH\HVRUVNLQDIIHFWHGZLWKFOHDQZDWHU
• Change clothing immediately if it becomes soiled with the tyre sealant.
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of water.
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• If any allergic reactions should occur get medical help immediately.
• Keep the sealant away from children.
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L714 06 01 01
Repairing a tyre
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Setting up the Tyre Mobility System

• 2SHQWKHÀDS2)LJRQWKHHOHFWULFFRPSUHVVRU
• 3XOO WKH FRQQHFWRU 4)LJ) and the compressor hose (5)LJ LQFOXGLQJ WKH SUHVVXUH JDXJH RXW RI WKH 6

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• Screw the compressor hose (5)LJRQWRWKHÀDQJH6)LJRIWKHW\UHVHDODQWFDQ ()LJ 5
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• 8QVFUHZWKHGXVWFDSIURPWKHYDOYHRIWKHGDPDJHGW\UH
• 6FUHZWKH¿OOHUKRVH10)LJRQWRWKHYDOYH ()LJ
• Insert the connector ()LJLQWRWKHFLJDUHWWHOLJKWHUVRFNHW
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• Move the switch ()LJ) on the compressor* to position I$IWHUPLQXWHVW\UHSUHVVXUHVKRXOGEHDWOHDVWEDU
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• 5HPRYHWKHHPSW\W\UHVHDODQWFDQDQGVFUHZWKHFRPSUHVVRUKRVH ()LJGLUHFWO\RQWRWKHYDOYH
• Insert the connector (4)LJLQWRWKHFLJDUHWWHOLJKWHUVRFNHW
• Move the switch ()LJ) on the compressor to position I$IWHUPLQXWHVW\UHSUHVVXUHVKRXOGEHDWOHDVW
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' Tire pressure sensors
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1. Disconnect the wheel from the hub by unscrewing the 5 screws (A-Fig.1) that secure it.
A
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• Disassemble the car’s wheel3RLQW$.
• 'HÀDWHWKHWLUH
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1. Position the wheel on the special tire changer.
2. To disassemble the tire from the rest of the wheel rim, follow the operations described in the tire changer’s user
and maintenance manual.
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Three types of tires can be installed on the car (Fig.2a):
A. PZERO CORSA
% PZERO PUNTO
Fig.2a
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• Disassemble the car’s wheel3RLQW$.
• 'HÀDWHWKHWLUH
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1. Place the wheel next to the bead breaking arm (A-Fig.3), verifying that the TPMS sensor (%)LJ) is located
on the side opposite the pressure area.
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damaged.
Fig.3
2. Rotate the wheel and repeat the bead breaking operation on the other side; again, make sure that the TPMS %
sensor (%)LJ) is positioned on the side opposite the bead breaking arm (A-Fig.4).
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damaged.
Fig.4
3
L714 06 01 03
3. Position the wheel on the tire changer, locking it into place using the column (C-Fig.5). Soften the tire to make
disassembly easier by using the sliding support (')LJ) and rotating the wheel (clockwise) several times. C
'
Fig.5
4. Insert the lever (()LJ) between the rim and the tire, careful that the TPMS sensor (%)LJ) is positioned (
approximately 10 cm away from where the lever is inserted.
10
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be irreparably damaged.
5. Press the lever downward (Fig.6) and activate the tire changer, rotating the wheel slightly more than 180°.
%
Fig.6
6. After this half rotation, the lever’s pressure will release the upper part of the tire from the rim (Fig.7).
Fig.7
4
L714 06 01 03
7. Insert the lever (()LJ) between the rim and the lower part of the tire, careful that the TPMS sensor (%)LJ)
is positioned approximately 10 cm away from where the lever is inserted.
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irreparably damaged.
5. Press the lever downward and activate the tire changer, rotating the wheel slightly more than 180° (Fig.8).
10 cm
% (
6. After this half rotation, the lever’s pressure will completely release the tire from the rim. Fig.8
A %
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Three types of tires can be installed on the car (Fig.9):
A. PZERO CORSA
% PZERO PUNTO
Fig.9
5
L714 06 01 03
' 'LVDVVHPEOLQJWKHWLUHSUHVVXUHVHQVRUV
• Disassemble the tire 3RLQW% of the sensor that must be replaced.
'LVDVVHPEOLQJWKHVHQVRU A
1. Insert the torsion bar (A-Fig.9) in the valve’s hole (%)LJ).
2. Unscrew the TPMS bolt and remove the sensor (C-Fig.9) using the torque wrench. %
Fig.9
3. After removing the sensor, insert the torsion bar again (A-Fig.10) in the valve’s hole (%)LJ).
A
4. Unscrew the valve (%)LJ) using the torque wrench.
5. Remove the nut, washer and the valve itself.

%
1RWH
If the valve, nut, washer and sensor are not damaged, they can be reused. The TPMS bolt, however, must
be replaced every time.
Fig.10
6
L714 06 01 05
$ :KHHOULPV
% 7LUHV
& 7LUHVZLWK7306
' Tire pressure sensors
A) Assembling the wheel rims and tires
1. With the vehicle raised on the car lift secure the wheel to the hub by tightening the 5 mounting screws
(A-Fig.1).
• %HYHU\FDUHIXOZLWKWKHZKHHOGXULQJDVVHPEO\WRSUHYHQWGHQWLQJRUGDPDJLQJWKHZKHHOULP
• $WWKHWLPHRIZKHHODVVHPEO\DSSO\WKHWLJKWHQLQJWRUTXHRQWKHVFUHZVD
A
Fig.1
1HYHU ORRVHQ WKH EROWV DUURZV VHFXULQJ WKH ZKHHO WULPV RQ ZKHHOV ZLWK EROWHGRQ ZKHHO WULPV
&DOOLVWRGXDOVSRNHGHVLJQ(Fig.2).
Fig.2
1
L714 06 01 05
% $VVHPEOLQJWKHWLUHV
1. Position the rim on the tire changer.

2. To assemble the tire onto the wheel rim, follow the operations described in the tire changer’s user and
maintenance manual.
A %
• ,QÀDWHWKHWLUH
• Assemble the car’s wheel 3RLQW$.
1RWH
Three types of tires can be installed on the car (Fig.2a):
A. PZERO CORSA
% PZERO PUNTO
Fig.2a
2
L714 06 01 05
& $VVHPEOLQJWKHWLUHVZLWK7306

A
1. Position the rim (A-Fig.3) on the tire changer.
1RWH
Apply grease/soap on the tire surfaces that will come into contact with the rim..
Fig.3
2. Insert the tire on the rim and secure the rim itself using the column (%)LJ). Check that the TPMS sensor (C-
Fig.4) is located approximately 10 cm from the column. %
,IWKH7306VHQVRU¶VSRVLWLRQLVQRWREVHUYHGZKLOHWKHORZHUSDUWRIWKHWLUHLVEHLQJLQVHUWHGRQWR
'
WKHULPLWFRXOGEHLUUHSDUDEO\GDPDJHG
3. Insert the lower part of the tire, placing the sliding support (')LJ) on the tire and rotating the wheel slightly
more than 180° (clockwise).
cm
10
Fig.4
3
L714 06 01 05
4. After inserting the lower part of the tire, position the wheel so that the TPMS sensor (C-Fig.5) is located
%
approximately 10 cm from the column (%)LJ).
,IWKH7306VHQVRU¶VSRVLWLRQLVQRWREVHUYHGZKLOHWKHWLUHLVEHLQJGH¿QLWLYHO\LQVHUWHGRQWRWKH 10 cm
ULPLWFRXOGEHLUUHSDUDEO\GDPDJHG
C
Fig.5
'
5. Insert the upper part of the tire, placing the sliding bearing (')LJ) on the tire and rotating the wheel slightly
more than 180° (clockwise).
6. After this half rotation, the pressure of the sliding support will correctly insert the tire onto the rim without
damaging the TPMS sensor (Fig.6).
• ,QÀDWHWKHWLUH Fig.6
• Assemble the car’s wheel 3RLQW$. A %
1RWH
Three types of tires can be installed on the car (Fig.7):
A. PZERO CORSA
% PZERO PUNTO
C. PZERO ROSSO
Fig.7
4
L714 06 01 05
' $VVHPEOLQJWKHWLUHSUHVVXUHVHQVRUV
A
1RWH
Check that there are no burrs or corrosion on the hole ($)LJ) where the valve is inserted.
)LJ
1. Insert the valve (%)LJ) with the head (which contains the threaded hole for connecting the TPMS sensor) % %
facing toward the inside of the rim.
Fig.9
C
2. Insert the torsion bar (C-Fig.10) in the valve’s hole (%)LJ).
Then insert the washer and nut and secure the valve using the torque wrench.
9DOYHDWWDFKPHQWWLJKWHQLQJWRUTXHG
Fig.10
5
L714 06 01 05
3. Install the sensor (')LJ), tightening the relevant TPMS bolt (()LJ):
Insert the torsion bar (C-Fig.12) in the valve’s hole (%)LJ), using the torque wrench. (
6HQVRUDWWDFKPHQWWLJKWHQLQJWRUTXHGZLWK/RFWLWHVHDODQW
0DNHVXUHWKDWWKH7306VHQVRU¶VWZRSRLQWVRIFRQWDFWUHVWDJDLQVWWKHULP)LJ '
Fig.11
Fig.12
6
L714 06 02 00
3DUNLQJEUDNH
The parking brake operates on the rear wheels.

The calipers acting on the wheel disks are controlled by two steel cables through two pulleys and a rocker arm that A
ensures a uniform force distribution.
C G
3DUNLQJEUDNH)LJ
A. Hand brake lever
B. Pulleys
C. Tie rod adjuster
D. Left-hand tie rod
E. Pads
F. Caliper
G. Right-hand tie rod F
D E B
Fig.1
1
L714 06 02 01
&KHFNLQJSURSHURSHUDWLRQRIWKHSDUNLQJEUDNH
It is working correctly if the car is braked after 3-4 clicks of the lever. If this is not the case, act on the tie-rod
registers (A-Fig.1) again to reset the correct lever stroke (060202).
A
Fig.1
1
L714 06 02 02
$GMXVWLQJWKHSDUNLQJEUDNH
• Remove the glove box into the tunnel (086303).
$GMXVWLQJWKHSDUNLQJEUDNH
1. Using a 10 mm wrench, adjust the register (A-Fig.1) until the rear wheels lock and then unscrew it at least two
turns.
Check that:
• when the lever is down the wheels are free to turn without rubbing between the brake shoes and disks.
• The parking brake lever’s stroke is 3-4 clicks.
If it is not, adjust the lever’s register again to obtain the correct stroke.
Fig.1
1
L714 06 02 03
$3DUNLQJEUDNHFDOLSHUGLVDVVHPEO\
%3DUNLQJEUDNHOHYHUGLVDVVHPEO\
&'LVDVVHPEOLQJWKHSDUNLQJEUDNHOHYHUFDEOHV
$3DUNLQJEUDNHFDOLSHUGLVDVVHPEO\
• Put the car on a car lift (000000).
A
'LVDVVHPEOLQJWKHFDOLSHU
1. Act on the screw (A-Fig.1) to zero set the automatic backlash device.
Fig.1
2. Use a pair of pliers to release the parking brake cable (B-Fig.2).
Fig.2
1
L714 06 02 03
3. Remove the 2 pins (C-Fig.3) from the calliper.
4. Remove the spring (')LJ) from its housing. '
Fig.3
5. Unscrew the 2 bolts (()LJ) securing the calliper.

F
6. Extract the calliper (F-Fig.4) and the pads (G-Fig.4) together.
G
7. If necessary, remove the pads from the calliper (G-Fig.4). (
Fig.4
8. Remove the snap ring (H-Fig.5) and extract the parking brake cable.
H
9. Remove the parking brake calliper (F-Fig.5).
F
The same procedure applies to both rear wheels.
Fig.5
2
L714 06 02 03
%3DUNLQJEUDNHOHYHUGLVDVVHPEO\ A B
• Disassemble the central tunnel (086303).
'LVDVVHPEOLQJWKHOHYHU
1. Unscrew the 3 screws (A-Fig.6) securing the parking brake lever (B-Fig.2).
2. Release the parking brake lever from the tie rod (C-Fig.6) behind it.
C
3. Disconnect the parking brake lever connector (')LJ). A A
'
Fig.6
3
L714 06 02 03
A C
C) 'LVDVVHPEOLQJWKHSDUNLQJEUDNHOHYHUFDEOHV
• Disassemble the rear wheels (060103).
• 'LVDVVHPEOHWKHUHDUDQGFHQWUHÀDWÀRRUV(082503).
B
'LVDVVHPEOLQJWKHFDEOHV Fig.7
1. To disassemble the glove box (A-Fig. 7), loosen 3 screws (B-Fig. 7) or remove the drink holder.
2. Disconnect the cables (C-Fig.7) from the parking brake lever.
3. Loosen the screws (')LJ) securing the parking brake cable fastening clamps to the chassis.
'
'
Fig.8
4
L714 06 02 03
4. On both sides, remove the clip (()LJ) and lower the spring (F-Fig.9) to disconnect the parking brake cable
(C-Fig.9) from the rear brake calliper.
C
Fig.9
5
L714 06 02 05
$3DUNLQJEUDNHDVVHPEO\RQWKHZKHHO
%3DUNLQJEUDNHOHYHUDVVHPEO\
C) $VVHPEOLQJWKHSDUNLQJEUDNHOHYHUFDEOHV
$3DUNLQJEUDNHDVVHPEO\RQWKHZKHHO
A
The procedure is the same for both rear wheels.
1. Insert the parking brake cable (A-Fig.1) and position the snap ring.
Fig.1
2. Position the pads on the calliper.
B
3. Insert the calliper (B-Fig.2) and pads (C-Fig.2) on the disk together.
C
4. Tighten the two bolts (D-Fig.2) securing the calliper.
%ROWDWWDFKPHQWWLJKWHQLQJWRUTXHD
D
Fig.2
1
L714 06 02 05
5. Position the spring (()LJ) in its housing.
6. Insert the two pins (F-Fig.3) on the calliper. (
7. Use a pair of pliers to attach the parking brake cable (G-Fig.7).

Fig.3
Fig.4
Act on the screw (H-Fig.4) to pre-load the automatic backlash device.
• Assemble the rear wheel .

• After reassembling all the parts, use the control lever a few times to activate the automatic backlash device and H
if necessary, adjust the parking brake .
Fig.5
2
L714 06 02 05
%3DUNLQJEUDNHOHYHUDVVHPEO\ D B
1. Connect the parking brake lever connector (A-Fig.6).
2. Connect the parking brake lever (B-Fig.6) to the tie rod (C-Fig.6) on the back of the lever.
3. To secure the parking brake lever, use the 4 screws (D-Fig.6) located below the lever.
• Assemble the central tunnel .

C
D D
Fig.6
3
L714 06 02 05
B
A
C) $VVHPEOLQJWKHSDUNLQJEUDNHOHYHUFDEOHV
1. On both sides, lower the spring (A-Fig.7) on the parking brake calliper, connect the cable (B-Fig.7) and position
WKH¿[LQJFOLSC-Fig.7).
C
Fig.7
2. Tighten the screws (')LJ) securing the parking brake cable fastening clamps to the chassis.
)LJ
4
L714 06 02 05
3. Connect the cables (()LJ) to the parking brake lever.

F (
4. Tighten 3 screws (G-Fig.9WRDVVHPEOHWKHJORYHER[F-Fig.9), or assemble the drink holder.
• $VVHPEOHWKHUHDUDQGFHQWUHÀDWÀRRUV.
• Assemble the rear wheels .
G
Fig.9
5
L714 06 07 00
%UDNHWHFKQLFDOGDWD
Standard Carbon Ceramic

• Four ventilated disks, hydraulic, dual circuit with power brake, ABS and ESP system
• Front brakes (Fig.1):

Disk diameter (Standard): 365 mm
Disk diameter (Carbon Ceramic): 380 mm
Disk thickness (Standard): 34 mm
Disk thickness (Carbon Ceramic): 38 mm
Calipers (Standard): 8 pistons
Calipers (Carbon Ceramic): 6 pistons
• Rear brakes (Fig.2):

Disk diameter (Standard): 335 mm Fig.1
Disk diameter (Carbon Ceramic): 356 mm
Disk thickness (Standard): 32 mm Standard Carbon Ceramic
Disk thickness (Carbon Ceramic): 32 mm
Calipers (Standard): 4 pistons
Calipers (Carbon Ceramic): 4 pistons
• Mechanical disk parking brake on rear wheels
Fig.2
1
L714 06 07 01
&KHFNLQJWKHEUDNHV\VWHPSLSHVFDOLSHUVDQGFRQQHFWLRQV
• Disassemble the tires (060103).
&KHFNUHJXODUO\
• tightening torques (000800)
• WKHLQWHJULW\RIWKHEUDNHV\VWHPSLSHVDQGFRQQHFWLRQV
• WKHSDGVIRUZHDULIQHFHVVDU\UHSODFH
• SURSHURSHUDWLRQRIWKHEUDNHV\VWHP
1
L714 06 07 03
A) TKHEUDNHFDOLSHU
B) %UDNHFDOOLSHUEOHHGQR]]OH
Standard Front Carbon Ceramic Front
C C
'LVDVVHPEOLQJWKHEUDNHFDOLSHU
• Put the car on a car lift (000000). A A
'LVDVVHPEOLQJWKHEUDNHFDOLSHU
1. Disconnect the connector signalling that the pads are worn:
• front brake caliper: 1 connector lefth side (A-Fig.1).
• rear brake caliper: 1 connector right side (B-Fig.1). Standard Rear Carbon Ceramic Rear
2. Unscrew the banjo bolt (C-Fig.1) that secures the hose to the caliper. Protect the pipe to prevent excessive
EUDNHÀXLGOHDNV8VHDSDQWRFROOHFWWKHÀXLG
B
3D\DWWHQWLRQWREUDNHÀXLGOHDNVULVNRISDLQWFRUURVLRQ C
C
B
Fig.1
1
L714 06 07 03
3. Unscrew the 2 screws (')LJ) that secure the brake calipers to the diskholder. Standard Front Carbon Ceramic Front
' '
7KHVHTXHQFHIRUGLVDVVHPEOLQJWKHEUDNHFDOLSHUVLVWKHVDPHIRUERWKWKHIURQWDQGUHDUZKHHOV
' '
Standard Rear Carbon Ceramic Rear
' '
'
'
Fig.2
2
L714 06 07 03
A
%'LVDVVHPEOLQJWKHEUDNHFDOOLSHUEOHHGQR]]OH A
'LVDVVHPEOLQJWKHEOHHGQR]]OH
1. Unscrew and remove the nozzle (A-Fig.3).
3UHVWDUHDWWHQ]LRQHDOOHIXRULXVFLWHGLOLTXLGRIUHQLSHULFRORGLFRUURVLRQHGHOODYHUQLFH A A
Fig.3
3
L714 06 07 05
A) TKHEUDNHFDOLSHU
B) %UDNHFDOOLSHUEOHHGQR]]OH
$$VVHPEOLQJWKHEUDNHFDOLSHU
1. Deposit a drop of medium strength thread sealant on each of the 2 screws that secure the brake caliper to the
Fig.1
diskholder (A-Fig.1).
2. Secure the brake caliper to the disk using the 2 screws (B-Fig.2).
6FUHZDWWDFKPHQWWLJKWHQLQJWRUTXHE B B
B B
B B
B
B
Fig.2
1
L714 06 07 05
3. Secure the hose to the caliper using the banjo bolt (C-Fig.3) and insert new copper washers. Standard Front Carbon Ceramic Front
4. Connect the connector signalling that the pads are worn:

• front brake caliper: 1 connector lefth side (')LJ).
C C
• rear brake caliper: 1 connector right side (()LJ).
5. Bleed the brakes .

' '
• Reassemble the wheel .

•.

7KHVHTXHQFHIRUDVVHPEOLQJWKHEUDNHFDOLSHUVLVWKHVDPHIRUERWKWKHIURQWDQGUHDUZKHHOV
%OHHGWKHEUDNHFLUFXLW
(
C
C
%HZDUHRIEUDNHÀXLGOHDNVULVNRISDLQWFRUURVLRQ (
Fig.3
2
L714 06 07 05
A
%$VVHPEOLQJWKHEUDNHFDOOLSHUEOHHGQR]]OH A
1. Position and screw on the nozzle (A-Fig.3).
%HZDUHRIEUDNHÀXLGOHDNVULVNRISDLQWFRUURVLRQ

Bleed the brake circuit . A
A
Fig.3
3
L714 06 11 01
CKHFNLQJWKHEUDNHÀXLGOHYHO 5LJKWKDQGGULYH
• 2SHQWKHIURQWOXJJDJHFRPSDUWPHQWDQGUHPRYHWKHÀDSWRDFFHVVWKHEUDNHÀXLGA-Fig.1).
A
• 8QVFUHZWKHUHVHUYRLU¶VFDSB-Fig.1DQGFKHFNWKDWWKHOHYHOLVDWWKH0$;PDUN
1RWH B
7KHOHYHOPDUNVDUHRQWKHULJKWVLGHRIWKHUHVHUYRLUDQGYLVLEOHZLWKDPLUURU
• :KHQWRSSLQJXSXVHRQO\WKHSUHVFULEHGÀXLGDQGLQWURGXFHLWZLWKDSHUIHFWO\FOHDQGU\V\ULQJH(QVXUHWKDW
WKHÀXLGLVXQFRQWDPLQDWHGDQGFRPHVIURPDVHDOHGFDQ
EUDNHÀXLGOHYHOW\SH
/HIWKDQGGULYH
%UDNHÀXLGFRUURGHVSDLQWLILWVSLOOVLPPHGLDWHO\ZDVKZHOOZLWKZDWHUDQGGU\
A
Fig.1
1
L714 06 11 03
'LVDVVHPEOLQJWKHYDFXXPWDQN
A
• Remove the engine compartment right side panel (081303).
1. Unscrew the screw (A-Fig.1) that secures the tank to the support bracket.
2. Disconnect the pipe (B-Fig.1).
3. Remove the vacuum tank (C-Fig.1).
Fig.1
1
L714 06 11 03
'LVDVVHPEOLQJWKHYDFXXPWDQN
B A C
• Remove the air intake manifolds (012903).
1. Unscrew the screw (A-Fig.2) that secures the tank to the manifolds.
3. Remove the vacuum tank (C-Fig.2).
Fig.2
2
L714 06 11 05
$VVHPEOLQJWKHYDFXXPWDQN
A
1. Tighten the 2 screws (A-Fig.1) securing the vacuum tank (B-Fig.1) to the support bracket.
2. Connect the pipe (C-Fig.1).
• Assemble the engine compartment right side panel (081305).
Fig.1
1
L714 06 11 05
$VVHPEOLQJWKHYDFXXPWDQN
C A B
1. Tighten the 2 screws (A-Fig.2) securing the vacuum tank (B-Fig.2) to the manifolds.
2. Connect the pipe (C-Fig.2).
• Assemble the air intake manifolds (012905).
Fig.2
2
L714 06 11 06
%OHHGLQJZLWKD¿OOHUEOHHGHUXQLW
1RWH
$¿OOHUEOHHGHUXQLWZLWKDPLQLPXPLQLWLDOSUHVVXUHRIEDUFDQEHXVHGWREOHHGWKHEUDNHSXPS$GMXVWWKH
¿OOHUEOHHGHUXQLW¶VSUHVVXUHWREDU A
Important!
• 7KHVWHSVIRU¿OOLQJDQGEOHHGLQJWKHEUDNHV\VWHPPXVWEHFORVHO\REVHUYHG
• %UDNHÀXLGFRUURGHVSDLQWLILWVSLOOVLPPHGLDWHO\ZDVKZHOOZLWKZDWHUDQGGU\
• &KHFNWKDWWKH¿OOHUEOHHGHUXQLWLV¿OOHGZLWKWKHSUHVFULEHGW\SHRIÀXLG
EUDNHÀXLGOHYHOW\SH
• 5HPRYHWKHIURQWDQGUHDUZKHHOV Fig.1
• 8QVFUHZWKHEUDNHÀXLGUHVHUYRLU¶VFDSA-Fig.1&RQQHFWWKH¿OOHUEOHHGHUXQLWKH¿OWHUFDQQRWEHUHPRYHG
• 7XUQRQWKH¿OOHUEOHHGHUXQLW&KHFNWKDWWKHSUHVVXUHLVEDU
1
L714 06 11 06
Front
7KHUHDUHWZREOHHGYDOYHVRQWKH%UHPERFDOLSHU2SHQWKHLQWHUQDORQH¿UVWDQGWKHQWKHH[WHUQDO
one.
• 8QVFUHZWKHEOHHGVFUHZVLQWKHSUHVFULEHGRUGHUDQGEOHHGWKHEUDNHV\VWHP
%OHHGRUGHU
1. 5+UHDUFDOLSHU
2. /+UHDUFDOLSHU
5+IURQWFDOLSHU
4. /+IURQWFDOLSHU
• :LWKWKH¿OOHUEOHHGHUXQLWRQOHDYHWKHFDOLSHU¶VEOHHGYDOYHVRSHQXQWLOEUDNHÀXLGFRPHVRXWZLWKRXWDLU
EXEEOHV
Important!
• 8VHDVXLWDEOHEOHHGSLSH,WPXVWEHSRVLWLRQHGWLJKWRQWKHEOHHGYDOYHVRWKDWDLUFDQQRW Rear
SHQHWUDWHLQWRWKHEUDNHV\VWHP
• $IWHUEOHHGLQJWKHEUDNHSHGDOVKRXOGQRWEHÀH[LEOH
• 'LVFRQQHFWWKH¿OOHUEOHHGHUXQLW IURPWKHEUDNHSXPSUHVHUYRLU
• ,IQHFHVVDU\WRSXSWKHEUDNHÀXLGDQGWKHQFORVHWKHUHVHUYRLUZLWKWKHFDS
• &DUU\RXWDURDGWHVWDQGDFWLYDWHWKH$%6V\VWHPDWOHDVWRQFH
Fig.2
2
L714 06 11 06
Manual bleeding Front
1RWH
7ZRDUHRSHUDWRUVDUHUHTXLUHGRQHLQWKHFDUDQGRQHIRUEOHHGLQJ
Important!
7KHUHDUHWZREOHHGYDOYHVRQWKH%UHPERFDOLSHU2SHQWKHLQWHUQDORQH¿UVWDQGWKHQWKHH[WHUQDO
one.
%OHHGRUGHU
1. 5+UHDUFDOLSHU
2. /+UHDUFDOLSHU
5+IURQWFDOLSHU
4. /+IURQWFDOLSHU
)RUHDFKFDOLSHU Rear
• )RUFHIXOO\DFWLYDWHWKHEUDNHSHGDODQGNHHSLWSUHVVHG
• 2SHQWKH5+UHDUEOHHGYDOYH
• )XOO\SUHVVWKHEUDNHSHGDO
• &ORVHWKHEOHHGYDOYHZKLOHNHHSLQJWKHSHGDOSUHVVHG
• 6ORZO\UHOHDVHWKHEUDNHSHGDO
7KLVSURFHGXUHPXVWEHFDUULHGRXW5 times for each caliper
Important!
$IWHUEOHHGLQJWKHEUDNHSHGDOVKRXOGQRWEHÀH[LEOH
• ,IQHFHVVDU\WRSXSWKHEUDNHÀXLGDQGWKHQFORVHWKHUHVHUYRLUZLWKWKHFDS
• &DUU\RXWDURDGWHVWDQGDFWLYDWHWKH$%6V\VWHPDWOHDVWRQFH
)LJ

L714 06 11 07
5HSODFLQJWKHÀXLGLQWKHEUDNHFLUFXLW 5LJKWKDQGGULYH
• 2SHQWKHIURQWOXJJDJHFRPSDUWPHQWDQGUHPRYHWKHÀDSA-Fig.1WRDFFHVVWKHEUDNHÀXLGUHVHUYRLU
• 8QVFUHZWKHUHVHUYRLUFDSB-Fig.1 A
5HSODFLQJWKHÀXLGLQWKHEUDNHFLUFXLW
B
Solution 1
• 8VHDSQHXPDWLFGHYLFHWKDWSUHVVXUL]HVWKHFLUFXLWDQGNHHSVLWFRQVWDQWO\IXOO
8QWLOQHZRLOEHJLQVWRH[LWFRQWLQXHWREOHHGWKHV\VWHP
7KHÀXLGUHSODFHPHQWSURFHGXUHPXVWEHFDUULHGRXWRQHYHU\EUDNHFDOLSHURQWKHFDOLSHU¶VLQWHUQDO
DQGH[WHUQDOEOHHGYDOYHV
/HIWKDQGGULYH
Solution 2
• 8VHDV\ULQJHWRUHPRYHWKHÀXLGLQVLGHWKHUHVHUYRLU5HSODFHZLWKQHZRLO
• Bleed each wheel XQWLOFOHDQRLOVWDUWVWRH[LW
A
7KHÀXLGUHSODFHPHQWSURFHGXUHPXVWEHFDUULHGRXWRQHYHU\EUDNHFDOLSHURQWKHFDOLSHU¶VLQWHUQDO
DQGH[WHUQDOEOHHGYDOYHV
B
Fig.1
1
L714 06 11 08
)LOOLQJDQGWRSSLQJXSWKHEUDNHFLUFXLWÀXLG 5LJKWKDQGGULYH
• 2SHQWKHIURQWOXJJDJHFRPSDUWPHQWDQGUHPRYHWKHÀDSA-Fig.1WRDFFHVVWKHEUDNHÀXLGUHVHUYRLU
A
E
)LOOLQJDQGWRSSLQJXSWKHEUDNHFLUFXLWÀXLG
• 5HPRYHWKHFDSRQWKHEUDNHFLUFXLWÀXLGUHVHUYRLUB-Fig.1
• 7RSXSWKHÀXLGOHYHO (000300) B
7KHOHYHORIWKHEUDNHFLUFXLWÀXLGPXVWDOZD\VEHEHWZHHQWKH0,1DQG0$;PDUNV
/HIWKDQGGULYH
Fig.1
1
L714 06 12 03
A) %UDNHERRVWHU
%%UDNHYDFXXPSXPS
C) Vacuum sensor
D) Disassembling the pan
('LVDVVHPEOLQJWKHEUDNHYDFXXPSLSH
A
$'LVDVVHPEOLQJWKHEUDNHERRVWHU C
• Disassemble the luggage compartment (080603).
Left hand drive Fig.1
• Disassemble the ABS control unit (061403).
Right hand drive
• Disassemble the air conveyor (volute) (026003).
'LVDVVHPEOLQJWKHEUDNHERRVWHU
1. Empty the reservoir (A-Fig.1) (061107). G
B
3. Disconnect the 2 pipes (C-Fig.1).

Fig.2
4. Disconnect the wiring harness (D-Fig.1).
5. 5HOHDVHWKH¿[LQJSLQE) and remove the pin locking the brake booster to the pedal cluster (F-Fig.3).
F
6. Unscrew the brake booster’s 2 stay-bolts (G-Fig.2).
7. ([WUDFWWKHEUDNHERRVWHU E
Fig.3
1
L714 06 12 03
%'LVDVVHPEOLQJWKHEUDNHYDFXXPHOHWWULFSXPS
A
• Disassemble the front bumper (080603).
Disassembling the pump

1. Loosen the 3 screws (A-Fig.4) that secure the support bracket to the chassis.
Fig.4
2. Disconnect the brake vacuum pipe (B-Fig.5) removing its antitheft clamp (C-Fig.5).
3. Disconnect the connector (D-Fig.5).
D
B
Fig.5
2
L714 06 12 03
4. Remove the brake vacuum pump (E-Fig.6).
Fig.6
3
L714 06 12 03
&'LVDVVHPEOLQJWKHYDFXXPVHQVRU
A
'LVDVVHPEOLQJWKHYDFXXPVHQVRU
1. Disconnect the sensor (A-Fig.7) from the brake booster reservoir.
2. Remove the clamp (B-Fig.7) and disconnect the pipe from the vacuum sensor.
3. Disconnect the connector (C-Fig.7) from the pressure sensor.
4. Remove the vacuum sensor.
Fig.7
4
L714 06 12 03
D) Disassembling the pan B
• Disassemble the luggage compartment (080603). A
• (PSW\WKHEUDNHÀXLGUHVHUYRLU(061107).
Fig.8
Disassembling the pan
1. Disconnect the pipe (A-Fig.8).
2. Disconnect the connector (B-Fig.8). D
3. Loosen the screw (C-Fig.8).
4. Release the pan(D-Fig.9) from its slot (E-Fig.9DQGH[WUDFWIURPWKHWZRXQLRQVF-Fig.9). F
%HZDUHRIDQ\UHVLGXDORLOOHDNV
E
Fig.9
5
L714 06 12 03
A
('LVDVVHPEOLQJWKHEUDNHYDFXXPSLSH
• 'LVDVVHPEOHWKHIURQWUHDUDQGFHQWUHÀDWÀRRUV(082503).
• Disassemble the central cooling circuit pipes (012103).
'LVDVVHPEOLQJWKHEUDNHYDFXXPSLSH
1. Cut the clamp to disconnect the pipe (A-Fig.10) from the brake vacuum pump.
2. Detach the two interlocking clamps (B-Fig.10).
B
Fig.10
3. Disconnect the connection (C-Fig.11) with the brake booster pipe.
Fig.11
6
L714 06 12 03
4. Release the clamp (D-Fig.12) securing the pipe to the chassis near the differential compartment.
D
Fig.12
5. Release the three clamps (E-Fig.13) securing the brake vacuum pump pipe to the center console.
E
Fig.13
6. Disconnect the front part from the rear part of the pipe (F-Fig.14).
Fig.14
7
L714 06 12 03
7. Detach the fastening (G-Fig.15) securing the rear part of the pipe with the power steering circuit return pipe.
8. Loosen the screw securing the brake vacuum pump pipe mounting bracket (H-Fig.15) to the chassis. H
9. Remove the rear part of the brake vacuum pump pipe (I-Fig.15). I
Fig.15
8
L714 06 12 05
A) %UDNH%RRVWHU
%%UDNHYDFXXPSXPS
C) Vacuum sensor
'$VVHPEOLQJWKHEUDNHRLOWDQN
($VVHPEOLQJWKHEUDNHYDFXXPSLSH
A
$$VVHPEOLQJWKHEUDNHERRVWHU
F
1. Position the brake booster’s 2 stay-bolts (A-Fig.1).
2. ,QVHUWWKHSLQDQGFOLSRQWKH¿[LQJSLQ%WRVHFXUHWKHEUDNHERRVWHUWRWKHSHGDOFOXVWHUC-Fig.2).

Fig.1
3. &RQQHFWWKHZLULQJKDUQHVVD-Fig.3).
4. Connect the 2 pipes (E-Fig.3). C
5. Connect the pipe (F-Fig.1).

B
6. Fill the reservoir (G-Fig.3).
• $VVHPEOHWKHOXJJDJHFRPSDUWPHQW(080605).
Left hand drive Fig.2
• $VVHPEOHWKH$%6FRQWUROXQLW(061405).
Right hand drive
• $VVHPEOHWKHDLUFRQYH\RUYROXWH(026005). G
D
Fig.3
1
L714 06 12 05
%$VVHPEOLQJWKHEUDNHYDFXXPHOHWWULFSXPS
1. 3XWWKHEUDNHSUHVVXUHSXPSA-Fig.4) inside its compartment.

A
Fig.4
2. 7LJKWHQWKHVFUHZVB-Fig.5WKDWVHFXUHWKHVXSSRUWEUDFNHWWRWKHFKDVVLV

B
3. Connect the connector (C-Fig.5). C
Fig.5
2
L714 06 12 05
4. ,QVWDOOWKHEUDNHYDFXXPSLSHD-Fig.6VHFXULQJLWZLWKLWVDQWLWKHIWFODPSE-Fig.6).
• $VVHPEOHWKHIURQWEXPSHU(080605).
• &KHFNWKDWWKHEUDNHYDFXXPSXPSLVSURSHUO\LQVWDOOHGDQGRSHUDWLQJE\PHDQVRIWKH/D5D$6HQJLQHFRQWURO
XQLW³´%DVLFVHWWLQJ(109000).
Fig.6
3
L714 06 12 05
&$VVHPEOLQJWKHYDFXXPVHQVRU
1. Connect the connector (A-Fig.7) on the sensor.
2. 6HFXUHWKHYDFXXPVHQVRUSLSHXVLQJWKHFODPSB-Fig.7).
3. Insert the sensor (C-Fig.7) inside the brake booster reservoir. A
Fig.7
4
L714 06 12 05
D) Assembling the pan

A
1. Insert the pan (A-Fig.8WRWKHWZRXQLRQVB-Fig.8) on the brake booster and clip into its slot (C-Fig.8).
2. 7LJKWHQWKHVFUHZ(D-Fig.9). B
3. Connect the connector (E-Fig.9).
4. Connect the pipe (F-Fig.9).

C
Fig.8
D
Fig.9
5
L714 06 12 05
B
($VVHPEOLQJWKHEUDNHYDFXXPSLSH
1. Position the rear part (A-Fig.10RIWKHEUDNHYDFXXPSXPSSLSH A
2. 7LJKWHQWKHVFUHZVHFXULQJWKHEUDNHYDFXXPSXPSSLSHPRXQWLQJEUDFNHWB-Fig.10) to the chassis.
3. 3RVLWLRQWKHIDVWHQHUC-Fig.10VHFXULQJWKHUHDUSDUWRIWKHSLSHZLWKWKHSRZHUVWHHULQJFLUFXLWUHWXUQSLSH C
Fig.10
4. &RQQHFWWKHIURQWSDUWWRWKHUHDUSDUWRIWKHSLSHD-Fig.11).
Fig.11
6
L714 06 12 05
5. Fasten the three clamps (E-Fig.12VHFXULQJWKHEUDNHYDFXXPSXPSSLSHWRWKHFHQWHUFRQVROH
E
Fig.12
F
6. Fasten the clamp (F-Fig.13VHFXULQJWKHSLSHWRWKHFKDVVLVQHDUWKHGLIIHUHQWLDOFRPSDUWPHQW
Fig.13
7. Connect the connection (G-Fig.14) with the brake booster pipe.
Fig.14
7
L714 06 12 05
8. 3RVLWLRQWKHWZRLQWHUORFNLQJFODPSVH-Fig.15).
9. Fasten the clamp to connect the pipe (I-Fig.15WRWKHEUDNHYDFXXPSXPS
• $VVHPEOHWKHFHQWUDOFRROLQJFLUFXLWSLSHV(012105).
• Assemble the battery (091505).
• $VVHPEOHWKHIURQWGLIIHUHQWLDO(040905).
• $VVHPEOHWKHHQWLUHHQJLQH(010005).
• $VVHPEOHWKHIURQWFHQWUHDQGUHDUYHKLFOHÀRRUV(082505).
H
Fig.15
8
L714 06 14 00
$%66\VWHP
During braking the ABS function allows the modulation of the braking force effectively applied to each wheel, thus
preventing one or more wheels from becoming blocked, which would otherwise cause the loss of control of the
vehicle.
The control unit carries out the corrections to the braking by reading the relative speed of each wheel, obtained by
special sensors (pick-up).
To guarantee a good signal quality, the distance between the pick-up and the phonic wheel must be between 0.9
÷ 1.0 mm. The electro-hydraulic control unit carries out all the corrections on the braking, using 4 ISO valves and 4
DUMP valves. When an ISO valve is closed, the disc brake calliper is isolated from the hydraulic pump.
The DUMP valve, on the other hand, is used to reduce the pressure of the corresponding disc brake calliper that
is present in the hydraulic circuit. If, during normal use of the vehicle, the ABS warning light on the dashboard is
switched on and the buzzer sounds at the same time, it means that the ABS control unit has found a fault in the
system. When the warning light is on the ABS does not work; this means that in the vehicle the braking system works
anyway, but the electronic control on the braking is deactivated.
$%6V\VWHPYDFXXPUHFRYHU\SXPS
The electric vacuum recovery pump is positioned in the front bumper area and is controlled by the MASTER engine
injection control unit only with the engine running.
Its operation is determined by a pressure sensor that calculates its drop and makes the pump cut in to maintain the
vacuum.
Its operation can be checked by means of the LaRa-AS engine control unit “01” Basic setting 8 (109000).
Fig.1
1
L714 06 14 02
%UDNHVZLWFKDGMXVWPHQW
It is located inside the passenger compartment, where it is mounted on to the pedal cluster on a bracket.
The adjustment of this component is critical, ensure that the switch is open when the pedal is at rest position. Simply
check whether or not the brake lights are on.
If the switch is incorrectly adjusted or damaged, the control unit acknowledges the situation by generating the
relative error message: stuck or inoperative brake switch.
%UDNHVZLWFK)LJ A
A. Brake/ABS switch
B. Pedal B Fig.1
&KHFNLQJSURFHGXUH
6HHFKDSWHUIRUSHGDODGMXVWPHQWDQGIRUVZLWFKDGMXVWPHQW
,IWKHDGMXVWPHQWLVQRWFDUULHGRXWSURSHUO\WKHHJHDUV\VWHPGRHVQRWZRUN
1
L714 06 14 03
$'LVDVVHPEOLQJWKH$%6FRQWUROXQLW
%'LVDVVHPEOLQJWKH$%6SLSHV
1
L714 06 14 03
$'LVDVVHPEOLQJWKH$%6FRQWUROXQLW /HIWKDQGGULYH
'LVDVVHPEOLQJWKHFRQWUROXQLW
1. Disconnect the main connector ($)LJ).
2. Disconnect the 6 pipes (%)LJ) connected to the control unit.
3. Remove the 2 screws (&)LJ) that secure the control unit to the bracket.
% A C
4. Prize the control unit mounting bracket and the aluminum part.
5. Remove the control unit. 5LJKWKDQGGULYH
If it is necessary to replace the ABS system electro-hydraulic unit, to assist tracing the required part use the number
stamped on the hydraulic unit and on the electronic unit plate.
% A C
)LJ
2
L714 06 14 03
/HIWKDQGGULYH
%'LVDVVHPEOLQJWKH$%6SLSHV
3
The ABS brake circuit is grouped as follows ()LJ):
A3
A2 A4
A1. Brake booster pump front connection pipe A1
A2. Brake booster pump front connection pipe
A3 Right rear brake calliper front connection pipe
A4 Right front brake calliper front connection pipe
A5. Left rear brake calliper front connection pipe
3 A6 A5
A6. Left front brake calliper front connection pipe
5LJKWKDQGGULYH
3 Right rear brake calliper rear connection pipe
3 Left rear brake calliper rear connection pipe
3
A3
A2 A4
A1
3 A6 A5
)LJ
3
L714 06 14 03
)52173$57
A
• Remove the wheels (060103).
'LVDVVHPEOLQJWKH$%6SLSHV
)RUULJKWKDQGGULYHYHKLFOHVRQO\UHPRYHWKHDLUFRQYH\RU$)LJ
)LJ
1. Unscrew the nuts (%)LJ) securing the pipes to the ABS control unit. % A1 A1 A2
A2
)LJ
2. Remove ABS pipes A1 and A2 ()LJ )LJ) by unscrewing the nuts (&)LJ) securing them to the brake
booster pump. A1
C C
)RUULJKWKDQGGULYHYHKLFOHV¿UVWUHPRYHSLSH$DQGWKHQSLSH$
A2
A1
A2
)LJ
4
L714 06 14 03
3. Remove ABS pipes A3 and A4 by unscrewing the nuts securing them to the corresponding connections with A3
the right rear brake calliper (')LJ) and the right front brake calliper (()LJ).
'
A4
)LJ
4. Remove ABS pipes A5 and A6 by unscrewing the nuts securing them to the corresponding connections with
the left rear brake calliper ())LJ) and the left front brake calliper (*)LJ).
G
A5
A6
)LJ
5
L714 06 14 03
5($53$57 A3
• Empty the engine coolant tank (012107). A
• Remove the wheels (060103). A5
• Disassemble the front differential ).
3 A
'LVDVVHPEOLQJWKH$%6SLSHV 3
)LJ
1. In the front section of the vehicle, unscrew the nuts ($)LJ) securing front ABS pipes A3 and A5 to rear ABS
pipes3 and 3.
C
2. For right pipe 3, disconnect the battery positive pole (%)LJ) and release the engine cooling pipe (&)LJ).
)LJ
3. Remove right ABS pipe 3 by unscrewing the nut (')LJ) securing it to the right rear brake calliper.
3
'
)LJ
6
L714 06 14 03
4. For left pipe 3, release the engine cooling pipes (()LJE\XQVFUHZLQJWKHVL[¿[LQJVFUHZV))LJ).
5. ,QWKHUHDUSDUWRIWKHFHQWHUFRQVROHORRVHQWKHVFUHZVHFXULQJWKHFODPS¿[LQJSLSH3 to the chassis. (
) )
)
)LJ
6. Remove left ABS pipe 3 by unscrewing the nut (*)LJ) securing it to the left rear brake calliper.
3
)LJ
7
L714 06 14 05
$$VVHPEOLQJWKH$%6FRQWUROXQLW
%$VVHPEOLQJWKH$%6SLSHV
1
L714 06 14 05
$$VVHPEOLQJWKH$%6FRQWUROXQLW /HIWKDQGGULYH
1. Position the control unit and secure it to the bracket using the 2 screws ($)LJ).
2. Connect the 6 pipes (%)LJ) to the control unit.
3. Attach the main connector (&)LJ).
• Assemble the luggage compartment (080605).
% C A
5LJKWKDQGGULYH
If it is necessary to replace the ABS system electro-hydraulic unit, to assist tracing the required part use the number
stamped on the hydraulic unit and on the electronic unit plate.
% C A
)LJ
2
L714 06 14 05
/HIWKDQGGULYH
%$VVHPEOLQJWKH$%6SLSHV
3
The ABS brake circuit is grouped as follows ()LJ):
A3
A2 A4
A1. Brake booster pump front connection pipe A1
A2. Brake booster pump front connection pipe
A3 Right rear brake calliper front connection pipe
A4 Right front brake calliper front connection pipe
A5. Left rear brake calliper front connection pipe
3 A6 A5
A6. Left front brake calliper front connection pipe
5LJKWKDQGGULYH
3 Right rear brake calliper rear connection pipe
3 Left rear brake calliper rear connection pipe
3
A3
A2 A4
A1
3 A6 A5
)LJ
3
L714 06 14 05
)52173$57
$VVHPEOLQJWKH$%6SLSHV
%
1. Position ABS pipes A5 and A6 by tightening the nuts securing them to the corresponding connections with the A5
left rear brake calliper ($)LJ) and the left front brake calliper (%)LJ).
A6
)LJ
2. Position ABS pipes A3 and A4 by tightening the nuts securing them to the corresponding connections with the A3
right rear brake calliper (&)LJ) and the right front brake calliper (')LJ).
C
A4
'
)LJ
3. Position ABS pipes A1 and A2 ()LJ)LJ) by tightening the nuts (()LJ) securing them to the brake booster A1
pump.
( (
)RUULJKWKDQGGULYHYHKLFOHV¿UVWSRVLWLRQSLSH$DQGWKHQSLSH$ A2
A1
A2
)LJ
4
L714 06 14 05
4. Tighten the nuts ())LJ) securing the ABS pipes to the ABS control unit. /HIWKDQGGULYH 5LJKWKDQGGULYH
) A1 A1 A2
A2
)LJ
)RUULJKWKDQGGULYHYHKLFOHVRQO\SRVLWLRQDQGIDVWHQWKHDLUFRQYH\RU*)LJ
G

• Assemble the wheels (060105).
)LJ
5
L714 06 14 05
5($53$57
$VVHPEOLQJWKH$%6SLSHV 3
1. Position left ABS pipe 3 by tightening the nut ($)LJ) securing it to the left rear brake calliper.
2. ,QWKHUHDUSDUWRIWKHFHQWHUFRQVROHWLJKWHQWKHVFUHZVHFXULQJWKHFODPS¿[LQJSLSH3 to the chassis. A
)LJ
3. For left pipe 3, secure the engine cooling pipes (%)LJE\WLJKWHQLQJWKHVL[¿[LQJVFUHZV&)LJ).
C C
C
)LJ
6
L714 06 14 05
4. Position right ABS pipe 3 by tightening the nut (')LJ) securing it to the right rear brake calliper.
3
'
)LJ
5. For right pipe 3, connect the battery positive pole (()LJ) and secure the engine cooling pipe ())LJ).
)
)LJ
6. Nella parte anteriore della vettura avvitare i dadi (*)LJFKH¿VVDQRLWXEL$%6DQWHULRULA3 e A5 ai tubi ABS
posteriori 3 e 3. A3
• Fill the engine coolant circuit (012107). G

A5
• $VVHPEOHWKHIURQWFHQWUHDQGUHDUYHKLFOHÀRRUV (082505).
• Assemble the wheels (060105).
3 G
3
)LJ
7
L714 06 15 01
3$':($5$1'%5$.(',6.:($57(67
7KHFDUKDVWZRW\SHVRIEUDNHVVWDQGDUGDQGFDUERQFHUDPLF
7KHWZREUDNLQJV\VWHPVZHDUGLIIHUHQWO\EDVHGRQWKHW\SHVRIPDWHULDOVXVHG
3$':($57(67
3DGZHDULVFKHFNHGXVLQJDVSHFLDOVHQVRUWKDWVLJQDOVWKHFRQGLWLRQRIWKHSDGV
The technical data regarding the pads can be found in chapter 060000.
,IWKHSDGVPXVWEHUHSODFHGDOZD\VFKHFNWKHGLVN¶VPLQLPXPWKLFNQHVV%UDNHGLVNZHDU

WHVW
%5$.(',6.:($57(67
• Remove the wheel .
&KHFNWKHPLQLPXPWKLFNQHVVRIWKHGLVN,IWKHPLQLPXPWKLFNQHVVLVOHVVWKDQWKHPLQLPXPDOORZHG
DIWHUJULQGLQJLWPXVWEHUHSODFHG
7KHWHFKQLFDOGDWDUHJDUGLQJWKHGLVNVFDQEHIRXQGLQFKDSWHU
1
L714 06 15 01
&DUERQ&HUDPLF'LVNV6SHFL¿FDWLRQV
If the holes of the disks are worn ()LJ), the disks must be replaced if:
• the wear exceeds the edge of the hole by more that one millimeter.
• there are more than 20 damaged holes on one disk.
• there are 3 consecutive holes damaged.
• there are residues that block one or more holes (the diameter of the holes must be 5.5 ± 0.5 mm).
)LJ
If the caliper attachment points are worn ()LJ), the disks must be replaced if:
• the wear around the hole exceeds the striking surface of the screw’s head by more than one millimeter (A- A
)LJ).
• more than 5 cracks are visible in the area that supports the calipers or if there is chipping.
• there are more than 3 damaged holes on one disk.
• the screw’s stud bolt is damaged or shows chipping.
)LJ
If the disk is worn ()LJ), it must be replaced if: % C '

• the edge of the disk is completely worn down (%)LJ).
• if there are obvious marks on the face of the disk (&)LJ).
• if there are cracks between the slotting on the circumference (')LJ).
• the depth of the cracks on the circumference of the disk are greater than 2 mm.
• more than 10 cracks are visible on the disk’s circumference.
)LJ
2
L714 06 15 01
There are 6 wear marks on the disk ()LJ) that indicate the its level of use. The disk must be replaced when:
• the disk’s surface has been reduced by more than 60% of the wear mark.
• none of the 6 wear marks are present.
• the wear mark cannot be used (covered by residues, silicone, etc.).
)LJ
Replace the disk when it shows cracks and fractures on its surface ()LJ).
)LJ
Check the bell ()LJ) and replace the disk when:
• the holes on the bell are not beveled but rather have sharp edges.
• WKHV\PEROVRQWKHHGJHRIWKHEHOODUHLQFRUUHFWVHHH[DPSOHRIDFRUUHFWEHOOLQWKH¿JXUH
If the bell is scratched, remove the scratches by polishing the surface.
Keep all of the parts of the brake disks clean and free of residues.
7KHUHPXVWEHDOHJLEOHVHULDOQXPEHURQWKHGLVNLWVHOILIWKLVQXPEHULVLOOHJLEOHUHSODFHWKHGLVN
)LJ

L714 06 15 01
Replace the disk when its weight becomes lower than the weight printed on the disk’s housing)LJ
(DFKGLVNKDVDVSHFL¿FZHLJKWZKLFKGLIIHUVIURPWKHRWKHUV
)LJ
4
L714 06 15 03
%5$.(6$1'3$'6',6$66(0%/<
$5HDUEUDNHGLVFNGLVDVVHPEO\
%)URQWEUDNHGLVFNGLVDVVHPEO\
&3DGVGLVDVVHPEO\
• 2QO\RULJLQDOSDGVVKRXOGEHXVHGDQGWKH\VKRXOGEHUHSODFHGSHUD[OH
• 7KHFDUKDVWZRW\SHVRIEUDNHVVWDQGDUGDQGFDUERQFHUDPLF
Standard
$ 5($5%5$.(6',6.
• ,IWKHGLVNVDUHUHSODFHG
Remove the brake caliper (060703) and the parking brake caliper (060203).
'LVDVVHPEOLQJWKHUHDUEUDNHGLVN
1. Unscrew the centering screw (A-Fig.1). Carbon Ceramic
2. Remove the brake disk.
'RQRWEXPSRUGDPDJHWKHFDUERQFHUDPLFEUDNHGLVNVLQDQ\ZD\ZKHQKDQGOLQJWKHP A
Fig.1
1
L714 06 15 03
% )5217%5$.(6',6. Standard
• ,IWKHGLVNVDUHUHSODFHG
Release the brake caliper (060703). %
'LVDVVHPEOLQJWKHUHDUEUDNHGLVN
1. Unscrew the centering screw (%)LJ).
2. Remove the brake disk.
'RQRWEXPSRUGDPDJHWKHFDUERQFHUDPLFEUDNHGLVNVLQDQ\ZD\ZKHQKDQGOLQJWKHP
Carbon Ceramic
% Fig.2
2
L714 06 15 03
& 3$'6 Standard
5($5$1')5217%5$.(3$'6
• Disconnect the connector for the pads (060703).
'LVDVVHPEOLQJ67$1'$5'EUDNHSDGVIURPFDOLSHUV
A
1. Remove the 2 pins (A-Fig.3) from the caliper.
2. Use a pliers to remove the pads from their seat.
Fig.3
'LVDVVHPEOLQJ&$5%21&(5$0,&EUDNHSDGVIURPFDOLSHUV Carbon Ceramic
1. Unscrew and remove the pin (%)LJ) from the caliper.
2. Remove the retaining springs (C-Fig.4) from the calliper.

'
3. Remove the bracket (d-Fig.4) from the caliper.
4. Use a pliers to remove the pads from their seat.
%
7KHIURQWEUDNHFDOLSHUSDGVKDYHJRWDOHIWDQGULJKWVLGHDUURZ
7KHUHDUEUDNHFDOLSHUSDGVKDYHJRWQRDUURZ
C
Fig.4
3
L714 06 15 03
3$5.,1*%5$.(3$'6
A
'LVDVVHPEOLQJSDGV
1. $FWRQWKHVSHFL¿FVFUHZA-Fig.5) to zero set the automatic backlash device.
Fig.5
2. Use a pair of pliers to release the parking brake cable (%)LJ).
Fig.6
3. Remove the 2 pins (C-Fig.7) from the caliper.

'
4. Remove the spring (')LJ) from its housing.
Fig.7
4
L714 06 15 03
5. Unscrew the 2 bolts (()LJ) securing the calliper.

F
6. Extract the calliper (F-Fig.8) and the pads (*)LJ) together.
*
7. Remove the pads from the calliper.
Fig.8
5
L714 06 15 05
%5$.(6$1'3$'6$66(0%/<
$5HDUEUDNHGLVFNDVVHPEO\
%)URQWEUDNHGLVFNDVVHPEO\
&3DGVDVVHPEO\
Standard
• Replace on all of the wheels and use original components only.
B
• 7KHFDUKDVWZRW\SHVRIEUDNHVVWDQGDUGDQGFDUERQFHUDPLF
'2127$66(0%/(67$1'$5'&20321(17621&$5%21&(5$0,&%5$.,1*6<67(06
A
$ )5217%5$.(6',6.
1. Position the brake disk and lock it into place using the centering screw (A-Fig.1).
• Assemble the brake caliper (060705).

• Reassemble the wheel (060105). Carbon Ceramic
• Run in the brake pads and disks (061512).
• 3RVLWLRQWKHGLVNVVWDQGDUGRQWKHKXEVVRWKDWWKHVLGHRIWKHGLVNZLWKWKHDUURZLVIDFLQJ

toward the outside of the car and the arrow (B-Fig.1) is facing the direction in which the wheel
turns.
• 2QWKHFDUERQFHUDPLFEUDNLQJV\VWHPWKHURWDWLRQGLUHFWLRQDUURZDQGWKHVLGHRIDVVHPEO\
//HIW55LJKWLVLQGLFDWHGRQWKHGLVN&)LJ
C
A Fig.1
1
L714 06 15 05
% 5($5%5$.(6',6.
Standard
1. Position the brake disk and lock it into place using the centering screw (B-Fig.2).
• Assemble the brake caliper (060705) and the parking brake (060205) WKHSDUNLQJEUDNHLV¿WWHGRQWKHUHDU
wheels only).
• Reassemble the wheel (060105). B
A
• 3RVLWLRQWKHGLVNVVWDQGDUGRQWKHKXEVVRWKDWWKHVLGHRIWKHGLVNZLWKWKHDUURZLVIDFLQJ

toward the outside of the car and the arrow (B-Fig.2) is facing the direction in which the wheel
turns.
• 2QWKHFDUERQFHUDPLFEUDNLQJV\VWHPWKHURWDWLRQGLUHFWLRQDUURZDQGWKHVLGHRIDVVHPEO\
//HIW55LJKWLVLQGLFDWHGRQWKHGLVN&)LJ
Carbon Ceramic
C Fig.2
2
L714 06 15 05
& 3$'6 Standard
5($5$1')5217%5$.(3$'6
$VVHPEOLQJ67$1'$5'EUDNHSDGVRQWRFDOLSHUV
1. Using a set of pliers, insert the pads inside their seat.
2. Position the plates and secure the plates and pads using the pins (A-Fig.3).
A
7KHSODWHVPXVWQRWEHORFNHGLQWRSODFH7KHUHVKRXOGEHDOLWWOHSOD\DORQJWKHD[LVRIWKHSLQV
$VVHPEOLQJ&$5%21&(5$0,&EUDNHSDGVRQWRFDOLSHUV
Fig.3
1. Using a set of pliers, insert the pads inside their seat.
Carbon Ceramic
2. Position the bracket (B-Fig.4) on the caliper.
3. Insert and tighten the pin (C-Fig.4) on the caliper.
4. Insert the retaining springs (')LJ) on the the calliper. B
• Connect the connector for the pads (060705).

• Assemble the wheel (060105).
C
• 7KHSDGVRIWKHIURQWEUDNHFDOLSHUVKDYHDUURZVWKDWLQGLFDWHWKHOHIWVLGHDQGWKHULJKWVLGH%H
YHU\FDUHIXOWKHUHIRUHGXULQJDVVHPEO\WRLQVHUWWKHSDGVZLWKWKHDUURZIDFLQJWKHGLUHFWLRQLQ
which the wheel turns.
• 7KHIURQWSDGVVKRXOGEHLQVHUWHGUDGLDOO\ZLWKUHVSHFWWRWKHEUDNHGLVN,IWKH\DUHGLI¿FXOWWR '
LQVHUWGRQRWIRUFHWKHSDGLQWRWKHFDOLSHU([WUDFWLWDQGWU\DJDLQDWWKHFRUUHFWDQJOH Fig.4
3
L714 06 15 05
3$5.,1*%5$.(3$'6
A
1. Position the pads on the calliper.
B
2. Insert the calliper (A-Fig.5) and pads (B-Fig.5) on the disk together.
3. 7LJKWHQWKHEROWVC-Fig.5) securing the calliper. C

%ROWDWWDFKPHQWWLJKWHQLQJWRUTXHD
Fig.5
4. Position the spring (')LJ) in its housing.
5 ,QVHUWWKHSLQV()LJ) on the calliper. '
Fig.6
6. Use a pair of pliers to attach the parking brake cable (F-Fig.7).
Fig.7
4
L714 06 15 05
7. $FWRQWKHVSHFL¿FVFUHZ*)LJ) to pre-load the automatic backlash device.
• Reassemble the rear wheel (060105).

• After reassembling all the parts, use the control lever a few times to activate the automatic backlash device and *
if necessary, adjust the parking brake (060202).
)LJ
5
L714 06 15 12
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3DGVRIQHZEUDNHV
New pads require a bedding-in period, approximately 400 km, before they provide optimum friction. The slightly
reduced braking effect can be compensated by applying greater pressure on the brake pedal. Do not strain the brakes
too much during the pad bedding in procedure.
Ceramic brake disks improve braking efficiency compared to standard disks because of the following
characteristics:
• better deceleration/load ratio at pedal
• better resistance to repeated braking with less wear of pads and disks
• KLJKHUSDGGLVNIULFWLRQFRHI¿FLHQWVZLWKFRQVHTXHQWLPSURYHGSHUIRUPDQFH
• they require a more precise running-in procedure
• 1HYHUDFFHOHUDWHDQGEUDNHVLPXOWDQHRXVO\
• 2EVHUYHWKHVSHHGOLPLWVRIWKHFRXQWULHVLQZKLFK\RXDUHGULYLQJ
• $OZD\VOHWWKHV\VWHPFRROGRZQEHWZHHQRQHEUDNLQJDQGDQRWKHU
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L714 06 18 00
(63IXQFWLRQ
The ESP function (Electronic Stability Program) controls the car’s dynamic behavior during fast cornering; when the
car’s speed and steering are not compatible with traction. In this situation the ESP uses the brake system and engine
torque to maintain the car’s trajectory.
7KH¿JXUHVKRZVWKHEHKDYLRURIDFDUFRUQHULQJDWDFRQVWDQWVSHHG
:LWKRXW(63)LJ
1. The driver steers, the lateral forces increase.
2. The vehicle begins to become unstable.
3. Countersteering, the driver loses control of the vehicle. Fig.1
4. The vehicle becomes uncontrollable.
:LWK(63)LJ
1. The driver steers, the lateral forces increase.
2. The vehicle begins to become unstable. The ESP intervenes, braking the front right wheel.
3. The vehicle remains under control.
4. The vehicle begins to become unstable. The ESP intervenes, braking the front left wheel until the
vehicle has been stabilized.
7KH(63DFWLYDWLRQGHSHQGVRQWKHSURJUDPVHOHFWHGIRUWKHJHDUER[LIWKH&256$PRGHZLWK(63
GLVFRQQHFWHGLVVHOHFWHGWKH(63GRHVQRWUHDFWLYDWHXQWLOLWLVUHHQJDJHGPDQXDOO\RUDIWHUWKH
engine is started. Fig.2
1
L714 06 18 00
7KH(63XVHVLQIRUPDWLRQSURYLGHGGLUHFWO\IURPVHQVRUV
• Yaw rate and lateral acceleration; sensor located in the passenger compartment on the bench
• Steering angle; sensor located on the steering column
• Brake pressure; sensor
• Wheel speed sensors; the same as for the ABS
'DWDSURFHVVHGGLUHFWO\E\WKHFRQWUROXQLWUHFHLYHGIURPVHQVRUVLJQDOV
• linear speed of the vehicle
• ÀRDWDQJOHGLUHFWLRQRIPRWLRQZLWKUHVSHFWWRWKHORQJLWXGLQDOD[LVRIWKHYHKLFOH
• lateral forces acting on the wheels
• sideslip angle
• lateral speed of the vehicle
7KH(63FRQWUROXQLWFRQWLQXRXVO\FKHFNVWKDWWKH\DZUDWHDQGÀRDWDQJOHGRQRWGLYHUJH,IVRWKHFRQWUROXQLW
brakes one or two wheels to create a yaw moment that places the car in the direction requested by the driver.
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UHÀHFWVWKHG\QDPLFEHKDYLRU
++&+LOO+ROGHU&RQWURO
The ³+LOO+ROGHU&RQWURO´++& system helps and makes it easier for the driver to drive off going uphill.
It goes into operation when the ESP detects a change of gradient when the vehicle is running.
7KH(63WKHUHIRUHVHWVLWVHOIXSWRLQWHUYHQHGXULQJWKHXSKLOOSLFNXSLI¿UVWJHDULVHQJDJHGDQGWKHEUDNHSHGDOLV
being pressed down.
In this case, the pressure of the brake calipers is kept for about 1.5 seconds after the brake pedal is released so the
driver can easily drive off pressing the accelerator pedal without the vehicle quickly backing up.
7KH+LOO+ROGHUIXQFWLRQLVQRWDFWLYDWHGZKHQGULYLQJRIIGRZQKLOOZLWK¿UVWJHDUHQJDJHG
The same is true when reverse gear is engaged. The system is activated in uphill starts (but in reverse gear), but is
deactivated in downhill starts.
2
L714 07 01 00
Chassis
High-strength box-section aluminum chassis with fused parts and sheet metal panels.
Fig.1
1
L714 07 11 02
*HUDER[DGMXVWPHQW Gear selection

terminal
A
Step 1
1. Check that both the selection terminal and the engagement terminal ($%)LJ) are enabled (not anchored Gear
onto the ends of the cables). The terminals are enabled when the spring is compressed and slightly turned so engagement B
terminal
that the ring nut locks into place.
2. Insert the tool (&)LJ) that holds the levers in place in the hole on the gear lever device and on the levers on
the gearbox. Check that the gearshift lever is only able to engage.
Tool for
3. Disable the gear selection lever terminal ($)LJ) and check that the terminal and cable are anchored together. KROGLQJOHYHUV C
in place
The gear selection has now been adjusted.
Tool for
KROGLQJOHYHUV C
in place
Step 2
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terminals.
1. Remove the tool that holds the levers in place (&)LJ) from the gear lever device and assemble the selector
using the two screws.
Fig.1
2. Position the lever exactly at the middle of the selector (Fig.2).
3. Disable the engagement lever terminal ($)LJ) and check that the terminal and cable are anchored together.
Gear engagement has now been adjusted.
4. Remove the tool that holds the levers in place (&)LJ) on the gearbox.
5. Check that the system works correctly by changing gears.
Fig.2
1
L714 07 11 03
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1. Position the lever and gear selection cable assembly.

%
2. Tighten the three screws ($)LJ) securing the gear selection cable support bracket to the gearbox.
)LJ
Secure the gear selection cables, release the safety springs (%)LJ) and position the corresponding clips
¿[LQJWKHPWRWKHEUDFNHW&)LJ).
4. 7LJKWHQWKHVFUHZVVHFXULQJWKHFODPSV¿[LQJWKHJHDUVHOHFWLRQFDEOHV')LJ) to the chassis and engine.
'
'
)LJ
5. Secure the air conditioning circuit pipes (()LJ) by fastening the corresponding brackets ())LJ).
( (
) )
)LJ
2
L714 07 11 05
Tighten the four screws (*)LJ) securing the gearbox lever assembly to the center console. G
)LJ
7. Position the ornament (+)LJ) of the switches on the center console and connect the corresponding connectors
(,)LJ). H I
8. Tighten the two screws (-)LJ5) securing the gearshift selector grid.
J
)LJ
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9. Position and tighten the gearbox lever knob (.)LJ).
• $VVHPEOHWKHDLU¿OWHU.
• Assemble the engine bay aesthetic panels .
• $VVHPEOHWKHFHQWUHDQGUHDUYHKLFOHÀRRUV.
)LJ

L714 07 11 05
%$VVHPEOLQJWKHJHDUVHOHFWLRQFDEOHV
1. Position the lever and gear selection cable assembly.

C
2. Tighten the three screws ($)LJ) securing the gear selection cable support bracket to the gearbox. A
C
Secure the gear selection cable, release the safety springs (%)LJDQGSRVLWLRQWKHFRUUHVSRQGLQJFOLSV¿[LQJ
them to the bracket (&)LJ).
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)LJ
4. 7LJKWHQWKHVFUHZVVHFXULQJWKHFODPSV¿[LQJWKHJHDUVHOHFWLRQFDEOHV')LJ) to the chassis and engine.
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)LJ
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L714 07 11 05
5. Position the snap rings (()LJ) securing the selection cables to the gearbox lever.
(
Position the clips ())LJ) securing the gear selection cable to the gearbox shift lever device.
)
)LJ
7. Tighten the six screws (*)LJ) securing the cover of the gearbox shift lever device.
2QFHJHDUVHOHFWLRQFDEOHDVVHPEO\LVFRPSOHWHDGMXVWWKHJHDUER[
• $VVHPEOHWKHDLU¿OWHU.
• Assemble the engine bay aesthetic panels .
• $VVHPEOHWKHFHQWUHDQGUHDUYHKLFOHÀRRUV.
G
)LJ
5
L714 07 13 03
'LVDVVHPEOLQJWKHlHYHUFRQWUROHJHDU
• Disassemble the driver side airbag module (088003). C A B C
• Disassemble the steering wheel (087503).
• Disassemble the steering wheel cover (087503).
'LVDVVHPEOLQJWKHOHYHUFRQWURO
1. Unscrew the 4 screws ($)LJ) that secure the lever control.
2. Disconnect the connector (%)LJ).
3. Remove the lever control (&)LJ).
A
Fig.1
1
L714 07 13 05
Assembling the lHYHUFRQWUROHJHDU
1. Connect the connector ($)LJ).
2. Screw the 4 screws (%)LJ) that secure the lever control (&)LJ).
C B A C
• Assemble the steering wheel cover (087505).

• Assemble the steering wheel (087505).
• Assemble the driver side airbag module (088005).
• Connect the battery (091500).
B
Fig.1
1
L714 08 01 03
'LVDVVHPEOLQJWKH fuse panel (passenger side footboard area)
• Remove the passenger side mat.
'LVDVVHPEOLQJWKHpanel B
1. Using a screwdriver or a coin, turn the 4 screws (A-Fig.1) (1/2 turn is enough) of the fuse panel (B-Fig.1)
EHWZHHQWKHÀRRUDQGWKHSDVVHQJHUJORYHER[
A A
Fig.1
1
L714 08 01 05
Assembling the fuse panel (passenger side footboard area)
1. Position the fuse panel (A-Fig.1) EHWZHHQWKHÀRRUDQGWKHSDVVHQJHUJORYHER[DQGuVLQJDVFUHZGULYHURUD

FRLQWXUQWKHVFUHZVB-Fig.1WXUQLVHQRXJK
• $VVHPEOHWKHSDVVHQJHUVLGHPDW. A
B B
Fig.1
1
L714 08 02 01
&KHFNLQJWKHEUDNHSHGDO)25(*($59(56,2121/<
1. Position a rod so that one end passes through near the steering wheel (Fig.1) and the other end is positioned
on the bottom left corner of the brake pedal (Fig.2).
2. Hold the pedal in the neutral position and mark the height at which the steering wheel is aligned on the rod.
3. Act on the brake pedal until the STOP lights switch on, and then mark the height at which the steering wheel is
aligned on the rod.
4. Measure the distance between the two marks. The pedal stroke MUST measure between 3 mm and 10 mm. If
these values do not correspond, adjust the SWITCH.
Fig.1
Fig.2
1
L714 08 02 02
Accelerator pedal adjustment
The accelerator pedal does not require any basic setting.
The MASTER engine injection control unit manages the pedal.

The pedal values can be seen by means of the LaRa-AS (109000) on both the MASTER and SLAVE control units,
XVLQJYHUVLRQGLDJQRVWLFVDWJURXSWKURWWOHERG\FRQWUROLQWKLVVSHFL¿FZLQGRZDUHWKHEORFNLQJVRIWKHYDOXHV
ranging from 62 to 68 that include the real values, those read and those processed by the system
7KH YDOXHV UHDG RQ WKH 6/$9( HQJLQH LQMHFWLRQ FRQWURO XQLW DUULYH WKURXJK WKH &$1 OLQH ZKHUHDV WKRVH RQ WKH
0$67(5FRQWUROXQLWDUHUHDGDQGDQDO\VHGE\WKHV\VWHP7KHUHIRUHLIWKHUHLVDPDOIXQFWLRQWKH\DUHWREH¿UVW
YHUL¿HGRQWKH0$67(5DQGWKHQRQWKH6/$9(
Fig.1
1
L714 08 02 03
$ 'LVDVVHPEOLQJWKHEUDNHFOXWFKSHGDOFOXVWHUPDQXDOJHDUER[YHUVLRQRQO\
B) Disassembling the accelerator pedal cluster H
$ 'LVDVVHPEOLQJWKHEUDNHFOXWFKSHGDOFOXVWHUPDQXDOJHDUER[YHUVLRQRQO\
• Disassemble the instrument cluster grille .
• Disassemble the instrument cluster .
• Disassemble the driver side dashboard assembly .
• Disassemble the brake booster reservoir .
A
Disassembly
1. Detach the pedal cluster support (A-Fig.1) by unscrewing the 4 mounting screws (B-Fig.1).
2. Remove the pedal cluster. B
To disassemble the pedal from the pedal cluster: B Fig.1
3. Detach the spring (C-Fig.2) connecting the pedal cluster support to the pedal (1 spring for automatic gearboxes,
2 springs for manual gearboxes).
4. Remove the pin (D-Fig.2) and secure the journal (E-Fig.2) between the pedal cluster and the connecting rod F
(F-Fig.2). D
5. Unscrew the screw (G-Fig.1) securing the pedal cluster shaft.
Remove the pedal (H-Fig.1) (2 pedals for manual gearboxes). E
G C
Fig.2
1
L714 08 02 03
B) Disassembling the accelerator pedal cluster

B
• 5HPRYHWKHÀRRUPDW
B
Disassembling the pedal
1. Unscrew the screw (A-Fig.3VHFXULQJWKHSHGDOFOXVWHUSODWHWRWKHFDUÀRRU A
2. Disconnect the connection (B-Fig.3).
C
3. Detach the 2 mounting pins (C-Fig.3) and extract the pedal (D-Fig.3).
Fig.3
2
L714 08 02 05
$ $VVHPEOLQJWKHEUDNHFOXWFKSHGDOFOXVWHUPDQXDOJHDUER[YHUVLRQRQO\
B) Assembling the accelerator pedal cluster A
$ $VVHPEOLQJWKHEUDNHFOXWFKSHGDOFOXVWHUPDQXDOJHDUER[YHUVLRQRQO\
To assemble the pedal on the pedal cluster:

1. Position the pedal (A-Fig.1) (1 pedal for automatic gearboxes, 2 for manual gearboxes) and insert the shaft.
2. Secure the shaft using the screw (B-Fig.2).
3. Secure the connecting rod (C-Fig.2) to the pedal using the journal (D-Fig.2) with the mounting pin (E-Fig.2).
4. Connect the pedal to the support using the spring (F-Fig.2) (1 spring for E-Gear cars, 2 for manual gearbox
cars).
G
To assemble the entire pedal cluster on the car:
5. Secure the pedal cluster support (G-Fig.1WRWKHFDUÀRRUXVLQJWKHVFUHZVH-Fig.1).
6FUHZDWWDFKPHQWWLJKWHQLQJWRUTXHE H
6. Run a brake pedal test .
H Fig.1
• Assemble the brake booster reservoir .

• Assemble the driver side dashboard assembly . C
• Assemble the instrument cluster . E
• Assemble the instrument cluster grille .
D
B F
Fig.2
1
L714 08 02 05
B) Assembling the accelerator pedal cluster
1. Position the pedal (A-Fig.3) on the mounting plate and snap on the 2 pins (B-Fig.3).
2. Screw the screw (C-Fig.3VHFXULQJWKHSHGDOFOXVWHUSODWHWRWKHFDUÀRRU A
3. Connect the connection (D-Fig.3).
• 3RVLWLRQWKHÀRRUPDW
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Fig.3
2
L714 08 06 01
&KHFNLQJWKHIURQWERQQHWDOLJQPHQW
When the front bonnet is closed, ensure it is correctly aligned with the rest of the car body. If unaligned, proceed as
follows:
• Using the 2 adjuster screws (A-Fig.1) on the lateral supports of the front bonnet (one screw per side).
&KHFNLQJWKHFORVXUHRIWKHIURQWERQQHW
&ORVHWKHERQQHW,QVHUWWZR¿QJHUVXQGHUQHDWKWKHIURQWERQQHWDQGDWWHPSWWRSUL]HXS(QVXUHWKHERQQHWGRHV
not open. If this is not the case, proceed as follows: A
• Check the position of the safety catch (B-Fig.2 8VH WKH PRXQWLQJ VFUHZ F-Fig.1 WR PRYH LW IRUZDUGV RU
backwards.
Fig.1
Fig.2
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L714 08 06 03
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L714 08 06 03
$'LVDVVHPEOLQJWKHIURQWERQQHWVXSSRUWSLVWRQV
1. Install a support which will prop up the front bonnet once the 2 pistons have been disassembled.
C
A
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in their place.
2. Using the tip of a screwdriver, lift the clamps ($)LJ) located in the 2 ball joints of each piston.
3. Once the clamp has been lifted, detach the ball joints (%)LJ) from the couplings (&)LJ) on the front bonnet
and luggage compartment.
)LJ
2
L714 08 06 03
%'LVDVVHPEOLQJWKHORFNFRYHUV
C
There are 4 lock covers inside the luggage compartment: '
B1) 2 side lock covers ($)LJ)
B2) one front lock cover (%)LJ)
B3) one rear lock cover (&)LJ)
%6LGHORFNFRYHUV
• Disassemble the front bonnet support pistons 3RLQW$.
'LVDVVHPEOLQJWKHVLGHORFNFRYHUV
1. Unscrew the piston mounting pawl (')LJ). A ( ) % ( A
2. Unscrew the screws (()LJ) securing the side lock covers to the luggage compartment.
)LJ
%)URQWORFNFRYHU
• Remove the 2 side lock covers 3RLQW%.
1. Unscrew the screws ())LJ) securing the front lock cover to the luggage compartment.
%5HDUORFNFRYHU
• Remove the 2 side lock covers 3RLQW%.
• Disassemble the windshield wipers (095503).
1. Unscrew the screws that secure the rear lock cover to the luggage compartment.
3
L714 08 06 03
&'LVDVVHPEOLQJWKHOXJJDJHFRPSDUWPHQWORFN
• Disassemble the front lock cover 3RLQW%.
'LVDVVHPEOLQJWKHOXJJDJHFRPSDUWPHQWORFN
1. Unscrew the 4 screws securing the luggage compartment lock ($)LJ) to the car and disconnect the wire that
opens the lock.
)LJ
4
L714 08 06 03
''LVDVVHPEOLQJWKHIURQWERQQHWORFN
A
1. Disconnect the lock ($)LJ) from the front bonnet by releasing it from the 3 screws (%)LJ).
2. Remove the lock.
)LJ
5
L714 08 06 03
('LVDVVHPEOLQJWKHOXJJDJHFRPSDUWPHQW
1. Unscrew the 4 screws ($)LJ) securing the luggage compartment to the chassis.
2. Lift the luggage compartment and disconnect the luggage compartment light connector (%)LJ6).
3. Remove the luggage compartment.
A A
)LJ
)LJ
6
L714 08 06 03
)'LVDVVHPEOLQJWKHIURQWERQQHW
Disassemble the front bonnet support pistons 3RLQW$.
'LVDVVHPEOLQJWKHIURQWERQQHW A
1. Detach the 2 hinges ($)LJ) from the front bonnet (%)LJ) by unscrewing the 2 mounting screws (C- C
)LJ).
2. Remove the front bonnet.
%
)LJ
7
L714 08 06 05
$)URQWERQQHWVXSSRUWSLVWRQV
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L714 08 06 05
A) Assembling the front bonnet support pistons
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their place.
1. Install each piston by applying pressure to the ball joints ($)LJ) until they snap into the couplings on the front
bonnet and luggage compartment.
)LJ
2
L714 08 06 05
%$VVHPEOLQJWKHORFNFRYHUV
C
There are 4 lock covers inside the luggage compartment: (
B1) 2 side lock covers ($)LJ)
B2) one front lock cover (%)LJ)
B3) one rear lock cover (&)LJ)
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1. Secure the side lock covers to the luggage compartment using the screws (')LJ).
2. Tighten the piston mounting pawl (()LJ).
• Assemble the front bonnet support pistons 3RLQW$. A ' ) % ' A
)LJ
%)URQWORFNFRYHU
1. Secure the front lock cover to the chassis using the screws ())LJ).
• Assemble the 2 side lock covers 3RLQW%.

• Assemble the front bonnet support pistons 3RLQW$.
%5HDUORFNFRYHU
1. Secure the rear lock cover to the luggage compartment using the screws.
• Assemble the 2 side lock covers 3RLQW%.

• Assemble the front bonnet support pistons 3RLQW$.
• Assemble the windshield wipers (095505).
3
L714 08 06 05
&$VVHPEOLQJWKHOXJJDJHFRPSDUWPHQWORFN
1. Secure the luggage compartment lock ($)LJ) to the car using the 4 screws and connect the wire that opens
the lock.
• Assemble the front lock cover 3RLQW%.
&$87,21
A
:KHQ DVVHPEO\ KDV EHHQ FRPSOHWHG HQVXUH WKH ORFN IXQFWLRQV FRUUHFWO\ 7R FKHFN WKH ORFN SURFHHG
DVIROORZVFORVHWKHOXJJDJHFRPSDUWPHQWERQQHWDQGHQVXUHLWLVSHUIHFWO\FORVHG$FWRQWKHµRSHQ
luggage compartment’ control located inside the car and try to gently lift the bonnet to ensure the safety
ORFNIXQFWLRQV )LJ
4
L714 08 06 05
'$VVHPEOLQJWKHIURQWERQQHWORFN
A
1. Connect the lock ($)LJ) to the front bonnet using the 3 screws (%)LJ).
&$87,21
:KHQ DVVHPEO\ KDV EHHQ FRPSOHWHG HQVXUH WKH ORFN IXQFWLRQV FRUUHFWO\ 7R FKHFN WKH ORFN SURFHHG %
DVIROORZVFORVHWKHOXJJDJHFRPSDUWPHQWERQQHWDQGHQVXUHLWLVSHUIHFWO\FORVHG$FWRQWKHµRSHQ
luggage compartment’ control located inside the car and try to gently lift the bonnet to ensure the safety
ORFNIXQFWLRQV
)LJ
5
L714 08 06 05
($VVHPEOLQJWKHOXJJDJHFRPSDUWPHQW
1. Insert the luggage compartment into its housing.

2. Connect the luggage compartment light connector (A)LJ5).
3. Secure the luggage compartment to the car using the 4 screws (%)LJ).
)LJ
% %
)LJ
6
L714 08 06 05
)$VVHPEOLQJWKHIURQWERQQHW
1. Secure the front bonnet ($)LJ) to the 2 hinges (%)LJ) using the 2 screws (&)LJ) (2 screws for each
hinge).
Assemble the front bonnet support pistons 3RLQW$. %

C
$OZD\VFKHFNWKDWWKHERQQHWORFNIXQFWLRQVFRUUHFWO\ A
&KHFNWKDWWKHUHDUKRRGLVFRUUHFWO\DOLJQHGZLWKWKHRWKHUERG\FRPSRQHQWV
)LJ
7
L714 08 06 05
*$VVHPEOLQJWKHKHDGOLJKWZDVKHU¿Q
1. 6HFXUHWKH¿Q$)LJ) to the car using the 2 screws (%)LJ). A
% %
)LJ
8
L714 08 07 02
Rear bumper alignment
• Remove the rear wheel stone guards (082103).
Alignment procedure
1. The rear bumper is bound to the fender by the locking catch (A-Fig.1).
2. When turning the adjustment screws (B-Fig.1), the bumper and fender undergo the same pressure and traction
(by way of the locking catch that keeps them in contact) so that they line up with each other correctly.
B A
Perform the alignment procedure on both sides, right and left, of the rear bumper.

• Assemble the rear wheel stone guards (082105).
B A
Fig.1
1
L714 08 07 02
A) Rear bumper
1. Position the rear bumper complete with the terminals.
2. Secure all of the screws (A-Fig.1) of the rear bumper on the cross member, those near the wheel arch (B-Fig.1)
and the lower ones (C-Fig.1).
3. Align the rear bumper with fender (080702).

• Assemble the rear wheel stone guards (082105). B
• Assemble the center grille (081305).
A
C
A
A
C
C
A
Fig.1
2
L714 08 07 02
B) Front bumper
A
1. Secure the 4 supports on the car (2 supports (A-Fig.2) per side).
A
2. Assemble the 4 side mounting brackets on the bumper (2 brackets (B-Fig.3) per side).
3. Insert the front bumper on the car, inserting the brackets in the respective supports.
Fig.2
B B
Fig.3
3
L714 08 07 02
4. Laterally secure the bumper using the 2 screws (C-Fig.4).
5. Secure the bumper at the top using the 4 screws (')LJ).
6. Disconnect the connections ((-Fig.4) of the turn signals.
7. Disconnect the connection (F-Fig.5) of the temperature sensor.

C
• $VVHPEOHWKHIURQWFDUÀRRU(082505). (
• Assemble the front lock cover (080605).
• Assemble the 2 front stone guards (082105).
• Assemble the 2 front wheels (060105).
Fig.4
' ' ' '

Fig.5
4
L714 08 07 03
A) Rear bumper
%)URQWEXPSHU
1
L714 08 07 03
A) Rear bumper
A1
• Remove the rear wheel stone guards (082103).
• Remove the center grille (081303).
'LVDVVHPEOLQJWKHUHDUEXPSHU
1. Remove the 4 screws ($)LJ) of the rear bumper on the cross member lower cross member and 2 screws
located on the upper cross member ($)LJ).
A A )LJ
2. Remove the 2 screws (%)LJ2) on the wheel arch (one on each side).
)LJ
2
L714 08 07 03
3. Remove the 4 lower screws (C)LJ3) (two on each side).
4. Remove the 2 screws (')LJ) that secure the bumper to the bottom of the vehicle.
'
)LJ
5. Remove the 3 screws (()LJ) that secure the bumper to the panel.
)LJ
3
L714 08 07 03
6. Remove the rear bumper complete with the terminals.
7. Disconnect the number plate lights and rear fog light connector ())LJ).
)LJ
8. Remove the bumper ()LJ).
)LJ
4
L714 08 07 03
%)URQWEXPSHU
• Remove the 2 front wheels (060103).
• Disassemble the 2 front stone guards (082103). A
• Disassemble the front lock cover (080603).
Disassembling the front grids

1. Disassemble the 2 side water radiator grids by loosening the 4 screws for each grid ($)LJ).
2. Disassemble the central power steering radiator grid by loosening the 3 screws (%)LJ). )LJ
% % %
)LJ
5
L714 08 07 03
Disassembling the front spoiler

1. /RRVHQWKH¿[LQJVFUHZV$)LJ) at the bottom of the vehicle.
A )LJ
2. /RRVHQWKH¿[LQJVFUHZV%)LJ) at the top of the vehicle.
3. Remove the front spoiler (&)LJ).
% C
)LJ
6
L714 08 07 03
Disassembling the front bumper
1. Disassemble the front air intake grids on both sides and loosen the screw ($)LJ) securing the front conveyor
to the bumper.
)LJ
2. Unscrew the 6 screws (%)LJ) securing the bumper at the bottom.
% %
)LJ
3. Unscrew the 2 screws (&)LJ) securing the bumper to the chassis.
C
C
)LJ
7
L714 08 07 03
4. Unscrew the 4 screws (')LJ) on the upper part of the bumper.
' ' ' '

)LJ
5. Unscrew the 2 side screws (()LJ).
6. Disconnect the connections ())LJ) of the turn signal lights (one on each side).
)LJ
8
L714 08 07 03
7. Disconnect the connection (*)LJ) of the temperature sensor.

G
)LJ
8. Remove the front bumper releasing the 4 brackets (+)LJ) (2 per side) on the bumper from the corresponding
H I
supports (,)LJ) on the vehicle.
)LJ

L714 08 07 05
A) Rear bumper
%)URQWEXPSHU
1
L714 08 07 05
A) Rear bumper
1. Connect the number plate lights and fog light connector ($)LJ).
)LJ
2. Position the rear bumper complete with the terminals.

%
3. Secure the 4 screws (%)LJ2) of the rear bumper on the cross member Lower cross member and 2 screws
located on the upper cross member (%)LJ).
% % )LJ
2
L714 08 07 05
4. Secure the 2 screws (C)LJ3) on the wheel arch (one on each side).
)LJ
5. Secure the 3 screws (')LJ) that secure the bumper to the panel.
'
)LJ
3
L714 08 07 05
6. Secure the 4 lower screws (()LJ5) (two on each side).
7. Secure the 2 screws ())LJ) that secure the bumper to the bottom of the vehicle.
8. Align the rear bumper with fender (080702).

• Assemble the rear wheel stone guards (082105).
• Assemble the center grille (081305).
)
&KHFNWKDWWKHUHDUEXPSHULVFRUUHFWO\DOLJQHGZLWKWKHRWKHUERG\FRPSRQHQWV
)LJ
4
L714 08 07 05
%)URQWEXPSHU A A A
Assembling protection devices
7KH IURQW EXPSHU SURWHFWLRQ GHYLFH FDQQRW EH DVVHPEOHG RQ YHKLFOHV LQWHQGHG IRU WKH 86 DQG
&DQDGLDQPDUNHWV
1. Apply a bead of butyl ($)LJ) on the front (%)LJ) bumper protection device.
)LJ
2. Position the protection device (%)LJ) on the front bumper and ensure it is correctly aligned.
)LJ
5
L714 08 07 05
Assembling the front spoilers

1. Fasten the spoiler ($)LJRQWRWKHXSSHUSDUWRIWKHYHKLFOHE\ZD\RIWKH¿[LQJVFUHZV%)LJ).
% A
)LJ
2. 7LJKWHQWKH¿[LQJVFUHZV&)LJ) at the bottom of the vehicle.
C )LJ
6
L714 08 07 05
Assembling the front grids

1. Install the two front water radiator grids by means of the 4 screws (')LJ) for each grid.
'
)LJ
2. Assemble the central power steering radiator grid by means of the 3 screws (()LJ).
( ( (
)LJ
7
L714 08 07 05
Assembling the front bumper

C
If the bumper does not have the temperature sensor support ($)LJ), install it by coupling it onto the
bracket (%)LJ).
1. Connect the temperature sensor (&)LJ) to the support.
% A
)LJ
2. Insert the front bumper on the vehicle, inserting the brackets (')LJ) in the respective supports
' (
(()LJ).
Check that the bumper is well-aligned with the metal panel, then adjust the brackets (()LJ) until the
bumper is perfectly aligned.
)LJ
8
L714 08 07 05
3. Laterally secure the bumper using the 2 screws (()LJ).
4. Connect the connections (*)LJ) of the turn signal lights.
)LJ
5. Secure the bumper at the top using the 4 screws (+)LJ).
H H H H
)LJ

L714 08 07 05
6. Tighten the 2 screws (,)LJ) securing the bumper to the chassis.

I
I
)LJ
7. Tighten the 6 screws (/)LJ) securing the bumper at the bottom.
L L )LJ
dal 8. Tighten on both sides the screw 0)LJsecuring the air conveyor to the bumper and then assemble the
grids.
• $VVHPEOHWKHIURQWFDUÀRRU(082505). M
• Assemble the 2 front stone guards (082105).
• Assemble the front lock cover (080605).
• Assemble the 2 front wheels (060105).
&KHFNWKDWWKHIURQWEXPSHULVFRUUHFWO\DOLJQHGZLWKWKHRWKHUERG\FRPSRQHQWV
)LJ
10
L714 08 11 03
',6$66(0%/,1*7+((;7(51$/5($59,(:0,552581,7
A
To disassemble the external rear-view mirror:
C
1. Prize up the mirror to release the slots ($)LJ) on the back from the couplings.
2. Disconnect the 2 connections (%)LJ). B
3. Remove the mirror (&)LJ). B
Fig.1
To disassemble the entire external rear-view mirror element:
D
• Disassemble the door cover (086803).
'LVDVVHPEOLQJWKHH[WHUQDOUHDUYLHZPLUURUHOHPHQW
4. Unscrew the 3 screws (')LJ) securing the external rear view mirror element to the door.
5. Disconnect the connection (()LJ). D
6. Remove the external rear-view mirror element ))LJ.
E
Fig.2
7KHFDULVHTXLSSHGZLWKH[WHUQDOUHDUYLHZPLUURUXQLWVRQHRQWKHULJKWDQGRQHRQWKHOHIW7KH

disassembly sequence is the same for both.
Fig.3
1
L714 08 11 05
$VVHPEOLQJWKHH[WHUQDOUHDUYLHZPLUURUXQLW
To assemble the entire external rear-view mirror element:

1. Position the external rear-view mirror element ($)LJ) and attach the connection (%)LJ).
2. Secure the external rear-view mirror element to the door using the 3 screws (&)LJ).
To assemble the external rear-view mirror:

3. Position the mirror (')LJ) and attach the 2 connections (()LJ).
4. Pressing on the mirror, insert the slots ())LJ) on the back into the couplings.
• Assemble the door cover (086805). A
7KHFDULVHTXLSSHGZLWKH[WHUQDOUHDUYLHZPLUURUXQLWVRQHRQWKHULJKWDQGRQHRQWKHOHIW7KH

disassembly sequence is the same for both. Fig.1
C
B
Fig.2
D
E
E
Fig.3
1
L714 08 13 03
$(QJLQHFRPSDUWPHQWVLGHSDQHOV
%(QJLQHFRPSDUWPHQWUHDUSDQHO
&(QJLQHFRPSDUWPHQWIURQWSDQHO
' 5HDUFHQWUDOJULG
( 8SSHUSDQHO
) $LULQWDNH
* 6LGHFRYHU
1
L714 08 13 03
$(QJLQHFRPSDUWPHQWVLGHSDQHOV
• Open the engine compartment and protect the rear left and right areas of the car with the cover. % A
• Remove the engine compartment rear panel 3RLQW%.
'LVDVVHPEOLQJWKHOHIWSDQHO
1. Remove the 4 mounting screws of the side panel cover (A)LJ1).
2. Remove the cover (%)LJ).
)LJ
'LVDVVHPEOLQJWKHULJKWSDQHO
1. Remove the 4 mounting screws of the side panel cover (A)LJ2).
2. Release the stop of the engine compartment shock absorber rod from its support and release the rod A C
(%)LJ2).
:$51,1*
1HYHUGLVDVVHPEOHWKHURGXQOHVVDQRWKHUVXSSRUWKDVDOUHDG\EHHQSRVLWLRQHGLQWKHLUSODFH
3. Remove the cover (C)LJ2).
)LJ
2
L714 08 13 03
A
• Open the engine compartment and protect the rear left and right areas of the car with the cover.
%
'LVDVVHPEO\WKHSDQHO
1. Remove the 8 screws ($)LJ) that secure the rear panel cover (%)LJ).
2. Remove the cover.
)LJ
3
L714 08 13 03
• Open the engine compartment and protect the rear left and right areas of the car with the cover.
'LVDVVHPEO\WKHSDQHO
1. Remove the 9 screws ($)LJ) that secure the front panel cover (%)LJ).
2. Remove the cover.
% A )LJ
4
L714 08 13 03
'5HDUFHQWUDOJULG
'LVDVVHPEOLQJWKHJULG
1. Remove the 11 screws ($)LJ) that secure the rear central grid to the respective housing on the rear bumper
and the upper panel.
2. Remove the rear central grid (%)LJ).
% A
)LJ
5
L714 08 13 03
(8SSHUSDQHO
• Remove the 2 rear lights (094503).
• Remove the central rear grid 3RLQW'. A
• Remove the rear element of the rear wheel arch (082103).
'LVDVVHPEOLQJWKHXSSHUSDQHO
1. Unscrew the 4 screws ($)LJ) securing the upper panel to the rear bumper.
2. Remove the 4 screws at the side of the upper panel that secure the corresponding plates: 2 screws (%)LJ)
per mounting plate.
3. Raise the upper panel (&)LJ) and extract it.
)LJ
% %
)LJ
6
L714 08 13 03
)) $LULQWDNH
• Remove the rear wheel arch (082103).
'LVDVVHPEOLQJWKHDLULQWDNH
1. Unscrew the 2 screws (A)LJ8) securing the air intake. %

2. Remove the two parts of the air intake (%)LJ).
A )LJ
7
L714 08 13 03
*6LGHFRYHU
• Remove the rear wheel arch (082103).
• Remove the 2 rear lights (094503).
• Disassemble the air intake (32,17)).
'LVDVVHPEOLQJWKHVLGHFRYHU
1. Remove the 2 screws (A)LJ9) securing the light support bracket with the heatproof guard.
A )LJ
2. Unscrew the 4 screws (%)LJ) that secure the side cover at the chassis bracket.
3. Unscrew the 2 screws (&)LJ) that secure the side cover at the grid.
)LJ
8
L714 08 13 03
4. Remove the side cover (')LJ).

'
)LJ
9
L714 08 13 05
$ (QJLQHFRPSDUWPHQWVLGHSDQHO
% (QJLQHFRPSDUWPHQWUHDUSDQHO
& (QJLQHFRPSDUWPHQWIURQWSDQHO
' 5HDUFHQWUDOJULG
( 8SSHUSDQHO
) $LULQWDNH
* 6LGHFRYHU
1
L714 08 13 05
$(QJLQHFRPSDUWPHQWVLGHSDQHO
Assembling the left panel

1. Position the side panel cover (A)LJ1) on the bulkhead and tighten the 5 screws (%)LJ1). A %
)LJ
Assembling the right panel
1. Position the side panel cover (A)LJ2) on the bulkhead and partially tighten the 5 screws (%)LJ2).
2. Secure the shock absorber rod support (C)LJ2) and tighten all of the screws.
% A
:$51,1*
1HYHUDVVHPEOHWKHURGXQOHVVDQRWKHUVXSSRUWKDVDOUHDG\EHHQSRVLWLRQHGLQWKHLUSODFH
• Assemble the engine compartment rear panel 3RLQW%.
)LJ
2
L714 08 13 05
%
1. Position the rear panel cover ($)LJ) on the edges of the internal panels of the engine compartment.
2. Tighten the 8 screws (%)LJ) of the cover. A
)LJ
3
L714 08 13 05
1. Position the front panel cover ($)LJ) and tighten the 9 screws (%)LJ) of the cover.
A % )LJ
4
L714 08 13 05
'5HDUFHQWUDOJULG
1. Position the rear central grid ($)LJ) in the respective housing.
2. Secure the grid using the 11 screws (%)LJ).
A %
)LJ
5
L714 08 13 05
(8SSHUSDQHO
1. Position the upper panel ($)LJ). A
2. Tighten the 4 screws at the middle of the upper panel to secure the corresponding plates: 2 screws (%)LJ) C
per mounting plate.
3. Secure the upper panel to the rear bumper using the 4 screws (&)LJ).
• Assemble the 2 rear lights (094505).

• Assemblee the central rear grid 3RLQW'.
• Assemble the rear element of the rear wheel arch (082105).
)LJ
% %
)LJ
6
L714 08 13 05
)$LULQWDNH
1. Position the two parts of the air intake ($)LJ).
2. Tighten the 2 screws (%)LJ10) securing the air intake.
% )LJ
7
L714 08 13 05
*6LGHFRYHU
A
1. Position the side cover ($)LJ).
)LJ
2. Tighten the 4 screws (%)LJ10) securing the side cover at the chassis bracket.
3. Tighten the 2 screws (C)LJ10) securing the side cover at the gridt.
%
)LJ
8
L714 08 13 05
4. Tighten the 2 screws (')LJ11) securing the light support bracket with the heatproof guard.
• Assemble the air intake (32,17)).

• Assemble the 2 rear lights (094505).
' )LJ
9
L714 08 16 03
A) Air conditioner grille

%$LUFRQGLWLRQHUFRQWUROXQLW
1
L714 08 16 03
• Remove the tunnel ornament (086303).
'LVDVVHPEOLQJWKHDLUFRQGLWLRQHUJULOOH
1. Prize up the 4 clips ($)LJ) along the edge of the air conditioner ornament, releasing them from their couplings
on the back.
2. Remove the air conditioner grille (%)LJ).
A
)LJ
)LJ
2
L714 08 16 03
%$LUFRQGLWLRQHUFRQWUROXQLW '
• Remove the tunnel ornament (086303).
• Disassemble the air conditioner grille.
'LVDVVHPEOLQJWKHDLUFRQGLWLRQHUFRQWUROXQLW
1. Unscrew the 2 screws ($)LJ) securing the air conditioner ornament at the bottom (%)LJ).
2. Detach the 6 connections from the respective ports (&)LJ) on the back of the ornament.
2. Remove the air conditioner control unit (')LJ).
% A )LJ
C C C C C C
)LJ
3
L714 08 16 05

%$LUFRQGLWLRQHUFRQWUROXQLW
1
L714 08 16 05
1. Position the air conditioner grille ($)LJ) so that the 4 clips (%)LJ) enter the corresponding couplings.
A
• Assemble the BJA push-button panel unit (086805).

• Assemble the tunnel ornament (086305).
)LJ
%
)LJ
2
L714 08 16 05
%$LUFRQGLWLRQHUFRQWUROXQLW A A A A A A
1. Attach the 6 connections to the respective ports ($)LJ) on the back of the control unit.
2. Secure the air conditioner control unit (%)LJ) at the bottom (&)LJ) using the screws (')LJ).
• Assemble the air conditioner grille.

• Assemble the BJA push-button panel unit (086805).
• &RQQHFWWKH/D5D$6V\VWHPDQGSURJUDPWKHDLUFRQGLWLRQHUXVLQJWKHFRUUHFWFDU¿OH(109000).
)LJ
C ' )LJ
3
L714 08 17 03
'LVDVVHPEOLQJWKHURRIVSRLOHU A A A A A
1. From the inside of the car, unscrew the 5 screws (A-Fig.1) securing the spoiler (B-Fig.1) to the roof.
2. Detach the spoiler.
3. Disconnect the connector (C-Fig.2).
B
Fig.1
1
L714 08 17 05
Assembling the roof spoiler
1. Distribute the 3M activator where the double-sided tape will be applied at the front and rear of the roof spoiler
(A-Fig.1). A
2. Position the double-sided tape:
• 2 layers at the rear (B-Fig.2)
• one layer at the front (C-Fig.2)
3. Position the 5 clips (D-Fig.2).
4. Secure the spoiler (E-Fig.3) to the roof, tightening the 5 screws (F-Fig.3) from the inside of the car.
C D B
Fig.1 Fig.2
F F F F F
E
Fig.3
1
L714 08 19 03
'LVDVVHPEOLQJWKHDLUYHQW
B A B
7KHUHDUHDLUYHQWVRQWKHFDU
A) 3 central (A-Fig.1)
B) 2 side (B-Fig.1)
1. Extract the vents from their housing, pulling them up out of their couplings (C-Fig.2).
:KHQH[WUDFWLQJWKHDLUYHQWVGRQRWGDPDJHWKHFRXSOLQJRUWKHYHQWLWVHOI
Fig.1
C C
Fig.2
1
L714 08 19 05
$VVHPEOLQJWKHDLUYHQW
7RDVVHPEOHWKHDLUYHQWVWKHGDVKERDUGPXVWEHSODFHGRQDZRUNEHQFK
1. Insert the vents in their housing following the guide (A-Fig.1) and press them into place.
2. Position the adhesive foam (B-Fig.2) on the back of the dashboard around the base of the 5 vents.
• Assemble the dashboard (086805).
Fig.1
1
5
2 3 4
Fig.2
1
L714 08 21 03
Disassembling the wheel arch
7KHUH DUH ZKHHO DUFK DVVHPEOLHV RQ WKH FDU RQH ZKHHO DUFK DVVHPEO\ IRU HDFK ZKHHO (DFK
ZKHHODUFKDVVHPEO\LVGLYLGHGLQWRHOHPHQWV
A) Front wheel arch element (A-Fig.1)
B) Rear wheel arch element (B-Fig.1)
3UHOLPLQDU\RSHUDWLRQVWKHVDPHIRUGLVDVVHPEOLQJERWKRIWKHZKHHODUFKHOHPHQWV
• Remove the wheel corresponding to the wheel arch you wish to disassemble (060103).
A) Disassembling the front wheel arch element B A

1. Unscrew the screws (C-Fig.2) securing the front wheel arch element. Fig.1
2. Remove the front wheel arch element.
B) Disassembling the rear wheel arch element

1. Unscrew the screws (D-Fig.2) securing the rear wheel arch element.
2. Remove the rear wheel arch element.
D C
Fig.2
1
L714 08 21 05
Assembling the wheel arch
7KHUH DUH ZKHHO DUFK DVVHPEOLHV RQ WKH FDU RQH ZKHHO DUFK DVVHPEO\ IRU HDFK ZKHHO (DFK
ZKHHODUFKDVVHPEO\LVGLYLGHGLQWRHOHPHQWV
A) Front wheel arch element (A-Fig.1)
B) Rear wheel arch element (B-Fig.1)
A) Assembling the front wheel arch element

1. Secure the front wheel arch element using the screws (C-Fig.2).
B) Assembling the rear wheel arch element

1. Secure the rear wheel arch element using the screws (D-Fig.2). B A
Fig.1
• Assemble the relative wheel (060105)

(this operation must be carried out to assemble both of the wheel arch elements).
D C
Fig.2
1
L714 08 25 03
$)URQWFDUÀRRU
%5HDUFDUÀRRUV
C6LGHFDUÀRRUV
'&HQWHUFDUÀRRU
1
L714 08 25 03
$'LVDVVHPEOLQJWKHIURQWFDUÀRRU
'LVDVVHPEOLQJWKHIURQWFDUÀRRU
1. Unscrew the central screw ($)LJ) and the screws (%)LJVHFXULQJWKHFDUÀRRUDORQJLWVSHULPHWHUC-
)LJ) to the car.
A
C
)LJ
2
L714 08 25 03
%'LVDVVHPEOLQJWKHUHDUFDUÀRRU
7KHUHDUHUHDUFDUÀRRUVRQWKHFDU
'LVDVVHPEOLQJWKHVLGHFDUÀRRUV
1. Unscrew the screws ($)LJ2VHFXULQJWKHUHDUFDUÀRRUVDORQJWKHLUSHULPHWHU%)LJ2) to the car.
% A
A %
)LJ
3
L714 08 25 03
&'LVDVVHPEOLQJWKHVLGHFDUÀRRUV
7KHUHDUHVLGHFDUÀRRUVRQWKHFDURQHÀRRUSHUVLGH
'LVDVVHPEOLQJWKHVLGHFDUÀRRUV
1. Unscrew the screws ($)LJ3VHFXULQJWKHVLGHFDUÀRRUVDORQJWKHLUSHULPHWHU%)LJ3) to the car.
% A
% A
)LJ
4
L714 08 25 03
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When the front bonnet is closed, ensure it is correctly aligned with the rest of the car body. If unaligned, proceed as
follows: A
• Use the two mounting screws (B-Fig.1) to check the position of the two hinges (A-Fig.1).
When the front bonnet is closed, ensure it is at the correct height compared to the rest of the car body. If unaligned,
proceed as follows:
• Check the position of the catch (C-Fig.2). Use the 3 screws (D-Fig.2) to center the catch with its housing.
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L714 08 27 03
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1. Unscrew the screws ($)LJ) securing the 3 rear hoods inside cover to the hood.
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compartment (&)LJ).
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3. Remove the rear hood.
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3. Unscrew the 2 screws (&)LJ) securing the spoiler to the engine hood (2 for side).
4. Unscrew the screw (')LJ) securing the spoiler’s base (1 for side).
5. Disconnect the 2 rear view camera connectors (()LJ).
6. Remove the spoiler ())LJ).
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4. 8QVFUHZWKH¿QQHGDQFKRUV))LJ) securing the cable (*)LJ) from the engine hood.
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1. Secure the 3 rear hoods inside cover to the hood using the screws ($)LJ).
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their place.
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Assembling the engine hood support
Disassemble the engine hood and tighten the 2 screws ($)LJ) securing the brackets to the chassis.
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1. Position the rear hood and secure it to the car using the 4 screws (%)LJ) securing the 2 hinges (&)LJ) (2
screws for each hinge).
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1. Connect the 2 rear view camera connectors ($)LJ).
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When the doors are closed, ensure they are correctly aligned with the rest of the car body. If unaligned, proceed as
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1. Position the internal door guard ($)LJ) so that its internal edges with the adhesive (%)LJ) adhere well to A
the perimeter of the opening in the door.
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1. Connect the connector (%)LJ) and the door opening cable (&)LJ) to the handle ($)LJ).
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1. Position the power window motor ($)LJ) and secure it to the door using the 3 screws (%)LJ). A
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1. Position the guide ($)LJ) and secure the bottom part to the door using the screw (%)LJ).
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2. Connect the connector (&)LJ).
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1
L714 08 45 03
$'LVDVVHPEOLQJWKHZLQGVFUHHQ
A
1. Disconnect all 4 connectors (5 if the car has a satellite tracking alarm):
• 2 mirror connectors
• 2 loudspeaker connectors
2. Using the special tool, remove the silicone around the perimeter of the windscreen. Ensure the Prime sticking
the windscreen to the body is removed.
3. Using suction cups, remove the windscreen ($)LJ).
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHRUVFUDWFKWKHZLQGVFUHHQGXULQJGLVDVVHPEO\
)LJ
2
L714 08 45 03
%'LVDVVHPEOLQJWKHUHDUZLQGRZ A
1. Using the special tool, remove the silicone around the perimeter of the window. Ensure that the Prime sticking
the window to the body is removed.
2. Remove the rear window ($)LJ).
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHRUVFUDWFKWKHUHDUZLQGRZGXULQJGLVDVVHPEO\
)LJ
3
L714 08 45 03
&'LVDVVHPEOLQJWKHIURQWVLGHZLQGRZ
1. Detach the duct ($)LJ) at the top of the front side window.
A
2. Using the special tool, remove the silicone around the perimeter of the front side window. Ensure that the Prime
sticking the side window to the body is removed.
3. Remove the front side window (%)LJ).
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHRUVFUDWFKWKHIURQWVLGHZLQGRZGXULQJGLVDVVHPEO\
)LJ
)LJ
4
L714 08 45 03
''LVDVVHPEOLQJWKHUHDUVLGHZLQGRZ
1. Detach the duct ($)LJ) at the top of the rear side window.
2. Using the special tool, remove the silicone around the perimeter of the rear side window. Ensure that the Prime
sticking the side window to the body is removed. A
3. Remove the rear side window (%)LJ).
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHRUVFUDWFKWKHUHDUVLGHZLQGRZGXULQJGLVDVVHPEO\
)LJ
)LJ
5
L714 08 45 03
('LVDVVHPEOLQJWKHHQJLQHKRRGZLQGRZ
• Disassemble the engine hood grids (082703).
'LVDVVHPEOLQJWKHKRRGZLQGRZ
1. Using the special tool, remove the silicone around the perimeter of the window. Ensure that the Prime sticking
the window to the engine hood is removed.
2. Using suction cups, remove the engine hood window ($)LJ).
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHRUVFUDWFKWKHJODVVGXULQJGLVDVVHPEO\
A
)LJ

L714 08 45 05
$:LQGVFUHHQ
% 5HDUZLQGRZ
& )URQWVLGHZLQGRZ
' 5HDUVLGHZLQGRZ
( (QJLQHKRRGZLQGRZ
1
L714 08 45 05
A) Assembling the windscreen

C
• Wear cotton gloves (to avoid direct contact with the windscreen’s surface).
A
1. Clean the surface of the body where the windscreen will be glued using a cloth and VITREX.
2. Protect the body near the windscreen’s housing with tape.

)LJ )LJ
Clean the surface of the windscreen where it will be glued using a cloth and VITREX.
(
4. Apply the BETAPRIME primer with the yellow cap (&)LJ) along the internal edge of the windscreen ($)LJ)
using the special pad (%)LJ).
The pad must be thrown away after use. The pad may not be used to apply different types of
products. )
'
5. Apply the BETAPRIME primer with the green cap ())LJ) along the internal edge of the windscreen (')LJ)
(where the BETAPRIME with the yellow cap was applied) using the special pad (()LJ).
products. )LJ )LJ
Apply the BETAPRIME primer with the red cap (/)LJ) along the edge of the body (*)LJ) where the
windscreen will be applied using the special pad (+)LJ).
H
• Assemble the rear-view mirror on the windscreen.
)LJ )LJ
2
L714 08 45 05
7. Secure the 7 shims (rubber spacers) (0)LJ) to the bottom of the windscreen.
8. Distribute the BETASEAL 1965 silicone (1)LJ) along the internal edge of the windscreen using:
• on the lower edge (2)LJ), the provided spout (3)LJ) preformed with an opening 15 mm high and 10 mm
wide.
M
• on the upper edge (4)LJ) and the 2 side edges (5)LJ), the provided spout (6)LJ) preformed with
an opening 10 mm high and 5 mm wide.
M
,IDSSOLFDWLRQPXVWEHLQWHUUXSWHGHJWRUHSODFHWKHVLOLFRQHFDUWULGJHGRQRWDOORZJDSVRIDLUWR
form in the silicone between the 2 applications.
)LJ
1
)LJ
)LJ
5
O
)LJ )LJ

L714 08 45 05
Position the windscreen (7)LJ) on the car, taking care that the silicone does not internally extend beyond
the edge. T
10. Using a thickness gauge (8)LJ), check that the distance between the windscreen and the side pillar is:
• 5 mm at the top (9)LJ)
• 5.5 mm at the bottom (=)LJ)
)LJ
)LJ )LJ
4
L714 08 45 05
11. After the correct thickness has been achieved, press along the edges of the windscreen to make the silicone
:
adhere well. Then secure the windscreen onto the car using the cloth tape (:)LJ).
12. Connect all 4 connectors (5 if the car has a satellite tracking alarm):
• 2 mirror connectors
• 2 loudspeaker connectors
)LJ
5
L714 08 45 05
%$VVHPEOLQJWKHUHDUZLQGRZ
• Wear cotton gloves (to avoid direct contact with the rear window’s surface).
1. Clean the surface of the body where the rear window will be glued using a cloth and VITREX.
2. Protect the body near the rear window’s housing with tape.
Clean the surface of the rear window where it will be glued using a cloth and VITREX.
A
4. Apply the BETAPRIME primer with the yellow cap (&)LJ) along the internal edge of the rear window (A-
)LJ) using the special pad (%)LJ). %
)LJ
products.
5. Apply the BETAPRIME primer with the green cap (')LJ) along the internal edge of the rear window (A-
)LJ) (where the BETAPRIME with the yellow cap was applied) using the special pad (%)LJ).
C
The pad must be thrown away after use. The pad may not be used to apply different types of '
products. (
Apply the BETAPRIME primer with the red cap (()LJ) along the edge of the body where the rear window
will be applied using the special pad.
)LJ )LJ )LJ

L714 08 45 05
7. Using double-sided tape, attach the 6 shims to the inside of the window:
• 4 at the corners ())LJ) G
• 2 at the midpoint at the top and bottom (*)LJ)
8. Distribute the BETASEAL 1965 silicone (+)LJ) along the internal edge of the rear window using the provided
spout (/)LJ) preformed by means of the special pliers (0)LJ) with an opening 10 mm high and 5 mm
wide. )
)LJ )LJ
H
)LJ
)LJ
7
L714 08 45 05
Position the rear window (1)LJ), taking care that the silicone does not internally extend beyond the edge. 1
10. After the window has been centered, press down on the edges so that the silicone adheres well.
11. Secure the rear window onto the car using the cloth tape (2)LJ).
)LJ
8
L714 08 45 05
C) Assembling the front side window
• Wear cotton gloves (to avoid direct contact with the front side window’s surface).
1. Clean the surface of the body where the front side window will be glued using a cloth and VITREX.
A
%
2. Protect the body near the front side window’s housing with tape. (
Clean the surface of the front side window where it will be glued using a cloth and VITREX.
4. Apply the BETAPRIME primer with the yellow cap ($)LJ) along the internal edge of the front side window
using the special pad. )LJ )LJ )LJ
products.
5. Apply the BETAPRIME primer with the green cap (%)LJ) along the internal edge of the front side window C
(where the BETAPRIME with the yellow cap was applied) using the special pad.
products.
Secure the 2 housings (&)LJ) for coupling the duct with the body using the rivets (')LJ) (2 rivets per
housing).
7. Apply the BETAPRIME primer with the red cap (()LJ) along the edge of the body where the front side
' '
window will be applied using the special pad.
)LJ

L714 08 45 05
8. Distribute the BETASEAL 1965 silicone (*)LJ) along the internal edge of the front side window ())LJ)
using the provided spout (+)LJ) preformed by means of the special pliers (/)LJ) with an opening 10 mm
high and 5 mm wide.
)LJ
G
)LJ
)LJ
10
L714 08 45 05
Position the front side window (0)LJ) inside the previously assembled housings, taking care that the silicone
does not internally extend beyond the edge.
M
10. Assemble the duct (1)LJ) inside the housings positioned at the top of the body of the side window.
11. After verifying the front side window’s correct position, hold it in place on the car using the special cloth tape
(2)LJ).
)LJ
)LJ
11
L714 08 45 05
'$VVHPEOLQJWKHUHDUVLGHZLQGRZ
• Wear cotton gloves (to avoid direct contact with the rear side window’s surface).
1. Clean the surface of the body where the rear side window will be glued using a cloth and VITREX.
A
%
2. Protect the body near the rear side window’s housing with tape. (
Clean the surface of the rear side window where it will be glued using a cloth and VITREX.
4. Apply the BETAPRIME primer with the yellow cap ($)LJ) along the internal edge of the rear side window
using the special pad. )LJ )LJ )LJ
products.
5. Apply the BETAPRIME primer with the green cap (%)LJ) along the internal edge of the rear side window
(where the BETAPRIME with the yellow cap was applied) using the special pad.
The pad must be thrown away after use. The pad may not be used to apply different types of C
products.
Secure the 4 housings (&)LJ) for coupling the duct with the body using the rivets (')LJ) (2 rivets per
housing).
7. Apply the BETAPRIME primer with the red cap (()LJ) along the edge of the body where the rear side
window will be applied using the special pad.
' '
)LJ
12
L714 08 45 05
8. Distribute the BETASEAL 1965 silicone (*)LJ) along the internal edge of the rear side window ())LJ)
using the provided spout (+)LJ) preformed by means of the special pliers (/)LJ) with an opening 10 mm
high and 5 mm wide.
)LJ
G
)LJ
)LJ

L714 08 45 05
10. Position the rear side window (0)LJ) inside the previously assembled housings, taking care that the silicone
does not internally extend beyond the edge.
11. Assemble the duct (1)LJ) inside the housings positioned at the top of the body of the side window.
12. After verifying the rear side window’s correct position, hold it in place on the car using the special cloth tape
(2)LJ).
)LJ
1
O
)LJ
14
L714 08 45 05
($VVHPEOLQJWKHHQJLQHKRRGZLQGRZ
%
• Wear cotton gloves (to avoid direct contact with the window’s surface).
1. Clean the surface of the engine hood involved in the window gluing procedure with a cloth and VITREX.
2. Clean the surface of the window where it will be glued using a cloth and VITREX.
Apply the BETAPRIME primer with the yellow cap (&)LJ) along the internal edge of the window ($)LJ)
using the special pad (%)LJ).
products.
A
)LJ
4. Apply the BETAPRIME primer with the green cap (')LJ) along the internal edge of the window (where the
BETAPRIME with the yellow cap was applied) using the special pad.
products.
C
'
G
)LJ )LJ )LJ
15
L714 08 45 05
5. Apply the BETAPRIME primer with the red cap (*)LJ) along the edge of the engine hood (()LJ) where
the window will be applied using the special pad ())LJ).
)
Secure the 12 clips (+)LJ) along the inside edge of the engine hood near the holes on the internal edge.
7. Secure the 4 shims (,)LJ) (rubber spacers) in the 4 corners of the engine hood window’s housing.
)LJ
)LJ

L714 08 45 05
8. Distribute the BETASEAL 1965 silicone (/)LJ) along the internal edge of the engine hood using the provided
spout (0)LJ) preformed with an opening 10 mm high and 5 mm wide.
,IDSSOLFDWLRQPXVWEHLQWHUUXSWHGHJWRUHSODFHWKHVLOLFRQHFDUWULGJHGRQRWDOORZJDSVRIDLUWR

form in the silicone between the 2 applications.
M
Position the window (1)LJ) on the engine hood, taking care that the silicone does not internally extend
beyond the edge.
)LJ
)LJ
17
L714 08 45 05
10. Using a thickness gauge (2)LJ), check the distance between the window and the internal edges of the
3
engine hood: then secure the window onto the engine hood using cloth tape (3)LJ).
3
11. Position weights (4)LJ) along the edge of the window so that the silicone adheres well between all of the
various surfaces.
• Assemble the 2 engine hood grids (082705).
)LJ
O
)LJ
18
L714 08 47 03
',6$66(0%/,1*7+(:,1'2:6
• 5HPRYHWKHVLGHFDUKL¿V\VWHPORXGVSHDNHU(097503).
• 'LVDVVHPEOHWKHGRRUVHDO(083703).
• 'LVDVVHPEOHWKHLQWHUQDOGRRUJXDUG(083703). A
'LVDVVHPEOLQJWKHZLQGRZV
1. 8QVFUHZWKHVFUHZA-Fig.1VHFXULQJWKHFODPSDWWKHIURQWRIWKHZLQGRZ
Fig.1
2. 5HPRYHWKHVLGHZLQGRZSODWHB-Fig.2IURPWKHJXLGHC-Fig.3RIWKHSRZHUZLQGRZDVVHPEO\DWWKHUHDURI

the door.
Fig.2
Fig.3
1
L714 08 47 03
3. ([WUDFWWKHVLGHZLQGRZ')LJ).

'
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHRUVFUDWFKWKHJODVVGXULQJGLVDVVHPEO\
Fig.4
2
L714 08 47 05
Assembling the windows

A
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHRUVFUDWFKWKHJODVVGXULQJDVVHPEO\
1. Insert the glass (A-Fig.1) inside the door, allowing it to slide along the guides.
2. Secure the glass at the rear of the door, inserting the plate (B-Fig.2) inside the guide (C-Fig.3).
Fig.1
Fig.2
Fig.3
1
L714 08 47 05
3. Tighten the screw that secures the clamp (')LJ) at the front.
• Assemble the internal door guard (083705).

• Assemble the door seal (083705).
• $VVHPEOHWKHVLGHFDUKL¿V\VWHPORXGVSHDNHU(097505). A
Fig.4
2
L714 08 53 03
'LVDVVHPEOLQJWKHVLGHPHPEHU
A
1. Remove the panel above the side member.
Fig.1
2. Remove the screw (A-Fig.1) at the rear, accessing it through the space created by the disassembled wheel
arch.
3. Unscrew the 3 screws (B-Fig.2) securing the side member to the car at the bottom.
4. Unscrew the 6 screws (C-Fig.3) securing the side member to the car at the top.
B
Fig.2
Fig.3
1
L714 08 53 03
5. Remove the side member from the 3 supports (')LJ).
6. Remove the side member (()LJ).
'
Fig.4
(
Fig.5
2
L714 08 53 05
Assembling the side member
1. Secure the 3 supports (A-Fig.1) using the screws at the rear of the car (2 screws per support).
2. Insert the side member (B-Fig.2) into the guides on the 3 supports.
Fig.1
B
Fig.2
1
L714 08 53 05
3. Secure the side member to the car at the top using the 6 screws (C-Fig.3). C
4. Secure the side member to the car at the bottom using the 3 screws (')LJ).
5. Secure the side member to the car at the rear using the screw (()LJ).
6. Assemble the panel above the side member.

• Assemble the rear wheel (060105).
Fig.3
'
Fig.4
Fig.5
2
L714 08 63 03
A) Tunnel end panels

%7XQQHORUQDPHQW
C) Tunnel
1
L714 08 63 03
$'LVDVVHPEOLQJWKHWXQQHOHQGSDQHOV
%
1. Carefully prize up the edge of the panel ($)LJXQWLOWKH¿QQHGDQFKRUVRQWKHSDQHOGHWDFKIURPWKHLU
KRXVLQJVRQWKHWXQQHO
2. 5HOHDVHWKHVORW%)LJIURPWKHEUDFNHW&)LJ A

A
3. 5HPRYHWKHSDQHO')LJ
)LJ
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHWKHOHDWKHUXSKROVWHU\GXULQJGLVDVVHPEO\SURFHGXUHV C
There are 2 tunnel end panels assembled inside the car (one on the right and one on the left). The
disassembly procedure is the same for both.
)LJ
'
)LJ
2
L714 08 63 03
%'LVDVVHPEOLQJWKHWXQQHORUQDPHQW A C C C %
1. 8QVFUHZWKHJHDUOHYHUNQREPDQXDOJHDUER[YHUVLRQRQO\
2. 5HPRYHWKHVFUHZVWKDWVHFXUHWKHJHDUOHYHUEORFNWRWKHRUQDPHQWPDQXDOJHDUER[YHUVLRQRQO\
3. 3UL]HXSWKHHGJHRIWKHRUQDPHQWWRUHOHDVHWKHFOLSV$)LJIURPWKHLUPRXQWVDQGWKHVORW%)LJIURP

WKHFRUUHVSRQGLQJJXLGH
4. 'HWDFKWKHFRQQHFWLRQV&)LJWKHUHDUHDQGQRWFRQQHFWRUVRQWKHPDQXDOJHDUER[YHUVLRQ
5HPRYHWKHWXQQHORUQDPHQW')LJ
,IWKHFDUIHDWXUHVDPDQXDOJHDUER[XQVFUHZWKHJHDUOHYHUNQREWRUHPRYHWKHWXQQHORUQDPHQW
)LJ
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHWKHOHDWKHUXSKROVWHU\GXULQJGLVDVVHPEO\SURFHGXUHV
'
)LJ
3
L714 08 63 03
&'LVDVVHPEOLQJWKHWXQQHO
• 'LVDVVHPEOHWKHEHQFK(086803)
• 5HPRYHWKHWXQQHORUQDPHQW3RLQW%
A
'LVDVVHPEOLQJWKHWXQQHO
1. 7RGLVDVVHPEOHWKHJORYHER[$)LJXQVFUHZWKHVFUHZV%)LJWKDWVHFXUHWKHWXQQHORUGLVDVVHPEOH
WKHGULQNVFDELQHW
2. 'LVFRQQHFWWKHFLJDUHWWHOLJKWHUFRQQHFWRU&)LJ
3. 8QVFUHZWKHVFUHZV')LJVHFXULQJWKHWXQQHO¶VEUDFNHW()LJXQGHUWKHGRFXPHQWKROGHU

%
)LJ
'
C
'
)LJ
4
L714 08 63 03
4. 8QVFUHZWKHVFUHZV))LJVHFXULQJWKHIURQWSDUWRIWKHWXQQHO

) G
'LVFRQQHFWWKHFRQQHFWRU*)LJ
6. 5HPRYHWKHWXQQHO+)LJ
)LJ
)LJ

L714 08 63 05
A) Tunnel end panels

%7XQQHORUQDPHQW
C) Tunnel
1
L714 08 63 05
A) Assembling the tunnel end panels

A
1. Position the tunnel end panel ($)LJ) so that the slot (%)LJ) enters the bracket (&)LJ).
2. $SSO\SUHVVXUHRQWRWKHSDQHOVRWKDWWKH¿QQHGDQFKRUV')LJ) enter the respective couplings.
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHWKHOHDWKHUXSKROVWHU\GXULQJDVVHPEO\SURFHGXUHV
)LJ
There are 2 tunnel end panels assembled inside the car (one on the right and one on the left). The
assembly procedure is the same for both. %
'
'
)LJ
)LJ
2
L714 08 63 05
%$VVHPEOLQJWKHWXQQHORUQDPHQW ' A A A C
1. Connect the 3 connections ($)LJ) to the respective ports on the tunnel ornament (%)LJ) (the manual
gearbox version has 2 connections).
2. Position the ornament so that the slot (&)LJ) at the front enters the guide.
3. Press the ornament in so that the 2 clips (')LJ) enter the couplings.
4. Secure the gearlever block to the ornament using the 2 screws (manual gearbox version only).
5. Tighten the gearlever knob (manual gearbox version only).
)LJ
)LJ
3
L714 08 63 05
C) Assembling the tunnel
1. Position the tunnel ($)LJ) and connect the special connector (%)LJ).
)LJ
2. Secure the tunnel at the front using the 2 screws (&)LJ).
C %
)LJ
4
L714 08 63 05
3. Secure the tunnel bracket (')LJ) at the rear using the 2 screws (()LJ).
(
4. Connect the cigarette lighter connector ())LJ)
'
)
(
)LJ
5. Secure the glove box (*)LJ) using the 3 screws (+)LJ), or assemble the drinks cabinet.

• Assemble the bench (086805). G
H
)LJ
5
L714 08 68 01
Inner trim FKHFN
&KHFNWKHWLJKWHQLQJWRUTXHVDQGWKHLQWHJULW\RIWKHSDQHOVDQGLQWHUQDOVDIHW\V\VWHPV

regularly.
&$87,21
7DNHSDUWLFXODUFDUHZKHQFKHFNLQJWKDWWKHVHDWEHOWVIXQFWLRQFRUUHFWO\
• 6ORZO\SXOORXWWKHVHDWEHOWVFKHFNLQJWKDWWKH\VOLGHQRUPDOO\
• )RUFHIXOO\MHUNRQWKHVHDWEHOWVFKHFNLQJWKDWWKH\LPPHGLDWHO\ORFN
,IWKH\PDOIXQFWLRQFDUU\RXWWKHQHFHVVDU\RSHUDWLRQV
,IWKHDLUEDJV\VWHPKDVEHHQDFWLYDWHGWKHVHDWEHOWVPXVWEHUHSODFHGDQGWKHFRQWUROXQLWVGLVSOD\LQJ
error codes must be reset.
1
L714 08 68 03
A) Cross member
% %HQFK
& $3LOODU
' $3LOODU
( )URQWVLGHPHPEHUFRYHU
) 6LGHPHPEHU
* %3LOODU
+ &3LOODU
, &HQWHUGDVKERDUGFRYHU
L) Instrumentation
M) Instrument cluster grille
1 ,QVWUXPHQWFOXVWHU
2 %-$SXVKEXWWRQSDQHO
3 6LGHFRYHU5+DQG/+
4 'ULYHUVLGHORZHUGDVKERDUGDVVHPEO\
5 3DVVHQJHUVLGHORZHUGDVKERDUGDVVHPEO\
6 'DVKERDUG
7 &RZOWRSFRYHU
U) Internal door handle
9 &DUKL¿V\VWHPORXGVSHDNHUJULG
= 'RRUFRYHU
; 5HDUYLHZPLUURU
: 5RRIOLQHU
1
L714 08 68 03
$'LVDVVHPEOLQJWKHFURVVPHPEHU
1. Prize up the edge of the cross member ($)LJWRUHOHDVHWKH¿QQHGDQFKRUV%)LJVHFXULQJLWIURPWKHLU %
KRXVLQJVDWWKHUHDURIWKHFDU
)LJ
2
L714 08 68 03
%'LVDVVHPEOLQJWKHEHQFK
1. 3UL]HXSWKHHGJHRIWKHEHQFK$)LJWRUHOHDVHWKH¿QQHGDQFKRUV%)LJVHFXULQJLWIURPWKHLUKRXVLQJV A

DWWKHUHDURIWKHFDU
)LJ
)LJ
3
L714 08 68 03
&'LVDVVHPEOLQJWKH$SLOODU
1. Prize up the edge of the A1 pillar ($)LJWRUHOHDVHWKH¿QQHGDQFKRU%)LJVHFXULQJLWIURPLWVKRXVLQJ

DQGWKHVORWV&)LJIURPWKHJXLGHV
% A C
)LJ
4
L714 08 68 03
''LVDVVHPEOLQJWKH$SLOODU A
• Disassemble the A1 pillar 3RLQW&
'LVDVVHPEOLQJWKH$SLOODU
1. 8QVFUHZWKHVFUHZ$)LJVHFXULQJWKH$SLOODU%)LJDWWKHWRS % C
2. 3UL]HXSWKHHGJHRIWKH$SLOODUWRUHOHDVHWKH¿QQHGDQFKRU&)LJVHFXULQJLWIURPLWVKRXVLQJ
)LJ
5
L714 08 68 03
('LVDVVHPEOLQJWKHIURQWVLGHPHPEHUFRYHU C
1. 3UL]HXSWKHHGJHRIWKHIURQWVLGHPHPEHUFRYHU$)LJWRUHOHDVHWKH¿QQHGDQFKRUV%)LJVHFXULQJ
LWIURPWKHLUKRXVLQJVDQGWKHVORW&)LJIURPWKHJXLGH
%
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHWKHOHDWKHUXSKROVWHU\GXULQJGLVDVVHPEO\SURFHGXUHV A
)LJ
6
L714 08 68 03
)'LVDVVHPEOLQJWKHVLGHPHPEHU C A
• 'LVDVVHPEOHWKHIURQWVLGHPHPEHUFRYHU3RLQW(
1. 8QVFUHZWKHVFUHZ$)LJVHFXULQJWKHIURQWSDUWRIWKHVLGHPHPEHU )LJ
2. 3UL]H XS WKH HGJH RI WKH VLGH PHPEHU WR UHOHDVH WKH ¿QQHG DQFKRUV %)LJ VHFXULQJ LW IURP WKHLU
KRXVLQJV
3. 5HPRYHWKHVLGHPHPEHU&)LJ
%
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHWKHOHDWKHUXSKROVWHU\GXULQJGLVDVVHPEO\SURFHGXUHV %
%
)LJ
7
L714 08 68 03
*'LVDVVHPEOLQJWKH%SLOODU
• Disassemble the side member3RLQW)
• Disassemble the seatbelt C
'LVDVVHPEOLQJWKH%SLOODU A
1. 5HPRYHWKHKDQGOH$)LJWKDWRSHQVWKHHQJLQHKRRGXVLQJWKHPRXQWLQJVFUHZWREHGRQHIRUWKHGULYHU
VLGH%SLOODURQO\
2. 8QVFUHZWKHPRXQWLQJVFUHZ%)LJ) at the bottom of the B pillar (&)LJ
3. 3UL]HXSWKHHGJHRIWKH%SLOODUWRUHOHDVHWKH¿QQHGDQFKRU')LJVHFXULQJLWIURPLWVKRXVLQJDQGWKHVORW

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of the dashboard (&)LJ
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7. 'LVFRQQHFWWKHGRRUKDQGOH/('GULYHUVLGHGRRURQO\
8. Lift the door up to release the slot (*)LJRQWKHGRRUFRYHUIURPWKHFRUUHVSRQGLQJGXFWRQWKHGRRU
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHWKHOHDWKHUXSKROVWHU\GXULQJGLVDVVHPEO\SURFHGXUHV )
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L714 08 68 03
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• Disassemble the roof lamp ' )
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L714 08 68 05
A) Cross member
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L) Instrumentation
M) Instrument cluster grille
1 ,QVWUXPHQWFOXVWHU
2 %-$3XVKEXWWRQSDQHO
3 6LGHFRYHU5+DQG/+
4 'ULYHUVLGHORZHUGDVKERDUGDVVHPEO\
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U) Internal door handle
9 &DUKL¿V\VWHPORXGVSHDNHUJULG
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L714 08 68 05
A) Assembling the cross member
1. Position the cross member ($)LJDQGVHFXUHLWWRWKHFDUE\SUHVVLQJWKH¿QQHGDQFKRUV%)LJ) into the %

couplings.
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L714 08 68 05
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1. Position the bench ($)LJDQGVHFXUHLWWRWKHUHDURIWKHFDUE\SUHVVLQJWKH¿QQHGDQFKRUV%)LJ) into A

the couplings.
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L714 08 68 05
C) Assembling the A1 pillar
1. Position the A1 pillar ($)LJWRLQVHUWWKH¿QQHGDQFKRU%)LJ) into its housing and the 2 slots (&)LJ) into
the guides.
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L714 08 68 05
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1. Secure the A pillar ($)LJE\LQVHUWLQJWKH¿QQHGDQFKRU%)LJ) into the coupling and tightening the screw
(&)LJ) at the top.
• Assemble the A1 pillar (3RLQW&).

A %
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L714 08 68 05
($VVHPEOLQJWKHIURQWVLGHPHPEHUFRYHU C
1. Position the front side member cover ($)LJLQVHUWLQJWKH¿QQHGDQFKRUV%)LJ) into the housings and
the slot (&)LJ) into the guide.
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6
L714 08 68 05
)$VVHPEOLQJWKHVLGHPHPEHU A C
1. Position the side member ($)LJE\LQVHUWLQJWKH¿QQHGDQFKRUV%)LJ) into their couplings.
2. Secure the front of the side member using the screw (&)LJ).
• Assemble the front side member cover 3RLQW(.

)LJ
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7
L714 08 68 05
*$VVHPEOLQJWKH%SLOODU
1. Position the B pillar ($)LJ) by inserting the slot (%)LJ) at the top of the pillar into the guide.
2. $SSO\SUHVVXUHRQWRWKH%SLOODUWRLQVHUWWKH¿QQHGDQFKRU&)LJ) into the coupling.
3. Secure the B pillar at the bottom using the screw (')LJ). A
4. Secure the handle that opens the engine hood (()LJ) to the B pillar using the mounting screw (to be done for
the passenger side B pillar only).
(
• Assemble the seatbelt .
• Assemble the side member 3RLQW).
)LJ
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C
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L714 08 68 05
H) Assembling the C pillar ' A
1. Position the C pillar ($)LJ) to insert the 2 slots (%)LJ) into the couplings.
2. $SSO\SUHVVXUHRQWRWKH&SLOODUWRLQVHUWWKH¿QQHGDQFKRU&)LJ) into the coupling.
3. Secure the C pillar to the car using the 3 screws (')LJ).
• Assemble the B pillar 3RLQW*.

• Assemble the cross member 3RLQW$.
'
C
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L714 08 68 05
,$VVHPEOLQJWKHFHQWHUGDVKERDUGFRYHU
1. Position the center dashboard cover ($)LJ) to insert the 2 slots (%)LJ) into the guides.
2. Connect the connector (&)LJ).
3. $SSO\SUHVVXUHRQWRWKHFHQWHUGDVKERDUGFRYHUWRLQVHUWWKH¿QQHGDQFKRUV')LJ) into the couplings.
A
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10
L714 08 68 05
L) Assembling the instrumentation

A
1. Position the instrumentation ($)LJ) and secure it to the car using the 2 screws (%)LJ).
2. Secure the instrumentation to the dashboard using the 2 screws (&)LJ).
3. Connect the connection (')LJ) at the rear of the instrumentation.
• Assemble the center dashboard cover3RLQW,
)LJ
% %
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C
C
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11
L714 08 68 05
M) Assembling the instrument cluster grille

A
1. Position the instrument cluster grille ($)LJ) to insert the 2 slots (%)LJ) into the guides (&)LJ).
2. Apply pressure onto the grille to insert the 2 clips (')LJ) into the respective couplings (()LJ).
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L714 08 68 05
1$VVHPEOLQJWKHLQVWUXPHQWFOXVWHU
1. Connect the connector on the back of the instrument cluster.

2. Position the instrument cluster ($)LJ) and secure it using the 2 screws (%)LJ).
% A
• Assemble the instrument cluster grille (3RLQW0).

• $IWHUDVVHPEO\FRQQHFWWKH/D5D$6V\VWHP5HVHWDQ\HUURUFRGHVDQGSURJUDPWKHLQVWUXPHQWFOXVWHU¿OHLI %
the instrument cluster was replaced ().
)LJ
13
L714 08 68 05
2$VVHPEOLQJWKH%-$SXVKEXWWRQSDQHO
C A (
1. Connect the connection ($)LJ) to the port (%)LJ on the rear of the BJA push-button panel unit (&
)LJ).
2. Position the BJA push-button panel unit to insert the 2 side slots (')LJ) into the respective guides ((
)LJ) of the dashboard.
)LJ
' % '
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14
L714 08 68 05
3$VVHPEOLQJWKHVLGHFRYHU5+DQG/+
1. Position the cover ($)LJ) and push to insert the clip (%)LJ) into the coupling.
A %
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15
L714 08 68 05
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A
1. Position the driver side lower dashboard assembly ($)LJ) and secure it at the top using the 2 stud bolts
(%)LJ).
2. Connect the connector (&)LJ) of the reverse gear button (E-GEAR version only).
3. Tighten the 3 mounting screws (')LJ).
• Assemble the instrument cluster 3RLQW1.

• Assemble the instrument cluster grille 3RLQW0. )LJ
• Assemble the left side cover 3RLQW3.
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16
L714 08 68 05
5$VVHPEOLQJWKHSDVVHQJHUVLGHORZHUGDVKERDUGDVVHPEO\
1. Position the passenger side lower dashboard assembly ($)LJ) and connect the connector (%)LJ).
2. Secure the 3 screws (&)LJ) through the glove box at the top.
3. Secure the screw (')LJ) at the rear of the lower dashboard assembly. A )
4. Secure the 2 side screws (()LJ).
5. Connect the connection of the passenger side airbag selector ())LJ).
• Assemble the right side cover 3RLQW3.
)LJ
(
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C
C
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17
L714 08 68 05
S) Assembling the dashboard

)
1. Position the dashboard ($)LJ) connecting the various connections.
2. Tighten the 2 screws (%)LJ) at the center securing the dashboard to the air conditioner.
3. Secure the passenger side airbag to the dashboard using the 4 screws (&)LJ).
)LJ
)LJ
)LJ
18
L714 08 68 05
4. Tighten the dashboard’s center screw (')LJ).

5. Tighten the 4 screws (()LJ) securing the 2 side air vents to the dashboard (2 screws per vent).
6. Tighten the 2 screws ())LJ) connecting the dashboard to the tunnel and the tunnel cover.
7. Tighten the 2 screws (*)LJ) through the space created by the instrument cluster.
• Assemble the instrumentation3RLQW/

• Assemble the center dashboard cover 3RLQW,
• Assemble the driver side lower dashboard assembly3RLQW4 '
• Assemble the passenger side lower dashboard assembly3RLQW5
• Assemble the two side covers3RLQW3
• Assemble the tunnel ornament
• $VVHPEOHWKHFDUKL¿V\VWHP )LJ
• Assemble the air conditioner ornament
• Assemble the air conditioner grille
• Assemble the BJA push-button panel 3RLQW2
• Assemble the instrument cluster3RLQW1
• Assemble the instrument cluster grille3RLQW0
• Assemble the passenger side seat
• Connect the LaRa-AS system and reset any error codes .
(
)LJ
G G
)LJ

L714 08 68 05
7$VVHPEOLQJWKHFRZOWRSFRYHU
1. Position the cowl top cover ($)LJWRLQVHUWWKH¿QQHGDQFKRU%)LJ) into the coupling. '
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altogether).
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A
2. Secure the 3 screws (&)LJ).
3. Tighten the mounting screw (')LJ).
• Assemble the A1 pillar3RLQW&

• Assemble the A pillar 3RLQW'
• Assemble the dashboard3RLQW6
)LJ
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20
L714 08 68 05
U) Assembling the internal door handle

A %
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• an upper part
• a lower part
1. Assemble the lower part ($)LJ) of the internal door handle using the screw (%)LJ).
2. Connect the connector (&)LJ) of the power window assembly.
3. Press the upper part of the internal door handle (')LJ) to insert it into the rest of the handle.
)LJ
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)LJ
21
L714 08 68 05
9$VVHPEOLQJWKHFDUKL¿V\VWHPORXGVSHDNHUJULG A
1. 3UHVV WKH KL¿ V\VWHP ORXGVSHDNHU JULG $)LJ) to insert the 4 slots (%)LJ) into the couplings on the
door.
2. 6HFXUHWKHKL¿V\VWHPORXGVSHDNHUJULGRQWRWKHGRRUXVLQJWKHVFUHZ&)LJ).
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22
L714 08 68 05
=$VVHPEOLQJWKHGRRUFRYHU
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1. Position the door cover ($)LJ) to insert the slot into the corresponding duct on the door.
2. Connect the door handle LED connector (driver side door only).
3. ,QVHUWWKH¿QQHGDQFKRU%)LJ) on the rear of the door into the coupling.
4. Tighten the screw (&)LJXQGHUWKHKL¿V\VWHPORXGVSHDNHUJULG
)LJ
5. Tighten the screw (')LJ) on the front of the cover.
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)LJ
23
L714 08 68 05
6. Tighten the screw (()LJ) under the door LED.

7. Connect the door LED connection ())LJ).
(
)LJ
8. insert the door LED (*)LJ).
• Assemble the internal door handle3RLQW8 G

• $VVHPEOHWKHFDUKL¿V\VWHPORXGVSHDNHUJULG3RLQW9
)LJ
24
L714 08 68 05
;$VVHPEOLQJWKHUHDUYLHZPLUURU
1. Position the rear-view mirror ($)LJ) onto the coupling (%)LJ) on the windscreen.
C
2. Turn the mirror 90° clockwise to insert it into the coupling.
3. Connect the connection (&)LJ).
A
)LJ
)LJ
25
L714 08 68 05
:$VVHPEOLQJWKHURRIOLQHU
1. Press on the roof liner ($)LJWRLQVHUWWKH¿QQHGDQFKRUV%)LJ) into their couplings.
2. Tighten the screw (&)LJ) securing the roof liner to the roof of the car at the front.
A
C
)LJ
%
%
)LJ
26
L714 08 68 05
3. Press the sun visor hooks (')LJ) to insert them into the respective couplings. L
4. Connect the 2 sun visor light connections (()LJ) (one connection per sun visor). 1
5. Secure the 2 sun visors ())LJ) by tightening the 2 screws (*)LJ) (one screw per sun visor).
6. Connect the passenger compartment interior light connection (+)LJ) and secure it by pressing it into the
roof liner.
7. Connect the volumetric sensor connection (/)LJ). 1 H
8. Press the volumetric sensor (0)LJ) onto the roof liner using the 2 couplings (1)LJ).
Secure the 2 clothes hooks (2)LJ) using the 2 screws (3)LJ).
M
• Assemble the roof lamp O
• Assemble the C pillar3RLQW+
• Assemble the A1 pillar3RLQW&
'
3
)LJ
G )
)LJ
27
L714 08 75 03
A) Steering wheel
%6WHHULQJZKHHOFRYHU
1
L714 08 75 03
$'LVDVVHPEOLQJWKHVWHHULQJZKHHO
• Disassemble the driver side airbag module (088003). %
'LVDVVHPEOLQJWKHVWHHULQJZKHHO
1. Unscrew the center screw ($)LJ) securing the steering wheel to the steering column.
2. Remove the steering wheel (%)LJ).
)LJ
2
L714 08 75 03
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A
• Disassemble the driver side airbag module (088003). C
• Disassemble the steering wheel 3RLQW$.
'LVDVVHPEOLQJWKHVWHHULQJZKHHOFRYHU
7KLVFRYHULVGLYLGHGLQWRFRPSRQHQWV
• XSSHU$)LJ
• ORZHU%)LJ
• OHIWVLGH&)LJ
• ULJKWVLGH')LJ
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)LJ
%
3
L714 08 75 03
1. Unscrew the mounting screw (()LJ) on the lower part of the cover.
2. Unscrew the 2 screws ())LJ) securing the 4 parts of the cover at the front.
3. Prize up the 4 edges of the cover to release the various clips (*)LJ) from the respective couplings (H-
)LJ).
'
)LJ
H
G
)
)
)LJ
4
L714 08 75 05
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1
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• ORZHU%)LJ
• OHIWVLGH&)LJ
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)LJ
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L714 08 75 05
1. Secure the cover’s lower part using the screw (()LJ).

2. Position the 3 remaining cover parts to insert the various clips ())LJ) into the corresponding couplings (G-
)LJ).
Secure the 4 parts at the front using the 2 screws (+)LJ).
• Assemble the steering wheel 3RLQW%.

• Assemble the driver side airbag module (088005).
• Connect the LaRa-AS system and reset any error codes (109000).
'
)LJ
G
)
H
H
)LJ

L714 08 75 05
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1. Position the steering wheel ($)LJ) on the steering column so that the steering wheel is correctly aligned.
2. Secure the steering wheel to the steering column using the center screw (%)LJ). A
• Assemble the driver airbag module (088005).

• Connect the LaRa-AS system and reset any error codes (109000).
)LJ
4
L714 08 80 00
Safety
&$87,21 A
• $LUEDJPRGXOHVPXVWDOZD\VEHSDFNHGLQVWDOOHGVKLSSHGDQGVWRUHGLQFRPSOLDQFHZLWKWKHODZVLQ
effect.
• 7KHUHPRYDOWHVWLQJDQGUHSODFHPHQWRIDLUEDJPRGXOHVPXVWEHFDUULHGRXWE\TXDOL¿HGSHUVRQQHO
• (DFKDLUEDJPXVWEH(;&/86,9(/<XVHGRQWKHYHKLFOHIRUZKLFKLWZDVGHVLJQHGDQGFDOLEUDWHG
3ODFHWKHH[SORGHGPRGXOHLQWKHSDFNDJHRIWKHQHZRQHDQGVHQGLWEDFNWRWKHPDQXIDFWXUHUIRU
disposal.
• 'R127XVHWHVWHUVWRFKHFNWKHDLUEDJPRGXOH¶VRSHUDWLRQ
• 'XULQJLQVWDOODWLRQDOZD\VNHHS\RXUZRUNDUHDFOHDQDQGWLG\$OZD\VPDNHVXUHWKDWQRREMHFWRU
foreign material has gotten or can get inside or near the module.
• 'R127WRXFKPHWDOSDUWVGXULQJDLUEDJPRGXOHLQVWDOODWLRQEHFDXVHVWDWLFFKDUJHVFRXOGFRPSURPLVH
WKHDLUEDJPRGXOH¶VHOHFWULFDOSDUWV
• 6FUXSXORXVO\IROORZWKHVDIHW\LQVWUXFWLRQVGXULQJWKHLQVWDOODWLRQRIDQDLUEDJV\VWHP:HDUSURWHFWLYH B
JRJJOHVDQGKHDWUHVLVWDQWJORYHV
• $OZD\VDUUDQJHWKHPRGXOHVZLWKWKHSODVWLFFRYHUIDFLQJXSZDUGVDQGDZD\IURPWKHERG\ZKLOH
handling.
• The same precautions used for front airbags apply to side airbags.
• 'R 127 SODFH FRYHUV RQ WKH VHDWV EHFDXVH WKH\ FRXOG FRPSURPLVH WKH RSHUDWLRQ RI WKH VLGH
airbags.
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Components (Fig.1)
A. Driver side airbag module
B. Passenger side airbag module
C. Seatbelt pretensioner
Fig.1
1
L714 08 80 00
1(9(5GRWKHIROORZLQJWRWKHFRPSRQHQWV)LJ
A. Grasp the wiring harness
B. Connect electrical power
C. Use tools (screwdriver, hammer, etc.)
' Weld
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• 1HYHUXVHWRROVVXFKDVKDPPHUVVFUHZGULYHUVEODGHVRURWKHUVKDUSREMHFWVZKLFKFRXOGGDPDJH
the system.
• 'RQRWDSSO\YROWDJHWRWKHDLUEDJZLULQJKDUQHVVWRWKHPRGXOHFRQQHFWRUVDQGRUWRWKHFRQWURO
XQLWEHIRUHLWLVFRPSOHWHO\LQVWDOOHGDQGWKHUHLVVRPHRQHDERDUGWKHYHKLFOHEHFDXVHDQHOHFWULF
system fault could deploy the airbag system.
• 'R127RYHUKHDWWKHFRPSRQHQWV'RQRWXVHQDNHGÀDPHVQHDUWKHDLUEDJFRPSRQHQWV
• 'R127GURSWKHPRGXOHRUWKHFRQWUROXQLW,IWKLVKDSSHQVGRQRWLQVWDOOWKHSURGXFW
• .HHSWKHDLUEDJFRPSRQHQWVGU\,IZHWGRQRWLQVWDOOWKHSURGXFW
• 'R127WDPSHUZLWKRUFXWWKHZLUHVRUFRQQHFWRUVRIWKHHQWLUHV\VWHP&XWWLQJDZLUHRUWDPSHULQJ
ZLWKDFRQQHFWRUFRXOGVHYHUHO\DIIHFWV\VWHPVDIHW\
• 1(9(5DWWHPSWWRRSHQDQGRUGHSOR\WKHDLUEDJV\VWHP
• $OZD\VFDOODGRFWRUDIWHUDQ\W\SHRIH[SRVXUHWRWKHJDV C '
Fig.2
2
L714 08 80 00
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between the driver or passenger’s body and the structures of the vehicle.
This is a “passive safety system” since it comes into action once a certain deceleration value is exceeded (which can
only result from hitting an obstacle) without the occupant acting in any way. The deployment conditions of the airbag
are governed by an electronic control unit (SDM) that continuously processes vehicle deceleration. An electric pulse
LVVHQWZKHQDSUHGH¿QHGWKUHVKROGLVH[FHHGHG7KLVKHDWVDQHOHFWULFDOUHVLVWDQFHKRXVHGLQWKHJDVJHQHUDWRU
ZKLFK LJQLWHV7KLV FDXVHV D FKHPLFDO ¿ULQJ UHDFWLRQ ZKLFK LQ WXUQ ¿UHV WKH S\URWHFKQLF FKDUJH7KH S\URWHFKQLF
FKDUJHUHDFWLRQJHQHUDWHVLQHUWJDVZKLFKLV¿OWHUHGDQGFRROHGE\PHWDO¿OWHUVDQGLVWKHQOHWRXWIURPWKHKROHVRQ
WKHJDVJHQHUDWRUFDVLQJFDXVLQJWKHEDJWRLQÀDWH7KHEDJSODFHVLWVHOIEHWZHHQWKHIURQWLQWHUQDOVWUXFWXUHRIWKH
vehicle and the occupant’s head (driver or passenger).
7KHLQÀDWHGEDJLVDVRIWEDUULHUWKDWVORZVGRZQWKHRFFXSDQW¶VKHDGGXULQJWKHFROOLVLRQ7KHEDJLVGHÀDWHGE\WKH
gas that is let out from a hole in the back of the bag by the action of the occupant moving forwards. The system is
deployed in thousandths of a second to anticipate the forward movement of the body during the deceleration caused
by the impact.
7KHS\URWHFKQLFFKDUJHLVFRQWDLQHGLQDVHDOHGFRQWDLQHULQWKHJDVJHQHUDWRU,WVRQO\SXUSRVHLVWRLQÀDWHWKHEDJ
,QQRFDVHFDQWKHGHYLFHWUDQVPLWDIRUPRIHQHUJ\ZKLFKFDQ¿UHDQ\RWKHUJDVJHQHUDWRUVVWRUHGLQWKHLPPHGLDWH
proximity.
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Please note that the gas generator is the only airbag system component containing a pyrotechnic charge.
The SDM is the control unit governing all the airbag system functions. The SDM is the only control unit in the system.
It contains both the accelerometer and the error memory. If the airbag warning light on the dashboard turns on during
normal vehicle operation, it indicates an airbag system malfunction. The malfunction will be stored in the SDM control
B
unit as soon as the dashboard warning light turns on. The airbag warning light indicates a failure without specifying
its nature. Run the SDM control unit diagnostic procedure to verify the cause of the error. The LARa-AS diagnostic A
system diagnoses the airbag control unit. To reset the system, see Gallardo Diagnostics.
C
'
B. Passenger side airbag module
C. Side airbag module
' Airbag control unit (SDM) (under the center console) Fig.3
3
L714 08 80 00
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7KHGULYHUVLGHDLUEDJPRGXOHFRQVLVWVRIDJDVJHQHUDWRU¿WWHGZLWKDEDJIROGHGLQWRDFRQWDLQHUZKLFKLVULYHWHG
to a metal plate. The metal plate connects all the components together to form a module installed on the center of
the steering wheel.
The bag is made of silicone-coated nylon. Its internal volume when fully deployed is approximately 60 liters. The bag
is folded in a special way.
7KHSODVWLFFRYHUKDVDKRUL]RQWDOSUHFXWEUHDNLQJOLQH¿OPKLQJHVDWWKHPLGGOH7KLVDOORZVWKHFRYHUWREUHDN

and the bag to be let out when deployed.
' A
'ULYHUVLGHDLUEDJ)LJ
B. Steering wheel mounting onto steering column
C. Steering wheel
' Driver side airbag module mounts
( Indicator switch (SMLS module) with pigtail connection ( C B
Fig.4
The gas generator on the driver side is pyrotechnic and cylindrical.
The gas generator consists of the following parts:

• a container consisting of two welded half-casings, one of which is perforated to let out the gas. The following
components are arranged inside the container:
• propellant contained in a sealed metal cylinder: when heated, this substance releases a considerable amount
of gas and a limited amount of solid particulate;
• an electric resistance or trigger which transforms the control unit electric pulse into a spark;
• a primer heats the propellant: it is activated by the spark generated by the electrical resistance;
• DPHWDOPHVK¿OWHULVXVHGWRNHHSWKHSUHVVXUHFRQVWDQWZLWKKROGVROLGSDUWLFXODWHDQGFRROWKHJDVZKLFK¿OOV
the bag
4
L714 08 80 00
&$87,21
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Do not subject the module to temperatures exceeding 107°C or lower than -35°C to prevent permanent damage to
the components with consequent system malfunctioning.
The pigtail connection is used to send the electric signal of the wires on the control unit side to the airbag module on
the driver side, guaranteeing electrical continuity during normal use of the steering wheel. The pigtail connection is
an integral part of the indicator switch (SMLS module) and cannot be disassembled.
5
L714 08 80 00
3DVVHQJHUVLGHDLUEDJPRGXOH
The passenger side airbag has two separate components:

• airbag module, which contains the bag and the gas generator (Fig.5)
• DLUEDJÀDS on the dashboard
Airbag module
7KHSDVVHQJHUVLGHDLUEDJKDVDSDLURIJDVJHQHUDWRUV¿WWHGZLWKDIROGHGQ\ORQEDJWKH\DUHKRXVHGDQGVHFXUHG
to a metal container activated by a metal plate that holds the bag. The bag is made of silicone-coated nylon. Its
internal volume when fully deployed is approximately 120 liters. The bag is folded in a special way. It is also externally
wrapped for protection and to keep it folded.
,PSRUWDQW
• 7DPSHULQJZLWKWKLVSURWHFWLYHZUDSSLQJLVSURKLELWHGZKLFKZRXOGSUHYHQWLWIURPIXQFWLRQLQJ
correctly.
• 'RQRWVXEMHFWWKHPRGXOHRUWKHÀDSWRWHPSHUDWXUHVH[FHHGLQJ&RUORZHUWKDQ&WR
Fig.5
SUHYHQWSHUPDQHQWGDPDJHWRWKHFRPSRQHQWVZLWKFRQVHTXHQWV\VWHPPDOIXQFWLRQLQJ
The airbag module is secured to the cross member by 4 bolts ($)LJ).

A
Fig.6
6
L714 08 80 00
Flap
The bottom of the dashboard near the passenger airbag module has a metal frame secured by means of screws
(%)LJ) to the dashboard and two bolts to the cross member.
7KHÀDSLVKLQJHGWRWKHSODVWLFVHPLULJLGÀDSE\PHDQVRIWZRFOLSVDWWKHIURQW$)LJ) and 6 rivets at the back
(&)LJ).
B A
:KHQWKHDLUEDJLVGHSOR\HGWKHÀDSLVUHOHDVHGIURPWKHFOLSVDWWKHERWWRP$)LJ) and rotates at the top (Fig.9)

thanks to the play provided by the metal rivets, tearing the leather on the outside.
Fig.7
Fig.8
Fig.9
7
L714 08 80 00
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&$87,21
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WRYHULI\
• &RQQHFWRUVFULPSLQJTXDOLW\DQGDQ\VLJQVRIDEUDVLRQWKHUPDOHIIHFWVRUFRQWDPLQDWLRQE\WKHJDV
generator
• :LULQJKDUQHVVDEUDVLRQVEXUQLQJDQGWHDUVLIPHWDOLQWUXGHVDVZHOO
7+((17,5($,5%$*:,5,1*+$51(660867%(5(3/$&(',)7+(5($5($1<2%9,286$120$/,(6
25'$0$*(&(175$/&211(&7,21
Visually inspect the airbag connectors for crimping quality, signs of abrasion, thermal effects or contamination by the
gas generator.
Replace the wiring harness if any damage to connectors is found.
Check the control unit error memory again after repairing the vehicle.
Replace the wiring harness if errors pertinent to the wiring are found. C B A G
A. Pretensioner
B. Side impact sensor (SIS)
C. Side airbag
' Driver side airbag
( Passenger side airbag
F. Airbag control unit
G. Ground connection
H. Passenger airbag exclusion key
H ( G ' F C B A
8
L714 08 80 03
A) Side airbag disassembly
% 3DVVHQJHUVLGHDLUEDJGLVDVVHPEO\
& 3DVVHQJHUVLGHDLUEDJÀDSGLVDVVHPEO\
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( 6HDWEHOWUHWUDFWRUGLVDVVHPEO\
) 'LVDVVHPEOLQJWKHVHDWEHOWEXFNOH
1
L714 08 80 03
A) Side airbag disassembly
• Remove the seat from the car (088203).
• Place the ignition key in the OFF position.
%
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'2 127 &$55< 287 $1< :25. 21 7+( $,5%$*¶6 &20321(176 :,7+287 ),567 3/$&,1* 7+( A
.(<21³2))´$1'',6&211(&7,1*7+(%$77(5<
$92,'5(67,1*7+(6($7217+(6,'(7+$7+2/'67+($,5%$*02'8/(
• Remove the seatback panel (088203).

• Unhook the fasteners of the seatback’s covering (088203).
• Remove the electronic seat control panel (088203).
'LVDVVHPEOLQJWKHDLUEDJ
1. Detach the airbag’s wiring harness located in the seat’s cushion.
2. Remove the side airbag module by unscrewing the two bolts in the frame’s housing ($)LJ), which may be
reached by moving the seatback’s padding (%)LJ).
)LJ
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81$77(1'('
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A
.(<21³2))´$1'',6&211(&7,1*7+(%$77(5<
'LVDVVHPEOLQJWKHDLUEDJ
)LJ
1. Disconnect the two passenger airbag module connectors.
2. Remove the four screws ($)LJ) that secure the airbag module to the dashboard cross member and remove
the module.
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(;3/2'('
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7KH ÀDS LV VXSSOLHG VHFXUHG WR WKH PHWDO IUDPH IRU PRXQWLQJ RQ WKH GDVKERDUG 7KH HQWLUH IUDPH PXVW
therefore be replaced.
'LVDVVHPEOLQJWKHÀDS
A
1. Unscrew the 24 screws ($)LJ) that secure the frame to the dashboard.
)LJ
2. 5HPRYHWKHIUDPHZLWKWKHÀDS
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L714 08 80 03
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The pigtail connection is an integral part of the SMLS module (indicator switch replacement).
'LVDVVHPEOLQJWKHÀDS
1. Check that the driver side airbag module is deactivated (disconnect both battery terminals and completely A
isolate them) for at least one minute.
2. Unscrew the two screws behind the steering wheel ($)LJ) using a hexagon wrench and gently remove the
module (%)LJ). )LJ
3. Disconnect the yellow connectors (&)LJ), the green connectors (')LJ) and the horn connectors ((
)LJ).
(
'
)LJ
5
L714 08 80 03
A
(6HDWEHOWUHWUDFWRUGLVDVVHPEO\
• Disassemble the B pillar (086803).
• Disassemble the seat (088203).
'LVDVVHPEOLQJWKHUHWUDFWRUV
1. Disconnect the connector ($)LJ) from the retractor (%)LJ).
2. Disassemble the retractor, removing the screw that secures it at the bottom.
%
3. Release the seatbelt guide (&)LJ), removing the screw (')LJ).
4. Remove the screw (()LJ) securing the end of the seatbelts ())LJ).
)LJ
'
C
)LJ )LJ
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L714 08 80 03
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C
• Disassemble the seat (088203).
'LVDVVHPEOLQJWKHVHDWEHOWEXFNOH
1. Disconnect the connection ($)LJ9).
2. Unscrew the screw (%)LJ9) securing the buckle (&)LJ9) to the seat.
%
)LJ
7
L714 08 80 05
A) Side airbag assembly

% 3DVVHQJHUVLGHDLUEDJDVVHPEO\
& 3DVVHQJHUVLGHDLUEDJÀDSDVVHPEO\
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) $VVHPEOLQJWKHVHDWEHOWEXFNOH
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A) Side airbag assembly
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A
1. Insert the side airbag module cable into the slot ($)LJ) located in the housing on the side of the seatback.
2. Carefully reposition the side airbag module (%)LJ) in its housing (&)LJ), securing it with the two bolts ((
)LJ).
%ROWDWWDFKPHQWWLJKWHQLQJWRUTXH.
)LJ
Arrange the wiring harness (')LJ) in the seat’s cushion.
• Reassemble the electronic seat control panel. %

• Secure the fasteners of the seatback’s covering .
• Reassemble the seatback panel .
• Assemble the seat in the car .
• Reconnect the battery , connect the LaRa-AS system and reset any error codes .
(
Then carry out the following operations:
• Resynchronization of remote controls
• Resynchronization of steering angle
• Resynchronization of power window zero position
C
'
)LJ )LJ
2
L714 08 80 05
%3DVVHQJHUVLGHDLUEDJDVVHPEO\
1. Secure the new passenger side airbag to the dashboard cross member using the four screws ($)LJ).
2. Connect the two passenger airbag module connectors.
,PSRUWDQW
,I UHSODFLQJ DIWHU PRGXOH LQWHUYHQWLRQ FKHFN IRU GDPDJH WR WKH ZLULQJ KDUQHVV DQG LI QHFHVVDU\ A
A
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• Reposition the dashboard .

• Reconnect the battery .
• Connect the LaRa-AS system and reset any error codes .
)LJ

L714 08 80 05
&3DVVHQJHUVLGHDLUEDJÀDSDVVHPEO\
1. Remove the metal frame ()LJ).
2. Assemble the metal frame, positioning the brackets ($%&)LJ) and tightening the 24 screws (')LJ).
)LJ
'
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)LJ
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4. 6HFXUHWKHDLUEDJÀDSWRWKHIUDPHXVLQJWKHULYHWVFDUHIXOO\DOLJQLQJLWZLWKWKHGDVKERDUG)LJ).
• Re-assemble the dashboard .

• After assembling the dashboard, reconnect the battery , connect the LaRa-AS system and reset any
error codes .
Then carry out the following operations:

)LJ
)LJ
5
L714 08 80 05
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C
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• 0DNHVXUHWKDWWKHZLULQJKDVEHHQSRZHUHGGRZQIRUDWOHDVWVHFRQGV
A
1. Connect the yellow connectors ($)LJ), the green connectors (%)LJ) and the horn connectors (&)LJ) to
the module.
2. Install the module (')LJLQVLGHWKHVWHHULQJZKHHOE\KDQGGRQRWIRUFHWKHPRGXOHLILWGRHVQRW¿WFRUUHFWO\

in the steering wheel.
Insert the two airbag module mounting screws (()LJ). Center the module correctly, tighten the screws at the
VSHFL¿HGWLJKWHQLQJWRUTXHLQGLFDWHGLQVHFWLRQF. )LJ
• Reconnect the battery , connect the LaRa-AS system and reset any error codes .
Then carry out the following operations: '

)LJ

L714 08 80 05
'
(6HDWEHOWUHWUDFWRUDVVHPEO\ C
A
1. Secure the end of the seatbelts ($)LJ) by means of the screw (%)LJ).
2. Secure the seatbelt guide (&)LJ) using the screw (')LJ).
. Assemble the retractor, tightening the screw at the bottom.
4. Connect the connector (()LJ) to the retractor ())LJ).
• Assemble the B pillar .

• Assemble the seat .
• Connect the LaRa-AS system and reset any error codes . %
)LJ )LJ
)LJ
7
L714 08 80 05
)$VVHPEOLQJWKHVHDWEHOWEXFNOH
A
1. Secure the seatbelt buckle ($)LJ14) to the seat using the screw (%)LJ14) applying (loctite) 52A43 medium
thread sealant.
)L[LQJVFUHZVWLJKWHQLQJWRUTXHD
2. Connect the connection (&)LJ14).
• Assemble the seat .

%
)LJ
8
L714 08 82 01
Repair the seat
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This repair procedure may be applied to MOMO seats that equip cars until V.I.N. 1916 excluded.
If the seatback’s covering near the side airbag is detached from the airbag housing as shown in (Fig.1), repair it as
follows:
• Remove the seat from the passenger compartment (088203).

A
• Disassemble the seatback panel (088203).
• Disassemble the side airbag (088003).
• Clean the internal part of the side airbag’s housing.

Fig.1
• Apply glue to the upholstery on the internal part of the side airbag’s housing as shown in (Fig.2).
5HFRPPHQGHGJOXH:DNRO6SH]LDO:)1U
Fig.2
1
L714 08 82 01
• Apply upholstery glue onto the edge of the covering out of place as shown in (Fig.3).
• Wait for the glue to dry slightly and then secure the leather edge to the frame, pulling the covering as much as
possible so that it does not have any wrinkles (Fig.4).
• Reassemble the side airbag .
• Reassemble the seatback panel .
• Reassemble the seat in the passenger compartment .
Fig.3
Fig.4
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L714 08 82 03
A) Headrest
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• Remove the seat from the passenger compartment 3XQWR1. A
• Remove the seatback cover 3XQWR+.
• Remove the side airbag (088003).
A A
'LVDVVHPEOLQJWKHKHDGUHVW
1. Unhook the rear fasteners ($)LJ) of the seatback’s covering from the frame.
2. Inserting a 5 mm Allen wrench into the slots on the seatback’s padding ()LJ), unscrew the four screws, two
on each side, that secure the headrest to the frame and remove the headrest.
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• Remove the headrest 3XQWR$.
A A
'LVDVVHPEOLQJWKHVHDWEDFNSDGGLQJ
1. Unhook the fasteners ($)LJ) of the seatback’s covering from the seat’s frame.
2. Lift up the upper edge of the covering (%)LJ) and the padding (&)LJ) in order to access the screws that
secure the handle bezel (')LJ).
)LJ
3. Remove the two screws (')LJ) that secure the handle bezel to the frame and remove it.
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L714 08 82 03
4. Remove the screws (()LJ) that secure the triangular LH and RH guards to the seat and remove both
guards.
5. Detach the seatback covering from the side airbag housing.
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Cars with VIN < 1916: The seatback covering in the side airbag area is glued to the airbag’s housing. Be
careful not to tear it during removal. (
Cars with VIN >= 1916: The seatback covering in the side airbag area is secured by means of slots and tabs.
To remove it, raise the tabs and remove the covering.
6. Remove the seatback covering, starting from the back and pulling toward the front.
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The covering is attached to the padding with Velcro. The part of the Velcro attached to the padding (with
)LJ
glue or staples) can easily become detached. Remove the covering slowly while holding the Velcro part
attached to the padding in place.
7. Remove the seatback’s padding by pulling it upward.
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• Remove the seat from the passenger compartment 3XQWR1. ' A
'LVDVVHPEOLQJWKHDGMXVWPHQWGHYLFH
1. Set the seat on the seatback to facilitate disassembly.
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2. Remove the connector of the longitudinal adjustment motor ($)LJ).
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3. Using an external battery, activate the seat’s longitudinal adjustment motor and move the rails toward the rear
part of the seat until the hole (')LJ) on the rail integral with the chassis (()LJ) provides access to the front
bolt (%)LJ) that secures the part of the rail integral with the seat ())LJ) to the seat’s frame (&)LJ).
4. Unscrew the front attachment bolt of the rail on the adjustment motor side.
5. Activate the motor in the opposite direction to expose the rear attachment bolt.
6. Unscrew the rear attachment bolt of the rail on the adjustment motor side.
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7. Without extracting the rail from the motion bar (%)LJ), free the motor from the frame by unscrewing the bolt
($)LJ).
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8. Rotate the motor 90° ()LJ). C
Important!
The adjustment motor contains a worm. A
In order to not damage the adjustment motor’s mechanism, URWDWHLWZLWKWKHPRWLRQEDUwithout forcing
the motor’s mechanism.
9. Extract the rail on the adjustment motor side (&)LJ). %

10. Remove the adjustment motor from the motion bar (')LJ).
11. Disassemble the motion bar (%)LJ) from the rail on the seatbelt buckle side. )LJ
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• Remove the seat from the passenger compartment.
• Remove the power seat control panel, if present.
• Remove the seat cushion padding.
A
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1. Remove the triangular guard on the seatbelt buckle side by unscrewing the screws ($)LJ) that attach it to the
seat.
2. Disassemble the seatback from the seat by unscrewing the bolts (%)LJ) that secure it to the cushion frame.
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Important!
After the seatback is disassembled, it will remain connected to the rest of the seat through the wiring
harness.
Be careful not to damage it during these operations.
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3. Detach the side covering’s fasteners from the seat’s frame:

• three fasteners inside the cushion (')LJ)
• one fastener on the outside of the cushion (&)LJ)
• one fastener on the back of the side (()LJ)
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4. Remove the side’s covering.
5. Remove the side’s padding.
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• Remove the seat from the passenger compartment 3XQWR1. '
• Remove the side airbag (088003). %
• Remove the seatback padding 3XQWR%. A
'LVDVVHPEOLQJWKHFRQWUROGHYLFH C
1. Detach the connector ($)LJ) of the lumbar support control device’s motor (%)LJ).
2. Pull the deformable part (&)LJ) of the lumbar support control device toward the seatbelt buckle side to
unhook its fasteners ()LJ) from the frame and remove it:
)LJ
If necessary, use a screwdriver as a lever.
3. Remove the two rivets (')LJ) that secure the lumbar support control device’s motor to the frame and
remove the motor using a drill with a 4 - 4.5 mm bit.
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1. Remove the triangular guard on the outer side of the seat by loosening the screws ($)LJ) that secure it to
the seat.
2. Remove the screws (%)LJ) that secure the seat controls to the frame.
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3. Unhook the seat control panel by pushing it upward to detach it from the clamps (()LJ).
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4. Detach the control unit by unscrewing the 3 screws (&)LJ).
5. Disconnect the wiring harness (')LJ).
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1. Set the seat on the seatback.
2. Detach the connector of the seat height adjustment motor ($)LJ). %
3. To facilitate the disassembly operations, manually place the seat at maximum height, activating the adjustment
motor with an external battery.
4. Disconnect the motor by unscrewing the 3 bolts (%)LJ) that secure it to the frame.
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1. Lightly force the seatback’s cover off, if necessary using a plastic tool as a lever and remove the 5 fasteners
($)LJ) that secure the cover to the seat’s frame.
2. Unhook the cover’s lower fastener (%)LJ), which secures it to the seat’s frame, and remove the cover.
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• Remove the seat from the passenger compartment 3XQWR1.
• Remove the seatback cover 3XQWR+. %
• Remove the seatback padding 3XQWR%. A
C
'LVDVVHPEOLQJWKHFRQWUROGHYLFH )LJ
1. Remove the connector ($)LJ) of the seatback inclination control motor (%)LJ).
2. Remove the screw (&)LJ) that secures the motor to the seatback frame using a 7[WRUTXHZUHQFK
3. Remove the clip (airbag side) (')LJ) and extract the motion bar (()LJ) from the other side; the motor
remains inside. '
4. Remove the motor.
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1. Unhook the front fasteners ($)LJ) and the rear fasteners (%)LJ) of the seat cushion’s covering from the A
seat’s frame.
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For the passenger’s side seat:
2. Partially free the seat’s cushion by pulling the front part upward.
3. Open up the Velcro on the covering on the rear of the seat (&)LJ) in order to expose where the seat is
inserted into the attachment rings of the infant car seat.
4. Very carefully, remove the rear edges of the covering and then the seat cushion’s padding (')LJ) from the %
car seat attachment rings (()LJ).
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5. Remove the seat cushion.
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For the driver’s side seat:
6. Completely remove the seat cushion.
7. Unhook the staples under the seat cushion that secure the covering to the padding.
8. Remove the padding starting from the back and proceeding toward the front (Fig.24).
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The covering is attached to the padding with Velcro (F-Fig.24). The part of the Velcro attached to the
padding (with glue or staples) can easily become detached. )
Remove the covering slowly while holding the Velcro part attached to the padding in place.
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• Remove the seat from the passenger compartment 3XQWR1.
Remove the seatback cover 3XQWR+.
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• Remove the headrest 3XQWR$. '
• Remove the seatback padding 3XQWR%.
• Remove the deformable part of the lumbar support control device 3XQWR(. %
• Remove the seatback inclination control motor 3XQWR,. )
'LVDVVHPEOLQJWKHVHDWFXVKLRQSDGGLQJ
1. Pull the handle to tilt the seatback ($)LJ) in order to access the locking device (%)LJ). (
2. Slightly loosen the tension of the tightening cables (&)LJ) and unhook the eyes (')LJ) from the anchoring )LJ
pins (()LJ).
Important!
The anchoring pins are equipped with a snap ring ())LJ) that holds the cable in place when it is tightened.
The cable unhooks without extracting the snap ring from the anchoring pin by removing the cable’s eye from
the pin at the point in which the eye’s shape is wider.
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3. Cut the clamps that secure the sheaths of the frame attachment cables (center of seatback) and free the upper
part (*)LJ) and lower part (+)LJ) of the sheath from the frame, by detaching the snap-in fasteners.
)LJ
16
L714 08 82 03
4. Remove the pin (,)LJ) that secures the handle unit to the frame.
5. Pulling the cables, free the handle unit ()LJ) from its housing and remove the bracket (/)LJ) that locks
the cable in place from the handle (0)LJ), if necessary using a screwdriver as a lever.
6. Free the cable from the bracket (/)LJ), widening the tabs with a screwdriver.
I
7. Free the tightening cables on the handle side from the frame by unscrewing the 2.5 mm Allen screw (1)LJ)
on each side and disassembling the plate (2)LJDQG7HÀRQSXOOH\3)LJ). Then extract the cable from
the seatback’s frame.
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1. Unscrew the screws ($)LJ) securing the 2 seat rails (%)LJ) to the bottom of the car (2 screws per rail). C
2. Disconnect the 3 wiring harnesses under the seat:

• red harness (&)LJ)
• yellow harness (')LJ) (
• black harness (()LJ)
3. Detach the fastener that secures the black wiring harness to the seat.
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4. Remove the seat.
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1. Carefully insert the brackets that secure the headrest into the seatback’s padding so that the holes correspond
with the holes on the frame.
Important!
• 8VLQJ\RXU¿QJHUVEHFDUHIXOQRWWRUXLQWKHVHDWEDFN¶VFRYHULQJDQGSDGGLQJGXULQJLQVHUWLRQ
• Do not insert the screws until the holes are perfectly aligned: Check proper insertion through the slots A
RQWKHVHDWEDFN¶VSDGGLQJDQGH[WHUQDOO\E\ORRNLQJWKURXJKWKHLQVSHFWLRQKROHDVZHOORQWKHXSSHU
part of the side airbag’s housing.
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secure a screw on one side without tightening and then lightly push on the headrest so that the screw
of the other bracket can be inserted.
2. Secure the headrest to the seatback’s frame using the 4 5-mm Allen screws.
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3. Arrange the leather inside the mouth where the headrest is inserted into the seat.
4. 6HFXUHWKHVHDWEDFN¶VOHDWKHUWRWKHIUDPHXVLQJWKHUHODWLYHIDVWHQHUV$)LJ).
• Reassemble the side airbag (088005).

• 5HDVVHPEOHWKHVHDWFRYHU3XQWR+.
• Reassemble the seat in the passenger compartment 3XQWR1.
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1. &DUHIXOO\DUUDQJHWKHSDGGLQJRQWKHVHDWEDFN¶VIUDPHHVSHFLDOO\WKHVLGHDLUEDJPRGXOHDUHD
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0DNHVXUHWKDWWKHSDUWZLWKWKH9HOFURLQWHJUDOZLWKWKHSDGGLQJLVZHOOVHFXUHG,IQHFHVVDU\IDVWHQLWWR
the padding again using upholstery glue or staples. A
2. $UUDQJH WKH FRYHULQJ RQ WKH SDGGLQJ E\ ¿UVW VHFXULQJ WKH ORZHU VWULS RI 9HOFUR DQG WKHQ WKH UHPDLQLQJ WZR
XSZDUG$)LJPDNLQJVXUHWKDWWKH\SHUIHFWO\FRLQFLGHE\DSSURSULDWHO\SXOOLQJRQWKHFRYHULQJ
3. 7XUQWKHFRYHULQJLQVLGHRXWWRFRYHUWKHVHDWEDFN)LJ).
4. 3XOODQGVPRRWKRXWWKHFRYHULQJWRSHUIHFWO\DGDSWLWWRWKHSDGGLQJ7KHFRYHULQJPXVWQRWFRQWDLQFUHDVHVRU
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wrinkles. The seams must be perfectly aligned with the edges of the padding.
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Cars with VIN < 1916: JOXHWKHFRYHULQJWRWKHIUDPH)LJ).
Cars with VIN >= 1916:LQVHUWWKHVORWV$)LJRIWKHFRYHULQJRQWRWKHPHWDOWDEVRQWKHIUDPH%)LJ).
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3RVLWLRQWKHKDQGOHEH]HODQGVHFXUHLWE\WLJKWHQLQJWKHWZRVFUHZV$)LJ).
7. ,QVHUWWKHFRYHULQJ¶VIDVWHQHUVRQWRWKHUHDUSDUWRIWKHIUDPH
8. 5HDVVHPEOHWKHVHDWEDFNSDQHO%)LJ).
9. 5HDVVHPEOHWKHVHDW¶VJXDUGVE\WLJKWHQLQJWKHWZRVFUHZVRQHDFKVLGH%)LJ).
• Install the headrest 3XQWR$.

• ,QVWDOOWKHVHDWEDFNFRYHU3XQWR+.
• Reassemble the seat in the passenger compartment 3XQWR1. A
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1. Position the motion bar.
2. ,QVHUWWKHPRWRURQWRWKHPRWLRQEDULQSRVLWLRQ$)LJ). ) I
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0DNHVXUHWKDWWKHVHDW¶VUDLOVDUHDOLJQHG$OLJQPHQWLVQHFHVVDU\ZKLOHDVVHPEOLQJWKHVHDWLQWKHYHKLFOH '
,IWKH\DUHQRWDOLJQHGPDQXDOO\DOLJQWKHUDLORQWKHDGMXVWPHQWPRWRUVLGHZLWKWKHUDLORQWKHVHDWEHOW
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buckle side.
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3. Insert the seat rail into the motion bar.
4. 5RWDWHWKHPRWRUWRJHWKHUZLWKWKHPRWLRQEDU%)LJ) in the opposite direction as regards disassembly.
5. $IWHUWKHPRWRULVLQSRVLWLRQORFNLWLQWRSODFHZLWKWKHEROW')LJ).
7LJKWHQWKHUHDUEROW&)LJ) that secures the seat rail to the seat frame. A
7. 8VLQJDQH[WHUQDOEDWWHU\DFWLYDWHWKHVHDW¶VORQJLWXGLQDODGMXVWPHQWPRWRUDQGPRYHWKHUDLOVWRZDUGWKHIURQW
SDUWRIWKHFDUXQWLOWKHKROH))LJRQWKHUDLOLQWHJUDOZLWKWKHFKDVVLV*)LJSURYLGHVDFFHVVWRWKHIURQW
EROWWKDWVHFXUHVWKHSDUWRIWKHUDLOLQWHJUDOZLWKWKHVHDW+)LJWRWKHVHDW¶VIUDPH()LJ).
8. Tighten the front bolt that secures the seat rail to the seat frame.
9. $WWDFKWKHFRQQHFWRURIWKHVHDW¶VORQJLWXGLQDODGMXVWPHQWPRWRU,)LJ). C
10. Reassemble the seat in the passenger compartment 3XQWR1.

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1. Position the padding of the sides on the frame.
2. &RYHUWKHSDGGLQJDJDLQZLWKWKHFRYHULQJDQGLQVHUWWKHIDVWHQHUV$)LJ).
3. 3XOODQGVPRRWKRXWWKHFRYHULQJWRSHUIHFWO\DGDSWLWWRWKHSDGGLQJ
7KHFRYHULQJPXVWQRWFRQWDLQFUHDVHVRUZULQNOHV
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4. 5HDVVHPEOHWKHVHDWEDFNRQWRWKHVHDWXVLQJWKHEROWV%)LJ) that secure it to the cushion frame.
5. Reassemble the seat cushion padding.
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seat.

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2. 3RVLWLRQWKHGHIRUPDEOHSDUWRIWKHOXPEDUVXSSRUWFRQWUROGHYLFHRQWKHVHDWEDFNIUDPH¶VVWULSVDQGORFNLWLQWR
place by pressing it.
3. 3XVKWKHGHIRUPDEOHSDUWGRZQZDUGSODFLQJLWLQFRQWDFWZLWKWKHWUDQVYHUVDOVWRSURG$)LJ).
4. Attach the connector to the motor.
• Reassemble the seatback padding 3XQWR%.

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2. $VVHPEOHWKHFRQWUROXQLWXVLQJWKHVFUHZV%)LJ).
3. 3RVLWLRQWKHVHDWFRQWUROVE\ORFNLQJWKHPLQWRSODFHZLWKWKHFODPSV&)LJ).
4. $WWDFKWKHVHDWFRQWUROVWRWKHIUDPHXVLQJWKHVFUHZV')LJ).

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5. 5HDVVHPEOHWKHWULDQJXODUJXDUGRQWKHRXWHUVLGHRIWKHVHDWXVLQJWKHVFUHZV()LJ) that secure it to the
seat. '

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Important!
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1. 6HFXUHWKHERWWRPRIWKHFRYHUWRWKHVHDW¶VIUDPHXVLQJWKHUHODWLYHIDVWHQHU$)LJ). A

2. 6HFXUHWKHFRYHUWRWKHVHDWEDFNE\LQVHUWLQJWKHSLQV%)LJDQGSUHVVLQJWKHFRYHUZKHUHWKHSLQVDUH
located until they are completely inserted.
• Reassemble the seat in the passenger compartment.

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1. ,QVHUWWKHPRWLRQEDURQWKHVHDWEHOWEXFNOHVLGHDSSUR[LPDWHO\FP
Important!
7KHPRWLRQEDUKDVDVSHFLDOVKDSH)LJ) that makes insertion into the hole possible only one way.
2. ,QVHUWWKHVHDWEDFNFRQWUROPRWRURQWRWKHPRWLRQEDU$)LJ).
3. ,QVHUWWKHEDUXQWLOLWHQWHUVWKHKROHDWWKHRWKHUHQGRIWKHVHDWDLUEDJVLGHDQGORFNLWLQWRSODFHZLWKWKH )LJ

clip.
4. 3RVLWLRQWKHPRWRUQHDUWKHEUDFNHW%)LJDQGVHFXUHLWWRWKHVHDWEDFN¶VIUDPHXVLQJWKHVFUHZ')LJ

SODFLQJWKHUXEEHUVHDOVLQEHWZHHQ&)LJ).
5. 7LJKWHQWKHVFUHZ')LJ) using a 7[torque wrench.
Attach the connector to the control motor’s wiring harness.
• Reassemble the seatback padding 3XQWR%.

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• Reassemble the side airbag (088005). '
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fasten it to the padding again using upholstery glue or staples.
1. $UUDQJHWKHFRYHULQJRQWKHSDGGLQJE\¿UVWVHFXULQJWKHIURQWVWULSRI9HOFUR%)LJ) and then the remaining

WZRWRZDUGWKHVHDWEDFNPDNLQJVXUHWKDWWKH\SHUIHFWO\FRLQFLGHE\DSSURSULDWHO\SXOOLQJRQWKHFRYHULQJ
2. 7XUQWKHIURQWSDUWRIWKHFRYHULQJLQVLGHRXWWRZUDSLWDURXQGWKHVHDWFXVKLRQ %
3. 8VLQJXSKROVWHU\JOXHRUVWDSOHVVHFXUHWKHFRYHULQJ¶VVLGHHGJHVXQGHUWKHSDGGLQJ)LJ). A
4. 3XOODQGVPRRWKRXWWKHFRYHULQJWRSHUIHFWO\DGDSWLWWRWKHSDGGLQJ7KHFRYHULQJPXVWQRWFRQWDLQFUHDVHVRU
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wrinkles.
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5. 3DUWLDOO\SRVLWLRQWKHVHDWFXVKLRQRQWKHIUDPH5HSRVLWLRQWKHUHDUHGJHVRIWKHSDGGLQJ&)LJ) and then

WKRVHRIWKHFRYHULQJLQWKHFDUVHDW¶VDQFKRULQJULQJV)LJ). '
Fully position the seat cushion from the front.
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7. &ORVHWKHFRYHULQJRYHUWKHULQJV)LJXVLQJWKHSURYLGHG9HOFUR')LJ).
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9. Fully position the seat cushion from the front.
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KRXVLQJ%)LJ).
2. $VVHPEOHWKH7HÀRQSXOOH\&)LJDQGWKHSODWH')LJWLJKWHQLQJWKH2.5 mm Allen screw ()LJ).
3. Assemble the handle unit by inserting the bracket that holds the tightening cable in place into the handle and A
WKHQDIWHUWKHFDEOHLVLQVHUWHGORFNLWLQWRSODFHE\SLQFKLQJWKHWZRWDEVZLWKDSOLHUV)LJ).
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5. Secure the handle to the seatback’s frame using the pin and lock it into place with the snap ring. (
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L714 08 82 05
,QVHUWWKHFDEOHRQWRWKHORZHUVLGH)LJ).
7. /RFNWKHVKHDWKRQWKHKDQGOHVLGHDQGWKHORZHUVLGHLQWRSODFHZLWKWKHVQDSLQIDVWHQHUVLIQHFHVVDU\XVLQJ
DVFUHZGULYHUDVDOHYHU
Important!
$IWHUDVVHPEO\WKHFDEOHPXVWQRWKDYHDQ\LUUHJXODUFXUYHV
8. 8VLQJDVFUHZGULYHUDVDOHYHURQWKHVHDWEDFNORFNLQJGHYLFHDWWDFKWKHH\HWKDWKRRNVWKHFDEOHRQWRLWV
anchoring pin.
Important!
+RRNWKHFDEOHRQWRWKHSLQZLWKRXWUHPRYLQJWKHVQDSULQJORFDWHGRQWKHODWWHUEXWUDWKHUXVLQJWKHVORWLQ
the cable itself.
)LJ
9. Secure the handle to the seatback frame using the pin.
10. 6HFXUHWKHVKHDWKVRIWKHFDEOHVWRWKHIUDPHE\DSSO\LQJWZRFODPSVDWWKHMRLQWRIHDFKVKHDWK
• Assemble the seatback inclination control motor 3XQWR,.

• $VVHPEOHWKHGHIRUPDEOHSDUWRIWKHOXPEDUVXSSRUWFRQWUROGHYLFH3XQWR(.
• Assemble the seatback padding 3XQWR%.
• Assemble the side airbag (088005).
• Assemble the seat in the passenger compartment 3XQWR1.
18
L714 08 82 05
1$66(0%/,1*7+(6($7
A
1. Position the seat in the passenger compartment.
2. Connect the 3 wiring harnesses under the seat:

• UHGKDUQHVV$)LJ) C
• \HOORZKDUQHVV%)LJ)
• EODFNKDUQHVV&)LJ)
3. 6HFXUHWKHEODFNZLULQJKDUQHVVWRWKHVHDWXVLQJWKH¿QQHGDQFKRU
'
4. 6HFXUHWKHVHDWWRWKHFDUÀRRUXVLQJWKHVFUHZV')LJVFUHZVSHUUDLO
:KHQDWWDFKLQJLQVHUWWKHVKLPEHWZHHQWKHVHDWUDLODQGWKHFDUÀRRU
%
)LJ )LJ
19
L714 08 83 00
(;7(51$/3$,17
0< 3DLQWFRORU 7\SH &RORUFRGH

From MY ‘08 Bianco Monocerus Pastello LY9C
From MY ‘08 Grigio Thalasso Metallic LX7W
From MY ‘08 Grigio Lynx Metallic LZ7S
From MY ‘06 Rosso Leto Metallic LZ3F
From MY ‘06 Nero Serapis Perlato LZ9Y
FromMY ‘06 Celeste Phoebe Pastello LR5D
From MY ‘06 Grigio Proteus Metallic LX7Z
From MY ‘06 Blu Fontus Perlato LZ5D
From MY ‘06 Verde Faunus Perlato LZ6E
From MY ‘06 Verde Picus Pastello LL6J
From MY ‘04 Giallo Midas 3-layer Perlato L0G1
From MY ‘04 Arancio Borealis 3-layer Perlato LOE2
From MY ‘04 Blu Caelum Metallic LY5Q
From MY ‘04 Giallo Halys Pastello LY1K
From MY ‘04 Grigio Altair Metallic LY7W
From MY ‘04 Nero Noctis (uni) Pastello LY9B
From MY ‘04 Bianco Cygnus Pastello LY9H
To MY ‘05 Rosso Metis Metallic LY3W
To MY ‘05 Nero Osyris Perlato LZ9W
To MY ‘05 Arancio Ymir Pastello LY2F
Random sample Verde Ithaca 3-layer Perlato 0077
Random sample Ballon White 3-layer Perlato 224009
Random sample Grigio Telesto Perlato 0098
1
L714 08 83 00
+RZWRREWDLQH[WHUQDOSDLQWIRUPXODV
1. Go to www.ppg.com
2. Click on Industrial.
3. Click on PPG OEM Coating.
4. &OLFNRQ$XWRPRWLYH5H¿QLVK
5. Select the geographical area on the map.
6. Select Products and Services for Body from the menu.
7. Click on Color Reproduction Systems.
8. &OLFNRQ$FFHVVRQOLQHFRORUUHJLVWHUE\HQWHULQJ\RXUHPDLODQG¿OOLQJLQWKHUHTXLUHG¿HOGVDQGDFFHSWWKH

conditions.
9. Select Auto Manufacturers and search using the Lamborghini window.
10. Enter the Lamborghini color code (indicated in the attached tables) or the name of the color in the description
¿HOG
11. After specifying the color code, click on Search.
12. Click on the color’s line.
13. Select the product lines; two painting systems normally appear: one solvent-based (DELTRON) and one water-
based (ENVIROBASE).
14. Click on the color’s line.
15. ,IWKHFDUUHTXLUHVDPXOWLOD\HUSDLQWLQJF\FOHWKHFRORUIRUPXODVIRUHDFKOD\HUDUHOLVWHG
2
L714 09 00 00
Technical data
(OHFWULFDOV\VWHP
Type 12V negative to ground
Recharging system Alternator and voltage regulator
Battery 12V – 100Ah – 410A DIN / 480 CEI /800 EN
Current rate with engine off and switch deactivated 20 mA
Spark plugs BOSCH F5KPP332
Distance between electrodes 0.75 ÷ 0.8 mm
1
L714 09 00 01
(OHFWULFDOV\VWHPFKHFN
&KHFNWKHHOHFWULFDOV\VWHPRQWKHFDUIXQFWLRQVFRUUHFWO\RQDUHJXODUEDVLV
In particular, ensure the following devices function:
• Lights: headlamps, number plate lights, brake lights, rear reverse light, interior lights, parking lights and indicator
lights.
In the case of any malfunctions, carry out the necessary procedures (094102-094103-094303-094503-094703-

• Interior systems: horn, electric starter, ignition and interference suppression system, electric contacts, central
ORFNLQJZLQGVFUHHQZLSHUVFDUKL¿V\VWHPFKRNHHOHFWULFYHQWLODWLRQV\VWHPHOHFWULFZLQGRZV
In the case of any malfunctions, carry out the necessary procedures (095103-090103-090503-092702-092703-

• Wiring harnesses and fuses

In the case of any malfunctions, carry out the necessary procedures (097303).
• Battery
In the case of any malfunctions, carry out the necessary procedures (091501-091503).
1
L714 09 01 00
Technical data
Starter
Type BOSCH
Rated voltage 12 V
Current rate with load 190 A (11.3 V)
Current rate with no load 40 A
1RWH
For information concerning the control units layout, pin-out, electrical connections and wiring diagrams see
Wiring Diagrams.
1
L714 09 01 03
• Disassemble the steering wheel cover (087503). A
C
'LVDVVHPEOLQJWKHLJQLWLRQNH\DVVHPEO\
1. Disconnect the ignition key assembly connection (A-Fig.1).
2. Using a hammer and chisel remove the 2 antitheft bolts (B-Fig.2) securing the ignition key assembly to the
steering column.
3. Remove the ignition key assembly (C-Fig.1).
Fig.1
Fig.2
1
L714 09 01 05
$VVHPEOLQJWKHLJQLWLRQNH\DVVHPEO\
A
1. Using a 13 mm wrench, tighten the 2 new mounting screws (A-Fig.1) of the ignition key assembly (B-Fig.2) until
the nut breaks off.
2. Connect the ignition key assembly connection (C-Fig.2).
• Assemble the steering wheel cover (087505).
Fig.1
C
B
Fig.2
1
L714 09 03 00
Technical data
Alternator
Type BOSCH 077 903 015P

Rated voltage 14V
Rated current 190A at 6,000 rpm
Integral electronic voltage regulator
1
L714 09 03 01
$OWHUQDWRUFKHFN
A pilot lamp on the control panel controls whether the alternator is functioning correctly. The pilot
lamp only lights up if there is a malfunction.
+RZHYHULWLVDGYLVDEOHWRUHJXODUO\FKHFNWKHDOWHUQDWRULVIXQFWLRQLQJFRUUHFWO\XVLQJWKHWHVWHU
• DFFHVVWKHDOWHUQDWRU3UHOLPLQDU\RSHUDWLRQV
• SRVLWLRQ WKH WHVWHU HOHFWURGHV EHWZHHQ WKH SRVLWLYH DQG QHJDWLYH SROHV ZKLOH WKH HQJLQH LV
idling
• HQVXUHWKHDOWHUQDWRULVLVVXLQJWKHFRUUHFWYDOXH
If the alternator pilot lamp lights up or the tester readings are incorrect, carry out the necessary procedures to repair
or replace the alternator .
1
L714 09 03 03
$'LVDVVHPEOLQJWKHDOWHUQDWRUEHOW
%'LVDVVHPEOLQJWKHDOWHUQDWRU
%'LVDVVHPEOLQJWKHDOWHUQDWRUEHOWWHQVLRQHU
''LVDVVHPEOLQJWKHGDPSHU
1
L714 09 03 03
$'LVDVVHPEOLQJWKHDOWHUQDWRUEHOW
• 'LVDVVHPEOHWKHUHDUÀDWÀRRU(082503).
'LVDVVHPEOLQJWKHDOWHUQDWRUEHOW A
Important!
Carry out this procedure when the engine is at ambient temperature.
%
1. Lower the automatic belt tensioner using a lever ($)LJ).
2. Remove the belt (%)LJ).
)LJ
2
L714 09 03 03
%'LVDVVHPEOLQJWKHDOWHUQDWRU
A
• Empty the engine coolant tank (012107).
• Disassemble the alternator belt 32,17$.
)LJ
'LVDVVHPEOLQJWKHDOWHUQDWRU %
Important!
C
1. /RRVHQWKHFRROLQJV\VWHPSLSHVXSSRUWE\ORRVHQLQJWKHFRUUHVSRQGLQJ¿[LQJVFUHZ$)LJ).
2. 2SHQWKHVKXQWER[%)LJ) and disconnect the negative cable from the battery (&)LJ).
Important!
&DUU\RXWWKHGLVDVVHPEO\SURFHGXUHYHU\FDUHIXOO\WRDYRLGFDXVLQJVKRUWFLUFXLWV
)LJ
7RHQVXUHRSHUDWRUVDIHW\FORVHXSWKHSRVLWLYHEDWWHU\FDEOHVKXQWER[
3. Disconnect the connector (')LJ) from the alternator. (

'
4. 'LVFRQQHFWWKHH[FLWDWLRQFDEOH()LJ).
)LJ
3
L714 09 03 03
5. Loosen the catch (*)LJ¿[LQJVFUHZ))LJ) on the two cooling pipes. H
Disconnect the two alternator cooling pipes (+)LJ).
) G
)LJ
7. Loosen the two screws (,)LJ) securing the alternator to the engine.
8. Remove the alternator (-)LJ).

J I
)LJ
4
L714 09 03 03
&'LVDVVHPEOLQJWKHDOWHUQDWRUEHOWWHQVLRQHU A
• Empty the engine coolant tank (012107).
• Disassemble the alternator belt 32,17$. %
• Disassemble the alternator 32,17%.
)LJ
'LVDVVHPEOLQJWKHEHOWWHQVLRQHU
Important!
1. Loosen the four screws ($)LJ) securing the alternator support (%)LJ) to the engine.
'
2. Loosen the screw (&)LJ) securing the alternator support (')LJ) to the belt tensioner.
)LJ
3. Loosen the screw (()LJ) securing the belt tensioner ())LJ) to the engine.
)
4. Remove the belt tensioner ())LJ).
)LJ
5
L714 09 03 03
''LVDVVHPEOLQJWKHGDPSHU
• Disassemble the alternator belt 32,17$.
'LVDVVHPEOLQJWKHGDPSHU
Important!
1. /RRVHQWKHVL[VFUHZV$)LJ) securing the damper (%)LJ) to the engine.

%
2. Remove the damper (%)LJ). A
)LJ

L714 09 03 05
TKLVVHFWLRQH[SODLQVKRZWRFDUU\RXWWKHIROORZLQJDVVHPEO\SURFHGXUHV
A) Assembling the alternator belt tensioner

%$VVHPEOLQJWKHDOWHUQDWRU
C) Assembling the alternator belt
'$VVHPEOLQJWKHGDPSHU
1
L714 09 03 05
A) Assembling the alternator belt tensioner

%
1. Position the belt tensioner ($)LJ).
2. Tighten the screw (%)LJ) securing the belt tensioner ($)LJ) to the engine.
3. Tighten the screw (&)LJ) securing the alternator support (')LJ) to the belt tensioner.
)LJ
4. Tighten the four screws (()LJ) securing the alternator support ())LJ) to the engine.
• Assemble the alternator 32,17%.

• Assemble the alternator belt 32,17&.
• Fill the engine coolant tank (012108).
'
)LJ
)LJ
2
L714 09 03 05
A %
%$VVHPEOLQJWKHDOWHUQDWRU
1. Position the alternator ($)LJ).
2. Tighten the two screws (%)LJ) securing the alternator to the engine.
)LJ
C
3. Connect the two alternator cooling pipes (&)LJ).
4. Tighten catch (()LJ¿[LQJVFUHZ')LJ) on the two cooling pipes.
' (
)LJ
3
L714 09 03 05
5. &RQQHFWWKHH[FLWDWLRQFDEOH))LJ).
Connect the connector (*)LJ) to the alternator.

)
G
)LJ
7. 2SHQWKHVKXQWER[+)LJ) and connect the negative cable to the battery (,)LJ). H
,PSRUWDQW
&DUU\RXWWKHDVVHPEO\SURFHGXUHYHU\FDUHIXOO\WRDYRLGFDXVLQJVKRUWFLUFXLWV ,
)LJ
8. )DVWHQWKHFRROLQJV\VWHPSLSHVXSSRUWE\WLJKWHQLQJWKHFRUUHVSRQGLQJ¿[LQJVFUHZ-)LJ).

• Fill the engine coolant tank (012108).
J
)LJ
4
L714 09 03 05
C) Assembling the alternator belt A
1. Lower the automatic belt tensioner using a lever ($)LJ).
2. Insert the belt (%)LJ).

%
Tension is automatically adjusted by an automatic spring-loaded adjuster.
)LJ
5
L714 09 03 05
'$VVHPEOLQJWKHGDPSHU
1. Position the damper ($)LJ).
2. 7LJKWHQWKHVL[VFUHZV%)LJ) securing the damper ($)LJ) to the engine.

A
%
)LJ

L714 09 05 03
$/HIWF\OLQGHUEDQNFRLOV
%5LJKWF\OLQGHUEDQNFRLOV
&5HPRYLQJWKHVSDUNSOXJV
$ 'LVDVVHPEOLQJWKHOHIWF\OLQGHUEDQNFRLOV
• Remove the left side panel in the engine compartment (081303).
'LVDVVHPEOLQJWKHFRLOV
1. Disengage the wiring harness from the engine by loosening the 2 screws (A-Fig.1). A
2. Disconnect the fuel pipe (B-Fig.2) using two wrenches in order to prevent damage. Fig.1
Fig.2
1
L714 09 05 03
3. Disconnect the actuator connector (C-Fig. 3).

' C
4. Disconnect the solenoid valve power supply connector (')LJ).
1RWH
Remove the 2 clamps that hold the connector cables together.
Fig.3
5. Disconnect the exhaust cam position sensor (()LJ).
Fig.4
2
L714 09 05 03
7. Disconnect the ground cable (F-Fig.5) by removing its screw.
Fig.5
G
8. Disconnect the 2 oil breather pipes (G-Fig.6).
Fig.6
9. Disconnect the wiring harness connector (H-Fig.7) and remove the 5 coils (I-Fig.7).
I
H
Fig.7
3
L714 09 05 03
% 'LVDVVHPEOLQJWKHULJKWF\OLQGHUEDQNFRLOV
• Remove the right side panel in the engine compartment (081303).
• Disengage the right engine injection control unit (098103).
• Remove the expansion tank (012103).
'LVDVVHPEOLQJWKHFRLOV
1. Disengage the wiring harness from the engine by loosening the 2 screws (A-Fig.9).
A
2. Disconnect the solenoid valve power supply connector (B-Fig.10).
Fig.9
Fig.10
4
L714 09 05 03
3. Disconnect the wiring harnesses (C-Fig.11) from the coils.

C
4. Remove the 5 coils (')LJ).
'
Fig.11
5
L714 09 05 03
& 'LVDVVHPEOLQJWKHVSDUNSOXJV
• Disassemble the left cylinder bank coils 3RLQW$.
• Disassemble the right cylinder bank coils 3XQWR%.
'LVDVVHPEOLQJWKHVSDUNSOXJV
For each spark plug:

1. Unscrew the spark plug (A-Fig.11) and remove it.
1RWH
Check the spark plug condition and, if necessary, replace it with a new one of the prescribed type; check
the distance between the electrodes.
A
7\SHRIVSDUNSOXJXVHG
Fig.12
6
L714 09 05 05
$6SDUNSOXJV
%/HIWF\OLQGHUEDQNFRLOV
&5LJKWF\OLQGHUEDQNFRLOV
$ $VVHPEOLQJWKHVSDUNSOXJV
For each spark plug:

1. Assemble the spark plug (A-Fig.1).
6SDUNSOXJDWWDFKPHQWWLJKWHQLQJWRUTXHE
1RWH
Check that the coil and contact between coil and spark plug are in good condition.
7\SHRIVSDUNSOXJXVHG
A
• Assemble the left cylinder bank coils 3RLQW%.
• Assemble the right cylinder bank coils 3XQWR&.
Fig.12
1
L714 09 05 05
% $VVHPEOLQJWKHOHIWF\OLQGHUEDQNFRLOV
%
1. Put the 5 coils (A-Fig.1) inside their seats.
2. Connect the wiring harness (%)LJ) to the coils.
Fig.1
Secure the wiring harness to the engine by tightening the 2 screws (&)LJ).
&
Fig.2
2
L714 09 05 05
4. Connect the ground cable (')LJ) by tightening its screw.
'
)LJ
5. Connect the actuator connector (()LJ).
6. Connect the solenoid valve power supply connector (F-Fig.4). ( F
1RWH
Bind the connector cables together using 2 clamps.
Fig.4
7. Connect the exhaust cam position sensor connector *)LJ.
Fig.5

L714 09 05 05
Connect the 2 oil breather pipes (H-Fig.6).

H
Fig.6
9. Connect the fuel pipe using two wrenches in order to prevent damage (I-Fig.7).
• $VVHPEOHWKHHQJLQHFRPSDUWPHQWOHIWVLGH¿QLVKLQJHOHPHQW.
• Connect the battery .
I
Fig.7
4
L714 09 05 05
& $VVHPEOLQJWKHULJKWF\OLQGHUEDQNFRLOV
%
1. Put the 5 coils ($)LJ) inside their seats.
2. Connect the wiring harness (%)LJ) to the coils.
)LJ
Secure the wiring harness to the engine by tightening the 2 screws (&)LJ).
&
Fig.9
5
L714 09 05 05
4. Connect the solenoid valve power supply connector (')LJ).
'
• Assemble the expansion tank .
• Secure the right engine injection control unit .
• $VVHPEOHWKHHQJLQHFRPSDUWPHQWULJKWVLGH¿QLVKLQJHOHPHQW.
'
Fig.10
6
L714 09 06 00
(1*,1(,1-(&7,21&21752/81,76
The two injection control units are identical to each other. They have the same software and hardware.
The system recognises the left and right cylinder banks by means of a ground pin on the engine wiring harness.
When writing the immobilizer system, the control unit that will operate as MASTER “01” (A-Fig.1) and the one that
will operate as SLAVE “11” (B-Fig.1DUHGH¿QHG
B
2QFHWKHZULWLQJSURFHGXUHLVFRPSOHWHGWKHFRQWUROXQLWVFDQQRORQJHUEHH[FKDQJHG
,QFDVHRIUHPRYDORUUHSODFHPHQWLWLVUHFRPPHQGHGWRPDUNWKHFRQWUROXQLWVLQRUGHUWRGLVWLQJXLVK
WKH0$67(5³ÍURPWKH6/$9(³´
([FKDQJLQJWKHFRQWUROXQLWVEHWZHHQRQHF\OLQGHUEDQNDQGWKHRWKHULVQRORQJHUDOORZHG
A
After the immobilizer system is set, you can place the control unit on another vehicle provided it is not locked in the
Fazit system. Once the control unit has been installed on another vehicle after the immobilizer has been set, it is
possible to repeat the exchange procedure only once more.
,IWKHFRQWUROXQLWLVPRYHGIURPRQHYHKLFOHWRDQRWKHUDQGLWKDVEHHQVHWDV6/$9(³´LWPXVW
UHPDLQ6/$9(³´LILWKDVEHHQVHWDV0$67(5³´LWPXVWUHPDLQ0$67(5³´
Use LaRa-AS to check and/or set the engine injection control units.
The MASTER is the control unit on cylinder bank 1 (1-5)

The SLAVE is the control unit on cylinder bank 2 (6-10) Fig.1
1
L714 09 11 03
Disassembling the starter
&$87,21
B
Always disconnect the battery before carrying out any operation on the starter (091500).
A
• 5HPRYHWKHUHDUFDUÀRRU (082503).
Disassembling the starter

1. Unscrew the nut under the cap (A-Fig.1).
2. Disconnect the connection (B-Fig.1).
3. Unscrew the 2 screws (C-Fig.1) securing the starter to the car.
4. Remove the starter (D-Fig.1).
C
Fig.1
1
L714 09 11 05
Assembling the starter
&$87,21
C
Always disconnect the battery before carrying out any operation on the starter (091500).
1. Secure the starter (A-Fig.1) to the engine using the 2 screws (B-Fig.1). D
2. Connect the connection (C-Fig.1).
3. Tighten the nut under the cap (D-Fig.1).
• $VVHPEOHWKHUHDUFDUÀRRU (082505).
• Connect the battery (091500).
B
Fig.1
1
L714 09 15 00
(PHUJHQF\VWDUWLQJZLWKDQH[WHUQDOEDWWHU\
If the engine does not start because the battery is dead, another car’s battery can be used with cables for emergency
starting.
&$87,21
• 1HYHUDWWHPSWWRMXPSVWDUWDFDUZLWKDIUR]HQEDWWHU\LWFRXOGEUHDNDQGFDXVHIXUWKHUGDPDJH
• 1HYHU XVH IDVW EDWWHU\ FKDUJHUV IRU HPHUJHQF\ VWDUWV 8VH RQO\ VHSDUDWH EDWWHULHV RU WKH VSHFLDO
DX[LOLDU\EDWWHU\
• )DLOXUHWRREVHUYHWKHSURFHGXUHVGHVFULEHGEHORZFDQOHDGWRLQMXU\RUGDPDJHGXHWRVSLOODJHRI
EDWWHU\DFLGRURYHUORDGLQJRIWKHYHKLFOH¶VHOHFWULFDOV\VWHPDOORIWKHFRQWUROXQLWVEHFRPHLUUHSDUDEO\
damaged beyond 17V).
• 1HYHUGLVFRQQHFWWKHV\VWHPEDWWHU\ZKHQWKHHQJLQHLVUXQQLQJ
• 'RQRWVWDUWWKHHQJLQHEHIRUHFRQQHFWLQJWKHEDWWHU\
A
1RWH
The battery should be replaced if its voltage is below 10V.
Fig.1
• Switch off all lights and any other electrical device in the car.
• Remove the panel in the luggage compartment (A-Fig.1).
• Remove the battery’s positive pole (RED) guard.
For the negative pole, secure the clamp onto the lock.
,PSRUWDQW
• Use an external battery with an identical voltage (12 Volt) and electrical cables with a section of at least
25 mm2 and isolated terminals.
• $OZD\VGLVFRQQHFWWKHJURXQGFDEOH¿UVWIURPWKHEDWWHU\¶VQHJDWLYHWHUPLQDOZKHQGLVFRQQHFWLQJWKH
battery from the system.
• Before connecting the battery to the system make sure that the latter is well insulated.
• Wrong polarization of the electronic control units power supply voltage (for example wrong battery
polarization) can cause breakage.
1
L714 09 15 00
&RQQHFWWKHSRVLWLYHSROHVWRWKHSRVLWLYHFDEOHUHG
• Secure one end to the positive pole of the dead battery (A-Fig.2). - +
• Secure the other end to the positive pole of the supply battery (%)LJ).
&RQQHFWWKHQHJDWLYHSROHVWRWKHQHJDWLYHFDEOHEODFN
• Secure one end to the negative pole of the supply battery (%)LJ).
• Secure the other end to the negative pole of the supply battery (A-Fig.2).
Starting the engine
• Start the engine of the car that is supplying the current and let it idle.
• Start the engine of the car with the dead battery. %
A
1RWH
The battery’s low voltage could require resynchronization of the ignition key before starting. In this case, turn
the key to ON and hold the LOCK/UNLOCK buttons down for approximately 30 seconds.
Fig.2
• If the engine does not start immediately, stop starting after 10 seconds and repeat after approximately 30
seconds.
• Leave the engine on and remove the cables in the opposite order described previously (remove the ground
FRQQHFWLRQ¿UVWDQGWKHQWKHSRVLWLYH
• Carry out the following operations:
Resynchronization of second remote control
Resynchronization of steering angle
Resynchronization of power window zero position
2
L714 09 15 01
0HDVXULQJWKHYROWDJH
The battery’s charge can be roughly determined by measuring the voltage at the ends of its terminals.
Important!
The battery must be at an ambient temperature of approximately 20°C and must not have been used for at
least 1 hour.
• Disconnect all of the battery’s users (some of these cannot be disconnected but their consumption is so low that
it will not affect the measurement).
• Remove the internal panel from the luggage compartment and uncover the positive terminal.
• Using a voltmeter (digital, if possible), measure the voltage between the positive and a sure ground connection Fig.1
such as the front luggage compartment’s lock. Evaluate the battery’s charge using the following table:
Voltage (V) 12.91 12.80 12.66 12.52 12.38 12.06 12.06 11.90 11.70 11.42
Charge (%) 99 90 80 70 60 50 40 30 20 10
The battery must be replaced if below 11 V.
1
L714 09 15 01
&KHFNLQJWKHHOHFWURO\WH
7KHEDWWHU\¶VFKDUJHPD\EHGHWHUPLQHGE\FDOFXODWLQJWKHVSHFL¿FGHQVLW\RIWKHHOHFWURO\WH
• Ensure that all of the battery’s loads have been disconnected.

• Remove the front luggage compartment tray to access the battery.
• Open the battery’s upper tray.
• Ensure that the electrolyte level covers the elements of each cell. If one or more elements are partially uncovered,
top up with distilled water.
• Using a water gauge (Fig.2FKHFNWKHVSHFL¿FGHQVLW\RIWKHHOHFWURO\WHRIHDFKFHOOEDVHGRQWKHIROORZLQJ

table, valid if the battery’s temperature is 20° (68°F):
%DXPpRU%pGHJUHHV

Fig.2
'HQVLW\
&KDUJH 0D[LPXP +LJK 'HDG
1RWH
7KHVSHFL¿FGHQVLW\YDULHVFRQVLGHUDEO\GHSHQGLQJRQWKHWHPSHUDWXUHLIWKHEDWWHU\¶VWHPSHUDWXUHLVQRW
20°C, the read value must be corrected using the chart (Fig.3).
Fig.3
2
L714 09 15 01
Important!
Check that the battery is completely charged (if necessary recharge it with a battery charger) and disconnect C
all of the car’s loads (radio, lights, A/C, etc.), except for those necessary for engine operation.
• Lift the vehicle on the car lift and connect a voltmeter and a 150A or higher ammeter clamp onto the alternator’s
%
output cable:
A
Voltmeter “V” and ammeter clamp “A” connection (Fig.4)
A. Battery
Fig.4
% Junction
C. Starter
• Start the engine and bring it to 2,000 rpm.
• Using the voltmeter, check that the voltage generated by the alternator falls within the values in the chart
(Fig.5).
• Using the ammeter clamp, check that the alternator supplies current. This current might initially be very high
(100A at 2,000 rpm) but then gradually decreases as the battery recharges. The current depends on the engine’s
speed (Fig.6).
Fig.5
,IDQRPDOLHVRFFXUFDUU\RXWWKHH[WUDRUGLQDU\PDLQWHQDQFHRSHUDWLRQVUHSRUWHGEHORZ
Fig.6
3
L714 09 15 01
([WUDRUGLQDU\PDLQWHQDQFH
,IWKHYROWDJHLVKLJKHUWKDQQRUPDO
• Remove the alternator (A-Fig.7) and check the voltage regulator, brushes and diodes unit.
Fig.7
4
L714 09 15 03
Disassembling the battery
1RWH
Turn off the instrument cluster and remove the key from the ignition.
Disassembling the battery

1. Disconnect the 2 terminals (A-Fig.1) from the battery.
2. Unscrew the 2 screws (B-Fig.1) that secure the bracket that locks the battery (C-Fig.1) in place.
3. Remove the battery (D-Fig.1).
A B C D A
Fig.1
1
L714 09 15 05
Assembling the battery
1. Position the battery and secure the bracket (A-Fig.1) using the 2 screws (B-Fig.1).
2. Connect the 2 terminals (C-Fig.1) to the battery (D-Fig.1).
C B A D C
Fig.1
1
L714 09 19 03
USA
&$1$'$
'LVDVVHPEOLQJWKHIURQWVLGHPDUNHU
• Raise the car on the car lift (000000). A
• Disassemble the front stone guard .
'LVDVVHPEOLQJWKHVLGHPDUNHU
1. Unscrew the 2 screws ($)LJ) securing the front side marker. %
Disconnect the side marker’s bulb (%)LJ). A
3. Remove the side marker (&)LJ).
)LJ
C
)LJ
1
L714 09 19 05
USA
&$1$'$
$VVHPEOLQJWKHIURQWVLGHPDUNHU
1. Secure the side marker ($)LJ) to the front bumper using the 2 screws (%)LJ).
Connect the side marker’s bulb (&)LJ).
• Assemble the front stone guard .

A
)LJ
C
%
)LJ
1
L714 09 20 03
USA
&$1$'$
'LVDVVHPEOLQJWKHUHDUVLGHPDUNHU
• Remove the 2 rear wheels (060103).
• Disassemble the 2 rear stone guards (082103).
'LVDVVHPEOLQJWKHVLGHPDUNHU
1. Unscrew the 2 screws ($)LJ) securing each side marker to the rear bumper.
2. Disconnect the connection (%)LJ).
3. Remove the rear side marker (&)LJ). A
%
A
)LJ
)LJ
1
L714 09 20 05
USA
&$1$'$
$VVHPEOLQJWKHUHDUVLGHPDUNHU
1. Position the 2 side markers ($)LJ) in their housings on the rear bumper and secure them using the 2 screws
(%)LJ) for each side marker.
2. Connect the connection (&)LJ).
• Assemble the 2 rear stone guards (082105).

• Assemble the 2 rear wheels (060105).
)LJ
%
C
%
)LJ
1
L714 09 27 02
$GMXVWLQJWKHEUDNHSHGDO6:,7&+
A
When the switch has been removed (192703), it is possible to increase or decrease the number of trips made by the
piston (A-Fig.1) (to get the lights to switch on earlier, increase the piston trips by pulling it outwards from the switch;
vice versa, to delay the lights switching on, reduce the piston trips by pressing it inwards towards the switch).
Fig.1
1
L714 09 27 03
%UDNHSHGDO6:,7&+GLVDVVHPEO\
• Remove the plastic covers on the pedals.
B
Switch disassembly
1. Disconnect the switch connector (A-Fig.1).
2. Turn the switch (B-Fig.1) anticlockwise and extract.
Fig.1
1
L714 09 27 05
%UDNHSHGDO6:,7&+DVVHPEO\
1. Pull the switch shaft (A-Fig.1) out 7 clicks.

2. Lock the switch in place using the safety clip on the back of the switch. B
3. Insert the switch into the housing on the pedal cluster (pointed part of the tip down (B-Fig.2ÀDWSDUWRIWKHWLS
up (C-Fig.2)).
4. Turn the switch clockwise and lock it into place (2 clicks).
5. Connect the connector (E-Fig.1) to the switch (D-Fig.1).
• Assemble the plastic covers on the pedals.

• Adjust the switch (092702).
D E
Fig.1
Fig.2
1
L714 09 41 01
+HDGODPSVGLUHFWLRQFKHFN
A
7KHGLUHFWLRQRIWKHKHDGOLJKWVLVFKHFNHGXVLQJDVSHFLDOWRRO$)LJ
Direct the headlights using the following procedure:
• Position the tool against the front tires.
• Extract the rod and place it at the height of the front headlights.
• Directly adjust the angle of the headlights (094102), referring to the direction indicated by the tool.
Fig.1
1
L714 09 41 02
Front combination lights adjustment
7KHIURQWFRPELQDWLRQOLJKWVHDFKKDYHDÀH[LEOHUHJLVWHUDQGDQDGMXVWPHQWGHYLFHLQVWDOOHGLQVLGHWKHDVVHPEO\
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(DFKFOXVWHUKDVRQHKLJKORZEHDPODPSWKHEHDP¶VDQJOHLVFKDQJHGE\DSRZHUUHÀHFWLQJEDIÀHSODWHLQVLGHWKH
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A
5HI 'HVFULSWLRQ $GMXVWPHQW
$)LJ /RZKLJKEHDPKHDGOLJKWKRUL]RQWDODGMXVWPHQW 7XUQLQJWKHOLJKWFORFNZLVHWRZDUGWKHLQVLGH
%)LJ /RZKLJKEHDPKHDGOLJKWYHUWLFDODGMXVWPHQW 7XUQLQJWKHOLJKWFORFNZLVHGRZQZDUG

Fig.1
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WKHZKHHODUFK
B
Fig.2
1
L714 09 41 03
$'LVDVVHPEOLQJWKHIURQWOLJKWV
%'LVDVVHPEOLQJWKHKHDGOLJKWQR]]OH
&'LVDVVHPEOLQJWKHOLJKWEXOEV
1
L714 09 41 03
$'LVDVVHPEOLQJWKHIURQWOLJKWV
• Remove the front wheels (060103). %
• Remove the side lock covers (080603).
C
A
'LVDVVHPEOLQJWKHIURQWOLJKWV
1. Remove the 4 screws ($)LJ) that secures the combination lights.
2. Remove the side bracket (%)LJ) by unscrewing the 2 screws (&)LJ).
)LJ
)LJ
2
L714 09 41 03
3. Disconnect the connection (')LJ).

)
4. Detach the headlight washer pump pipe (()LJ).
5. Remove the front lights ())LJ).
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OLJKWVPXVWEHKDQGOHGZLWKFDUH'DQJHURIGHDWK
$YRLGWRXFKLQJWKHKDORJHQEXOEVZLWK\RXUKDQGVDVWKLVUHGXFHVWKHLUHI¿FLHQF\,IFRQWDFWZLWK
KDQGVRFFXUVFOHDQWKHEXOEWKRURXJKO\ZLWKDOFRKRO
3
L714 09 41 03
%) 'LVDVVHPEOLQJWKHKHDGOLJKWQR]]OH A
3UHOLPLQDU\RSHUDWLRQV % %
• Remove the side upholstery covers (080603). C
• Disassemble the front lights (point A).
'LVDVVHPEOLQJWKHQR]]OH
1. 5HOHDVHWKHSODVWLFFRYHUÀDS$)LJ.
2. Loosen the 2 screws %)LJ securing the nozzle to the combination light.
3. Remove the nozzle &)LJ.
4. Raise the tab ()LJ to extract and remove the nozzle tip ')LJ.
'
)LJ
4
L714 09 41 03
&'LVDVVHPEOLQJWKHbulbs
a b
c
Ref. 'HVFULSWLRQ 3URFHGXUH
A. low / high beam headlights a. Turn the cover counter-clockwise and remove it (a)LJ).
b. Turn the bulb mounting (b)LJ) counter-clockwise and release
from its holder and remove it.
c. Disconnect the connection (c)LJ).
A
% Indicator light a. Turn the bulb mounting ring nut anticlockwise, release from
its holder and remove.
c. Remove the bulb
)LJ
5
L714 09 41 05
A) Assembling the front lights
%$VVHPEOLQJWKHKHDGOLJKWQR]]OH
C) Assembling the light bulbs
1
L714 09 41 05
A) Assembling the front lights

C
1. Connect the connection ($)LJ).
2. Connect the headlight washer pump pipe (%)LJ1).
3. Position the combination lights (&)LJ).
A %
)LJ
2
L714 09 41 05
4. Secure the bracket (')LJ) onto the car using the 2 screws (()LJ).
5. Tighten the 4 screws ())LJ3) that secure the combination lights. )
'
• Assemble the side lock covers (080605).

• Assemble the front wheel arches (082105). (
)
• Adjust the front lights (094102).
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OLJKWVPXVWEHKDQGOHGZLWKFDUH'DQJHURIGHDWK
$YRLGWRXFKLQJWKHKDORJHQEXOEVZLWK\RXUKDQGVDVWKLVUHGXFHVWKHLUHI¿FLHQF\,IFRQWDFWZLWK
KDQGVRFFXUVFOHDQWKHEXOEWKRURXJKO\ZLWKDOFRKRO
)LJ
3
L714 09 41 05
%) $VVHPEOLQJWKHKHDGOLJKWQR]]OH
1. Position the nozzle tip ($)LJ) on the stem (%)LJ).
2. Position the nozzle (&)LJ) on the combination light.
3. $WWDFKWKHSODVWLFFRYHUÀDS')LJ). %
4. Tighten the 2 screws (()LJ) securing the nozzle to the combination light. A
)LJ
• Assemble the front lights (Point A).
• Assemble the side upholstery covers (080605).
'
• Assemble the front wheel arches (082105).
( (
)LJ
4
L714 09 41 05
C) Assembling the bulbs

b c
a
Ref. 'HVFULSWLRQ 3URFHGXUH
A. low / high beam headlights a. Connect the connection (D)LJ).

b. Position the bulb mounting (E)LJ) inside its holder and turn it
clockwise.
c. Fasten the cover by turning it clockwise (F)LJ).
A
% Indicator light a. Assemble the lamp.
b. Attach the lamp mounting ring nut onto its holder and turn it
clockwise to lock it into place
)LJ
5
L714 09 43 03
Disassembling the license plate light

B B
1. Prize up the edge of the license plate light (A-Fig.1) to release it from the housing.
2. Disconnect the 2 connections (B-Fig.1).
3. Remove the license plate light
To remove the bulb (C-Fig.1) unhook it from the side clips (D-Fig.1).
D A C D
Fig.1
1
L714 09 43 05
Assembling the license plate light

C C
To assemble the bulb (A-Fig.1) secure it to the side clips (B-Fig.1).
1. Connect the 2 connections (C-Fig.1).
2. Snap the license plate light (D-Fig.1) into the housing.
B D A B
Fig.1
1
L714 09 45 03
',6$66(0%/,1*7+(5($5&20%,1$7,21/,*+76
• Disassemble the rear wheel arch element of the rear wheel arch (082103).
• Remove the rear grid (081303).
• Remove the rear wheels (060103). A
• Disassemble the stone guard (082103).
A
'LVDVVHPEOLQJWKHUHDUFRPELQDWLRQOLJKWV
1. Unscrew the 4 screws (A-Fig.1) at the rear of the combination lights.
2. Disconnect the connection/s (B-Fig.2):

Fig.1
• 1 connection for European version
• 2 connections for USA version

B
C
3. Remove the rear combination lights (C-Fig.2).
Fig.2
1
L714 09 45 03
To disassemble the light support bracket with the heatproof guard:

'
• Disassemble the rear bumper (080703).
• Disassemble the rear combination lights.
'LVDVVHPEOLQJWKHVXSSRUW (
7. Loosen the 4 screws (()LJ) to remove the frame .(')LJ).
8. Unscrew the lower screw (F-Fig.3).
9. Unscrew the 2 top bolts (*-Fig.3).
10. Extract the light support bracket with the heat-proof guard (+)LJ).
7KHOLJKWVXSSRUWEUDFNHWZLWKWKHKHDWSURRIJXDUGLVVHFXUHGDWWKHERWWRPZLWKWKHVFUHZ(L-Fig.3)
VKDUHGZLWKWKHFRPELQDWLRQOLJKWVWKLVVFUHZZDVDOUHDG\UHPRYHGZKHQWKHFRPELQDWLRQOLJKWV
were disassembled).
L * F
Fig.3
2
L714 09 45 03
'LVDVVHPEOLQJWKHWKLUGEUDNHOLJKW
1. Release the two covers using a screwdriver (A-Fig.4).
2. Unscrew the 2 screws (B-Fig.5) securing the third brake light to the spoiler.
A A
3. Disconnect the connection.
4. Remove the third brake light.
Fig.4
B B
Fig.5
3
L714 09 45 03
'LVDVVHPEOLQJWKHUHDUIRJOLJKW
3UHOLPLQDU\RSHUDWLRQV B
• Disassemble the rear bumper (080703).
'LVDVVHPEOLQJWKHUHDUIRJOLJKW
1. Unscrew the 5 screws (A-Fig.6).
2. Remove the rear fog light unit (B-Fig.6).
A Fig.6
4
L714 09 45 03
',6$66(0%/,1*7+(BULBS
5HI 'HVFULSWLRQ 3URFHGXUH

C C C C C
A. %UDNHDQGSDUNLQJOLJKW D 3XVKGRZQRQWKHORFNLQJ¿QVDQGUHPRYHWKHODPSKROGHU B
unit.
b. Pull back the connector locking catch. A A A
c. Press down on the connector base and remove the lamp.
B. Reverse light a. Turn the bulb mounting ring nut anticlockwise, release from
c. Remove the bulb.
B C C C C C
C. Indicator light a. Turn the bulb mounting ring nut anticlockwise, release from
c. Remove the bulb.
A A A
b c
Fig.7
5
L714 09 45 03
5HI 'HVFULSWLRQ 3URFHGXUH
' Third brake light a. Detach the 2 covers on the third brake light.
b. 8QVFUHZWKH¿[LQJVFUHZVRQWKHWKLUGEUDNHOLJKWXQGHU
the covers.
c. Disconnect the connection.
'
( Rear fog light a. Turn the bulb mounting ring nut anticlockwise, release from
b. Remove the bulb.
Fig.8
6
L714 09 45 05
$66(0%/,1*7+(5($5&20%,1$7,21/,*+76 A
To assemble the light support bracket with the heatproof guard
1. Position the light support bracket with the heat-proof guard (A-Fig.1).
2. Secure the 2 top bolts (B-Fig.1).
3. Secure the lower screw (C-Fig.1).
7. Tighten the 4 screws (E-Fig.1) to position the frame (D-Fig.1).
7KHOLJKWVXSSRUWEUDFNHWZLWKWKHKHDWSURRIJXDUGLVVHFXUHGDWWKHERWWRPZLWKWKHVFUHZ(F-Fig.1)
VKDUHGZLWKWKHFRPELQDWLRQOLJKWVthis screw must be secured after the rear combination lights
KDYHEHHQDVVHPEOHG F B C
• Assemble the rear bumper (080705).

• Assemble the stone guard (082105).
• Assemble the rear combination lights.
D
Fig.1
1
L714 09 45 05
Assembling the rear combination lights
1. Position the combination lights (*)LJ) and connect the connection/s (+)LJ):
• 1 connection for European version +
• 2 connections for USA version
2. Reset the 4 striker plates (L-Fig.3), screwing them in counter-clockwise.
3. Put the headlight into its seat and align it with the body. Fig.2
4. Put the 4 screws (M-Fig.4) in one at a time and tighten them by hand while paying attention that the combination
lights stay aligned with the body.
In this way the striker plates are correctly positioned.
L
5. Thoroughly tighten the 4 screws (M-Fig.4).
6. Check that alignment with the body is correct; if not, repeat the procedure from step 2.
L
Fig.3
• Assemble the rear grid (081305).

• Assemble the rear wheel arch element of the rear wheel arch (082105).
Fig.4
2
L714 09 45 05
$VVHPEOLQJWKHWKLUGEUDNHOLJKW
1. Connect the connector.

A A
2. Secure the third brake light to the spoiler using the 2 side screws (A-Fig.5). Fig.5
3. Snap in the two covers (B-Fig.6).
B B
Fig.6
3
L714 09 45 05
Assembling the rear fog light
1. Position the rear fog light unit (A-Fig.7). A
2. Secure the 5 screws (B-Fig.7).
• Assemble the rear bumper (080705).
B Fig.7
4
L714 09 45 05
',6$66(0%/,1*7+(BULBS
5HI Description 3URFHGXUH

C C C C C
A. Brake and parking light a. Connect the lamp to the connector. B
b. Lock the connector catch by pulling towards the base of the
lamp. A A A
c. Fit the lamp-holder unit in its housing.
B. Reverse light a. Assemble the lamp.

clockwise to lock it into place.
B C C C C C
C. Indicator light a. Assemble the lamp.
A A A
a b
Fig.8
5
L714 09 45 05
5HI Description 3URFHGXUH
D. Third brake light a. Connect the third brake light connection.

b. Secure the third brake light by tightening the 2 screws
under the covers.
c. Position the 2 covers on the third brake light.
D
E. Rear fog light a. Assemble the lamp.
Fig.9
6
L714 09 47 03
'LVDVVHPEOLQJWKHURRIODPS
1. Prize up the edge of the roof lamp to release the 4 clips (A-Fig.1) from their couplings.
2. Disconnect the 2 connections (B-Fig.1).
C
3. Remove the roof lamp (C-Fig.1).
A
A
Fig.1
1
L714 09 47 05
Assembling the roof lamp
1. Connect the 2 connections (A-Fig.1).

2. Press the 4 clips (C-Fig.1) of the roof lamp (B-Fig.1) into their couplings. B
C
C
Fig.1
1
L714 09 51 03
'LVDVVHPEOLQJWKHKRUQ
• Disassemble the front upholstery cover (080603).
A A
'LVDVVHPEOLQJWKHKRUQ B
1. Disconnect the connections (A-Fig.1).
2. Unscrew the screws (B-Fig.1) securing the horns to the chassis.
3. Remove the horns (C-Fig.1).
C
Fig.1
1
L714 09 51 05
Assembling the horn
1. Tighten the horn (A-Fig.1) onto the chassis using the screw (B-Fig.1).
2. Reconnect the horn connection (C-Fig.1).
• Assemble the front upholstery cover (080603). C C

B
A
Fig.1
1
L714 09 53 03
• Disassemble the front stone guard (082103). A
• Disassemble the front bumper (080703).
'LVDVVHPEOLQJWKHIURQWWXUQVLJQDO
1. Unscrew the 2 screws (A-Fig.1) securing the front turn signal. B
2. Disconnect the turn signal’s bulb (B-Fig.1). A
3. Remove the turn signal (C-Fig.2).
Fig.1
C
Fig.2
1
L714 09 53 05
Assembling the front turn signal

1. Secure the front turn signal (A-Fig.1) to the front bumper using the 2 mounting screws (B-Fig.2).
2. Connect the turn signal’s bulb (C-Fig.2).
• Assemble the front bumper (080705).

• Assemble the front stone guard (082105).
• Assemble the front wheel (060105).
A
Fig.1
C
B
Fig.2
1
L714 09 55 03
7KLVVHFWLRQH[SODLQVKRZWR
$'LVDVVHPEOHWKHZLQGVKLHOGZLSHUDUPV
%'LVDVVHPEOHWKHZLQGVKLHOGZLSHUPHFKDQLVP
&'LVDVVHPEOHWKHZLQGVKLHOGZLSHUPRWRU
''LVDVVHPEOHWKHZLQGVKLHOGZLSHUZDVKHUVROXWLRQUHVHUYRLU
1
L714 09 55 03
A) How to disassemble the windshield wiper arms
How to disassemble the windshield wiper arms A A

1. Remove the screw caps ($)LJ).
2. Loosen the 3 screws securing the windshield wiper arms to the pin (%)LJ).
3. Disassemble the windshield wiper arms (&)LJ).
)LJ
C
%
%
)LJ
2
L714 09 55 03
%'LVDVVHPEOLQJWKHZLQGVKLHOGZLSHUPHFKDQLVP %
% %
• Disassemble the front stone guard (082103).
• Disassemble the rear lock cover (080603).
'LVDVVHPEOLQJWKHZLQGVKLHOGZLSHUPHFKDQLVP A
1. Disassemble the windshield wiper.
2. Disconnect the connector ($)LJ). )LJ
3. Unscrew the 3 screws (%)LJ) securing the windshield wiper mechanism at the top.
4. By means of the space created by the stone guard, remove the screw (&)LJ) at the bottom of the windshield
wiper mechanism. C
5. Remove the windshield wiper mechanism (')LJ) through the space created by the disassembled stone
guard.
'
)LJ
3
L714 09 55 03
C) 'LVDVVHPEOLQJWKHZLQGVKLHOGZLSHUPRWRU
• Disassemble the front stone guard (082103). A A
'LVDVVHPEOLQJWKHZLQGVKLHOGZLSHUPRWRU
1. Unscrew the 3 side screws ($)LJ) and the center screw (%)LJ) securing the windshield wiper motor to the
support bracket (&)LJ).
C
2. Remove the windshield wiper motor (')LJ) through the space created by the disassembled stone guard.
)LJ
'
)LJ
4
L714 09 55 03
C %
'+RZWRGLVDVVHPEOHWKHZLQGVKLHOGZLSHUZDVKHUVROXWLRQUHVHUYRLU
• Disassemble the upholstery covers (080603).
• Remove the air conveyor (026003). Left hand drive only. %
C
• Disassemble lifting system (040303) Left hand drive only.
• Disassemble the ABS control unit (061403). Right hand drive only. A
A
)LJ
+RZWRGLVDVVHPEOHWKHZLQGVKLHOGZLSHUZDVKHUVROXWLRQUHVHUYRLU
'
1. Empty the windshield wiper washer solution reservoir.
)
3RVLWLRQDVXLWDEOHFRQWDLQHUWRFROOHFWWKHZDVKHUVROXWLRQ
(
2. Loosen the 4 screws ($)LJ).
3. 'LVFRQQHFWWKH¿OOLQJSLSH%)LJ) from the windshield wiper washer solution reservoir by loosening the clamp
(&)LJ).
4. Disconnect the 3 connectors (')LJ).
5. Disconnect the pipes on the windshield wiper circuit (()LJ). )
6. Remove the reservoir ())LJ).
'
(
)LJ
5
L714 09 55 05
A) Assembling the windshield wiper arms

%$VVHPEOLQJWKHZLQGVKLHOGZLSHUPHFKDQLVP
C) Assembling the windshield wiper motor
'$VVHPEOLQJWKHZLQGVKLHOGZLSHUZDVKHUVROXWLRQUHVHUYRLU
1
L714 09 55 05
A) Assembling the windshield wiper arms

A
Assembling the windshield wiper arms A

%
%
1. Position the windshield wiper arms ($)LJ).
2. Tighten the 3 screws securing the windshield wiper arms to the pin (%)LJ).
)LJ
3. Insert the screw caps (&)LJ).
(QVXUHWKHZLQGVKLHOGZLSHUVDUHDGMXVWHGDVIROORZV
C
'ULYHUVLGHZLQGVKLHOGZLSHU FPFRPSDUHGWRWKHZLQGVKLHOG C
3DVVHQJHUVLGHZLQGVKLHOGZLSHU FPFRPSDUHGWRWKHZLQGVKLHOG
)LJ
2
L714 09 55 05
%$VVHPEOLQJWKHZLQGVKLHOGZLSHUPHFKDQLVP
1. Secure the windshield wiper mechanism ($)LJ) at the top using the 3 screws (%)LJ).
2. Connect the connector (&)LJ). '
3. Secure the mechanism at the bottom using the screw (')LJ).
4. Assemble the windshield wiper.
• Assemble the rear lock cover .

• Assemble the front stone guard .
A
)LJ
% %
)LJ
3
L714 09 55 05
C) Assembling the windshield wiper motor
1. Secure the windshield wiper motor ($)LJ) to the support bracket (%)LJ) using the 2 side screws (&)LJ)
and the center screw (')LJ).
• Assemble the front stone guard . A

)LJ
'
C C
)LJ
4
L714 09 55 05
A
'$VVHPEOLQJWKHZLQGVKLHOGZLSHUZDVKHUVROXWLRQUHVHUYRLU
C
1. Position the reservoir ($)LJ).
2. Connect the 3 connectors (%)LJ).
3. Connect the pipes on the windshield wiper circuit (&)LJ).
4. &RQQHFWWKH¿OOLQJSLSH')LJ) to the windshield wiper washer solution reservoir by fastening the clamp ((
)LJ). A
2. Tighten the 2 screws ())LJ).
%
)LOOWKHZLQGVKLHOGZLSHUZDVKHUVROXWLRQUHVHUYRLU C
• Assemble the air conveyor . Left hand drive only.

• Assemble lifting system Left hand drive only. )LJ
• Assemble the ABS control unit . Right hand drive only. /HIWKDQGGULYH 5LJKWKDQGGULYH
• Assemble the side upholstery covers . ( '
'
(
)
)
)LJ
5
L714 09 56 00
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The electronic control unit governs and activates the various airbag modules and is secured to the car’s tunnel under
the console (Fig.1).
The control unit is connected to:

• front airbags (driver side airbag module and passenger side airbag module)
• LH and RH side airbags
• LH and RH seatbelt pretensioners
• LH and RH side impact sensors
On the inside, the control unit has:
• an electromechanical sensor which discriminates the “activation/deactivation” conditions according to the
vehicle’s longitudinal deceleration;
• an electromagnetic safety sensor operating with the electromechanical sensor; both sensors must enable the
“activation” condition for the system to be deployed;
Fig.1
The electronic control unit analyzes the signals coming from the internal and external sensors (side impact) and,
based on appropriate strategies (which consider the impact’s force and angle), normally activates:
• In the case of frontal impact: the driver side airbag module, the passenger side airbag module and the two
seatbelt pretensioners.
• In the case of side impact: the side airbag and the seatbelt pretensioner on the side of the impact.
The control unit has a self-diagnostic feature that checks the entire system’s operation when the ignition key is turned
to “ON”. During the test a red warning light on the dashboard turns on. The warning light turns off approximately four
seconds after the engine is started if the system is working correctly.
1
L714 09 56 00
A. Control unit
% Front airbag activation sensor (' and ()
C. Safety sensor
% C
' Passenger side airbag
( Driver side airbag
F. Side impact sensor (not present on Superleggera model) ( '
G. Side airbag A
H. Seatbelt pretensioner
F F
G G
H H
Fig.3
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L714 09 56 03
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• Ensure that the system is deactivated by disconnecting the battery inside the front luggage compartment.
B
1. Remove the light push-button panel (BJA) (A-Fig.1) from its housing in the center console and disconnect the
connectors (B-Fig.1).
2. Prize up the tunnel control panel (C-Fig.2) and disconnect the relative connectors. A
3. Remove the bezel from the console.

Fig.1
Fig.2
1
L714 09 56 03
4. Remove the two lower socket head screws (')LJ) and release the two upper clips (()LJ). Extract the air
conditioner control unit.
(
5. Disconnect the air conditioner control unit connectors (F-Fig.4). '
6. The airbag control unit (G-Fig.5UHPDLQVRQWKHÀRRURIWKHFHQWHUFRQVROH,QVLGHWKHDLUFRQGLWLRQHUFRQWURO

unit compartment, remove the 3 screws that secure the airbag control unit.
7. Move the airbag control unit just enough to disconnect the connectors.
8. Remove the airbag control unit (G-Fig.5).
Fig.3
Fig.4
Fig.5
2
L714 09 56 05
Assembling the SDM control unit
0DNH VXUH WKDW WKH FRQWURO XQLW GRHV QRW SUHVHQW VLJQV RI ZHDU VFUDWFKHV RU RLO &KHFN WKDW QR A
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1. Insert the airbag control unit into the center console, checking that the car’s travel direction coincides with the
arrow on the control unit.
2. Connect the two connectors; the yellow-orange Siemens connector with the same one on the wiring harness,
properly rotating the tab to lock it in place. Fig.1
3. Properly position the control unit, checking that the wiring harness is not squeezed between the control unit and
its support.
4. Secure the control unit using the 3 retaining screws. C
5. Connect the connectors to the air conditioner control unit.
6. Insert the air conditioner control unit into the center console’s housing, hooking it at the top onto the two clips
(A-Fig.1). Secure the air conditioner control unit at the bottom using the two socket head screws (B-Fig.1). D
7. Snap the center console’s bezel in place.

Fig.2
8. Connect the connectors (C-Fig.2) of the light push-button panel (BJA) (D-Fig.2) and then insert it into the center
console’s housing.
9. Connect the connectors of the buttons of the tunnel control panel (E-Fig3) and then insert the panel.
E
• Reconnect the battery cables and then carry out the following operations:
• Use the LaRa system to program the air conditioner control unit (109000). Fig.3
1
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• 6'LVDVVHPEOLQJWKHIURQWUHDUDQGFHQWUHÀDWÀRRUV(082503).
• Disassembling the propeller shaft (030703).
• Disassembling the front differential (040903).
• Disassembling the luggage compartment tray (080603).
• Disassembling the battery (091503).
'LVDVVHPEOLQJWKHSRVLWLYHEDWWHU\FDEOHIURQWSDUW
1. Open the positive battery cable shunt box ($)LJ) located on the rear right part of the vehicle.
A
)LJ
2. Disconnect the positive battery cable (%)LJ) from the rear shunt box ($)LJ).
3. Remove the clamp (&)LJ) near the shunt box.
C %
)LJ
2
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4. 5HPRYHWKH¿YHULJLGFODPSV')LJ) securing the positive battery cable to the center console.
'
'
'
)LJ
3
L714 09 72 03
5. Loosen the screw (()LJ) on the fuse box (megafuse) cover ())LJ) inside the vehicle on the front right
wheel arch in the passenger compartment.
)LJ
6. To disconnect the connection in the fuse box (megafuse), unscrew a nut (*)LJ).
)LJ
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7. Remove the seal on the chassis (+)LJ) and remove the cable (,)LJ).
H
)LJ
5
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• 'LVDVVHPEOLQJWKHUHDUÀDWÀRRU(082503).
• Disassembling the aesthetic panels (Engine Bay) (081303).
• 'LVDVVHPEOLQJWKHDLU¿OWHU(013303).
'LVDVVHPEOLQJWKHSRVLWLYHEDWWHU\FDEOHUHDUSDUW
1. Open the positive battery cable shunt box ($)LJ) located on the rear right part of the vehicle.
)LJ
2. Disconnect the positive battery cable (%)LJ) from the rear shunt box ($)LJ).
)LJ
6
L714 09 72 03
3. Remove the two clamps (&)LJ) near the shunt box.
)LJ
4. Remove the two rigid clamps (')LJ) securing the positive battery cable to the chassis.
'
'
)LJ
7
L714 09 72 03
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5. Unscrew the nut ())LJ) securing the positive rear battery cable to the alternator (*)LJ).
)LJ
6. Disconnect the 3 clamps (+)LJ) securing the cable on the gearbox assembly (,)LJ).
)LJ
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7. Disconnect the connector (/)LJ) from the starter (1)LJ).
M
8. Unscrew the nut (0)LJ) securing the rear positive cable to the starter (1)LJ)
1
)LJ
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• Disassembling the luggage compartment tray (080603).
• Disconnect the battery (091500)
'LVDVVHPEOLQJWKHQHJDWLYHEDWWHU\FDEOH
1. Loosen the screw fastening the battery cable to the chassis ($)LJ).
)LJ
9
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1. Insert the positive battery cable ($)LJ) in the vehicle, near the front right wheel arch in the passenger
compartment and position the seal on the chassis (%)LJ).
)LJ
2. Connect the connection in the fuse box (megafuse) and tighten the nut (&)LJ)
)LJ
2
L714 09 72 05
3. Insert the cover on the fuse box (megafuse) (')LJ) and tighten the screw (()LJ)
'
)LJ
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4. 6HFXUHWKH¿YHULJLGFODPSV')LJ) to the center console.
'
'
'
)LJ
4
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5. Insert the clamp (()LJ) near the shunt box.
Connect the positive battery cable ())LJ) from the rear shunt box (*)LJ).
( )
)LJ
7. Close the positive battery cable shunt box (*)LJ).
• $VVHPEOHWKHIURQWUHDUDQGFHQWUHÀDWÀRRUV(082505).
• Assembling the propeller shaft (030705).
• Assemble the front differential (040905).
• Assemble the luggage compartment tray .
• Assemble the battery (091505).
)LJ
5
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C
$VVHPEOLQJWKHSRVLWLYHEDWWHU\FDEOHUHDUSDUW
1. Tighten the nut (B-Fig.7) securing the rear positive cable to the starter (C-Fig.7).
2. Connect the connector (A-Fig.7) to the starter (C-Fig.7).
)LJ
3. Insert 3 clamps (')LJ8) to secure the cable to the wiring harness on the gearbox assembly (()LJ8).
'
)LJ
4. Connect the positive rear battery cable to the alternator ())LJ9) and tighten the nut (*)LJ9).
) G
)LJ

L714 09 72 05
5. Assemble the two rigid clamps (+)LJ10) securing the positive battery cable to the chassis.
)LJ
. Insert the two clamps (,)LJ11) near the shunt box.
)LJ
7
L714 09 72 05
7. Connect the positive battery cable (/)LJ12) from the rear shunt box (0)LJ13).
)LJ
8. Close the shunt box (0)LJ13).
• $VVHPEOLQJWKHUHDUÀDWÀRRU(082505).
• $VVHPEOLQJWKHDLU¿OWHU(013305).
• Assembling the aesthetic panels (Engine Bay) (081305).
• Connect the battery (091500)
)LJ
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$VVHPEOLQJWKHQHJDWLYHEDWWHU\FDEOH
1. Tighten the screw fastening the battery cable to the chassi $)LJ
• Disassembling the luggage compartment tray .

)LJ
9
L714 09 73 00
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• Disconnect the ground cable from the battery’s negative terminal before removing electronic components.
• Always use adequate measuring equipment to carry out electrical measurements on electronic components.
• Make sure that electronic device cables (length, type of conductor, positioning, clamping, shielding continuity
where required, grounding, etc.) are correct for the system and carefully restored to the original condition after
service.
• Never insert or remove the connector from the electronic control units while powered.
• In case of temperatures over 80°C (drying ovens) remove the electronic control units.
• When making connections, tighten the connector nuts (temperature, pressure sensors, etc.) to the prescribed
torque (000800).
• Electronic control unit measuring at plugs, plug connections and electrical connections of components is to be
carried out only using the appropriate equipment. Never use improper tools such as metal wires, screwdrivers,
clips or suchlike. Besides the danger of short circuits, these methods could damage the plug connections and
subsequently cause contact problems.
5HOD\IXVHVXSSRUWSRVLWLRQV)LJ
1. Maxi fuse box
2. Main fuse box
3. Main relay box
4. Engine relay support
5. Engine fuse support
Fig.1
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L714 09 73 00
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3RV Value Function 3RZHU

1. 200 A Maxi fuse box 30
2. 50 A A/C Fan – Seat Heating 30
3. 80 A Water Radiator Fans 30
4. 50 A Key, ILM(Lights), +75 30
5.
6.
7. 50 A Main fuse box 30
8. 60 A ESP 30
9. 100 A Engine/Gearbox 30
10. - Power windows, seats, lifting 30
Fig.2
2
L714 09 73 00
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1. 30 A Lifting system 30 21. 5A Push-button panels 15
2. 15 A A/C system 30 22. 7.5 A A/C-Press.Sens. 15
3. 10 A GFA, CAN plug 30 23. 5A Homelink 15
4. 20 A +12V power outlet 30 24.
5. 20 A RNS-E 30 25. 5A SMLS 15
6. 26. 7.5 A GFA 15
Fig.3
Cigarette lighter 30 27 5 A TPMS
7. 20 A
(ONLY NAR) 15
8. 15 A Recirc. Pump, A/C solenoid valve 30 28. 5A Airbag 15
9. 15 A Rear spoiler 30 29. 7.5 A Central instruments, OBDII conn. 15
10. 20 A Horns 30 30. 5A Instrument Cluster (Kombi) 15
11. 30 A +75 75 31.
12. 20 A +75 (Windshield wiper) 75 32.
13. 10 A ECU ESP (30b) 30 33. 3A Heated nozzles 75
14. 34.
15. 25 A Vacuum pump 30 35.
16. 7,5 A Rear spoiler 15 36.
17. 25 A ECU ESP (30VR) 30 37. 5A Brake pedal switch 30
18. 38. 5A LIGHTS push-button panel 30
19. 15 A ECU ESP, Brake pedal switch 15 39. 5A SMLS 30
20. 40. 10 A Right Door Module 30
41. 10 A Left Door Module 30
42. 5A Instrument cluster, OBDII conn. 30
43. 10 A ZKE - Antitheft 30
44. 7.5 A RVC, TV, Bluetooth 30
3
L714 09 73 00
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Pos. Base Colour Code ID Number PR-Nr. Description

1.
2. Gray 141 951 253 B 53 Lifting system relay
3. Black 8Z0 951 253 395 Vacuum pump
3.1.
4. Black 8Z0 951 253 395 +75 relay
4.1. Black 8Z0 951 253 395 Horns relay
5.
6.
0$;,)86(
3RV Fuse carrier colour Value 351U 3RZHU

A Red 40 A ECU ESP 30
% Black 0A ENGINE 0
Fig.4
4
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Pos. Base Colour Code 351U ID Number 'HVFULSWLRQ

1. Blue 8K0 951 253 643 Main relay
2. Gray 8K0 951 253 643 Secondary air pump relay 2
3. Purple 8D0 951 253 A 373 +50_1 relay
4. Red 8D0 951 253 A 373 +50_2 relay
5.
6. Orange 8K0 951 253 643 Secondary air pump relay 1
7. Green 8K0 951 253 643 Engine relay
8. White 357 927 843 A +G1E 179 E-Gear (SCAM) oil pump
9.
0$;,)86(
Pos. Fuse carrier colour Value PR-Nr. 'HVFULSWLRQ Power

A Black 50 A Secondary air pump 1 30
B Brown 40 A Fuel pump supply 87 HR
C
D Red 50 A Secondary air pump 2 30
Fig.5
E
5
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)IXVHVEODFN

1.
2.
3. 15 A Engine Sol. Valve supply MOT_EKP
4.
5. 15 A Post-catalytic converter oxygen sensor 87 HR
6. 15 A Pre-catalytic converter oxygen sensor 87 HR QRWXVHG
7. 10 A Engine Solenoid Valve supply 87 HR
8. 30 A Coil supply 87 HR
9. 15 A Injector supply 87 HR
10. 5A Brake pedal switch, clutch sensor 87 HR
11. 5A Water radiator fans 87 HR
12.
.'IXVHVEODFN Fig.6

1. 10 A E-Gear (+G1E) 15
5A Reverse switch (+G0X)
2. 5A Engine Control Units 15
3. 5A WIV sensor (oil level) 15
4.
5.
6.
7. 5A Engine Control Units 30
8. 30 A E-Gear, oil pump 30
9. 25 A E-Gear 30
10.
11.
6
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% % A
• 5HPRYHWKHFDUKL¿V\VWHPORXGVSHDNHUJULG(086803).
'LVDVVHPEOLQJWKHFDUKL¿V\VWHPVLGHORXGVSHDNHUV
1. 'LVFRQQHFWWKHFRQQHFWRUV$)LJFRQQHFWHGWRWKHSRUWV%)LJRIWKHFDUKL¿V\VWHPORXGVSHDNHU
2. 8QVFUHZWKHVFUHZV&)LJVHFXULQJWKHFDUKL¿V\VWHPORXGVSHDNHUVWRWKHGRRU A
3. 5HPRYHWKHFDUKL¿V\VWHPORXGVSHDNHU')LJ).
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• 'LVDVVHPEOHWKH%-$SXVKEXWWRQSDQHO(086803). A A
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1. ,QVHUWWKHPXOWLPHGLDV\VWHPH[WUDFWLRQNH\VLQWRWKHVSHFLDO¿VVXUHV$)LJRQWKHIURQWSDQHO
2. ([WUDFWWKHPXOWLPHGLDV\VWHP%)LJ).
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• 5HOHDVHWKHVSRLOHU(082703).
• 'LVDVVHPEOHWKHWKLUGEUDNHOLJKW(094503).
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1. 5HOHDVHWKHFRYHUXVLQJDVFUHZGULYHU$)LJ).
2. 8QVFUHZWKHVFUHZV&)LJDQGUHOHDVHWKHFRYHU %)LJ).
3. 8QVFUHZWKHVFUHZV')LJVHFXULQJWKHEUDFNHWRQWRWKHVSRLOHU
4. 5HPRYHWKHFDPHUDXQLW
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5. 'LVFRQQHFWWKHWZRFRQQHFWRUV
6. 8QVFUHZWKHVFUHZV()LJ) DQGUHPRYHWKHFDPHUD.
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• 'LVDVVHPEOHWKH.RPELLQVWUXPHQWFOXVWHU(086803).
• 'LVDVVHPEOHWKHPXOWLPHGLDV\VWHP(097503).
'LVDVVHPEOLQJWKHDQWHQQDDQGDQWHQQDFDEOH
1. 'LVFRQQHFWWKHDQWHQQDFDEOHIURPWKHPXOWLPHGLDV\VWHP516(EOXHFRQQHFWRU)LJ).
)LJ
2. )UHHWKHDQWHQQDFDEOHIURPWKHFODPSVWKDWVHFXUHLWWRWKHGDVKERDUGZLULQJKDUQHVVDQGUHPRYHLWIURPWKH
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3. 8QVFUHZWKHQXW$)LJRQWKHSLQWKDWVHFXUHVWKHEUDFNHWRQWKHULJKWVLGHDQGUHPRYHWKHDQWHQQDFDEOH¶V

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4. 8QVFUHZWKHQXW&)LJDQGUHPRYHWKHDQWHQQD')LJIURPWKHEUDFNHW

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• 'LVDVVHPEOLQJWKHUHDUEHQFK(086803).
'LVDVVHPEOLQJWKH&'FKDQJHU
1. 'LVFRQQHFWWKHFRQQHFWRU$)LJIURPWKH&'FKDQJHU%)LJ).

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2. 3UHVVGRZQRQWKHIDVWHQLQJWDEVRQERWKVLGHV&)LJ).
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3. 5HPRYHWKH&'FKDQJHUIURPWKHFRUUHVSRQGLQJPRXQWLQJEUDFNHW')LJ).
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% % A
1. Connect the 2 connectors ($)LJ) to the 2 ports (%)LJ) on the loudspeaker.
2. Position the loudspeaker (&)LJ) and secure it to the door using the 3 screws (')LJ).

• $VVHPEOHWKHFDUKL¿V\VWHPORXGVSHDNHUJULG(086805).
' '
'
)LJ
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L714 09 75 05
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1. Connect the 3 wiring harnesses ($)LJ) and the 2 cables (%)LJ) in the rear ports of the multimedia
V\VWHP A
2. ,QVHUWWKHPXOWLPHGLDV\VWHP&)LJDQGVHFXUHLWLQSODFHXVLQJWKHNH\VWREHLQVHUWHGLQWRWKHVSHFLDO
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¿VVXUHV')LJ).
A
• Assemble the BJA push-button panel (086805).
% %
)LJ
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)LJ
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1. Secure the camera ($)LJ) onto the relative bracket using the two screws (%)LJ).
2. Connect the two connectors.
3. Positioning the camera unit and secure the relative bracket onto the spoiler using the two screws (&)LJ).
( ' (
)LJ
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L714 09 75 05
Position the support bracket as far to the rear of the car as possible, using the slot on the spoiler ()LJ).
)LJ
4. 3RVLWLRQWKHFRQWUROWHPSODWHRQWKHVFUHHQRIWKHPXOWLPHGLDV\VWHPWRYHULI\FRUUHFWSRVLWLRQLQJRIWKHFDPHUD
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5. Secure the cover (')LJ)XVLQJWKHVFUHZV()LJ).

6. Secure the cover ())LJ).
)LJ
• Fasten the third brake light (094505).

• Assemble the spoiler (082705).
5
L714 09 75 05
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• Disassemble the Kombi instrument cluster (086803).
• 'LVDVVHPEOHWKHPXOWLPHGLDV\VWHP(097503).
Assembling the antenna

1. Connect the antenna cable to the antenna ($)LJ).
)LJ
2. Secure the antenna onto the bracket (%)LJ) using the nut (&)LJ). C
)LJ
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L714 09 75 05
3. $VVHPEOHWKHEUDFNHWDQGDQWHQQDWRJHWKHURQWKHFURVVPHPEHUXVLQJ0ÀDQJHGQXWV')LJ).

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ULQJ()LJRQWRWKHSLQWKDWVHFXUHVWKHEUDFNHWRQWKHULJKWVLGH
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)LJ
4. Pass the antenna cable through, securing it with the clamps to the dashboard wiring harness, to the housing of
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5. &RQQHFWWKHDQWHQQDFDEOHWRWKHQHZPXOWLPHGLDV\VWHP516(EOXHFRQQHFWRU)LJ).
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• 5HDVVHPEOHWKH.RPELLQVWUXPHQWFOXVWHU(086805).
• $VVHPEOHWKHQHZPXOWLPHGLDV\VWHP3RLQW%.
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1. Place the CD changer ($)LJRQWKHVSHFL¿FPRXQWLQJEUDFNHW%)LJ).
2. Connect the connector (&)LJ) to the CD changer ($)LJ).
• Assemble the rear bench (086805).
)LJ
9
L714 09 81 00
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Location of front control units (Fig.1) F

A. ZKE control unit
B. ILM control unit
C. Main relay (C1) and fuse box (C2) B
D. GFA control unit G A
E. AIRBAG control unit C
F. Indicator switch
E D
G. TPMS control unit
C1 B
E
C2
D
Fig.1
1
L714 09 81 00
Location of rear control units (Fig.2) , H

H. Cylinder bank 1-5 engine injection control unit (MASTER)
, Cylinder bank 6-10 engine injection control unit (SLAVE)
L. E-gear control unit
M. Fuse box
1 Yaw sensor control unit
O. Bluetooth control unit
3 Fuel pump control unit
Q. CD loader
M L Q 1 O
M
L H
Q
1
O
,
Fig.2
2
L714 09 81 00
7306
7LUHSUHVVXUHFKHFN
B A D C E
7306FRPSRQHQWVOD\RXW)LJ
A. TPMS Control unit
B. Front antenna
C. Rear antenna
D. Front trigger
E. Rear trigger
D E
D
C
A B
Fig.3
3
L714 09 81 03
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& (JHDUFRQWUROXQLW
' %OXHWRRWKFRQWUROXQLW
( )XHOSXPSFRQWUROXQLW
) Yaw sensor control unit
* )XVHER[DQGUHOD\
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, *)$FRQWUROXQLW
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0 =.( control unit
1 0DLQIXVHER[
2 )URQWFRPELQDWLRQOLJKWVFRQWUROXQLW
3 Indicator switch
Q) Control unit support plate
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L714 09 81 03
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• Disassemble the engine compartment right side panels .
1RWH
Ensure that the ignition key is in the OFF position and disconnect the battery .
1. Unscrew the 2 bolts ($)LJ) securing the control unit and remove the bracket (%)LJ).
A C %
2. Extract the control unit (&)LJ).
3. Remove the 4 antitheft bolts (D-Fig.1) using a gripper.
4. Disconnect the two control unit connectors (()LJ).
. Remove the control unit.
'
(
'
)LJ
2
L714 09 81 03
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• Disassemble the engine compartment left side panels .
1RWH
1. Unscrew the 2 bolts ($)LJ) securing the control unit and remove the bracket (%)LJ).
2. Extract the control unit (&)LJ). A
3. Remove the 4 antitheft bolts (')LJ) using a gripper.
4. Disconnect the two control unit connectors (()LJ2).
. Remove the control unit.

%
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(
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)LJ
3
L714 09 81 03
C'LVDVVHPEOLQJWKH(JHDUFRQWUROXQLW
• Using the LaRa-AS system, identify the software version of the e-gear control unit that must be replaced and
make a note of it .
1RWH
The software version of the e-gear control unit and the engine control units must correspond.
If the e-gear control unit software version cannot be read, check the software version of the LIE control units
using the LDAS system and request the correct software version from the factory.
' %
• If possible, read the clutch data using the LaRa-AS system and make a note of it . C A
• Disassemble the bench .
1RWH
1. Disconnect the two connectors ($)LJ3) of the control unit (%)LJ3). )LJ
2. Unscrew the 2 bolts (&)LJ3) and remove the bracket (')LJ3).
3. Remove the control unit.
4
L714 09 81 03
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1RWH
1. Unscrew the 2 bolts ($)LJ).
A % C
2. Remove the bracket (%)LJ).
3. Disconnect the connector (&)LJ) of the control unit.
4. Remove the control unit (')LJ).
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)LJ

L714 09 81 03
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• Remove the fuse box and relay 3RLQW*. % %
• Remove the control unit support plate 3RLQW4.
• Empty the tank .
1RWH A
1. Detach the plate ($)LJE\XQVFUHZLQJWKH¿[LQJVFUHZV%)LJ).
2. Disconnect the 2 fuel tubes (&)LJ) so the control unit can be removed from its seat. C
3. Unscrew the 2 bolts (')LJ).

'
4. Remove the control unit (()LJ) pulling it by the connector.
Disconnect the connector ())LJ) of the control unit.
Remove the control unit. ) (
)LJ

L714 09 81 03
)'LVDVVHPEOLQJWKHyaw sensor control unit
1RWH
1. Unscrew the 2 bolts ($)LJ).
2. Disconnect the connector (%)LJ) of the control unit.

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3. Remove the control unit (&)LJ).
)LJ
7
L714 09 81 03
*'LVDVVHPEOLQJWKHIXVHER[DQGUHOD\
1RWH
'LVDVVHPEOLQJWKHIXVHER[DQGUHOD\
1. Unscrew the 2 bolts ($)LJ) that secure the relay bracket.
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2. Remove the relay bracket (%)LJ) and disconnect all the relays one by one.
1RWH
After the bracket relays have been removed, reconnect them to their connectors in order to prevent losing
their positions.
3. Disconnect the connectors (&)LJ).
4. Disconnect the cable (')LJ) by removing its screw (()LJ). A ' (
C
)LJ
8
L714 09 81 03
Svitare i 2 bulloni ())LJFKH¿VVDQRODVFDWRODIXVLELOL (*)LJ).
Scollegare il connettore e rimuovere la scatola fusibili.
)LJ
9
L714 09 81 03
+'LVDVVHPEOLQJWKHDLUEDJFRQWUROXQLW
• Disassemble the central tunnel .
1RWH
1. Disconnect the two control unit connectors ($)LJ).
2. Unscrew the 3 bolts (%)LJ) securing the control unit.
%
A
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)LJ
10
L714 09 81 03
,'LVDVVHPEOLQJWKHDLUEDJVHQVRUV
• Disassemble the front and centre side member covers .
1RWH
There are three airbag sensors in the vehicle: One inside the main airbag control unit and two in the side
members.
'LVDVVHPEOLQJWKHVHQVRUV
1. Disconnect the connector ($)LJ) from the side impact sensor (SIS) (%)LJ).
2. To remove the side impact sensor, loosen the screw (&)LJ¿[LQJLWWRWKHVLGHPHPEHU
3. Remove the sensor (%)LJ).
A %
)LJ
11
L714 09 81 03
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• Remove the passenger side footboard .
1RWH A
Ensure that the ignition key is in the OFF position and disconnect the battery . %
%
1. Disconnect the control unit connections ($)LJ).
2. Unscrew the 3 bolts (%)LJ) securing the control unit.
)LJ
12
L714 09 81 03
0'LVDVVHPEOLQJWKH,/0FRQWUROXQLW
A A
• Remove the passenger side footboard .
• Disassemble the passenger side lower dashboard assembly .
• Remove the main fuse box 3RLQW1.
• Remove the ZKE control unit 3RLQW0. %
1RWH
1. Remove the 4 relays ($)LJ) fitted on the control unit.
2. Disconnect the 3 control unit connections (%)LJ).

C
3. Unscrew the 3 bolts (&)LJ) securing the control unit support bracket.
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4. Remove the entire support, including bracket and control unit.
Unscrew the 2 bolts ($)LJ) securing the control unit. ' '
Remove the control unit (%)LJ).
C C
)LJ
13
L714 09 81 03
1'LVDVVHPEOLQJWKH=.(FRQWUROXQLW
• Disassemble the passenger side lower dashboard assembly . A A
1RWH
1. Unscrew the 3 bolts ($)LJ) securing the control unit support bracket.
)LJ
2. Remove the entire support, including bracket and control unit.

%
3. Disconnect the control unit connections (%)LJ).
4. Unscrew the 4 bolts (&)LJ) securing the control unit.
Remove the control unit (')LJ).
'
C C
)LJ
14
L714 09 81 03
2'HWDFKLQJWKHPDLQIXVHER[
A A
• Disassemble the passenger side lower dashboard assembly .
1RWH
'HWDFKLQJWKHPDLQIXVHER[
1. Unscrew the 2 bolts ($)LJ) securing the fuse box (%)LJ).
)LJ
)LJ

L714 09 81 03
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• Disassemble the front combination lights .
1RWH
1. Unscrew the 2 screws ($)LJ) securing the control unit to the combination lights.
2. Remove the control unit (%)LJ).
)LJ
)LJ

L714 09 81 03
Q) 'LVDVVHPEOLQJWKHLQGLFDWRUVZLWFK
A
• Disconnect the battery.
• Disassemble the driver side airbag module ).
• Disassemble the steering wheel .
• Disassemble the steering wheel cover .
1RWH
A A
)LJ
'LVDVVHPEOLQJWKHLQGLFDWRUVZLWFK
C
1. Disconnect the 3 electrical connectors ($)LJ).
2. Unscrew the 2 screws (%)LJ) that secure the indicator switch.
3. Remove the indicator switch (&)LJ).
)LJ
%
17
L714 09 81 03
5'LVDVVHPEOLQJWKHFRQWUROXQLWVXSSRUWSODWH
%
1RWH
• Ensure that the ignition key is in the OFF position and disconnect the battery .
• When disassembling the control unit support plate, protect the center console from possible
abrasions.
'LVDVVHPEOLQJWKHSODWH
1. Disconnect the 3 ground connectors ($)LJ) from the chassis.
2. Loosen the 8 screws (%)LJ) that secure the control unit support bracket to the chassis.
3. Disengage the control unit support plate (&)LJ).
&$87,21
To completely remove the plate, it is necessary to remove all the control units fastened onto the plate as it
remains connected to the vehicle with its wires.
A A A
)LJ
18
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' %OXHWRRWKFRQWUROXQLW
( )XHOSXPSFRQWUROXQLW
) Yaw sensor control unit
* )XVHER[DQGUHOD\
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, *)$FRQWUROXQLW
/ ,/0FRQWUROXQLW
0 =.( control unit
1 0DLQIXVHER[
2 )URQWFRPELQDWLRQOLJKWVFRQWUROXQLW
3 Indicator switch
Q) Control unit support plate
1
L714 09 81 05
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1RWH
1. Connect the two connectors ($)LJ) to the control unit and secure them with 4 new antitheft bolts (%)LJ).
2. Put the control unit (&)LJ) into its seat.
3. Position the bracket (')LJ) and secure the control unit using the 2 bolts (()LJ).
• $VVHPEOHWKHHQJLQHFRPSDUWPHQWULJKWVLGH¿QLVKLQJHOHPHQW. A %
1RWH
Write the immobilizer of the replaced control unit using the VAS-PC software .
Use the LaRa-AS “Basic setting” system (109000) for the software checks and settings .
:$51,1*!
%
'RQRWH[FKDQJHWKHHQJLQHLQMHFWLRQFRQWUROXQLWV0$67(5DQG6/$9(WKH\DUHQRW
LQWHUFKDQJHDEOH([FKDQJLQJWKHFRQWUROXQLWVFRXOGMHRSDUGL]HYHKLFOHRSHUDWLRQ
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)LJ
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L714 09 81 05
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1RWH
1. Connect the two connectors ($)LJ) to the control unit and secure them with 4 new antitheft bolts (%)LJ).
2. Put the control unit (&)LJ) into its seat.
3. Position the bracket (')LJ) and secure the control unit using the 2 bolts (()LJ).
• $VVHPEOHWKHHQJLQHFRPSDUWPHQWOHIWVLGH¿QLVKLQJHOHPHQW. A % C
1RWH
Write the immobilizer of the replaced control unit using the VAS-PC software .
:$51,1*! %
'RQRWH[FKDQJHWKHHQJLQHLQMHFWLRQFRQWUROXQLWV0$67(5DQG6/$9(WKH\DUHQRW
LQWHUFKDQJHDEOH([FKDQJLQJWKHFRQWUROXQLWVFRXOGMHRSDUGL]HYHKLFOHRSHUDWLRQ
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L714 09 81 05
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1RWH
1. Put in the control unit ($)LJ).
2. Put in the bracket (%)LJ) and secure it with the 2 bolts (&)LJ).
3. Connect the two connectors (')LJ).

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1RWH

)LJ
4
L714 09 81 05
A
'$VVHPEOLQJWKHEOXHWRRWKFRQWUROXQLW
1RWH
Assembling the control unit
2. Connect the connector (&)LJ) to the control unit.
3. Put in the bracket (%)LJ).
4. Tighten the 2 bolts (')LJ).
1RWH
Use the LaRa-AS “Basic setting” system (to set up the control unit).
' % C
)LJ
5
L714 09 81 05
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A %
1RWH
1. Connect the connector ($)LJ) of the control unit (%)LJ).
2. Put the control unit into its seat matching up the mounting bracket of the control unit with the 2 holes on the
chassis.
3. Tighten the 2 bolts (&)LJ).
4. Connect the 2 fuel pipes (')LJ).
5. Assemble the plate (()LJ), tightening the 4 screws ())LJ). '
C
• Assemble the control unit support plate 3RLQW4.
• Assemble the fuse box and relays 3RLQW*.
) )
)LJ

L714 09 81 05
)$VVHPEOLQJWKHyaw sensor control unit
1RWH
1. Position the control unit ($)LJ).
2. Connect the connector (%)LJ) to the control unit.
3. Tighten the 2 bolts (&)LJ).
• Assemble the bench . %

• Use the LaRa-AS system (ABS/ESP) to set up and reset the error codes to zero.
A
)LJ
7
L714 09 81 05
G) Assembling the IXVHER[DQGUHOD\
1RWH
A
1. Connect the connector and put it in the fuse box ($)LJ).
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2. Fasten the fuse box by tightening the 2 bolts (%)LJ).
)LJ
8
L714 09 81 05
3. Connect the cable (&)LJ) and secure it with the screw (')LJ).
4. Connect the connectors (()LJ).
5. Put in the relays ())LJ8).
:DUQLQJ
Be sure to reconnect the relays to their connectors!
Put the relay bracket (*)LJ) in, complete with the relays, and tighten it with the 2 bolts (+)LJ).

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(
)LJ
9
L714 09 81 05
H) Assembling the airbag control unit
1RWH
1. Position the control unit ($)LJ).
2. Tighten the 3 bolts (%)LJ) securing the control unit.
3. Connect the two connectors ($)LJ) to the control unit.
• Assemble the center console .

• Use the LaRa-AS system to delete any errors that may be in the memory.
%
A
% %
)LJ
10
L714 09 81 05
I) Assembling the side airbag sensors
1RWH
There are three airbag sensors in the vehicle: One inside the main airbag control unit and two in the side
members.
'LVDVVHPEOLQJWKHVHQVRUV
1. Remove the side impact airbag sensor ($)LJ).
2. ,QVHUWWKHVLGHLPSDFWVHQVRU6,6DQGWLJKWHQWKH¿[LQJVFUHZ%)LJ) to the side member.
3. Connect the connector (&)LJ) to the side impact sensor (SIS) ($)LJ).
• Assemble the front and centre side member covers .

C A
)LJ
11
L714 09 81 05
/$VVHPEOLQJWKH*)$FRQWUROXQLW
1RWH
1. Put in the control unit ($)LJ). C

%
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3. Connect the connectors (&)LJ) to the control unit.
1RWH
Use the LDAS32 system for the software checks and settings.
• Assemble the passenger side footboard .

• Connect the battery . A
)LJ
12
L714 09 81 05
0$VVHPEOLQJWKH,/0FRQWUROXQLW
( (
1RWH
'
2. Fasten the control unit by tightening the 2 bolts (%)LJ).
3. Position the entire support, including bracket and control unit, on the chassis.
4. Tighten the 3 bolts (&)LJ) securing the control unit support bracket.
5. Connect the 3 connectors (')LJ) to the control unit.
Put the 4 relays (()LJ) on the control unit.

C
1RWH A
Use the LaRa-AS “Basic setting” system for the software checks and settings (set up the control
units by means of the “automatic mode”). % %
• Install the ZKE control unit 3RLQW0.

• Install the fuse box 3RLQW1.
• Assemble the passenger side lower instrument panel assembly .
• Assemble the passenger side footboard .
• Connect the battery . C C
)LJ
13
L714 09 81 05
1$VVHPEOLQJWKH=.(FRQWUROXQLW
A
1RWH
% %
1. Mount the control unit ($)LJ) on its support bracket.
3. Connect the connectors (&)LJ) to the control unit.

C
4. Install the entire support, including the bracket and control unit, on the vehicle chassis by tightening the 3 bolts
(')LJ).
1RWH
Use the LaRa-AS “Basic setting” system for the software checks and settings (set up the control
units by means of the “automatic mode”).

• Connect the battery . )LJ
' '
)LJ
14
L714 09 81 05
2$WWDFKLQJWKHPDLQIXVHER[
1RWH A A
1. Tighten the 2 screws ($)LJ) securing the fuse box (%)LJ) to the support bracket.

)LJ
)LJ
15
L714 09 81 05
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1RWH
1. Position the control unit ($)LJ) on the combination lights.
2. Tighten the 2 screws (%)LJ) securing the control unit to the combination lights.
• Assemble the front combination lights .
)LJ
)LJ

L714 09 81 05
Q) Assembling the indicator switch A
1RWH
1. Insert the indicator switch ($)LJ).
2. Tighten the 2 screws (%)LJ) that secure the indicator switch.

)LJ
%
3. Connect the 3 electrical connectors (&)LJ).
1RWH
Use the LaRa-AS “Basic setting” system for the software checks and settings (set up the steering
DQJOHE\PHDQVRIWKH³DXWRPDWLFPRGH´¿UVW60/6WKHQ$%6.
• Assemble the steering wheel cover .

• Assemble the steering wheel . C C
• Assemble the driver side airbag module. )LJ
17
L714 09 81 05
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A
1RWH
• Ensure that the ignition key is in the OFF position and disconnect the battery .
• When assembling the control unit support plate, protect the center console from possible abrasions.
1. Secure the control unit support plate by tightening the 8 screws ($)LJ) to the chassis.
2. Connect the 3 ground connectors (%)LJ) to the chassis.

% % %
)LJ
18
L714 09 82 00
7306
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7306FRPSRQHQWVOD\RXW)LJ
A. TPMS Control unit
% Front antenna
C. Rear antenna
' Trigger
The TPMS ECU ($)LJ) monitors the tire pressure of the four wheels during driving.
7KH GULYHU LV QRWL¿HG LI D VXEVWDQWLDO GURS LQ SUHVVXUH RFFXUV E\ PHDQV RI V\PEROV DQG PHVVDJHV DSSHDULQJ
RQ WKH LQVWUXPHQW SDQHO¶V GLVSOD\ 7KH V\VWHP RSHUDWHV E\ PHDQV RI VHQVRUV V)LJ ORFDWHG RQ WKH ZKHHOV
&RPPXQLFDWLRQEHWZHHQWKHVHVHQVRUVDQGWKHWLUHSUHVVXUHFRQWUROV\VWHPWDNHVSODFHZLWKRXWWKHXVHRIFDEOHV ' ' )LJ
(trigger ')LJ).
7KHWLUHSUHVVXUHDOVRGHSHQGVRQWKHWLUHWHPSHUDWXUHWKHWLUHSUHVVXUHLQFUHDVHVHYHU\&WKHWHPSHUDWXUH
ULVHV7KHWLUHVKHDWXSGXULQJGULYLQJFDXVLQJWKHWLUHSUHVVXUHWRULVH$GMXVWWKHWLUHSUHVVXUHRQO\ZKHQWKHWLUHV A
DUHFROGWKDWLVDWDPELHQWWHPSHUDWXUH7KHUHFRPPHQGHGWLUHSUHVVXUHVDUHVWDWHGLQWKHXVHUDQGPDLQWHQDQFH
ERRNOHWVDQGRQWKHVWLFNHURQWKHGRRUSLOODU
Important!
• 'RQRWPRGLI\WKHWLUHSUHVVXUHZKHQWKHWLUHVDUHRYHUKHDWHGWKLVFRXOGGDPDJHWKHPRUHYHQ
FDXVHWKHPWRH[SORGH&KDQJHWKHSUHVVXUHRQO\ZKHQWKHWLUHVDUHDWDPELHQWWHPSHUDWXUH
• :KHQUHSODFLQJDWLUHGRQRWORRVHQRUH[FKDQJHWKHVHQVRUVRUYDOYHV2QO\WKHVHDOVKRXOG
EHUHSODFHGDQGLIQHFHVVDU\WKHYDOYHLWVHOIDQGWKHZKHHO¶VHOHFWURQLFFRPSRQHQW
)LJ
• 5HPHPEHUWKDWWKH7LUH0RELOLW\6\VWHPHPHUJHQF\UHSDLUNLWFRXOGGLVWRUWWKHWLUHSUHVVXUH
FRQWUROV\VWHP¶VUHDGLQJVRUFRPSURPLVHLWVRSHUDWLRQ7KHSUHVVXUHFRQWUROV\VWHP¶VVHQVRU
must therefore be replaced.
• 7KHVHQVRUEDWWHULHVODVWDSSUR[LPDWHO\\HDUVDIWHUZKLFKWKH\PXVWEHUHSODFHG
,QVXI¿FLHQWWLUHSUHVVXUHLQFUHDVHVIXHOFRQVXPSWLRQDQGWLUHZHDU
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Use the Airbag Simulator (A-Fig.1) to check problems related to the airbag module or to its wiring harness. A
The Airbag Simulator is connected in place of the charge (module) and simulates its electrical resistance, which
can be checked using LaRa-AS (109000).
7KHYHKLFOHLVHTXLSSHGZLWKDQFRQWUROXQLW¿UVWJHQHUDWLRQDQGVRWKHFRQGLWLRQVRIWKHUHVLVWDQFHFDQQRWEH

displayed. It is necessary to go to into version 2 “tdc coding” and check any error codes.
Connect the Airbag Simulator and perform a reset:
• if the system resets itself, the error was related to the module
• if the error persists, check the related electrical wiring harness
Replace the control unit each time the error codes relate to crashes as it cannot be reset. In the case of a sensor
error or side airbag error, the control unit can only be reutilized one more time. Fig.1
7KHV\VWHP&$1127EHUHVHWDIWHUWKHFRQWUROXQLWZDVUHXWLOL]HGIRUWKH¿UVWDQGRQO\WLPH7KH

control unit must therefore be replaced.
1
L714 10 01 10
OBD II CODES
(2%'6\VWHP6XPPDU\7DEOH
&RPSRQHQW6\VWHP )DXOW 0RQLWRU6WUDWHJ\'HVFULSWLRQ Malfunction Criteria 6HFRQGDU\3DUDPHWHUV 0,/,OOXP2%'
7HLO6\VWHP Code Überwachungsstrategie )HKOHUNULWHULXP =XVlW]OLFKH3DUDPHWHU Lampe
)HKOHU
code
3.2.12.2.8.3.1.1.
Catalyst P0421 Direct measurement of ratio of OSC vs. Borderline catalyst ambient temperature 3 DCY
Bank 1 P0431 Oxygen Storage Capacity OSC engine speed
Bank 2 catalyst temperature
PDVVDLUÀRZ
GHOWDPDVVDLUÀRZ
delta catalyst temperature
3.2.12.2.8.3.1.2.
0LV¿UH P0300 FUDQNVKDIWVSHHGÀXFWXDWLRQ emission threshold time from start 3 DCY
P0301 VLQJOHRUPXOWLSOHPLV¿UH PLV¿UHUDWH05VWLQWHUYDOO IAT
P0302 time after engine start
P0303 camshaft revolution
P0304 emission threshold engine speed
P0305 PLV¿UHUDWH05 engine torque
P0306 fuel cut off
P0307 ECT @ start
P0308 catalyst damage if ECT @ start
P0309 PLV¿UHUDWH05 WKDQZDLWXQWLODFWXDO(&7
P0310
3.2.12.2.8.3.1.3.
Oxygen P0606 sensor IC self check sensor offset correction battery voltage 3 DCY
Sensor IC Check engine start
front engine speed
Bank 1 engine idle
Bank 2
P0606 sensor IC self check VHQVRU,&SRZHU battery voltage
supply voltage engine start
engine speed
P0606 communication check communication
CPU - Sensor IC
P0606 communication check communication
CPU - Sensor IC
1
L714 10 01 10
Oxygen P0132 short to battery plus YLUWXDOPDVV90 battery voltage 3 DCY

Sensor P0152 1HUQVWYROWDJH81 engine start
front DGMXVWPHQWYROWDJH,$ engine speed
Bank 1
P0131 short to ground YLUWXDOPDVV90 battery voltage
Bank 2
P0151 1HUQVWYROWDJH81 engine start
DGMXVWPHQWYROWDJH,$ engine speed
P2237 open circuit enrichment or lean out battery voltage

P2240 SXPSFXUUHQW,3 O2S signal front engine start
delta lambda value setting engine speed
lambda control
heater control
electrical adjustment
O2S ceramic temperature
lambda modulation
amplitude
for
P2237 open circuit mass air integral battery voltage
P2240 SXPSFXUUHQW,3 in exhaust gas engine start
engine speed
lambda control
electrical adjustment
O2S front
lambda value
P2237 open circuit O2S signal front battery voltage
P2240 SXPSFXUUHQW,3 and engine start
fuel cut off engine speed
(9$36\VWHP
Oxygen P2626 open circuit O2S signal front battery voltage 3 DCY
Sensor P2629 DGMXVWPHQWYROWDJH,$ engine start
front engine speed
Bank 1 O2S ceramic temperature
Bank 2 modeled exhaust temperature
fuel cut off
P2243 open circuit O2S signal front battery voltage
P2247 1HUQVWYROWDJH81 engine start
engine speed
internal resistance
heater control
for
2
L714 10 01 10
Oxygen P2251 open circuit O2S signal front battery voltage 3 DCY
Sensor P2254 YLUWXDOPDVV90 engine start
front engine speed
Bank 1 internal resistance
Bank 2 heater control
for
P2414 signal range check internal voltage battery voltage
P2415 signal range check internal voltage engine start
engine speed
fuel cut off
desired lambda
O2S calibrated resistance
O2S
P0133 signal dynamic check O2S signal front lambda control
P0153 vs. Modeled O2S signal engine load
engine speed
actual Lambda
P2231 FRXSOLQJZLWKKHDWHU delta O2S signal front modeled exhaust temperature
P2234 elapsed time since last O2S battery voltage
KHDWHUVZLWFKRQ O2S heater duty cycle
engine speed
desired lambda
measured lambda
engine load
Oxygen P2196 out of range trim control after catalyst catalyst temperature 3 DCY
Sensor P2198 adaptive value engine speed
front engine load
Bank 1 PDVVDLUÀRZ
Bank 2 lambda control
P2195 out of range trim control after catalyst second control loop
P2197 adaptive value O2S rear
secondary air
fuel cut off
catalyst heat-up
3
L714 10 01 10
Oxygen Sensor P0032 short to battery plus signal current engine start 3 DCY
Heater P0052 heater engine speed
front battery voltage
P0031 short to ground signal voltage
Bank 1 heater control
P0051 heater
Bank 2 for at least
P0030 open circuit signal voltage
P0050 heater
P0135 out of range high heater duty cycle battery voltage
P0155 and heater control
O2S ceramic temperature fuel cut off
modeled exhaust temperature
P0606 rationality check delta resistance battery voltage
measured vs. modeled
P0135 RXWRIUDQJHORZ sensor ceramic temperature battery voltage
P0155 time after engine start
engine shut off time
ECT @ start
fuel cut off
Oxygen Sensor P0138 short to battery plus signal voltage battery voltage 3 DCY
5HDU P0158 engine speed
Bank 1 26UHDUGHZSRLQW
Bank 2 O2S rear
and
for
P0137 short to ground signal voltage battery voltage
P0157 engine speed
26UHDUGHZSRLQW
O2S rear
and
for
ECT @ off
ECT @ start
4
L714 10 01 10
Oxygen Sensor P0140 signal activity check signal voltage battery voltage 3 DCY
5HDU P0160 engine speed
Bank 1 26UHDUGHZSRLQW
Bank 2 modeled exhaust temp. O2S rear
and and
O2S rear internal resistance modeled exhaust temperature
for
lambda control*
RQO\IRUVLJQDOYROWDJH
P0136 heater coupling check delta O2S signal rear battery voltage
P0156 engine speed
O2S rear heater has been 26UHDUGHZSRLQW
VZLWFKHGRIILQWKHODVW O2S rear
and
for
P0139 oscillation check signal output ist not oscillating at PDVVDLUÀRZ
P0159 reference value O2S rear
ready since
catalyst temperature
Oxygen Sensor P0038 short to battery plus signal current heater 3 DCY
Heater P0058 26UHDUGHZSRLQW
rear heater
Bank 1 engine speed
Bank 2 battery voltage
P0037 short to ground signal voltage heater
P0057 26UHDUGHZSRLQW
heater
P0036 open circuit signal voltage engine speed
P0056 battery voltage
P0141 rationality check heater resistance battery voltage
P0161 modeled exhaust temperature
engine shut off time
IAT
5
L714 10 01 10
3.2.12.2.8.3.1.4.
Evap Purge , value P0444 open circuit signal voltage evap purge valve 3 DCY
7(9(6ODYH P1491 engine speed
battery voltage
P0458 short to ground signal voltage evap purge valve
7(9(6ODYH
P1490 engine speed
battery voltage
7(9(6ODYH P0459 short to battery plus signal current evap purge valve
P1489 engine speed
battery voltage
Evap Purge P0441 functional check deviation lambda control ignition 3 Fahrzyl.
System or battery voltage
deviation idle control engine speed
7(96ODYH P1494 engine speed deviation
time after engine start
ECT
or substitute ECT
IAT
IAT @ engine start
altitude
Fuel Pump Control Unit P025D short to battery plus signal current engine speed 3 DCY
battery voltage
P025C short to ground signal voltage
P025A open circuit signal voltage
/RZ3UHVVXUH)XHO6\VWHP P2539 out of range high signal voltage 3 DCY
Sensor
P2541 RXWRIUDQJHORZ signal voltage
)XHO5DLO3UHVVXUH6HQVRU P0190 out of range high sensor voltage 3 DCY
HDS2, Slave P018A
HDS2, Slave P0192 RXWRIUDQJHORZ sensor voltage
P018C
)XHO5HJXODWRU9DOYH P2296 short to battery plus signal voltage battery voltage 3 DCY
)XHO5HJXODWRU9DOYH P129D valve
engine relay
P129C valve
engine relay
P129B
)XHO5DLO3UHVVXUH&RQWURO P2293 rationality check fuel pressure regulator Time since start or fuel cut off 3 DCY
et point deviation Fuel cut off
6
L714 10 01 10
Fuel System P0171 system to lean adaptive value lambda control 3 DCY
multiplicative evap purge valve
Bank 1 P0172 system to rich ECT
Fuel System P0175 system to rich adaptive value engine speed
multiplicative PDVVDLUÀRZ
Bank 2 P0174 system to lean engine load
delta fuel adaption
Fuel System P0171 system to lean adaptive value lambda control 3 DCY
additive evap purge valve
Bank 1 P0172 system to rich ECT
Fuel System P0175 system to rich adaptive value engine speed
additive PDVVDLUÀRZ
Bank 2 duration of multiplicative check
P0174 system to lean
engine load
delta fuel adaption
Fuel System P2097 RXWRIUDQJHORZ Signal offset rich catalyst temperature 3 DCY
P2099 engine speed
engine load
PDVVDLUÀRZ
lambda control
second control loop
P2096 out of range high Signal offset lean
O2S front
P2098
O2S rear
secondary air
fuel cut off
catalyst heat-up
IAT P0112 RXWRIUDQJHORZ IAT 3 DCY
Sensor
P0113 out of range high IAT
ECT Sensor P0117 RXWRIUDQJHORZ ECT 3 DCY
P0118 out of range high ECT
P0116 rationality check ECT ECT
ORZHUPRGHOHGWHPSHUDWXUH
7
L714 10 01 10
997$FWXDWRU P0010 open circuit signal voltage camshaft valve 3 DCY

intake P0020 engine speed
Bank 2
P2088 short to ground signal voltage camshaft valve
P2092 engine speed
battery voltage
P2089 short to battery plus signal current camshaft valve
P2093 engine speed
battery voltage
P0011 functional check adjustment angle difference ECT
P0021 stuck check engine speed
number of checks time after engine start
P000A functional check adjustment angle difference ECT
P000C VORZUHVSRQVH engine speed
997$FWXDWRU P0013 open circuit signal voltage camshaft valve 3 DCY
exhaust P0023 engine speed
Bank 2
P2090 short to ground signal voltage camshaft valve
P2094 engine speed
battery voltage
P2091 short to battery plus signal current camshaft valve
P2095 engine speed
battery voltage
P0015 functional check adjustment angle difference ECT
P0025 stuck check engine speed
P000B functional check adjustment angle difference ECT
P000D VORZUHVSRQVH engine speed
8
L714 10 01 10
MAF Sensor P0103 out of range high MAF 1 signal 3 DCY

MAF 1 + MAF 2 P010D MAF 2 signal
P0102 RXWRIUDQJHORZ MAF 1 signal
P010C MAF 2 signal
P0101 rationality check WRWDOPDVVDLUÀRZ time after engine start
P010B YVORZHUWKUHVKROGPDS battery voltage
or throttle position
WRWDOPDVVDLUÀRZ
vs. upperr threshold map
or
WRWDOPDVVDLUÀRZ lambda control
YV&DOFXODWHGPDVVDLUÀRZ engine load
and throttle position
IXHOV\VWHPPXOW ECT
or or substitute ECT
WRWDOPDVVDLUÀRZ time after engine start
YV&DOFXODWHGPDVVDLUÀRZ
and
IXHOV\VWHPPXOW
6$,53XPS P2258 short to battery plus signal current relay 3 DCY
5HOD\&RQWURO P2260 engine speed
battery voltage
P2257 short to ground signal voltage relay
P2259 engine speed
battery voltage
P0419
6$,59DOYH&RQWURO P0414 short to battery plus signal current relay 3 DCY
engine speed
battery voltage
P0414 short to ground signal voltage relay
engine speed
P0413 open circuit signal voltage battery voltage
6$,5 P0491 rationality check relative secondary air 3 DCY
0DVV)ORZ0RQLWRULQJ P0492 PDVVÀRZ
Bank 1
Bank 2
¿OWHUHGVHFRQGDU\DLU relative secondary air
PDVVÀRZ PDVVÀRZ
Number of measures
6$,53UHVVXUH6HQVRU P0410 rationality check pressure sensor signal 3 DCY
Bank1 P0410
Bank2
9
L714 10 01 10
6$,55HJXODWRU9DOYH P2440 rationality check relative secondary air 3 DCY

Bank1 P2442
Bank2
Altitude Sensor P0606 out of range signal voltage 3 DCY
P0606 out of range altitude sensor signal
Phase Sensor P0343 rationality check signal voltage high 3 DCY
Sensor 1 P0342
VLJQDOYROWDJHORZ
Sensor 2 P0341
Sensor 3 signal voltage
Sensor 4 P0368 rationality check signal voltage high
P0367
VLJQDOYROWDJHORZ
P0366
signal voltage
P0348 rationality check signal voltage high
P0347
VLJQDOYROWDJHORZ
P0346
signal voltage
P0393 rationality check signal voltage high
P0392
VLJQDOYROWDJHORZ
P0391
signal voltage
997 P0016 rationality check adaptive value engine speed sensor 3 DCY
Intake P0018 phase sensor
Bank 1 cam adaption
Bank 2
rationality check adaptive value engine speed sensor
phase sensor
cam adaption
rationality check GLIIHUHQFHEHWZHHQ engine speed sensor
adaptive value phase sensor
actual time value camshaft adjustment
engine start
cam adaption
cam shaft
for at least
10
L714 10 01 10
997 P0017 rationality check adaptive value engine speed sensor 3 DCY
exhaust P0019 phase sensor
Bank 1 cam adaption
Bank 2
rationality check adaptive value engine speed sensor
phase sensor
cam adaption
rationality check GLIIHUHQFHEHWZHHQ engine speed sensor
adaptive value phase sensor
actual time value camshaft adjustment
engine start
cam adaption
cam shaft
for at least
Engine Speed P0321 rationality check counted versus reference teeth engine speed 3 DCY
Sensor
P0321 rationality check reference gap teeth during engine start
during engine start ZDLWWZRFUDQNVKDIWUHYV
P0321 rationality check reference gap engine speed
normal operation
P0322 rationality check engine speed for at least
phase signal phase sensor
P0322 signal range check engine speed
9HKLFOH6SHHG P0501 Plausibilitätsprüfung comparison fuel cut off 3 DCY
engine speed engine speed
ECT
Accelerator PP P2123 out of range high signal voltage battery voltage 3 DCY
Sensor 1
P2122 RXWRIUDQJHORZ signal voltage battery voltage
Accelerator PP P2128 out of range high signal voltage battery voltage
Sensor 2
P2127 RXWRIUDQJHORZ signal voltage battery voltage
Accelerator PP P2138 rationality check GLIIHUHQFHEHWZHHQ signal voltage APP1
Sensor 1 1/2*APP1 - APP2 signal voltage APP2
Sensor 2
11
L714 10 01 10
Throttle Position P0122 RXWRIUDQJHORZ signal voltage 3 DCY

Sensor 1 P3026
P0123 out of range high signal voltage
P3027
P0121 rationality check | TPS 1 - TPS 2 | TPS electrical range
P3025 and unthrottled regime condition
| actual TPS 1 - calc, value | engine speed
or
engine speed
RQO\LI736!736
| actual TPS 1 - calc, value | TPS 2
unthrottled regime condition
engine speed
Throttle Position P0222 RXWRIUDQJHORZ signal voltage 3 DCY
Sensor 2 P3029
P0223 out of range high signal voltage engine speed
P3030 or TPS 1
P0221 rationality check | TPS 1 - TPS 2 | TPS electrical range
P3028 and unthrottled regime condition
| actual TPS 1 - calc, value | engine speed
or
engine speed
RQO\LI736!736
| actual TPS 1 - calc, value | TPS 2
unthrottled regime condition
engine speed
12
L714 10 01 10
Throttle Actuator P2106 signal range check fault message CJ230 (&0SRZHUVWDJH 3 DCY
P3031
P2101 signal range check duty cycle
P0639
Throttle Actuator P0638 functional check time fuel cut off
Ignition On P3035 to open over reference point throttle position
functional check time
P3035 engine speed
close movement WRFORVHEHORZUHIHUHQFHSRLQW
vehicle speed
IAT
ECT
Throttle Actuator P0638 functional check time fuel cut off
Basic Setting P3035 to open over reference point throttle position
battery voltage
P0638 functional check time
engine speed
P3035 close movement WRFORVHEHORZUHIHUHQFHSRLQW
vehicle speed
P0638 functional check time IAT
P3035 WRFORVHEHORZUHIHUHQFHSRLQW ECT
P0638 functional check time
P3035 open movement to open over reference point
Throttle Actuator P0638 rationality check repeated learning of fuel cut off
Basic Setting P3032 ORZHUVWRSOLPLW open movement
TPS 1 signal voltage limp home
or engine speed
TPS 2 signal voltage vehicle speed
or accelerator PP
TPS 1 signal voltage battery voltage
after learning ECT
or IAT
GLIIHUHQFHEHWZHHQ
TPS 1 signal voltage
DIWHUOHDUQLQJDQGOHDUQWORZHUOLPLW
P0638 functional check ¿UVWOHDUQLQJRIORZHUVWRSOLPLW
P3032
13
L714 10 01 10
,05XQQHU)ODSV P2014 RXWRIUDQJHORZ signal voltage 3 DCY.

Bank 1 P2019
Bank 2
P2017 out of range high signal voltage
P2022
P2004 stuck open check Difference desired-actual position Engine speed 3 Fahrzyl.
P2005 ECT
battery voltage
adaption
P2006 stuck closed check Difference desired-actual position Engine speed
P2007 ECT
battery voltage
adaption
,05XQQHU)ODSV P2008 open circuit signal voltage UXQQHUÀDSV 3 DCY
6ROHQRLG9DOYH engine speed
P2010 short to battery plus signal current UXQQHUÀDSV
engine speed
battery voltage
Injector valves P062B communication check 3 DCY
Communication CPU
,QMHFWLRQ9DOYHV
High Pressure Fuel System
P2146 short to battery plus high pressure system current injection valve 3 DCY
cylinder #1 and #3
P2149 ORZVLGHVLJQDOFXUUHQW
cylinder #4 and #5
P2152 engine speed
cylinder #2
cylinder #6 and #8
P216A
cylinder #9and #10
P216D
cylinder #7
cylinder #1 and #3 P2146 short to ground high pressure system current injection valve
cylinder #4 and #5 P2149 engine speed
cylinder #2 P2152 battery voltage
cylinder #6 and #8 P2155
cylinder #9and #10 P216A
cylinder #7 P216D
14
L714 10 01 10
,QMHFWLRQ9DOYHV
/RZ3UHVVXUH)XHO6\VWHP
P0262 short to battery plus ORZVLGHVLJQDOFXUUHQW injection valve 3 DCY
cylinder #1
P0265 engine speed
cylinder #2
cylinder #3
P0271
cylinder #4
P0274
cylinder #5
P0277
cylinder #6
P0280
cylinder #7
P0283
cylinder #8
P0286
cylinder #9
P0289
cylinder #10
cylinder #1 P0261 short to ground ORZVLGHVLJQDOFXUUHQW injection valve
cylinder #2 P0264 high pressure system current
cylinder #3 P0267 engine speed
cylinder #5 P0273
cylinder #6 P0276
cylinder #7 P0279
cylinder #8 P0282
cylinder #9 P0285
cylinder #10 P0288
cylinder #1 P0201 open circuit ORZVLGHVLJQDOFXUUHQW injection valve
cylinder #2 P0202 high pressure system current
cylinder #3 P0203 engine speed
cylinder #5 P0205
cylinder #6 P0206
cylinder #7 P0207
cylinder #8 P0208
cylinder #9 P0209
cylinder #10 P0210
cylinder #1 P0201 booster timer check ORZVLGHVLJQDOFXUUHQW injection valve
cylinder #2 P0202 booster time engine speed
cylinder #4 P0204
cylinder #5 P0205
cylinder #6 P0206
cylinder #7 P0207
cylinder #8 P0208
cylinder #9 P0209
cylinder #10 P0210
15
L714 10 01 10
Ignition Coils
cylinder #1
P2301 short to battery plus signal voltage battery voltage 3 DCY
cylinder #2
P2304 engine speed
cylinder #3
P2307
cylinder #4
P2310
cylinder #5
P2313
cylinder #6
P2316
cylinder #7
P2319
cylinder #8
P2322
cylinder #9
P2325
cylinder #10
P2328
cylinder #1 P2300 short to ground signal voltage
cylinder #2 P2303
cylinder #3 P2306
cylinder #4 P2309
cylinder #5 P2312
cylinder #6 P2315
cylinder #7 P2318
cylinder #8 P2321
cylinder #9 P2324
cylinder #10 O2327
cylinder #1 P0351 open circuit signal current
cylinder #2 P0352
cylinder #3 P0353
cylinder #4 P0354
cylinder #5 P0355
cylinder #6 P0356
cylinder #7 P0357
cylinder #8 P0358
cylinder #9 P0359
cylinder #10 P0360
16
L714 10 01 10
0DLQ5HOD\ P0687 short to battery plus signal current main relay 3 DCY
signal current ECM keep alive time
and main relay
sense circuit voltage
P0686 short to ground signal voltage ECM keep alive time
and main relay
and
P0688 open circuit sense circuit voltage main relay
rationality check GLIIHUHQFHEHWZHHQ ECM keep alive time
and
camshaft actuator
(QJLQH5HOD\ P0659 short to battery plus signal current (QJLQH5HOD\ 3 DCY
engine speed
battery voltage
P0658 short to ground signal voltage (QJLQH5HOD\
engine speed
P0657 open circuit signal voltage battery voltage
96HQVRU5HIHUHQFH P0643 out of range high supply voltage threshold values dep. 3 DCY
P0653 RQLQWHUQDO9UHIHUHQFH
P0699 voltage
P0642 RXWRIUDQJHORZ supply voltage
P0652
P0698
P0641 communication check internal fault
P0651
P0697
ECM P0601 LQWHUQDOFKHFNVXPYHUL¿FDWLRQ internal check sum 3 DCY
P0604 5$0FKHFN ZULWHDELOW\FKHFN
P0605 520FKHFN check
P0606 ((3520FKHFN check
GULYHE\ZLUHPRGXOHFKHFN check
17
L714 10 01 10
Fuel Supply P0606 GULYHE\ZLUHPRGXOHFKHFN engine torque 3 DCY

Shut off
engine speed
engine regime
ADC Check
accelator position
ignition angle
U0401 GULYHE\ZLUHPRGXOHFKHFN CAN rationality check Master/Slave
CAN U0001 communication check CAN Bus battery voltage 3 DCY
CAN U002 communication check CAN Bus Batteriespannung 3 Fahrzyl.
Internal CAN U0037 communication check CAN Bus battery voltage 3 DCY
Master
U0115 communication check Time out check
Slave
U0100 communication check Time out check
Coding of ECU U0302 Correct coding of gear model 2%'UHOHYDQW*HDU(&8ZURQJFRGHG 3 DCY
CAN - Gear interface U0402 coummunication check CAN Bus Batteriespannung 3 Fahrzyl.
U0101 coummunication check Timeout Check
18
L714 10 90 00
/D5D$6',$*126,66<67(0
Connection to the diagnosis outlet and system start up

A
• Switch on the PC (A-Fig.1);
C
• connect the adapter (B-Fig.1) to the PC com port;
• turn the ignition key OFF;
• connect the adapter to the OBDII connector (C-Fig.1) in the car, located on the right of the steering column.
• turn the ignition key ON.
Fig.1
• start the LaRa-AS program by double clicking the icon on the desktop.
• The system starts automatically, showing the last screen opened on the car’s display (Fig.2).
Fig.2
1
L714 10 90 00
1RWH
The selected car may be changed by clicking on the arrow next to “*DOODUGR0<´ (A-Fig.3):
• Gallardo Coupé MY04-08
• Gallardo Spyder MY06-08
• Gallardo Coupé MY09 B
• Murcielago MY04-07
• Murcielago LP640 MY08 C
• Murcielago LP640 MY09
The Gallardo LaRa-AS system features the following function modes: A
• $XWRPDWLF0RGH(B-Fig.3): allows a series of tasks to be carried out automatically such as set up, VIN script,
remote control resynchronisation, etc.; necessary to enable a few electronic devices (control units) after they
have been replaced on the car.
Fig.3
• Analysis mode (C-Fig.3): allows accurate control of every electronic device on board the car.
2
L714 10 90 00
$1$/<6,602'(
The LaRa-AS system analysis mode allows accurate control of every electronic device on board the car.
The following is possible for each device:
• GLVSOD\RILGHQWL¿FDWLRQGDWDDQGIXQFWLRQSDUDPHWHUV
• display (and reset) of any errors stored in the control units.
• HQDEOHPHQW RI DFWLYH WHVWV WKDQNV WR VSHFLDO ¿OHV FDOOHG µPHDVXUHPHQW ¿OHV¶ ZKLFK PRQLWRU WKH GHVLUHG
parameters.
This mode is activated by pressing $QDO\VLV0RGH on the LaRa-AS program start-up screen (Fig.16).
Fig.4
In analysis mode, the LaRa-AS program windows feature a series of permanently accessible icons and pull-down
menus which mean the following (Fig.17): A
A. control bar for quickly accessing the “Analysis Mode” functions.

B. combo box for selecting the type of task you would like to carry out on the selected ECU. B
C. combo box for selecting the ECU to be analyzed from those available.
Fig.5
3
L714 10 90 00
&RQWUROEDULFRQ
67$57$ after selecting the ECU and the function that must be checked, this green button starts
communication.
(icon valid for all model versions).
6723% this button ends communication.

Alternatively, communication may be interrupted by removing the keys from the control
panel.
Folder this button shows where the LaRa-AS system automatically saves the information:
VDYH • UHFRUGLQJ¿OHVIXQFWLRQLQDFWLYH
)LOHV& • ORJ¿OHVIROGHUIRUVDYLQJ/D5D$6¿OHVUHZULWWHQDIWHUHDFKRSHUDWLRQHJFOXWFKZULWLQJ
RUUHDGLQJWKHFUHDWHGUHSRUW¿OHPXVWEHVDYHGZLWKDQRWKHUQDPHEHFDXVHZKHQWKH
system is closed, or following a new operation, it is automatically rewritten, deleting
previous information.
• Output Files: function inactive C
• [OP)LOHVIROGHUZKHUHWKHV\VWHPVDYHVUHSRUW¿OHVLQ[OP
6DYH' inactive functions (not used by the system).

(icon not valid for all model versions).
Create inactive functions (not used by the system).

PHDVXUHPHQW( (icon not valid for all model versions).
5HFRUGLQJ) inactive functions (not used by the system). ' ( F

(icon not valid for all model versions).
4
L714 10 90 00
3UHIHUHQFHV* this button displays the type of interface to be used for communication.
Read only.
'LDJQRVWLFJXLGH+ this button accesses documents created for diagnosis and the system’s other functions within
LaRa-AS.
Example:
if an ECU presents error codes, press the “Diagnostic guide” icon to view the codes without
interrupting communication: the system will open an Acrobat document showing the relative
error codes. Select a code to open the relative document which explains the problem, possible
remedies and the tests that must be carried out (diagnosis tree). H
,QIRUPDWLRQV, this button provides read-only information, displaying the installed version of the LaRa-AS
software and the owner of the license.
5
L714 10 90 00
The functions shown in the pull-down menu of operations change, or better yet increase, depending on the type of
ECU selected.
To verify the possibilities provided by the system, after selecting the ECU and the function on the diagnosis document,
click on the “Diagnostic guide” icon ( ). The system supplies all of the information on settings corresponding to the
VHOHFWLRQV,IQRWKLQJLVGLVSOD\HGWKHVHSDUDPHWHUVPD\RQO\EHPRGL¿HGE\/DPERUJKLQLDQGFDQQRWEHFKDQJHG
by dealers.
The following functions are possible (Fig.6):
01 (&8LGHQWL¿FDWLRQ LQGLFDWHVDOOWKHLGHQWL¿FDWLRQGDWDRIWKHVHOHFWHGFRQWUROXQLWIRUH[DPSOHWKLVIXQFWLRQ
can be used to check whether the control unit is read correctly by the system, etc.)
02 '7&PHPRU\FRQWHQWV display, save and reset present error codes
03 Actuator test XVHGRQO\IRUVSHFL¿F(&8V
04 Basic setting it activates the system Routines according to the control units selected
05 (UDVH'7&PHPRU\ currently not used
07 3DUDPHWHUFRGLQJ FRGL¿HVWKHFRQWUROXQLWVLQFRPSOLDQFHZLWKWKHGRFXPHQWDWLRQDOORZVDFRQWUROXQLWWR
be programmed for various markets and different uses
08 0HDVXUHPHQWYDOXHV on-line reading of control unit variables indicating the function correct or not depending
on the values A
10 Adjustment VSHFL¿FVHWWLQJVIRUWKHYDULRXVFRQWUROXQLWV
11 Coding 2 used to activate settings
Fig.6
16 Security Access currently not used
17 'LDJQRVWLF6HVVLRQ currently not used
18 9DOYHDQGSXPSWHVW currently not used
29 System adaptation currently not used
30 ,QLWLDOIXHO¿OOLQJ currently not used
32 Flash programming UHÀDVKIRUHJHDUDQGHQJLQHFRQWUROXQLW
33 6WDQGDUG'LDJQRVWLF displays the engine parameters
6
L714 10 90 00
(&8LGHQWL¿FDWLRQ
7KH³(&8LGHQWL¿FDWLRQÍXQFWLRQLGHQWL¿HVWKHVRIWZDUHYHUVLRQLQVWDOOHGRQWKHVHOHFWHGFRQWUROXQLW
• Turn the ignition key to ON.

• Connect the computer to the diagnosis outlet OBDII A
• Select the control unit to be checked (ES: 02 E-GEAR A-Fig.7) and start the connection ( ).
$OOLGHQWL¿FDWLRQGDWDRIWKHFRQWUROXQLWDUHUHDGFig.7).
Fig.7
'7&PHPRU\FRQWHQWV
The “DTC memory contents” function displays the error codes, if any, on the selected control unit.
A
• Connect the computer to the diagnosis outlet OBDII
• Select the control unit to be checked (ES: 02 E-GEAR A-Fig.8) and start the connection ( ). B
The error memory content of the control unit is displayed (Fig.8).
1RWH
For more information, you can enable the “ Freeze Frame Data” (B-Fig.8), which displays the time and
conditions in which the errors occurred.
C
Once the causes of the errors are eliminated, delete the memory content using the “Delete” command (C-Fig.8). Fig.8
7
L714 10 90 00
%DVLFVHWWLQJSHUFHQWUDOLQD(*($5
The “Basic setting” function allows you to make the initial settings on the selected control unit (E-GEAR).
The settings are divided into 7 different block numbers (Routines).
Clutch Kiss Point Self tuning (Routine 1)
1RWH
Routine 1 is performed when:
• the clutch is replaced
• the E-gear control unit is replaced
• the gearbox is removed and reassembled
• Select routine 1 inside the block number (A-Fig.9).
• Start the engine and bring water temperature to > 60°C.
• Start the connection ( ) and press the start push-button (B-Fig.9).
Routine 1 readapts the position of the clutch and calculates the correct Kiss Point value.
displays the operation result:

line 1 0 = positive result (Kiss Point successfully calculated) A
255 = non-compliant result
line 2 displays the Kiss Point value at the end of the procedure
line 3 displays the engine speed, expressed in rpm
displays the clutch speed, expressed in rpm (the value ranges between 0 and 130); the speed at the time
when the clutch starts to transmit the engine’s motion.
line 4
The system performs the approach operation 10 times in order to properly calibrate the Kiss Point
value.
In order to store the Kiss Point value that has just been calculated in the system, turn the ignition key to OFF and
Fig.9
wait about one minute to allow the control unit to turn itself off (check this value in MWB 10). B
:KHQWKHSURFHGXUHLV¿QLVKHGWKHV\VWHPDOZD\VDXWRPDWLFDOO\UHVWRUHVWKH.LVV3RLQWYDOXHHYHU\WLPHWKHYHKLFOH
is started (when certain temperature and operating conditions are reached) to keep the pickup of the vehicle in
optimum condition according to clutch wear.
8
L714 10 90 00
Grid Self tuning (Routine 2)
1RWH
A
Routine 2 lets you set the engagement /selection grid regarding the gears.
the values “1” and “2” indicating the odd and even gears, respectively, that are engaged are displayed
intermittently during operation.
it displays the following values at the end of the operation: Fig.10
line 1 B
14 = positive result (engagement /selection grid performed)
8 = non-compliant result (grid not performed due to electrical problems)
9 = non-compliant result (grid not performed because idle gears are not found)
line 2 0 = unacceptable grid
1 = acceptable grid
In order to store the grid value, turn the ignition key to OFF and wait for approx. 1 minute to allow the control unit to
turn off (check this value in MWB 64).
9
L714 10 90 00
Clutch Characteristic Self tuning (Routine 3) (adaptation to degree of deterioration)
1RWH
:DUQLQJ
Routine 3 is performed ONLY for clutch replacement. If performed in other conditions, you risk damaging the A
clutch.
When the clutch is replaced, Routine 3 must be the FIRST operation to perform with the basic setting.
• Turn the ignition key to OFF and wait about one minute to allow the control unit to turn itself off, then turn the
key back to ON.
• Connect the computer to the diagnosis outlet OBDII.
Fig.11
Routine 3 calculates the new degree of deterioration value and writes the new clutch. B

line 1 0 = positive result (wear index successfully calculated)
255 = non-compliant result
line 2 diplays the degree of deterioration value (when the clutch is new, the value is 4000)
line 3 not used
line 4 not used
Once the new degree of deterioration is calculated, start the engine and run it until it reaches a temperature of about
&DQGXVHWKHYHKLFOHLQWRZQWUDI¿FIRUDERXWPLQXWHVLQRUGHUWRFRPSOHWHO\DGDSWWKHFOXWFKDQGLWVGHJUHH
of deterioration.
10
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Neutral Engagement (Routine 4)
1RWH
• Turn the ignition key to OFF and wait about one minute to allow the control unit to turn itself off, then turn the A
key back to ON.
Routine 4 checks if the position of the idle gear is correct (the condition is checked only if a correct gear engagement
grid has been created – Routine 2 -).

riga 1 3 / 14 = gear in neutral Abb.12
B
9 = idle gear not found
11
L714 10 90 00
Hydraulic circuit discharge (Routine 5)
1RWH
• the E-gear oil level is checked
• gearbox is replaced
• the E-gear kit is replaced
A
key back to ON.
Routine 5 empties the pressure inside the E-gear circuit.
displays activation of the solenoid valve:

line 1 0 = not activated Fig.13
B
1 = activated
displays the pressure value (during the pressure release phase, it continuously drops until it reaches
line 2
value 0)
displays the clutch status:
line 3 1 = activated
0 = not activated
displays the status of the hydraulic circuit:
0 = not activated
When the pressure reaches 0 bar, you can work on the circuit without risking pressure leaks.
1RWH
Work on the circuit with the key OFF. If you turn the ignition key to ON, the system automatically brings
pressure back inside the circuit.
12
L714 10 90 00
Hydraulic circuit bleeding (Routine 6)
1RWH
• the clutch circuit has to be bled (e.g. if the thrust bearing is replaced)
key back to ON.
A
• Connect the pipe to the gearbox bleeding point
Routine 6 lets you bleed the clutch circuit.
displays the opening and closing of the bleed valve (opens/closes it 30 times)
line 1 0 = not activated
1 = activated Fig.14
B
line 2 displays the pressure value
displays the clutch status:
0 = not activated
displays the status of the hydraulic circuit:
0 = not activated
1RWH
Every time the clutch is bled it is then necessary to repeat Routine 5 in order to re-establish the correct oil
level.
13
L714 10 90 00
0HDVXUHPHQWYDOXHV(*($5
The “Measurement values” function display information about the vehicle in real time:
/HYHU&RPXQLFDWLRQ
Total of detected comunication with the lever
Lever Comunication Lever initialisation status 0 = not active , 1 = active
0:%
Problem disable lever status 0 = not active , 1 = active
answer active information 0 = not active , 1 = active
0:%
'LVWULEXWHG)XQFWLRQ
Key lock status 0 = not active , 1 = active
engaged gear 1,2,3,4,5,6,R,N0,N1,N2,N3,N4
0:% Anti Rolling Function
Handbrake status 0 = not active , 1 = active
Kl 15 status 0 = not active , 1 = active
YHULH¿HGOHYHUSRVLWLRQ +,-,U,X,R
0:% Gearbox not shifting
brake satus 0 = not active , 1 = active
software shift lock status 0 = not active , 1 = active
vehicle speed km/h
engine speed rpm
0:% Gearbox not shifting
brake satus 0 = not active , 1 = active
YHULH¿HGOHYHUSRVLWLRQ +,-,,U,X,R
cranking release status 0 = not active , 1 = active
Kl50 (cranking request) 0 = not active , 1 = active
0:% engine doesn’t start
brake status 0 = not active , 1 = active
14
L714 10 90 00
Scam Status
DC Pump Commanded 0 = not active , 1 = active
pump temperature °C
0:% hydraulic
system pressure bar
Shift valve status 0 = not active , 1 = active

Gear 1 Valve current A corrente assorbita
0:% Valves
gear 2 Valve current A corrente assorbita
Clutch current A corrente assorbita
Gear 1 Valve dither magnitude A corrente assorbita

0:% Valves
gear 2 Valve dither magnitude A corrente assorbita
Clutch valve current magnitude A corrente assorbita
clutch wear index default = 4000 , default max = 15000
0:% Clutch status
clutch closed position default min = 1050 , default max = 2000
clutch closed position (learned) default min = 1050 , default max = 2000
Clutch Position normal value >1000 Closed; < -200 Opened
clutch kiss point default = 480; 300 < Kiss Point < 800
0:% Clutch status
clutch reference position bit
Clutch temperature °C
R - position gear (learned , valve not default value : XGbGearTunOf_7 = 699
commanded)
0:% Adapatative Value for R R - position shift (learned) default value : XGbGearShiftTun = 366
current gear position reading by gear position sensor
current shift position reading by shift position sensor
N - position gear (learned , valve not default value : XGbGearTunOf_0 = 409
commanded)
0:% Adapatative Value for N N - position shift (learned) default value : XGbGearShiftTun = 366
15
L714 10 90 00
1 - position gear (learned , valve not default value : XGbGearTunOf_1 = 325

commanded)
0:% Adapatative Value for 1 1 - position shift (learned) default value : XGbGearShiftTun = 475
commanded)
commanded)
commanded)
commanded)
commanded)
16
L714 10 90 00
Voltage
Kl 30 voltage V
0:% Voltage
Sensor supply voltage V
(QJLQH,QWHUIDFH
driver wish torque Nm
engine generated torque Nm
0:% engine interface
gearbox wish torque Nm
gearpox protection torque Nm
engine speed rpm
targhet engine speed rpm
0:% engine interface
synchronisation time s
]ZLVFKHQJDVÀDJ 0 = not active , 1 = active
Shift active (hold value for 1 second) 0 = not active , 1 = active
Status of desired torque (values sommed up) 0=no request; 1=reducing request; 2=increasing
request
0:% Shift interface control
enable torque request (hold value for 1 0 = not active , 1 = active
second)
]ZLVFKHQJDVÀDJ 0 = not active , 1 = active
pick up active (hold value for 1 second) 0 = not active , 1 = active
torque reference Nm
0:% spunto function
speed reference rpm
clutch torque Nm
engine emergency off (hold until Hl 15 off) 0 = not active , 1 = active
0:% interface control
,QSXWV
Clutch Speed rpm
Clutch Position bit
0:% All inputs I
Engine speed (by wire) rpm
Engine speed (by CAN) rpm
17
L714 10 90 00
Oil Pressure 35 bar < pressure < 55

Door switch bit
0:% All inputs II
Kl50 status 0 = not active , 1 = active
Kl15 status 0 = not active , 1 = active
Gear Position sensor value bit
Shift Position sensor value bit
0:% All inputs III
Brake switch 0 = not active , 1 = active
Kickdown status 0 = not active , 1 = active
Customer Habits
% of system ON time in “manual e sprort” %
mode
% of system ON time in “corsa ” mode %
0:% Customer habits I
% of system ON time in “automatic” mode %
% of system ON time in “automatic-sportl” %
mode
Lauch Control Counter (total number LC %
activated)
0:% Customer habits II Launch control status %
Total number of gearshift [value x 100] %
6QDSVKRWVW'7&
DTC decimal code
related failure type
0:% Snapshot 1
time since power up or time since Kl15 off s
gas pedal value %
vehicle speed Km/h
0:% Snapshot 2
engine rpm rpm
engine torque Nm
YHUL¿HGOHYHUSRVLWLRQ +,-,A,U,V,X,R
0:% Snapshot 3
DC pump commanded active = 1 , not active = 0
system pressure bar
18
L714 10 90 00
door switch status door open = 1 , door closed = 0

Kl 50 status
0:% Snapshot 4 brake status brake pressed = 1 , brake not pressed = 0
cranking release status cranking released = 1 , cranking not released
=0
pick up active pick up active = 1 , pick up not active = 0
torque reference Nm
0:% Snapshot 5
speed reference rpm
clutch torque Nm
shifting active shifting active = 1 , shifting not active = 0
status of desired torque no request = 0 , reducing request = 1 , increasing
request = 2 , error detected = 3
0:% Snapshot 6
=ZLVFKHQJDVÀDJ ÀDJVHW ÀDJQRWVHW
clutch status clutch open = 0 , clutch controlled = 1 , clutch
closed = 2 , error detected = 3
gear 1 valve current A
gear 2 valve current A
0:% Snapshot 7
shift valve current valve active = 1 , valve not active = 0
clutch valve current A
clutch position
0:% Snapshot 8
clutch wear index default = 4000 , default max = 15000
clutch temperature °C
Kl 30 voltage V
sensor supply voltage V
0:% Snapshot 9
target gear 1,2,3,4,5,6,R,N0,N1,N2,N3,N4
last engaged gear 1,2,3,4,5,6,R,N0,N1,N2,N3,N4
0:% Snapshot 10
driving mode A , A Sport , M , M Sport , N , R
Kickdown status shifting active = 1 , shifting not active = 0
19
L714 10 90 00
)DXOW,GVIRU'7&HQWULHV
1° DTC decimal code
1° DTC failure type
0:% DTC 01
0:% DTC 02
0:% DTC 03
'HYHORSHUV0%V
MM Hw Version - HW version - Serial number
0:% TCU HW Information
Software Version - Boot Version
0:% TCU SW Information
0:% Lever information
CAN version number

(CAN-multiplex info from engine coding
0:%
engine_2 message) transmission coding
max engine torque
20
L714 10 90 00
information on Last grid learning 0= positive; 1: in progress; 255= negative

TXDOL¿FDWLRQELWIRUJULGGDWDLQ((3520 0=Data in EEPROM old* or invalid or new TCU;
0:% Adaptation Status 1= Data in EEPORM valid
Clutch kiss point learning status 0= positive; 1: in progress; 255= negative
clutch wear index status 0= positive; 1: in progress; 255= negative
R-Position gear (learned, valve commanded) bit
N-Position gear (learned, valve commanded) bit
0:% Adaptation Status S-Cam
1-Position gear (learned, valve commanded) bit
0:% Adaptation Status S-Cam
Plausibility result Display of two Bytes in binary
format
(Result of plausibility check
0:%
of grid self learning)
GearPos Variation Odd gears

Variation of Gear-and GearPos Variation Even gears
0:% Shiftpositions due to ShiftPos Variation
GridMovementAdaption Mileage at last requested successful
GridSelfTuning
21
L714 10 90 00
04 Basic setting (for engine injection control units)
The “Basic setting” function allows you to make the initial settings on the selected control unit (engine injection).
Default setting: throttle (throttle body) adaptation (Routine 60) (Setting)

0$67(5
1RWH
• the throttle is adapted
• Engine OFF (on both the MASTER “01” and SLAVE “11” control units).
• Turn the ignition key to ON. A
displays the throttle potentiometer 1 angle:

line 1 minimum 10%
maximum 20%
displays the throttle potentiometer 1 angle:
line 2 minimum 80% B
maximum 90% 6/$9(
displays the step counter:
line 3 minimum 0
maximum 8
ADP is OK = adaptation is not necessary A
line 4
ERROR = repeat adaptation
OK = successfully completed
Fig.15
B
22
L714 10 90 00
Electric vacuum pump test (Routine 8) (Test)
1RWH
• the brake vacuum pump is tested.
• Engine OFF (on MASTER “01” control unit).
• 3UHVVWKHEUDNHIRUFHIXOO\WZLFH³7HVW21´DSSHDUVLQ¿HOG\RXKHDUWKHSXPSVWDUWXS.
displays the brake status: A

line 1 enabled
not enabled
displays the pump status:
line 2 pump ON
pump OFF
line 3 GLVSOD\VWKHEUDNLQJIRUFHDPSOL¿HUSUHVVXUHWKHSUHVVXUHGURSVZLWK³7HVW21´
Test ON
Test OFF
line 4 displays the operation result: Fig.16
Sys. OK = rated values successfully reached B
Sys. not OK = rated values not reached
23
L714 10 90 00
Load control valve adaptation (Tumble) (Routine 142/144) (Setting)
1RWH
Routine 142/144 is performed when: 0$67(5
• the load control valve adaptation (tumble) status is checked.
• Select routine 142 (load control valve adaptation MASTER “01”) or 144 (load control valve adaptation SLAVE A
“11”) inside the block number (A-Fig.17).
• Start the engine at idle speed.
• Start the connection ( ) and press the start push-button (B-Fig.17)
• Once adaptation on the MASTER “01” control unit is complete, repeat the operation on the SLAVE “11” control
unit.
line 1 displays the real LBK position, expressed as percentage

line 2 displays the theoretical LBK position, expressed as percentage
line 3 LBK adaptation offset B
displays the operation result (cylinder bank adaptation status): 6/$9(
line 4 ADP is OK = rated values successfully reached
ERROR = rated values not reached
Fig.17
B
24
L714 10 90 00
Oxygen sensor thrust test (PRE) (Routine 199) (Setting + Test)
1RWH
• sthe oxygen sensor thrust test is performed. 0$67(5

• Start the engine and take the water temperature to > 80°C. A
• 3UHVV WKH DFFHOHUDWRU SHGDO GRZQ ¿UPO\ DQG TXLFNO\ ! PLQ WR PDNH WKH USP GURS GRZQ (propulsion
phase)
line 1 displays the engine rpm

line 2 displays the operating status
line 3 xxxxxx10 = rated values successfully reached
ERROR = rated values not reached B
line 4 not used 6/$9(
• Wait until the rated values are displayed in the 3rd¿HOG

• Switch over to engine II electronics (control unit 2).
• Wait for the rated values to appear in the 3rd¿HOGDQRWKHUTXLFNKDUGSUHVVGRZQRQWKHDFFHOHUDWRUPD\EH
A
necessary.
Fig.18
B
25
L714 10 90 00
Tank bleed valve diagnosis (Routine 190) (Test)

0$67(5
1RWH
• the tank bleed valve diagnosis is carried out. A

line 1 displays the TEV (pulsing rate) opening percentage

line 2 displays the oxygen sensor regulator average value percentage
line 3 displays the idle speed regulator percentage (diagnosis value with diagnosis enabled)
displays the result of the TEV test:
line 4 TEV is OK = rated values successfully reached
6/$9(
1RWH
7KHWHVWUXQVDXWRPDWLFDOO\WZLFHEHIRUHWKH¿QDOUHVXOWLVGLVSOD\HG A
B Fig.19
26
L714 10 90 00
Intake camshaft adjustment solenoid valves diagnosis (Routine 191) (Test)
1RWH
• the intake camshaft adjustment solenoid valves diagnosis is run. 0$67(5

• Select routine 191 inside the block number (A-Fig.20) on the MASTER “01” control unit.
• Start the engine and bring it to 2200 rpm. A
• Wait for the values to be reached and then repeat the procedure on the SLAVE “11” control unit.
line 1 displays the rpm

line 2 vdisplays the load expressed as percentage
line 3 --
displays the result of the intake camshaft adjustment:
line 4 Sys. OK = rated values successfully reached
6/$9(
Fig.20
B
27
L714 10 90 00
Exhaust camshaft adjustment solenoid valves diagnosis (Routine 192) (Test)
1RWH
Routine 192 is performed when: 0$67(5
• the exhaust camshaft adjustment solenoid valves diagnosis is run.
• Select routine 192 inside the block number (A-Fig.21) on the MASTER “01” control unit. A
• Start the engine and bring it to 2200 rpm.
• Wait for the rated values to be reached and then repeat the procedure on the SLAVE “11” control unit.
line 1 displays the rpm

line 2 displays the load expressed as percentage
line 3 not used
displays the result of the exhaust camshaft adjustment:
line 4 Sys. OK = rated values successfully reached B
ERROR = rated values not reached 6/$9(
Fig.21
B
28
L714 10 90 00
Diagnosis of the exchange of oxygen sensors downstream of the catalytic converter and knock sensors
(POST) (Routine 195) (Test)
1RWH 0$67(5
• the diagnosis of the exchange of oxygen sensors downstream of the catalytic converter and knock
sensors is performed.

A
• Wait until the values are reached.
displays the combustion shock sensor test result:

B
line 2 displays the cylinder bank 1 sensor voltage, sensor 2
6/$9(
line 3 non utilizzato
A
B
Fig.22
29
L714 10 90 00
Diagnosis of the oxygen sensor upstream of the catalytic converter / aging (PRE) (Routine 193) (Test)
1RWH
Routine 193 is performed when: 0$67(5
• the diagnosis of the oxygen sensors upstream of the catalytic converter / aging is performed.
• Select routine 193 inside the block number (A-Fig.23). A
• Switch over to engine electronics (MASTER “01”).
• Wait until the rated values are reached and switch over to engine II electronics (SLAVE “11”).
line 1 displays the dynamic factor

B1-P1 OK = rated values successfully reached (cylinder bank 1) B
line 2
B2-P1 OK = rated values successfully reached (cylinder bank 2)
6/$9(
line 3 not used
line 4 not used
Fig.23
B
30
L714 10 90 00
Checking the oxygen sensors downstream of the catalytic converter / ready operation status (POST)
(Routine 194) (Test)
1RWH 0$67(5
• the oxygen sensors downstream of the catalytic converter / ready operation status are checked.
A
line 1 displays sensor 2 voltage

displays the operation result: B
B1-S2 OK = rated values successfully reached (cylinder bank 1)
line 2 6/$9(
B2-S2 OK = rated values successfully reached (cylinder bank 2)
line 3 not used
line 4 not used
A
Fig.24
B
31
L714 10 90 00
Diagnosis of the tank seal (LDP) (only for USA) / Secondary air system (SL) (Routine 198) (Test)
1RWH
• diagnosis of the tank seal (LDP) (only for USA) / Secondary air system (SL) is performed.
1RWH
The secondary air pump (and relevant diagnosis) goes into operation only once every time the engine is
started, so RESTART THE ENGINE BEFORE REPEATING THE TEST.
displays the result of the tank seal (ONLY USA VERSION):

line 1 Sys. OK = rated values successfully reached Fig.25
B
line 2 not used
line 3 GLVSOD\VWKHUHOHYDQWVHFRQGDU\DLUÀRZH[SUHVVHGDVSHUFHQWDJH
32
L714 10 90 00
Detection of irregular engine ignition (Routine 14) (Test)
1RWH
• engine ignition is checked.
• Select routine 14 inside the block number (A-Fig.26) on the SLAVE “11” control unit.
1RWH
Perform the test for at least 5 seconds.
line 1 displays the engine rpm at idle

line 2 displays the load expressed as percentage
line 3 Total counter of irregular ignitions (value < 5)
displays the operation result: Fig.26
B
line 4 enabled = rated values successfully reached
blocked = rated values not reached
33
L714 10 90 00
0HDVXUHPHQWYDOXHVengine injection control unit)
The “Measurement values” function display information about the vehicle in real time:
*HQHUDO
Engine speed Coolant temperature Oxygen sensor adjustment value Oxygen sensor adjustment value
QPRW WPRWOLQ Cylinder bank 1 / Cylinder bank 3 Cylinder bank 2 / Cylinder bank 4
IUBZ IUBZ
[1/min] [°C] [%] [%]
min: 500 min: 80 min: -15 min: -15
max: 7200 max: 115 max: 15 max: 15
*HQHUDO
Engine speed Load Injection time Air mass
QPRW UO WLBO PVKIPBZ
[1/min] [%] [ms] [g/s]
min: 500 min: 7 min: 0.5 min: 1.5
max: 7200 max: 100 max: 6.5 max: 400
,GOHYDOXHV ,GOHYDOXHV ,GOHYDOXHV ,GOHYDOXHV
min: 500 min: 12 min: 0.5 min: 1.5
max: 800 max: 23 max: 1.5 max: 3.5
003 General
Engine speed Air mass Throttle angle (potentiometer) Ignition timing (real value)
QPRW PVKIPBZ ZGNED zwout, 9
[1/min] [g/s] [%] [°v.OT]
min: 500
min: 500 min: 1.5 min: 0 min: -10
max: 7200 max: max: 100 max: 50
min: 500 min: 1.5 min: 0 min: -5
max: 800 max: 3.5 max: 3 max: 20
*HQHUDO
Engine speed Battery voltage Coolant temperature Intake air temperature WDQVOLQ
QPRW ZXEBZ WPRWOLQ
[1/min] [V] [°C] [°C]
min: 500 min: 12 min: 80 min: Outside temperature
max: 7200 max: 15 max: 115 max: 115
34
L714 10 90 00
*HQHUDO
Engine speed Load Speed Speed
QPRW UO Y¿OBZ 87
[1/min] [%] [km/h] Text
min: 500 min: 7 min: 0 Minimum
max: 7200 max: 100 max: 250 Partial load
Full load
Release
Enrichment
*HQHUDO
Engine speed Load Intake air temperature Altitude correction
QPRW UO WDQVOLQ IKR
[1/min] [%] [°C] [%]
min: 500 min: 7 min: Outside temperature min: -50
max: 7200 max: 100 max: 115 max: 20
'LUHFWLQMHFWLRQPRGH
Engine speed Load Coolant temperature Direct injection mode
QPRW UO WPRWOLQ EGHPRGBZ
0 homog., oxy. sens.=1
1 homogeneous, poor
2 homogeneous / layer
3 Layer
[1/min] [%] [°C]
4 Layer / cat. Conv. Heat.
5 Free
6 Free
7 Combustion shock protection
(OHFWULFYDFXXPSXPSVKRUWWULSGLVSOD\LQ0DVWHURQO\
- &RQWUROFRQGLWLRQV engine off; ignition enabled, automatic gearshift in “P” or “N”
- Start the short trip with the “Activation” button
3UHVVWKHEUDNHIRUFHIXOO\WZLFH³7HVW21´DSSHDUVLQ¿HOG
:DLWXQWLO³6\VW2.´LVGLVSOD\HGLQ¿HOG
Brake activation Pump command BKV absolute pressure Result
recognised%BEUN %BENYHS SENYBZ 603
Text Text [mbar] Text
Not enabled Pump OFF Test OFF
Enabled Pump ON Test ON
6\VW2.
Syst. not OK
35
L714 10 90 00
:,97LPHEHWZHHQPDLQWHQDQFHRSHUDWLRQVH[WHQGHG
Oil level Oil alarm threshold Fuel consumption signal Equivalent consumption
ROIVWBZ VZROIVW NYDNELBZ DHTNYBZ
[mm] [mm] [-] [-]
Turning it on
010 Turning it on
Engine speed Load Throttle angle (potentiometer) Ignition timing (real value)
QPRW UO ZGNED ]ZRXW
[1/min] [%] [%] [°v.OT]
min: 500 min: 7 min: 0 min: -10
max: 7200 max: 100 max: 100 max: 50

min: 500 min: 12 min: 0 min: -5
max: 800 max: 23 max: 3 max: 20
011 Turning it on
Engine speed Coolant temperature Intake air temperature Ignition timing (real value)
QPRW WPRWOLQ WDQVOLQ ]ZRXW
[1/min] [°C] [°C] [°v.OT]
min: 500 min: 80 min: Outside temperature min: -10
max: 7200 max: 115 max: 115 max: 50
014 Switch recognition
Engine speed Load Cumulative switch counter Switch recognition status,
QPRW UO I]DEJVBZ 232
[1/min] [%] [] Text
min: 500 min: 7 0 enabled
max: 7200 max: 100 locked
6ZLWFKUHFRJQLWLRQGLVSOD\LQ6ODYHRQO\
Counter cyl. 1 Counter cyl. 2 Counter cyl. 3 Switch recognition status,
)]DEJ]\OBZB I]DEJ]\OBZB I]DEJ]\OBZB 232
[] [] [] Text
0 0 0 enabled
locked
36
L714 10 90 00
)]DEJ]\OBZB I]DEJ]\OBZB I]DEJ]\OBZB 232
[] [] [] Text
0 0 0 enabled
locked
I]DEJ]\OBZB I]DEJ]\OBZB I]DEJ]\OBZB 232
[] [] [] Text
0 0 0 enabled
locked
/RDGVSHHGIRUVZLWFKUHFRJQLWLRQZLQGRZLIVZLWFKHV !DUHQRWGHWHFWHGGLVSOD\LQ6ODYHRQO\
Lower speed ref. value Upper speed ref. value Lower load ref. value Upper load ref. value
DIQPQ DIQPQ DIQPQ DIQPQ
[1/min] [1/min] [%] [%]
min: 500 min: 500 min: 7 min: 7
max: 7200 max: 7200 max: 100 max: 100
Counter cyl. 10 Switch recognition status,
I]DEJ]\OBZB 232
[] Text
0 enabled
locked
&RPEXVWLRQVKRFNDGMXVWPHQW
Call-up of ignition timing Call-up of ignition timing Call-up of ignition timing Call-up of ignition timing
cyl. 1 / 6 cyl. 2 /7 cyl. 3 / 8 cyl. 4 / 9
GZNU]B GZNU]B GZNU]B GZNU]B
[°KW] [°KW] [°KW] [°KW]
min: 0 min: 0 min: 0 min: 0
max: 12 max: 12 max: 12 max: 12
37
L714 10 90 00
Call-up of ignition timing
cyl. 5 / 10
GZNU]B
[°KW]
min: 0
max: 12
Engine speed Load Call-up of ignition timing cyl. 1 / 6 Call-up of ignition timing cyl. 2 / 7
QPRW UO GZNU]B GZNU]B
[1/min] % [°KW] [°KW]
max: 7200 max: 100 max: 12 max: 12
Engine speed Load Call-up of ignition timing cyl. 3 / 8 Call-up of ignition timing cyl. 4 / 9
QPRW UO GZNU]B GZNU]B
[1/min] [%] [°KW] [°KW]
max: 7200 max: 100 max: 12 max: 12
Engine speed Load Call-up of ignition timing cyl. 5 /10
QPRW UO GZNU]B
[1/min] [%] [°KW]
min: 500 min: 7 min: 0
max: 7200 max: 100 max: 12
&RPEXVWLRQVKRFNDGMXVWPHQWFRPEXVWLRQVKRFNVHQVRUYROWDJHV
cyl. 1 / 6 cyl. 2 / 7 cyl. 3 / 8 cyl. 4 / 9
UNUQBZB UNUQBZB UNUQBZB UNUQBZB
[V] [V] [V] [V]
max: 15 max: 15 max: 15 max: 15
&RPEXVWLRQVKRFNDGMXVWPHQWFRPEXVWLRQVKRFNVHQVRUYROWDJHV
cyl. 5 / 10
UNUQBZB
[V]
min: 0
max: 15
38
L714 10 90 00
&RPEXVWLRQVKRFNVHQVRUFRQWUROVKRUWWULS
- Function 04 (default setting)
3UHVVWKHEUDNHSHGDODQGDWWKHVDPHWLPHSUHVVWKHDFFHOHUDWRUSHGDOWRWKHÀRRUWKHVSHHGLVDXWRPDWLFDOO\VHWDWUSPĺ³7HVW21´
- Wait until ³6\VW2.´LVGLVSOD\HGLQ¿HOG
Engine speed Load Coolant temp. Result
QPRW UO WPRWOLQ 165
[1/min] [%] [°C] Text
ª 2200 min: 7 min: 80 Test ON
max: 100 max: 115 Test OFF
6\VW2.
Syst. not OK
2[\JHQVHQVRUVWDWXV
Cylinder bank 1 / 3, Cylinder bank 1 / 3, Cylinder bank 2 / 4, sensor 1 Cylinder bank 2 / 4, sensor 2
sensor 1 sensor 2 49 50
47 48
0 adjustment enabled 0 adjustment enabled 0 adjustment enabled 0 adjustment enabled
%B,U %B,UKN %B,U %B,UKN
1 sensor ready for use 1 sensor ready for use 1 sensor ready for use 1 sensor ready for use
%BVEEYN %BVEEKN %BVEEYN %BVEEKN
2 sensor heating on 2 sensor heating on 2 sensor heating on 2 sensor heating on
%BKVYH B_hshe %BKVYH B_hshe 2
3 cat. conv. obstruction 3 adjustment enabled 3 cat. conv. obstruction 3 adjustment enabled
removal enabled %B,UKNS removal enabled %B,UKNS
%B,UND %B,UND
4 free 4 free
2[\JHQVHQVRUYROWDJHV
Cylinder bank 1 / 3, Cylinder bank 1 / 3, Cylinder bank 2 / 4, sensor 1 Cylinder bank 2 / 4, sensor 1
sensor 1 sensor 1 Real oxygen sensor value Rated oxygen sensor value
Real oxygen sensor value Real oxygen sensor value ODPVRQLBZ ODPVEJBZ
ODPVRQLBZ ODPVEJBZ
[] [] [] []
min: 0.7 min: 0.7 min: 0.7 min: 0.7
max: 2 max: 2 max: 2 max: 1
0L[WXUHDGDSWDWLRQYDOXHVGHWHFWHG
Cylinder bank 1 / 3, Cylinder bank 1 / 3, Cylinder bank 2 / 4, sensor 1, Cylinder bank 2 / 4, sensor 1,
sensor 1, sensor 1, minimum RUDBZ partial load IUDBZ
minimum RUDBZ partial load IUDBZ
[%] [%] [%] [%]
min: - 4 min: - 15 min: - 4 min: - 15
39
L714 10 90 00
2[\JHQVHQVRUDGMXVWPHQWYDOXH
Cylinder bank 1 / 3, adju- Cylinder bank 1 / 3, oxy- Cylinder bank 2 / 4, adjustment value Cylinder bank 2 / 4, oxygen sensor
stment value gen sensor upstream of IUBZ upstream of cat. conv. voltage
IUBZ cat. conv. voltage XXOVXYBZ
XXOVXYBZ
[%] [V] [%] [V]
min: - 15 min: 0 min: - 15 min: 0
&KHFNLQJWKHDJLQJRIF\OLQGHUEDQNR[\JHQVHQVRUVXSVWUHDPRIFDWFRQYVKRUWWULS
3UHVVWKHEUDNHSHGDODQGDWWKHVDPHWLPHSUHVVWKHDFFHOHUDWRUSHGDOWRWKHÀRRUDXWRPDWLFVSHHGDGMXVWPHQWĺ³7HVW21´
- Wait until ³%6RN´LVGLVSOD\HGLQ¿HOG
Engine speed Cylinder bank 1 / 3 Cylinder bank 1 / 3 dynamic value Result
QPRW exhaust gas temperature G\QOVXBZ 951
WDEJP
[1/min] [°C] [] Text
ª 2200 min: Test ON
0.3 Test OFF
%6RN
B1-S1 not ok
&KHFNLQJWKHDJLQJRIF\OLQGHUEDQNR[\JHQVHQVRUVXSVWUHDPRIFDWFRQYVKRUWWULS
Engine speed Cylinder bank 2 / 4 Cylinder bank 2 / 4 dynamic value Result
QPRW exhaust gas temperature- G\QOVXBZ 1022
WDEJP
[1/min] [°C] [] Text
ª 2200 min: Test ON
0.3 Test OFF
%6RN
B2-S1 not ok
40
L714 10 90 00
2[\JHQVHQVRUUHDG\RSHUDWLRQDIWHUFDWFRQYVKRUWWULS
- Wait until ³%%6RN´LVGLVSOD\HGLQ¿HOGVDQG
Cylinder bank 1 / 3 sensor Result Cylinder bank 2 / 4 sensor voltage, Result
voltage, sensor 2 113 sensor 2 114
XVKN XVKN
[V] Text [V] Text
min: 0 Test ON min: 0 Test ON
max: 1 Test OFF max: 1 Test OFF
%6RN %6RN
B1-S2 not ok B2-S2 not ok
&\OLQGHUEDQNR[\JHQVHQVRUVǻR[\JHQVHQVRUVKRUWWULS
Load Cylinder bank 1 / 3 sensor ǻ±R[\JHQVHQVRUF\OLQGHUEDQN Result
UOV voltage, sensor 2 GODWUPRBZ 976
XVKN
[%] [V] [] Text
min: 7 min: 0 min: - 0.03 Test ON
max: 100 max: 1 max: 0.03 Test OFF
%6RN
B1-S1 not ok
&\OLQGHUEDQNR[\JHQVHQVRUVǻR[\JHQVHQVRUVKRUWWULS
Load Cylinder bank 2 / 4 sensor ǻ±R[\JHQVHQVRUF\OLQGHUEDQN Result
UOV voltage, sensor 2 GODWUPRBZ 976
XVKN
[%] [V] [] Text
min: 7 min: 0 min: - 0.03 Test ON
max: 100 max: 1 max: 0.03 Test OFF
%6RN
B2-S1 not ok
41
L714 10 90 00
+HDWLQJ2[\JHQVHQVRUVF\OLQGHUEDQN
Resistor inside cylinder Pulsing rate cylinder bank Resistor inside cylinder bank 1 / 3, Status
bank 1 / 3, sensor 1 1/3, sensor 1 sensor 2 123
ULQOVXBZ 669 ULQKBZ
[Ohm] [%] [kOhm] Text
min: 0 min: min: 0 Heat.nC ON
max: 500 max: max: 0.5 Heat.nC OFF
+HDWLQJ2[\JHQVHQVRUVF\OLQGHUEDQN
Resistor inside cylinder Pulsing rate cylinder bank Resistor inside cylinder bank 2 / 4, Status
bank 2 / 4, sensor 1 2/4, sensor 1 sensor 2 125
ULQOVXBZ 780 ULQKBZ
[Ohm] [%] [kOhm] Text
min: 0 min: min: 0 Heat.nC ON
max: 500 max: max: 0.5 Heat.nC OFF
$JLQJRIR[\JHQVHQVRUVDIWHU&DW0DVWHUVKRUWWULS
Engine speed Cylinder bank 1 / 3 cat. Cylinder bank 1 / 3 sensor voltage, Result
QPRW conv. temperature sensor 2 378
NDWP XVKN
[1/min] [°C] [V] Text
§ min: 200 min: 0 Test ON
%6RN
B1-S2 not ok
$JLQJRIR[\JHQVHQVRUVDIWHUF\OLQGHUEDQNFDWFRQYVKRUWWULS
Engine speed Cylinder bank 2 / 4 cat. Cylinder bank 2 / 4 sensor voltage, Result
QPRW conv. temperature sensor 2 379
WNDWP XVKN
[1/min] [°C] [V] Text
%6RN
B1-S2 not ok
42
L714 10 90 00
&KHFNLQJF\OLQGHUEDQNFDWFRQYFRQYHUVLRQVKRUWWULS
- The short trips in blocks 034 / 035 / 036 / 037 / 038 / 039 / 043 / 044 must be completed with “ok”
- Wait until ³.DW%RN´LVGLVSOD\HGLQ¿HOG
Engine speed Cylinder bank 1 / 3 Cylinder bank 1 / 3 cat. conv. conver- Result
QPRW cat. conv. temperature sion value measured 486
WNLKNPBZ RVFGNWIBZ
[1/min] [°C] [-] Text
Test OFF
.DW%RN
KatB1 not ok
&KHFNLQJF\OLQGHUEDQNFDWFRQYFRQYHUVLRQVKRUWWULS
- The short trips in blocks 034 / 035 / 036 / 037 / 038 / 039 / 043 / 044 must be completed with “ok”
- Enable the short trip with button “4” (Test ON)
- Wait until “.DW%RN´LVGLVSOD\HGLQ¿HOG
Engine speed Cylinder bank 2 / 4 cat. Cylinder bank 2 / 4 cat. conv. conver- Result
QPRW conv. temperature sion value measured 487
WNLKNPBZ RVFGNWIBZ
[1/min] [°C] [-] Text
ª 2200 min: 300 min: 1 Test ON
Test OFF
.DW%RN
KatB2 not ok
rpm adjustment
050 rpm increase
Real rpm Theoretical rpm Air conditioning availability Air conditioner compressor
QPRWOO QVRO %BQDF %BNRH
[1/min] [1/min] Text Text
min: 500 min: 500 A/C-High Compr. ON
max: 2550 max: 2550 A/C-Low Compr. OFF
,GOHYDOXHV ,GOHYDOXHV
min: 500 min: 500
max: 800 max: 800
43
L714 10 90 00
USPVZLWFKRYHURSHUDWLRQV
Real rpm Theoretical rpm Gear notch (Automatic) Battery voltage
QPRWOO QVRO JDQJL ZXEBZ
[1/min] [1/min] [0-7] [V]
min: 500 min: 500 P,N = 0 min: 12
max: 2550 max: 2550 gear = 1-6 max: 15
R=7
USPLQFUHDVHJHQHUDWRUORDG
Real rpm Theoretical rpm Air conditioning availability Windscreen/rear window heating
QPRWOO QVRO %BVDFF %BVIVFY%BVNVF
[1/min] [1/min] Text [%]
min: 500 min: 500 on on
max: 2550 max: 2550 off off
USPLQFUHDVHJHQHUDWRUORDG
Real rpm Theoretical rpm Battery voltage Generator torque
QPRWOO QVRO ZXEBZ PGJHQF
[1/min] [1/min] [V] [Nm , W , %]
min: 500 min: 500 min: 12 min:
max: 2550 max: 2550 max: 15 max:
,GOHVSHHGUHJXODWRUVZLWFKLQV\VWHPVKDYLQJHOHFWURQLFDFFHOHUDWRU
Real rpm Speed Pedal value indicator angle Throttle angle
QPRWOO 87 (potentiometer) (potentiometer)
ZSHGBZ ZGNED
[1/min] Text [%] [%]
min: 500 Minimum min: 0 min: 0
max: 2550 Partial load max: 100 max: 100
Full load
Release
Enrichment
6WDELOL]DWLRQRILGOHVSHHG
Real rpm Idle speed regulator Idle speed regulator Operating conditions
QPRWOO Torque change Dissipated torque adaptation 20
GPOOULBZ GPYDGBZ
[1/min] [%] [%] 0 Air con. compressor %BNRH
1 Gear notch engaged B_fs
min: 500 min: - 3 min: - 3
2 Air cond. available B_nac
max: 2550 max: 5 max: 3
3 Rear window heating%BVNVF
4 free
5 Windscreen heating B_sfsc
44
L714 10 90 00
6WDELOL]DWLRQRILGOHVSHHG
Real rpm Theoretical rpm Idle speed regulator Compressor load signal
QPRWOO QVRO Torque change 20
GPOOULBZ
[1/min] [1/min] [%] 0 Air con. compressor %BNRH
1 Gear notch engaged B_fs
min: 500 min: 500 min: - 3
max: 2550 max: 2550 max: 5
4 free
6WDELOL]DWLRQRILGOHVSHHGDLUFRQGLWLRQLQJFRPSUHVVRUSUHVVXUHVLJQDO
Real rpm Theoretical rpm Air conditioning compressor Compressor load signal
QPRWOO QVRO %BNRH PNROVF
[1/min] [1/min] Text [Nm]
min: 500 min: 500 Compr. ON min: 0
max: 2550 max: 2550 Compr. OFF max: 40
(QJLQHVXSSRUW
Engine speed Load Engine support
QPRW UO %BPROD
[1/min] [%] Text
min: 500 min: 7 on
max: 2550 max: 100 off
Throttle control
7KURWWOHDGDSWDWLRQVKRUWWULS
- Wait until ³$'3RN´LVGLVSOD\HGLQ¿HOG
Throttle angle (potentio- Throttle angle (potentio- DVE adaptation status Operating condition
meter 1) meter 2) OUQVWDW OUQVWDW
XGNSBZ XGNSBZ
[%] [%] [] Text
min: 3 min: 3 min: 0 ADP in progress
max: 93 max: 97 max: 8 $'3RN
ERROR
45
L714 10 90 00
(OHFWURQLFDFFHOHUDWRU
Engine speed Battery voltage Throttle angle Operating conditions
QPRW ZXEBZ ZGNED 20
[1/min] [V] [%]
min: 500 min: 12 min: 0 0 Air con. compressor %BNRH
max: 7200 max: 15 max: 100 1 Gear notch engaged B_fs
4 free
(OHFWURQLFDFFHOHUDWRUSRWHQWLRPHWHUYROWDJHV
Throttle angle (potentio- Throttle angle (potentio- Pedal value indicator angle Pedal value indicator angle
meter 1) meter 2) (potentiometer 1) (potentiometer 2)
XGNSBZ XGNSBZ XSZJBZ XSZJBZ
[%] [%] [%] [%]
max: 93 max: 97 max: 97 max: 49
.LFNGRZQDGDSWDWLRQVKRUWWULS (not D3), display in Master only
8SRQUHTXHVWSUHVVWKHDFFHOHUDWRUSHGDOWRWKHÀRRU
Pedal value indicator Kick-down point detected Kick-down Result
angle (potentiometer 1) (potentiometer 1) 284 ]ONG%BDXWJHW
XSZJBZ XSZNGBZ
[%] [%] Text Text
min: 12 min: 0 - Enable
max: 97 max: 5 Not enabled ADP. in progress
Kick-down $'3RN
ERROR
7KURWWOHSRWHQWLRPHWHUDGDSWDWLRQYDOXHV
Potentiometer 1 lower Potentiometer 2 lower Potentiometer 1 gap Potentiometer 2 gap
adaptation adaptation XGNQOSU XGNQOSU
XGNSDVUBZ XGNSDVUBZ
[V] [V] [V] [V]
min: 0.2 min: 4.1 min: 0.55 min: 4.05
max: 0.9 max: 4.9 max: 0.59 max: 4.45
46
L714 10 90 00
6SHHGDGMXVWPHQWV\VWHP*5$GLVSOD\LQ0DVWHURQO\

Real speed Switch positions Theoretical speed Switch positions
Y¿OBZ 193 Y]LHOBZ 194
[km/h]
min: 0 0 Stop light switch B_bl min: 0 0 GRA on (CAN) B_fgrhsc
max: 250 1 Brake pedal switch max: 250 1 Set (GRA on) B_fgratc
B_br 2 Delay B_fgrtdc
2 Clutch switch 3 Acceleration B_fgrtuc
%BNXSSO 4 Setting B_fgrsec
3 GRA released 5 Pickup B_fgrwac
B_fgrtet 6 Free
4 ACC-SG available 7 GRA on S_fgrhs
B_acc
5 Main switch touched
&:**)*5+
6 GRA status for CAN
CAN Statgra(0
7 GRA status for CAN
CAN Statgra(1\
*HDUER[VWDWXV
Engine speed Load Gear notch (automatic gearshift) Converter clutch
QPRW UO JDQJL %BZNDXI%BZN%BZNU
[1/min] [%] [0-7] Text
min: 500 min: 7 P,N = 0 clutch on
max: 7200 max: 100 Gear = 1-6 clutch off
R=7 clutch adj.
ERROR
Reduction of emissions
3XUJHFKHFNVKRUWWULSGLVSOD\LQ0DVWHURQO\
- Wait until ³7(9RN´LVGLVSOD\HGLQ¿HOG
Purge percentage opening Mean oxygen sensor Idle speed regulator, diagnosis value for Result
(pulsing rate) variator value enabled diagnosis 195
WDWHRXW LNDNGLIIBZ UPVWHYXIBZ
[%] [%] [%] Text
min: 0 Test ON
max: 100 Test OFF
TEV ok
TEV not ok
47
L714 10 90 00
7DQNVHDOWHVW±OHDNGLDJQRVLVSXPS/'3VKRUWWULSGLVSOD\LQ0DVWHURQO\LQWKH86YHUVLRQ

- Wait until ³6\VWRN´LVGLVSOD\HGLQ¿HOG
Reed contact status Error message Result
235 236 238
Text Text Text
Reed open - Test ON
Reed closed Small leak Test OFF
Considerable leak 6\VWRN
Breakage Syst. not ok
$FWLYDWHGFKDUFRDOWDQNFXWRIIYDOYHFKHFN$$9VKRUWWULSGLVSOD\LQ0DVWHURQO\LQWKH86YHUVLRQ'RQO\
Reed contact status Error message Test status Result
1461 1462 1463 1464
Text Text Text Text
Reed open - - Test ON
Reed closed Breakage Syst. test Test OFF
Measurement 6\VWRN
END measurem. Syst. not ok
&KHFNLQJF\OLQGHUEDQNVHFRQGDU\DLUV\VWHPVKRUWWULS
- short trips in blocks 034/035 must end with “ok”
3UHVVWKHEUDNHSHGDODQGDWWKHVDPHWLPHSUHVVWKHDFFHOHUDWRUSHGDOWRWKHÀRRUWKHUSPLVDXWRPDWLFDOO\VHWDWUSPĺ³7HVW21´
- Short trip can be executed only once with every engine ignition
Engine speed Air mass Cylinder bank 1 / 3 secondary air mass Result
QPRW PVKIPBZ UPVO 239
[1/min] [g/s] [%] Text
ª 1400 Test ON
Test OFF
6\VWRN
Syst. not ok
Breakage
48
L714 10 90 00
&KHFNLQJF\OLQGHUEDQNVHFRQGDU\DLUV\VWHPVKRUWWULS
- short trips in blocks 034/035 must end with “ok”
:DLWXQWLO³6\VW2.´LVGLVSOD\HGLQ¿HOG
- Short trip can be executed only once with every engine ignition
Engine speed Air mass Cylinder bank 2 / 4 secondary air mass Result
QPRW PVKIPBZ UPVO 239
[1/min] [g/s] [%] Text
ª 1400 Test ON
Test OFF
6\VWRN
Syst. not ok
Breakage
([KDXVWJDVYDOYHGLVSOD\LQ0DVWHURQO\'RQO\
Engine speed Load Exhaust gas valve
QPRW UO %BDENO
[1/min] [%] Text
min: 500 min: 7 on
max: 7200 max: 100 off
6SHFLDOEORFNV
,8035'LDJQRVLVIUHTXHQF\VWDWLVWLFVRQO\LQWKH86YHUVLRQ
Default setting LXPSWNBZ LXPSWNBZLXPSWNBZLXPSWNBZ
inactive Mileage IUMPR record number General Denominator Ignition Cycle Counter
active IUMPR record number corresponding CDT Numerator Denominator
086 Ready bit and cycle
5HDG\ELW &\FOHÀDJ &\FOHÀDJ &\FOHÀDJ
1=not ended 1=not ended 1=not ended 1=not ended
0=ended 0=ended 0=ended 0=ended
49
L714 10 90 00
0 Catalytic converter 0 Cyl.bank 1 cat.conv. 0 B1-S1 el. =BOVY 0 B2-S1 el. =BOVY
%BNDWUG\ =BNDW 1 B1-S2 el. Z_lsh 1 B2-S2 el. Z_lsh2
1 Free 1 Cyl.bank 2 cat.conv. 2 B1-S1 Z_pllsu 2 B2-S1 Z_pllsu2
2 AKF system B_tesrdy =BNDW 3 B1-S2 Z_lash 3 B2-S2 Z_lash2
3 SL System B_slsrdy 2 LDP Z_lpd 4 B1-S1 Z_dylsu 4 B2-S1 Z_dylsu
4 Free 3 TEV Z_tes 5 SLS B1 Z_sls 5 Free
ȜB_lsrdy 4 Heating B1-S1 =BKVY 6 SLS B2 Z_sls2 6 Free
6HQVRUȜKHDWLQJ 5 Heating B2-S2 Z_hsh 7 Free 7 Free
B_hsrdy 6 Heating B2-S1 =BKVY
7 Free 7 Heating B2-S2 Z_hsh2
5HDG\DQG(UURU)ODJV
5HDG\ELW (UURUÀDJ (UURUÀDJ (UURUÀDJ
1=not ended 1=not ended 1=not ended 1=not ended
0=ended 0=ended 0=ended 0=ended
0 Catalytic converter 0 Cyl.bank 1 cat.conv. 0 B1-S1 el. =BOVY 0 B2-S1 el. =BOVY
%BNDWUG\ =BNDW 1 B1-S2 el. Z_lsh 1 B2-S2 el. Z_lsh2
1 Free 1 Cyl.bank 2 cat.conv. 2 B1-S1 Z_pllsu 2 B2-S1 Z_pllsu2
2 AKF system B_tesrdy =BNDW 3 B1-S2 Z_lash 3 B2-S2 Z_lash2
3 SL System B_slsrdy 2 LDP Z_lpd 4 B1-S1 Z_dylsu 4 B2-S1 Z_dylsu
4 Free 3 TEV Z_tes 5 SLS B1 Z_sls 5 Free
ȜB_lsrdy 4 Heating B1-S1 =BKVY 6 SLS B2 Z_sls2 6 Free
6HQVRUȜKHDWLQJ 5 Heating B2-S2 Z_hsh 7 Free 7 Free
B_hsrdy 6 Heating B2-S1 =BKVY
7 Free -d 7 Heating B2-S2 Z_hsh2
&\FOHÀDJIRUDGGLWLRQDO2Q%RDUGGLDJQRVHV
&\FOHÀDJ &\FOHÀDJ &\FOHÀDJ
1=not ended 1=not ended 1=not ended
0=ended 0=ended 0=ended
0 Cyl. bank 2 eshaust DN 0 Stop light switch 0 Free
Z_anws2 Z_brems 1 Free
1 Cyl. bank 1 eshaust DN 1 Clutch switch 2 Free
Z_anws =BNXSSO 3 Thermostat Z_thm
2 Cyl. bank 2 intake DN 2 LL adjustment Z_llr 4 Free
Z_enws2 3 Speed signal =BYI] 5 GRA control lever Z_grbh
3 Cyl. bank 1 intake DN 4 LL switch - 6 B2 oxygen sensor adaptation Z_frau2
Z_enws 5 Tmot sensor Z_tm 7 B1 oxygen sensor adaptation Z_frau
4 Combustion shock 6 Throttle potentiometer
sensor 4 =BNV =BGN
5 Combustion shock 7 Air mass meter Z_lm
sensor 3 =BNV
6 Combustion shock
sensor 2 =BNV
7 Combustion shock
sensor 1 =BNV
50
L714 10 90 00
2%''LVSOD\LQ0DVWHURQO\
km travelled with MIL Tank level
kmstmil, 353 %BWDO
1HVVXQDYLVXDOL]]D]LRQH
QHOODYHUVLRQH86
[km] Text
min: 0 ok
max: 65535 too low
3RZHULQFUHDVH
([KDXVWWLPLQJ0DVWHUGLVSOD\LQ0DVWHURQO\
Engine speed Master pulsing rate Master theoretical speed adjustment, Master real speed adjustment,
QPRW WDQZUDDBZ ZQZVDBZ ZQZDBZ
[1/min] [%] [°KW] [°KW]
min: 500 min: 0 min: - 22 min: - 25
max: 7200 max: 100 max: 15 max: 18
0DVWHULQWDNHWLPLQJGLVSOD\LQ0DVWHURQO\
Engine speed Master pulsing rate Master theoretical speed adjustment Master real speed adjustment,
QPRW WDQZUHHBZ ZQZVHBZ ZQZHBZ
[1/min] [%] [°KW] [°KW]
min: 500 min: 0 min: - 18 min: - 21
max: 7200 max: 100 max: 20 max: 23
6ODYHLQWDNHWLPLQJGLVSOD\LQ6ODYHRQO\
Engine speed Slave pulsing rate Slave theoretical speed adjustment Slave real speed adjustment
QPRW WDQZUHHBZ ZQZVHBZ ZQZHBZ
[1/min] [%] [°KW] [°KW]
min: 500 min: 0 min: - 18 min: - 21
max: 7200 max: 100 max: 20 max: 23
7LPLQJDGDSWDWLRQYDOXHV
Master intake DN phase Slave intake DN phase Master exhaust DN phase position Slave exhaust DN phase position
position position GZQZVSDBZ GZQZVSDBZ
GZQZVSHBZ GZQZVSHBZ Display in Master only Display in Slave only
Display in Master only Display in Slave only
[°KW] [°KW] [°KW] [°KW]
min: -7 min: -7 min: -7 min: -7
51
L714 10 90 00
,QWDNHWLPLQJVKRUWWULS
- Wait until ³6\VW2.´LVGLVSOD\HGLQ¿HOGVDQG
Master real speed adjust- Slave real speed adjust- Master result Slave result
ment ZQZHBZ ment ZQZHBZ 140 140
Display in Master only Display in Slave only Display in Master only Display in Slave only
[°KW] [°KW] Text Text
min: -21 min: -21 Test ON Test ON
max: 23 max: 23 Test OFF Test OFF
6\VWRN 6\VWRN
Syst. not ok Syst. not ok
,QWDNHOLQHVZLWFKRYHU'LVSOD\LQ0DVWHURQO\
Engine speed Load Coolant temperature Power supply line status
QPRW UO WPRWOLQ %BVX
[1/min] [%] [°C] Text
min: 500 min: 7 min: 80 SU-V OFF
max: 7200 max: 100 max: 115 SU-V ON
([KDXVWWLPLQJVKRUWWULS
- Wait until ³6\VWRN´LVGLVSOD\HGLQ¿HOGVDQG
Master real speed adjust- Slave real speed adjust- Master result Slave result
ment ZQZDBZ ment ZQZDBZ 619 619
Display in Master only Display in Slave only Display in Master only Display in Slave only
[°KW] [°KW] Text Text
min: -25 min: -25 Test ON Test ON
max: 18 max: 18 Test OFF Test OFF
6\VWRN 6\VWRN
Syst. not ok Syst. not ok
,QWDNHOLQHVQRZYDOYHVZLWFKRYHUGLVSOD\LQ0DVWHURQO\'RQO\
Engine speed Load Coolant temperature Switchover valve status
QPRW UO WPRWOLQ %BOXNO
[1/min] [%] [°C] Text
min: 500 min: 7 min: 80 on
max: 7200 max: 100 max: 115 off
52
L714 10 90 00
([KDXVWWLPLQJ6ODYHGLVSOD\LQ6ODYHRQO\
Engine speed Slave pulsing rate Slave theoretical speed adjustment Slave real speed adjustment
QPRW WDQZUDDBZ ZQZVDBZ ZQZDBZ
[1/min] [%] [°KW] [°KW]
min: 500 min: 0 min: - 22 min: - 25
max: 7200 max: 100 max: 15 max: 18
&RPSDWLELOLW\EORFNV
ȜDGMXVWPHQWLQWHUUXSWLRQE\GHIDXOWVHWWLQJ
Engine speed Coolant temperature Cylinder bank 1 / 3 oxygen sensor Cylinder bank 1 / 3 oxygen sensor varia-
QPRW WPRWOLQ variator IUBZ tor %BOU
[1/min] [°C] [%] Text
min: 500 min: 80 min: - 15 5HJȜ2))
max: 7200 max: 115 max: 15 5HJȜ21
100 Readiness code
5HDG\ELW Engine Temperature: Time from engine start OBD status
1=not ended WPRWOLQ WQVHBZ 142
0=ended
0 Catalytic converter min: 80 min: 0 0 No warm-up-cycle detected B_nowuc
%BNDWUG\ max: 115 max: 6528 1 Warm-up-cycle detected B_wuc
1 Free 2 Free
2 AKF system B_tesrdy 3 Free
3 SL System B_slsrdy 4 At least 1 error detected
4 Free 5 Trip completed B_trip
6HQVRUȜDJLQJ 6 Driving Cycle detected B_dcy
%B,VUG\ 7 MIL on B_mil
6HQVRUȜKHDWLQJ
B_hsrdy
7 Free
Fuel injection
,QMHFWLRQ
Engine speed Load Injection time Air mass
QPRW UO WLBO PVKIPBZ
[1/min] [%] [ms] [g/s]
min: 500 min: 7 min: 0.5 min: 1.5
max: 7200 max: 100 max: 6.5 max: 400
min: 500 min: 12 min: 0.5 min: 1.5
max: 800 max: 23 max: 1.5 max: 3.5
53
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,QMHFWLRQ
Engine speed Coolant temperature Intake air temperature Injection time
QPRW WPRWOLQ WDQVOLQ WLBO
[1/min] [°C] [°C] [ms]
min: 500 min: 80 min: Outside temperature min: 0.5
max: 7200 max: 115 max: 115 max: 6.5
)XHOSXPSDGMXVWHGDVQHHGHGGLVSOD\LQ0DVWHURQO\
Real fuel pressure Fuel pressure regulator I EKP adaptation value Fuel pump status
SENLVWBZ SENVLDBZ SENVDGJBZ 1021
[mbar] Text
min: 4800 Test OFF
max: 6700 ADP in progress
ADP ok
ERROR
&UDQNLQJDGDSWDWLRQYDOXHV
Engine cranking tempera- Cold cranking enrichment Cold cranking enrichment sector 1 Cold cranking enrichment sector 2
ture WPVW sector 0 NVWD NVWD NVWD
[°C] [%] [%] [%]
min: -48 min: 0 min: 0 min: 0
max: 143 max: 16 max: 16 max: 16
)XHOSXPSVGLVSOD\LQ0DVWHURQO\
Fuel Rail pressure EKP pulsing rate Run-down time
SULVWBZ OHSZQENVBZ WDEVWBZ
[bar] [%] [s]
min: 20 min: 0
max: 120 max: 8160
54
L714 10 90 00
)XHOGHOLYHU\V\VWHPVKRUWWULS
Engine speed Mean value cylinder bank Mean value cylinder bank 2 / 4 oxygen Result text, 213
QPRW 1 / 3 oxygen sensor regu- sensor regulator IUPBZ
lator IUPBZ
[1/min] [%] [%] Text
min: 500 min: -15 min: -15 Test ON
max: 7200 max: 15 max: 15 Test OFF
6\VWRN
Syst. not ok
/RDGIXOOORDGHQULFKPHQW
Engine speed Coolant temperature Injection time Throttle angle (potentiometer)
QPRW WPRWOLQ WLBO ZGNED
[1/min] [°C] [ms] [%]
min: 500 min: 80 min: 0.5 min: 0
max: 7200 max: 115 max 6.5 max: 100
0XOWLF\OLQGHUEDQNV\VWHPH[KDXVWJDVWHPSHUDWXUH
Cylinder bank 1 exhaust Cylinder bank 1 sensor Cylinder bank 2 exhaust gas temp. Cylinder bank 2 sensor enrichment
gas temp. enrichment factor WDEJP factor
WDEJP IUPBZ IUPBZ
[°C] [%] [°C] [%]
113 Load
Engine speed Load Throttle angle (potentiometer) Ambient pressure
QPRW UO ZGNED SXVBZ
[1/min] [%] [%] [mbar]
min: 500 min: 7 min: 0 min: 500
max: 7200 max: 100 max: 100 max: 7200
%ORFNVRIFRPPXQLFDWLRQEHWZHHQWKH(&8V
$65)'5
Engine speed ASR/FDR rated torque Engine torque Status
QPRW mi n(miasrl_w,miasrs_w)* (miist-mdverl)*MDNORM, 147 148
MDNORM, 146
[1/min] [Nm] [Nm] Text
min: 500 min: 0 min: 0 ASR active
max: 7200 max: 700 max: 540 ASR n.active
55
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*HDUER[
Engine speed Rated gearbox torque Engine torque Status
QPRW PLJVBZ (miist mdverl)*MDNORM, 147 149
[1/min] [Nm] [Nm] Text
min: 500 min: 0 min: 0 Engine contr. interv.
max: 7200 max: 700 max: 540 No contr. interv.
&$1%XVPHVVDJHV
Gearbox ABS Instrument panel Air conditioning
219 218 430 548
Connections info Connections info Connections info Connections info
- - - -
Gearbox 0 ABS 0 Panel 0 Air conditioner 0
Gearbox 1 ABS 1 Panel 1 Air conditioner 1
&$1%XVPHVVDJHV
Distance Steering angle sensor Airbags Elec. central unit
220 221 453 750
Connections info Connections info Connections info Connections info
- - - -
Distance 0 St. angle 0 Airbags 0 El. CU 0
Distance 1 St. angle 1 Airbags 1 El. CU 1
&$1%XVPHVVDJHV
Steering wheel
760
Connections info
-
Steering wheel 0
Steering wheel 1
&$1%XVPHVVDJHV
Electric ignition switch Engine control unit
813 827
Connections info Connections info
- -
El. ign. sw. 0 Engine 1
El. ign. sw. 1 Engine 0
Slave_Eins 1
Slave_Eins 0
56
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&$1%XVPHVVDJHV
Battery/energy manager TOG sensor (WIV) Gateway
1164 1163 1465
Connections info Connections info Connections info
- - -
E-Manager 0 Oil level 0 Gateway 0
E-Manager 1 Oil level 1 Gateway 1
Cooling
&RROLQJDFFRUGLQJWRW\SLFDOGLDJUDPGLVSOD\LQ0DVWHURQO\
Coolant temperature Thermostat pulsing rate

WPRWOLQ WYNPWU
[°C] [°C]
min: 80 min: Outside temperature
max: 115 max: 115
&RROLQJDFFRUGLQJWRW\SLFDOGLDJUDPGLVSOD\LQ0DVWHURQO\
Coolant temperature Rated speed coolant tem- Thermostat pulsing rate tvkmtr, 478
WPRWOLQ perature tmotsoll, 479
[°C] [°C] [%]
min: 80 min: 80 min: 0
max: 115 max: 115 max: 100
&RROLQJGLVSOD\LQ0DVWHURQO\
Heating potentiometer Cooling status
XKHSRWL 598
[%] 0 No error in system %BNPWUH
1 Thermostat control active WYNPWU
2 Fan control active WYOXHV
3 Adjusted deviation GNPWV!
4 Fan 2 level active B_lues2
5 Fan 1 level active B_lues1
6 Free
7 Coded B_hlon
57
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134 Temperatures
Oil temperature Ambient temperature Intake air temperature: Coolant temperature
instrument panel instrument panel WDQVOLQ WPRWOLQ
WROF WXPF
[°C] [°C] [°C] [°C]
min: 0 min: - 40 min: Outside temperature min: 80
max: 150 max: 60 max: 115 max: 115
)DQFRQWUROGLVSOD\LQ0DVWHURQO\
Fan 1 control pulsing rate Fan 2 control pulsing rate
WYOXHV WYOXHV
[%] [%]
min: 0 min: 0
max: 100 max: 100
136 Fan control relays
Extra water pump Fan coasting
%B]ZS %BQOVJOV
Display in Master only Display in Master only
[Text ] [Text ]
Pump ON On
Pump OFF Off
137 Air conditioning requirements
Air conditioning availability Air conditioner compres- Air conditioning system pressure Air conditioning system fan request
%BQDF sor %BNRH SNRGUF WYOXHVVF
Text Text [bar] [%]
A/C-Low Compr. ON min: 0 min: 0
A/C-High compr: OFF max: 40 max: 100
7KHUPRVWDWGLDJQRVLVVKRUWWULSFDQQRWEHPDGH'LVSOD\LQ86YHUVLRQRQO\
Engine cranking tempera- Mean engine air mass Mean engine speed Result
ture WPVW POPGWKP YIPGWKP 1053
[°C] [g/s] [km/h] Text
Test ON
Test OFF
6\VWRN
Syst. not ok
Breakage
58
L714 10 90 00
7KHUPRVWDWGLDJQRVLVVKRUWWULSFDQQRWEHPDGH'LVSOD\LQ86YHUVLRQRQO\

Engine temperature when Real air mass integral Rated air mass integral Result
diagnosed GLPOH]WKP VLPOH]WKP 1053
PZWKPBZ
[°C] [kg] [kg] Text
Test ON
Test OFF
6\VWRN
Syst. not ok
Breakage
'LUHFWLQMHFWLRQ
)ORZFRQWUROYDOYH069KLJKSUHVVXUHLQMHFWLRQSXPS
Using the IXQFWLRQ³´, the delivery control valve is disabled and the Rail pressure is lowered to a low pressure level (for repairs on the fuel
system)
Flow control valve closing Rated Rail pressure Real Rail pressure Flow control valve status
angle SUVROOBZ SULVW %BPVYRII
GZPVYVBZ
[°KW] [bar] [bar]
min: 0 min: 25 min: 25 deactivated %BPVYRII
max: 220 max: 110 max: 120 active %BPVYDFW
,GOHYDOXH 25
)XHOGHOLYHU\V\VWHP
High pressure system Rail pressure regulator Rail pressure system status
adaptation KGUHUUIBZ GNYEGHBV
SUGUBZ
[bar] [mm³]
/RDGKDQGOLQJYDOYH/%.VKRUWWULSDGDSWDWLRQF\OLQGHUEDQN0DVWHU
- Engine at idle conditions
Real position load han- Theoretical position load Potentiometer voltage offset value, Adaptation status, Master
dling valve, Master handling valve Master 514
OENLVWUBZ OENVROBZ XOENRIIVBZ
[%] [%] [V] Text
min: 0 min: 0 min: 0.3 -
max: 100 max: 100 max: 1.5 ERROR
locked
ADP. ok
ADP. in progress
59
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'LUHFWLQMHFWLRQPRGH
Direct injection mode
EGHPRGBZ
0 homog., oxy. sensor = 1
1 homogeneous, pour
2 homogeneous / layer
3 Layer
4 Layer / cat. Conv. Heat.
5 Free
6 Free
7 Combustion shock protection
/RDGKDQGOLQJYDOYH/%.VKRUWWULSDGDSWDWLRQF\OLQGHUEDQN6ODYH
- Engine at idle conditions
:DLWXQWLO³$'3RN´LVGLVSOD\HGLQ¿HOG
Real position load Theoretical position load Potentiometer voltage offset value, Adaptation status
handling valve - Cylinder handling valve cylinder bank 2 1710
bank 2 OENVROBZ XOENRIVBZ
OENLVWUBZ
[%] [%] [V] Text
min: 0 min: 0 min: 3.5 -
max: 100 max: 100 max: 4.7 ERROR
locked
$'3RN
ADP. in progress
Starter control
6WDUWHUFRQWUROGLVSOD\LQ0DVWHURQO\
Starter request terminal 50 Complementary measure- Starter relay 1 Starter relay 2
%BNOSO ment line cl. 50 R %BVWVW %BVWVW
%BNOU
Text Text Text Text
off off off off
on on on on
6WDUWHUFRQWUROGLVSOD\LQ0DVWHURQO\
Interlock switch
6BSQNS
Text
off
on
60
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33 Standard diagnostic
The “Standard diagnostic” function is used for the engine injection control units only:
• 01 MASTER A
• 11 SLAVE
To access the function, follow these directions:

• Select the control unit to be checked “Engine electronics I” (A-Fig.27) and start the connection ( ).
Fig.27
• Select “33 Standard diagnostic” (A-Fig.28).
Fig.28
61
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The “Standard diagnostic” function displays any error codes, the software version and its value ranges (Fig.29).
The value ranges can be displayed in detail (A-Fig.30E\VHOHFWLQJWKHYDULRXVVSHFL¿FJURXSVB-Fig.30):

Fig.29
2. General
3. 0LV¿UH
4. Knocking sensor
5. Lambda oxygen sensor
6. rpm adjustment A
7. Throttle body control
8. Exhaust noise reduction valve
9. Special MWB
10. Variable valve timing
11. Compatibility
12. Direct Fuel injection IDS B
13. Torque request
14. CAN communication
15. Cooling
16. Starter control Fig.30
1RWH
7KHGLVSOD\VDUHGLYLGHGRQWKHVSHFL¿FF\OLQGHUEDQN,WLVWKHUHIRUH127SRVVLEOHWRFKHFNERWKFRQWURO
XQLWVDWWKHVDPHWLPHHDFKKDVLWVLQSXWVDQGVSHFL¿FYDOXHV
Therefore, simultaneous display is NO longer possible today.
62
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³*HQHUDO´
Group “2 General” (Fig.31GLVSOD\VYDULRXVSDUDPHWHUVIURPPEZWRZLWKWKHSUHFLVHVSHFL¿FDWLRQDQGWKHLU 0$67(5

exact correspondence.
A
1RWH
$GGLWLRQDOLQIRUPDWLRQFDQEHVHHQZKHQWKHVSHFL¿FER[LVVHOHFWHGPHDVXUHPHQWXQLWRSHUDWLRQUDQJH«
(A-Fig.31)
This feature is enables for all windows of the groups.
6/$9(
Fig.31
63
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³0LV¿UH´
7KH³0LV¿UH´JURXSFig.32GLVSOD\VWKHPLV¿ULQJFRXQWHUVDQGUHOHYDQWFRQQHFWHGSDUDPHWHUV 0$67(5
1RWH
This function is enabled only for the SLAVE control unit, whereas the parameters of the “2 General” group
are displayed for the MASTER control unit.
6/$9(
Fig.32
64
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³.QRFNLQJVHQVRU´
The “4 Knocking sensor” group (Fig.33) displays the parameters of the mb values regarding the knocking sensors 0$67(5
and various counters.
1RWH
The parameters displayed in this group are activated during engine running, and if an anomalous knocking
occurs.
In the case of error, it is therefore necessary to check the parameters in this special window.
6/$9(
Fig.33
65
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³/DPEGDR[\JHQVHQVRU´
The “5 Lambda oxygen sensor” group (Fig.34) displays all mb values regarding the pre and post-catalyst oxygen 0$67(5
sensors.
1RWH
If there are oxygen sensor failures, use this special window.
6/$9(
Fig.34
66
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³USPDGMXVWPHQW´
The “6 rpm adjustment” group (Fig.35) displays the mb values concerning engine rpm and spark advance adjustment 0$67(5
if accessories are activated.
6/$9(
Fig.35
67
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³7KURWWOHERV\FRQWURO´
The “7 Throttle body control” group (Fig.36GLVSOD\VWKHVSHFL¿FSDUDPHWHUVRIWKHWKURWWOHERGLHVDQGWKHDGMXVWPHQWV 0$67(5

required by the potentiometer of the accelerator pedal.
1RWH
&RQVXOWWKLVVSHFL¿FZLQGRZIRUDQ\HUURUVDVVRFLDWHGZLWKWKHWKURWWOHERGLHV
6/$9(
Fig.36
68
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³([KDXVWQRLVHUHGXFWLRQYDOYH´
The “8 Exhaust noise reduction valve” group (Fig.37) displays the condition of the exhaust valve and the engine 0$67(5
torque and rpm.
1RWH
This function is only active on the MASTER control unit.
&RQVXOWWKLVVSHFL¿FZLQGRZIRUDQ\H[KDXVWYDOYHSUREOHPV.
Fig.37
69
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³6SHFLDO0:%´
The “9 Special MWB” group (Fig.38GLVSOD\VVSHFL¿FPEYDOXHVZLWKELWUHDGLQJ. 0$67(5
1RWH
These parameters can be requested by Lamborghini and analyzed in-house in special cases.
They are of NO use during routine maintenance.
6/$9(
Fig.38
70
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³9DULDEOHYDOYHWLPLQJ´
The “10 Variable valve timing” group (Fig.39) indicates the parameters regarding the valve timing and its range of 0$67(5
operation.
6/$9(
Fig.39
71
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³&RPSDWLELOLW\´
The “11 Compatibility” group (Fig.40GLVSOD\VVSHFL¿FFKDQQHOVIRULQWHUQDO/DPERUJKLQLXVH. 0$67(5
1RWH
These parameters can be requested by Lamborghini and analyzed in-house in special cases.
They are of NO use during routine maintenance.
6/$9(
Fig.40
72
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³'LUHFW)XHOLQMHFWLRQ,'6´
The “12 Direct Fuel Injection DIS” group (Fig.41) indicates the parameters regarding the injection system and the 0$67(5
high and low pressure system.
1RWH
)RUDQ\SUREOHPVZLWKWKHKLJKDQGORZSUHVVXUHV\VWHPFRQVXOWWKLVVSHFL¿FZLQGRZ
6/$9(
Fig.41
73
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³7RUTXHUHTXHVW´
The “13 Torque request” group (Fig.42) indicates the injection times and displays the parameters associated with 0$67(5
them so they can be changed.
6/$9(
Fig.42
74
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The “14 CAN communication” group (Fig.43) indicates the statuses of the various control units and their can lines 0$67(5
that interact with the engine injection control units.
1RWH
&RQVXOWWKLVVSHFL¿FZLQGRZIRUDQ\SUREOHPVDVVRFLDWHGZLWKWKH&$1
6/$9(
Fig.43
75
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³&RROLQJ´
The “15 Cooling” group (Fig.44) displays the parameters of the fans with the various temperatures. 0$67(5
1RWH
For any problems connected to water temperature, air conditioning system and fan operation, consult this
VSHFL¿FZLQGRZ
6/$9(
Fig.44
76
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³6WDUWHUFRQWURO´
The “16 Starter control” group (Fig.45) indicates the activation conditions of the various relays concerning engine 0$67(5
startup.
1RWH
This function is only active on the MASTER control unit.
Fig.45
77
L714 10 90 00
$8720$7,&02'(
To gain access to the “Automatic mode” function, the software has to read the VIN written on the Combi instrument
cluster.
1RWH
If the Combi instrument cluster is new, the VIN has to be written no longer by means of the LaRa-AS, but
through the VAS-PC software (109200).
• Select the “Gallardo Coupè MY09” vehicle (Fig.46).

• Turn the key ON
Fig.46
• Select “Automatic mode” (Fig.47)
Fig.47
78
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• ,QDXWRPDWLFPRGHWKHV\VWHPDXWRPDWLFDOO\UHDGVWKHYHKLFOH¶V9,1WKDWLVGLVSOD\HGLQWKH¿HOGA-Fig.48)
• click NEXT (B-Fig.48) to gain access to the automatic setting functions.
Fig.48
0HQXIXQFWLRQV
The following functions are enabled in the “Menu functions” window (Fig.49):
a window appears from where it is possible to automatically program

Setup replaced control units with the original vehicle data. This function DISABLED
QHHGVWREHHQDEOHGE\WKH]LS¿OH
LGHQWL¿HVWKHVRIWZDUH\HDURISURGXFWLRQDQGWKH&RGLQJFRXQWU\RI
(&8LGHQWL¿FDWLRQ ENABLED
destination of the car) for every control unit on board the vehicle
(*HDU6QDS the E-gear parameters can be read in automatic mode ENABLED
checks the hardware and software of the ECUs against the Lamborghini
(&8&KHFN DISABLED
database
used while checks are being run on the vehicle to verify and print any
5HDG)DXOWFRGH0HPRU\ ENABLED
errors found
Learn remote allows automatic synchronisation of replaced remote controls ENABLED Fig.49
(UDVH)DXOW&RGH0HPRU\ automatically deletes errors in the memory ENABLED
DXWRPDWLFDOO\ FRPSLOHV D YHKLFOH ¿OH ZKHQ WKH YHKLFOH DUULYHV DW
'RFXPHQWDWLRQ WKH GHDOHU DQG WKHQ UHFHLYHV WKH FRUUHFW YHKLFOH ¿OH ZLWK DOO RI WKH ENABLED
automatic functions enabled
79
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The disabled SETUP and ECU CHECK windows (highlighted in grey) will become enabled only after the
“Documentation” function is completed; click “Documentation” (A-Fig.50).
Fig.50
Wait for the system to complete the ECU reading procedure (Fig.51).
Fig.51
80
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:KHQWKHUHDGLQJLV¿QLVKHGWKHV\VWHPUHTXHVWVDXWKRULVDWLRQWRFRQQHFWWRWKH/DPERUJKLQLZHEVLWHYLD,QWHUQHW
connection (Fig.52).
1RWe
Connection can be made later by clicking “No” (A-Fig.52).
,WLVLPSRUWDQWWRUHPHPEHUWKDWWKH¿OHFUHDWHGLQDQ\FDVHUHPDLQVYDOLGIRUWZRGD\VZKHUHDVWKHRQH
UHFHLYHGKDVDVHYHQGD\YDOLGLW\ZLWKYHKLFOHVSHFL¿FDWLRQV.
Fig.52
If the connection is not accepted, you can gain access later by clicking “Action” (A-Fig.53) and then selecting
“Upload” (B-Fig.53). The system connects to the Lamborghini website and the software is opened even if the vehicle B
is disconnected.
Fig.53
81
L714 10 90 00
To establish a connection with the Lamborghini site, an enabled token is necessary, without which the system will
not work.
1RWe
Uploading can only be done via Internet, in observance of the system’s minimum requirements recommended
E\/DPERUJKLQLDQGSURYLGHGWKDWWKLVLQIRUPDWLRQLVVHQWLQWLPHQRODWHUWKDQWZRGD\VDIWHUWKH¿OHLV
created.
A
After connecting to the Lamborghini site, the token’s “Username” and “Password” must be entered (A-Fig.54).
Press “OK” (B-Fig.54WRVWDUWXSORDGLQJWKH]LS¿OH

B
Fig.54
:KHQXSORDGLQJRIWKHFRUUHFWYHKLFOH¿OHKDV¿QLVKHGFOLFN³&ORVHÁ-Fig.55) to disconnect from the Internet.
Fig.55
82
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7KHV\VWHPZLOODXWRPDWLFDOO\XQ]LSWKH¿OHUHFHLYHGDQGDOOWKHZLQGRZVDUHHQDEOHGZKHQWKHSURJUDPLVUHRSHQHG
(Fig.56) (they stay enabled for seven days).
Fig.56
6HW8S
7KHDXWRPDWLFVHWXSV\VWHPLVHQDEOHGRQO\DIWHUWKH]LS¿OHIRUWKHYHKLFOHEHLQJWHVWHGEHFRPHVDYDLODEOH7KH]LS
¿OHPDNHVLWSRVVLEOHWRDXWRPDWLFDOO\ZULWHFRGLQJDQGFDUU\RXWEDVLFFRQWUROXQLWVHWWLQJVLQFDVHRIUHSODFHPHQW
The screen shows the list of ECUs in the vehicle (to be set when they are replaced).
7RVHWXSWKH$,5%$*FRQWUROXQLWVHOHFWWKHUHODWLYH¿HOGDQGFOLFN³6HW8S´$)LJ; the control unit will be

programmed automatically.
A Fig.57
83
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When setup has been completed, the green tick (A-Fig.58) indicates that the operation has been carried out
A
successfully.
7R VHW XS WKH (1*,1( FRQWURO XQLWV LI RQH RU ERWK DUH UHSODFHG VHOHFW WKH UHODWLYH ¿HOGV DQG FOLFN ³6HW 8S´
(A-Fig.59)WKHFRQWUROXQLWZLOOEHSURJUDPPHGDXWRPDWLFDOO\ZULWLQJWKHFRGLQJWKDWLGHQWL¿HVWKHW\SHRIJHDUER[
(e-gear or manual).
1RWe
The engine control units can be setup at the same time or individually.
Fig.58
Fig.59
A
84
L714 10 90 00
successfully.
Fig.60
7RVHWXSWKH(*($5FRQWUROXQLWVVHOHFWWKHUHODWLYH¿HOGDQGFOLFN³6HW8S´$)LJ; the control unit will be

programmed automatically, writing the country of use coding for OBDII codes.
A Fig.61
85
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successfully.
Fig.62
7RVHWXSWKH$%6(63FRQWUROXQLWVVHOHFWWKHUHODWLYH¿HOGDQGFOLFN³6HW8S´$)LJ; the control unit setup

includes writing the coding to identify the type of gearbox (manual or automatic) and the type of brakes (steel or
carboceramic), as well as the basic settings for the steering sensor on the SMLS control unit and the yaw rate sensor
(YRATE).
Fig.63
A
86
L714 10 90 00
The setup wizard for the ABS/ESP control units is the following:
- Turn the steering wheel 90° right and left, then press OK (A-Fig.64).
Fig.64
- Wait for the system to process the subsequent screen. Do not press anything (Fig.65).
Fig.65
87
L714 10 90 00
- Press YES (C-Fig.66) to continue.
Fig.66
- Check the vehicle is horizontal and press OK ')LJ to continue.
'
Fig.67
88
L714 10 90 00
- Wait for the system to process the subsequent screen. Do not press anything (Fig.68).
Fig.68
- Press YES (F-Fig.69) to end the setup procedure: The green tick indicates that the operation has been carried
out successfully.
Fig.69
89
L714 10 90 00
7RVHWXSWKH$,5&21',7,21(5FRQWUROXQLWVHOHFWWKHUHODWLYH¿HOGDQGFOLFN³6HW8S´$)LJ.
Fig.70
A
Press OK (A-Fig.71) ZKHQUHTXHVWHGWKHFRQWUROXQLWVHWXSZLOOVWDUWDXWRPDWLFDOO\ZULWLQJWKHFRGLQJDQGEDVLFÀDS

settings.
When setup has been completed, the green tick indicates that the operation has been carried out successfully.
Fig.71
90
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7RVHWXSWKH,/0FRQWUROXQLWVHOHFWWKHUHODWLYH¿HOGDQGFOLFN³6HW8S´$)LJ.
The control unit setup will start automatically, writing the coding for the country of use in terms of the use of the
lights.
A Fig.72
successfully.
Fig.73
91
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7RVHWXSWKH60/6FRQWUROXQLWVHOHFWWKHUHODWLYH¿HOGDQGFOLFN³6HW8S´$)LJ.
The control unit setup will start automatically, writing the coding for indicator switch to identify the gearbox (automatic
or manual).
A Fig.74
successfully.
Fig.75
92
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7RVHWXSWKH,167580(17&/867(5FRQWUROXQLWVHOHFWWKHUHODWLYH¿HOGDQGFOLFN³6HW8S´$)LJ.
The control unit setup will start automatically, writing the coding for the instrument cluster in terms of onboard
accessories (computer, navigation system, etc.) depending on the country of destination and the type of gearbox.
A Fig.76
successfully.
Fig.77
93
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7RVHWXSWKH*)$FRQWUROXQLWVHOHFWWKHUHODWLYH¿HOGDQGFOLFN³6HW8S´$)LJ.
The control unit setup will start automatically; the writing of the coding will depend on the presence of the lifting
system.
A Fig.78
successfully.
Fig.79
94
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7RVHWXSWKH,17(5,25$/$50FRQWUROXQLWVHOHFWWKHUHODWLYH¿HOGDQGFOLFN³6HW8S´$)LJ.
The control unit setup will start automatically, writing the coding for the alarm system, the frequencies required by
each country of destination and the relative settings.
A Fig.80
successfully.
Fig.81
95
L714 10 90 00
7RVHWXSWKH=.(FRQWUROXQLWVHOHFWWKHUHODWLYH¿HOGDQGFOLFN³6HW8S´$)LJ.
To codify the ZKE control unit, carry out the basic settings on the frequencies used in the country of destination and
the keys featuring the remote control to open and close the doors.
A Fig.82
The setup wizard for the ZKE control unit is the following:
- Press “OK” to start (A-Fig.83).
Fig.83
96
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- Press OK (B-Fig.84) WRFRQ¿UPWKHFRGHRINH\
Fig.84
- When setup has been completed, the green tick (C-Fig.85) indicates that the operation has been carried out
successfully.
Fig.85
97
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7RVHWXSWKH632,/(5FRQWUROXQLWVHOHFWWKHUHODWLYH¿HOGDQGFOLFN³6HW8S´$)LJ.
A Fig.86
successfully.
Fig.87
98
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6DYLQJHQJLQHGDWD
The engine data can be saved in the “Analysis modeÉ\VHOHFWLQJWKH³6WDUWIURPOLVW«´FRPPDQGLQWKHWRSEDU

(A-Fig.88).
1RWH
The program, which is used for saving, is independent from the selection of the control unit in the centre A
bar.
Fig.88
Start the program by clicking on “OK” (A-Fig.89).
Fig.89
99
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The system connects automatically, querying the following control units in sequence:
• 01 Engine electronics I (Fig.90)
• 11 Engine electronics II (Fig.91)
• 21 G.F.A. (Fig.92)
Fig.90 Fig.91 Fig.92
:KHQWKHSURJUDPHQGVWKHV\VWHPRSHQVD¿OHLQ[OPIRUPDWWKDWFDQEHVDYHGDQGVHQWWR$XWRPRELOL/DPERUJKLQL
RUWKHVSHFL¿FIROGHUFDQEHRSHQHGFig.93).
Fig.93
100
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2QFHWKHVSHFL¿FIROGHULVRSHQHGVDYHWKH¿OHDV«VRDVWRQRWRYHUZULWHWKRVHDOUHDG\VDYHGLQW[WFig.94) or

.xml (Fig.95) format.
1RWH
These data are used by Automobili Lamborghini technicians for requests for help, warranty works, etc.
Fig.94
Fig.95
101
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(FXLGHQWL¿FDWLRQ
8VHWKH³(&8LGHQWL¿FDWLRQ´VFUHHQFig.96WRFUHDWH¿OHVLQ[OPIRUPDWIHDWXULQJWKHFRQWUROXQLW31VVRIWZDUH

VWDWXVDQGLGHQWL¿FDWLRQFRGHV
Fig.96
5HDG)DXOW&RGH0HPRU\
Use the “Read Fault Code Memory” screen (Fig.97) to display every error code of the control units on the vehicle
DQGFUHDWHDQ[OP¿OH
&OLFNRQWKHVSHFL¿FFRQWUROXQLWWRGLVSOD\WKHFRGHVDQGUHODWLYHGHVFULSWLRQV
.
Fig.97
102
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(UDVH)DXOW&RGH0HPRU\
Use the “Erase Fault Code Memory” screen(Fig.98) to delete automatically the errors present in every control unit;
RQFHWKHSURFHGXUHKDVEHHQFRPSOHWHGWKHV\VWHPFUHDWHVDQ[OP¿OHZKLFKLVVWRUHGLQDVSHFL¿FIROGHU
Fig.98
(JHDU6QDS
Use the “E-gear Snap” screen (Fig.99) to store the e-gear system data. The system consults the gearbox control
XQLWDQGFUHDWHVDQ[OP¿OH
Fig.99
103
L714 10 90 00
7KH[OP¿OHFDQEHVHQWWR/DPERUJKLQLIRUGLDJQRVLVRUWURXEOHVKRRWLQJFig.100).
7KLV¿OHLVDOVRVWRUHGDXWRPDWLFDOO\LQWKH[OPIROGHU
Learn remote Fig.100
Use the “Learn Remote” screen (Fig.101) to set the remote controls; if the remote controls are replaced, the system
will ask how many remote controls you want to program (the number ranges from a minimum of 1 to a maximum of
5).
Fig.101
104
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While following the procedure, the system will ask you to activate the remote controls in sequence (Fig.102) if they
are recognised it will give the OK, otherwise programming will be denied.
Fig.102
105
L714 10 90 00
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1RWH
$VZHOODVWKHFRGLQJWKH]LS¿OHDOVRFRQWDLQVWKHVRIWZDUHXSGDWHVIRUWKHHQJLQH*)$DQG(JHDUFRQWURO
units.
Engine control unit (ECU) updates

The engine control units are updated using the following procedure:
1. Select “ECU check” (Fig.103) from the “Menu Functions” screen (Automatic mode).
Fig.103
2. Select the 2 engine control units and start the control unit check up (Fig.104).
Fig.104
106
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3. If the result is “OK”, the engine control units have been updated (Fig.105).
Fig.105
4. If the result is “NOK”, you will return to LaRa-AS in “Analysis Mode”. Select one control unit at a time and start
WKH³ÀDVKSURJUDPPLQJ´Fig.106).
Fig.106
107
L714 10 90 00
5. 6HOHFWWKHW\SHRI¿OHFig.107).
Fig.107
6. 7KHV\VWHPDFFHVVHVWKH]LS¿OHIROGHUFig.108).
Fig.108
108
L714 10 90 00
7. 2SHQWKH9,1IROGHURIWKHYHKLFOH\RXZLVKWRUHÀDVKFig.109WR¿QGWKHYHKLFOHVRIWZDUH¿OH
Fig.109
8. Press “Start” to launch the link (Fig.110) and wait about 18 minutes until you receive feedback about the
outcome of the MASTER control unit update.
If the update is incorrect, repeat the procedure.
9. Once the MASTER control unit has been updated, repeat the procedure for the SLAVE control unit.
Fig.110
109
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GFA control unit update

The GFA control unit is updated using the following procedure:
Fig.111
2. The system will start to control the automatic software update of the GFA control unit (Fig.112).
Fig.112
110
L714 10 90 00
3. 2QFHWKHFKHFNKDV¿QLVKHGUHJDUGOHVVRIWKHRXWFRPHWKHV\VWHPZLOODVN\RXZKHWKHU\RXZDQWWRFDUU\RXW
the update; select “YES” (Fig.113) to carry out the update.
Fig.113
4. The system opens LDAS automatically, which will also update the GFA control unit automatically (Fig.114).
1RWH
This procedure is similar to the former MYs, the only difference being that now, it is possible to select just
the GFA, excluding the LIEs.
Fig.114
111
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E-Gear control unit update

The E-Gear control unit is updated using the following procedure:
Fig.115
2. Select the E-Gear control unit and start the control unit check up (Fig.116).
Fig.116
112
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3. If the result is “OK”, the E-Gear control unit has been updated (Fig.117).
Fig.117
4. If the result is “NOK”, you will return to LaRa-AS in “Analysis Mode”. Select the E-Gear control unit and start the
³ÀDVKSURJUDPPLQJ´Fig.106).
Fig.118
113
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5. 6HOHFWWKHW\SHRI¿OHFig.119).
Fig.119
6. 7KHV\VWHPZLOOPDNHWZRVRIWZDUH¿OHVDYDLODEOHZKLFKDUHDOUHDG\ORDGHGLQWKHV\VWHPFig.120):

- EUROPE
- USA
Select the corresponding area and go ahead with the writing as for the former MYs.
Fig.120
114
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7. 6HOHFWWKHVRIWZDUH(XURSHRU86$RQZKLFK\RXZLVKWRUHÀDVKWKHYHKLFOHFig.121).
Fig.121
8. Press “Start” to launch the link (Fig.122); at the end, you will receive feedback about the outcome of the E-Gear
control unit update.
If the update is incorrect, repeat the procedure.
Fig.122
115
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/'$6',$*1267,&6<67(0
Connection to the diagnosis outlet and system startup B
LDAS32 is a tool based on a CAN line interface between a personal computer and the vehicle’s control units
to monitor the engine condition parameters, developed to supply all the information useful for engine tuning and
diagnostics (including OBD II). A
C
The following is possible with the LDAS32:
• 6WRUHG HUURU PHVVDJHV PD\ EH GLVSOD\HG LQ DFFRUGDQFH ZLWK 2%' ,, VSHFL¿FDWLRQV ZLWKRXW XVLQJ WKH VFDQ
tool. D
• The engine condition may be displayed in real time and any necessary adjustments may therefore be made.
• 'DWDVWRUHGE\WKH(&8DFTXLUHGGXULQJHQJLQHRSHUDWLRQPD\EHGRZQORDGHGDQGVDYHGLQD¿OH
2QO\WKH*)$SDUDPHWHUVDUHGLVSOD\HGLQ*DOODUGR)/0<
Fig.1
The system basically consists of:

• LDAS SOFTWARE: Install on personal computer.
• PC-CAN INTERFACE: interface between the personal computer (parallel port) and the CAN line in the car
A. Computer
B. Parallel port connection
C. CAN line connection
D. Fuse panel
• Remove the passenger side mat and, using a screwdriver or a coin, turn the screws (1/2 turn is enough) of the
fuse panel (()LJEHWZHHQWKHÀRRUDQGWKHSDVVHQJHUJORYHER[
• Start the computer.
• &RQQHFWWKH3&&$1,17(5)$&(WRWKHYHKLFOH¶V&$1FRQQHFWRUQH[WWRWKH*)$FRQWUROXQLWDIWHUUHPRYLQJ
the cap that contains the 120 Ohm resistor essential for distinguishing the CAN lines.
• Turn the key to ON. Start the engine if required. Fig.2
• Start the LDAS32 program by double clicking on the icon on the desktop or selecting it from the Windows
menu.
• When started the program’s initial screen will appear, shown in (Fig.2).
1
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Screen description
&$502'(/6(/(&7,216&5((1
To access the program’s functions, click on “LDAS32 Application” and then select “System” from the pull-
down menu ($)LJ). A
A window (%)LJ) is shown for selecting the car model. Select Gallardo and year of production and then
press the 2.EXWWRQ.
B
Fig.3
³'DWD'LVSOD\´0(186&5((1
The “Data Display” pull-down menu (Fig.4) includes the following items:
*)$*$//$5'2)/
/,)7,1*B',$*B9
Fig.4
2
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³*)$*$//$5'2)/´6&5((1
The %$6( screen (Fig.5GLVSOD\VWKHLQSXWVRQWKH*)$FRQWUROXQLW
• 3RUW*B9$/: driver’s door (reads a value equal to 6/7 open and 999/1000 closed)
• /Z7\UHB9$/: oil pressure switch (reads from engine OFF 1023 and engine ON 0)
• )(PSB9$/: reverse gear button (reads 615 OFF and 240 ON)
• 7([WB9$/: CORSA – SPORT buttons (read 500 norm – 208 sport – 688 corsa)
• 3%UNB9$/: AUTO button (reads 613 norm – 240 Auto)
• .DY5B9$/: E-gear levers (read 730 norm – 420 UP – 300 DOWN – 230 N)
Fig.5
3
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³/,)7,1*',$*´6&5((1
The Lifting Diag screen (Fig.6) displays the parameters related to the lifting system.
3DUDPHWHUOLVW
1 2 3
1. 9HKLFOHVSHHG 4
2. Lamborghini parameter 5 8 13
9
3. 3UHVVXUHUHDGE\WKH*)$WKURXJKWKHVHQVRUPRXQWHGRQWKHK\GUDXOLFFRQWUROXQLW 6 10
14
11 15
4. User button for lifting/lowering the vehicle 7 12 16
(value changes according to pressure applied to button) 17
5. Lifting warning light (coincides with the one on the dashboard)
6. 9HKLFOHOLIWLQJORZHULQJVROHQRLGYDOYHFRQWUROWKHQXPHULFDOYDOXHLQGLFDWHVFXUUHQWDEVRUSWLRQLIDOZD\V
zero, solenoid valve probably faulty)
7. Turns on if target is reached (UP or DOWN).
8. Down position upper limit pressure diagnosis
(pressure discharged too often, valves probably jammed)
9. Down position lower limit pressure diagnosis (pressure restored too often, probable circuit leak or jammed Fig.6
valve)
10. UP position lower limit pressure diagnosis (pressure restored too often, probable circuit leak or jammed
valve)
11. Target timeout diagnosis
WKH83RU'2:1SRVLWLRQSUHVVXUHZDVQRWUHDFKHGZLWKLQWKHH[SHFWHGWLPH
12. 6SHHGVLJQDOGLDJQRVLVLQFRQVLVWHQF\EHWZHHQWKHVSHHGUHDGE\WKH*)$VHQVRUDQGWKHVSHHGVHQWE\
the ESP).
13. Pressure sensor electrical diagnosis (sensor disconnected -HI- or shorted to ground -LO-)
14. UP absorption electrical diagnosis
(the solenoid valve that controls lifting absorbs too much current -HI- or too little -LO-)
15. DOWN absorption electrical diagnosis
(the solenoid valve that controls lowering absorbs too much current -HI- or too little -LO-)
16. DOWN valve consistency diagnosis
(activation of the solenoid valve for lowering caused an increase in pressure)
17. UP valve consistency diagnosis
(activation of the solenoid valve for lifting caused a drop in pressure)
,IDQ HUURU RFFXUV WKH FRUUHVSRQGLQJ FRXQWHU LV VHWDWPD[LPXP DQGZLWK HDFKWULS LV GHFUHDVHGRQH XQLW LIWKH
error does not repeat). The counter with the highest value corresponds to the last error that occurred. The diagnosis
counters are reset when LDAS diagnosis is reset.
4
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7KLVLWHPRQWKHKRUL]RQWDOPHQXGLVSOD\VWKHHQJLQHRSHUDWLRQGDWDSUHYLRXVO\VDYHGWRD¿OHWKURXJK³21OLQH
PRGH±6DYHWR%LQDU\¿OH´VHHODWHU
The “2IIOLQHPRGH´ pull-down menu includes the functions shown in Fig.7.
7KH³/RDG%LQDU\)LOHÍXQFWLRQLVDOZD\VDFWLYH7KHRWKHUIXQFWLRQVEHFRPHDFWLYHZKHQWKHELQDU\¿OHKDV
¿QLVKHGORDGLQJVKRZQE\DVSHFLDOZLQGRZ
For details on the other functions, see “On line mode” menu.
To display the binary data, the program’s hardware key must be inserted.
Fig.7
³21/,1(02'(´6&5((1
The “On line mode” (Fig.8) pull-down menu holds all the engine data (operation times and errors). Notes for
each pull-down menu screen are supplied for properly interpreting its data.
Fig.8
5
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³6$9('$7$,1%,1$5<),/(´6&5((1
This screen (Fig.9DOORZVGDWDDFTXLUHGIURPWKHFRQWUROXQLWWREHVDYHGLQDOLH¿OHDQGVWRUHGIRUVXEVHTXHQW

display and analysis.
'XULQJVDYLQJDIWHUFHUWDLQFRQQHFWLRQFKHFNVWKHSURJUDPUHTXHVWVD¿OHQDPHVRWKDWLWPD\EHVWRUHGLQWKH
&?/'$6?'(9,&(?folder.
Fig.9
$IWHUHQWHULQJWKH¿OHQDPHWKHGDWDLVDFWXDOO\VDYHG
When this is done a screen (Fig.10) appears which summarizes the saved data in logical groups.
7KH/('QH[WWRWKHYDULRXVJURXSVLQGLFDWHVWKDWVDYLQJZDVVXFFHVVIXOJUHHQRUWKDWLWIDLOHGUHG
Fig.10
6
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7KH VFUHHQ DOORZV GDWD DFTXLUHG IURP WKH FRQWURO XQLW WR EH VDYHG LQ DQ DFT ¿OH $6&,, IRUPDW DQG VWRUHG IRU
subsequent display and analysis.
This data can be viewed using any “NotePad” program and appears as shown in Fig.11.
'XULQJ VDYLQJ DIWHU FHUWDLQ FRQQHFWLRQ FKHFNV WKH SURJUDP UHTXHVWV D ¿OH QDPH VR WKDW LW PD\ EH VWRUHG LQ D
folder.
Fig.11
$IWHUHQWHULQJWKH¿OHQDPHWKHGDWDLVDFWXDOO\VDYHG
When this is done a screen (Fig.12DSSHDUVZKLFKVXPPDUL]HVWKHVDYHGGDWDLQORJLFDOJURXSV7KH/('QH[WWR

the various groups indicates that saving was successful (green) or that it failed (red).
7KHVFUHHQGLVSOD\VWKHSDUDPHWHUVUHJDUGLQJWKH*)$RQO\ZKHUHDVWKHRWKHUSDUDPHWHUVUHJDUGLQJ
WKHRWKHUFRQWUROXQLWVGLVSOD\WKHQHJDWLYH/('UHG8VH/D5D$6IRUWKHRWKHU*DOODUGR
)/0<FRQWUROXQLWV
Fig.12
7
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The screen (Fig.13) supplies information regarding the type of map, version, year of manufacture and series number
RIWKHWZR/,(VWKH*)$DQGWKH9,1
7KHVFUHHQGLVSOD\VWKHSDUDPHWHUVUHJDUGLQJWKH*)$RQO\8VH/D5D$6IRULQIRUPDWLRQ

DERXWWKH*DOODUGR)/0<HQJLQHLQMHFWLRQFRQWUROXQLWV
Fig.13
8
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The “Commands” pull-down menu (Fig.14) includes the following items:

• Reset Diagnostic Data: resets the errors in the system only with the key turned to ON
• Lifting system commands: permits manual control of certain output signals of the lifting system.
• 3URJUDPSHUPLWVWKH*)$VRIWZDUHWREHXSGDWHG
Fig.14
5(6(76&5((1
The screen (Fig.15) shows the outcome of the automatic error reset.
If the outcome is positive, the error display is empty.
7KLV RSHUDWLRQ UHVHWV WKH OLIWLQJ V\VWHP FRXQWHUV RQ WKH *)$ RQO\ 8VH /D5D$6 IRU WKH
*DOODUGR)/0<HQJLQHHUURUFRGHV
Fig.15
9
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The Lifting system commands screen (Fig.16) allows manual control of the lifting system with the engine
running.
A
B
The “Manual/LDAS (A)” push-button ($)LJ) opens another window to switch to manual (operation however D
remains unaltered).
C
The push-button (%)LJVWDUWVWKHOLIWLQJWREORFNWKHOLIWLQJSUHVVWKHSXVKEXWWRQDJDLQVRWKHVROHQRLGYDOYH

is not continuously energized, leading to the risk of damaging it.
The push-button (&)LJVWDUWVWKHORZHULQJWREORFNWKHORZHULQJSUHVVWKHSXVKEXWWRQDJDLQVRWKHVROHQRLG

valve is not continuously energized, leading to the risk of damaging it. Fig.16
Both the lifting and lowering push-buttons are green when enabled.
The two bars (')LJ) indicate the amps the solenoid valves absorb during the lifting and lowering phases,
depending on the push-button selected.
The bar turns yellow as absorption increases.

7KHZDUQLQJOLJKWRQWKHLQVWUXPHQWFOXVWHUÀDVKHVGXULQJWKLVRSHUDWLRQDQGDVVRRQDVWKHZLQGRZRSHQV
and quits only when the window is closed.
10
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,002%,/,=(5:,7+'2:1/2$'$1'9$63&/$0%25*+,1,
Introduction
The new Gallardo LP 560-4 MY09 is equipped with a modern electronic immobilizer system called “Immobilizer 4
with download”.
This antitheft device blocks vehicle ignition, making its use impossible if a control unit or key are not original or have
B
been tampered with.
The Immobilizer 4 system involves the following vehicle components:

• the two Master 01 (A) & Slave 11 (B) engine control units
• the Immobilizer 25 control unit (integrated in the Kombi 17)
• the ignition keys A
A secret code is concealed inside each component. It is processed and recognised at each start-up by the Immobilizer
25 control unit placed inside the instrument cluster (Kombi 17). If the code read on all components involved coincides,
ignition is permitted. In the event the Immobilizer 25 control unit recognises an inconsistency amongst the secret
codes of the vehicle components, power supply to the engine will be immediately cut off after about three seconds
from ignition, and the word SAFE will appear on the instrument cluster display. It will be impossible to start the engine
until the inconsistency previously found is resolved.
The VAS PC Lamborghini software must be used for managing replacement of the components involved in the
Immobilizer 4 (Fig.1).
The Immobilizer 25 control unit is an integral part of the Kombi, and therefore cannot be replaced
separately.
The VAS PC Lamborghini software allows the components installed on the vehicle to be synchronized with the virtual
YHKLFOHFRQ¿JXUDWLRQLQWKHSURGXFWLRQGDWDEDVH7RSHUIRUPWKHV\QFKURQL]DWLRQFRQQHFWWKHVRIWZDUHWRWKHYHKLFOH
using the OBD II outlet and the laptop to the Internet using a network outlet at the same time. In this way, the VAS
PC software will be able to exchange information between the vehicle and the production database.
1R,PPRELOL]HUFRGHLQ2))/,1(PRGHLVSHUPLWWHG
Fig.1
1
L714 10 92 00
9$63&LQVWDOODWLRQ
To install the software, you need:
• CD 1 VAS PC BASE SOFTWARE

• CD 2 VAS PC LAMBORGHINI
• CD 3 VAS PC URL ADDRESS (contains the settings for Internet connection)
• USB memory stick containing the VAS PC license and the ALM software for managing the license.
7KH$/0VRIWZDUHLVDOVRIRXQGLQVLGH&'9$63&%DVHVRIWZDUHDVD=,3¿OHLQVLGHWKH$/0IROGHU
Start installation by inserting CD 1 into the Lamborghini diagnosis tester drive and follow the instructions on the
screen:
Fig.2
1. 6HOHFWWKHGHVLUHGODQJXDJH(QJOLVKDQGFRQ¿UPE\FOLFNLQJRQ³2N´Fig.2).
,QWKHFXUUHQWYHUVLRQRIWKHLQVWDOODWLRQWKHODQJXDJHPXVWEHVHOHFWHGH[DFWO\DVSHUWKHGHVFULSWLRQV
ZKHQUHTXHVWHGDOZD\VVHOHFWWKH(1*/,6+ODQJXDJH
2. Start installation by clicking on the “Install VAS PC BASE SOFTWARE” push-button (Fig.3).
Fig.3
2
L714 10 92 00
3. 5HDGWKHFRQWUDFWXDOWHUPVDQGFRQ¿UPE\FOLFNLQJRQWKH³$JUHH´SXVKEXWWRQFig.4).
Fig.4
4. Continue installation by clicking on the “start installation” push-button (Fig.5).
Fig.5
3
L714 10 92 00
5. Wait until the system has completed the installation process (Fig.6).
Fig.6
6. 6HOHFWWKHODQJXDJH\RXZDQWWRXVHGXULQJLQVWDOODWLRQ86(QJOLVKDQGFRQ¿UPE\FOLFNLQJRQ³2N´Fig.7).
Fig.7
4
L714 10 92 00
Fig.8
8. 6HOHFWWKHODQJXDJH\RXZDQWWRXVHGXULQJLQVWDOODWLRQ86(QJOLVKDJDLQDQGFRQ¿UPE\FOLFNLQJRQ³2N´

(Fig.9).
Fig.9
5
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9. :KHQLQVWDOODWLRQLV¿QLVKHGSUHVV³)LQLVK´WRH[LWLQVWDOODWLRQFig.10).
Fig.10
10. 6HOHFWWKHODQJXDJH\RXZDQWWRXVHGXULQJLQVWDOODWLRQ86(QJOLVKDJDLQDQGFRQ¿UPE\FOLFNLQJRQ³2N´

(Fig.11).
Fig.11
6
L714 10 92 00
11. Press “Ok” to continue (Fig.12).
Fig.12
12. Press “Quit” to end installation (Fig.13).
Fig.13
7
L714 10 92 00
:KHQLQVWDOODWLRQLV¿QLVKHGWKHEDVHVRIWZDUHXVHU¶VOLFHQVHKDVWREHLQVWDOOHG,WLVIRXQGLQVLGHWKH86%PHPRU\
stick, and has to be transferred onto the hard disk of the laptop.
7RWUDQVIHUWKHOLFHQVH¿OHWKHGHGLFDWHGVRIWZDUHKDVWREHXVHG$XWRPDWLRQ/LFHQVH0DQDJHU
7KH$/0VRIWZDUHVHWXS¿OHLVRQ86%VWLFNLQVLGHWKH$/0IROGHU
7KH$/0VRIWZDUHLVDOVRIRXQGLQVLGH&'9$63&%DVHVRIWZDUHDVD=,3¿OHLQVLGHWKH$/0IROGHU
1. /DXQFK VHWXS E\ FOLFNLQJ WZLFH RQ WKH VHWXS ¿OH LQ WKH $/0?352'8.7?3&6B*OREDO?$/0BB
?UHO?LQVWDOO?VHWXSIROGHUFig.14).
2. After having launched the setup, you are asked to select the language for this installation. Select English and
SUHVV³2N´WRFRQ¿UPFig.14).
Fig.14
3. Continue by clicking on “Next” (Fig.15).
Fig.15
8
L714 10 92 00
4. Continue by clicking on “Next” (Fig.16).
Fig.16
5. Accept the license terms and continue by clicking on “Next” (Fig.17).
Fig.17
9
L714 10 92 00
6. Select the type of installation (Typical) and continue by clicking on “Next” (Fig.18).
Fig.18
7. Select the language (English) and continue by clicking on “Next” (Fig.19).
Fig.19
10
L714 10 92 00
8. Press “Install” to start installation (Fig.20).
Fig.20
Fig.21
11
L714 10 92 00
10. :KHQLQVWDOODWLRQLV¿QLVKHGSUHVV³)LQLVK´WRH[LWLQVWDOODWLRQFig.22).
Fig.22
After the ALM software is installed, insert the USB stick with the VAS PC license and launch ALM by selecting the
license management window, clicking on the icon that appears on the desktop:
Select the USB mobile support from the left-hand menu (A-Fig.23) and highlight the license found inside this
support.
Then click on the license with the right key and select “Transfer…”.
A
Fig.23
12
L714 10 92 00
Select the local disk where the license is to be transferred to and press “OK” (Fig.24).
Fig.24
Close the ALM software after the license has been transferred.
The VAS PC base software can be started after the license has been transferred.
Select the ADMINISTRATION menu and use the ENTER WORKSHOP CODE function (Fig.25).
Fig.25
13
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Then enter the 969 importer code and the 5-digit workshop code assigned by Lamborghini (found on the USB stick
label). Afterwards, enter the workshop ID name and press send “Q” two times (Fig.26).
It will not be possible to enter the workshop ID name during subsequent steps.
Exit the Administration section. Now the software function menu has to be complete.
Fig.26
To update the system with the Lamborghini guided functions, at this point insert CD 2 GFF Lamborghini into the
GLDJQRVLVODSWRSGULYHDQGVHOHFWWKH$'0,1,675$7,21PHQXIURPWKH¿UVWSDJHRIWKH9$63&VRIWZDUHSUHYLRXVO\
started.
7KHQ VHOHFW WKH ¿UVW IXQFWLRQ RQ WKH ,QVWDOO 8SGDWH OLVW DQG SUHVV WKH SXVKEXWWRQ ³2N´ WR FRQ¿UP LQVWDOODWLRQ
(Fig.27).
Fig.27
14
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The Lamborghini guided functions will be installed, updating the base software.
7KHFRQQHFWLRQFRQ¿JXUDWLRQVPXVWQRZEHXSGDWHGE\SXWWLQJ&'85/LQWRWKHODSWRSGULYH
After inserting the CD, select the “Expanded functions” function from the “administration” menu (Fig.28).
Fig.28
Press OK to enable the function (Fig.29).
Fig.29
15
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Do not remove the CD from the drive in spite of the message appearing on the screen and press OK (Fig.30).
Fig.30
Select the “Network settings” menu (Fig.31).
Fig.31
16
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Select the “Import Importer Selections” function (Fig.32).
Fig.32
7KHPHVVDJH³9$.,7KHLPSRUWZDV¿QLVKHGVXFFHVVIXOO\´ZLOODSSHDU1RZSUHVV2.Fig.33).
Fig.33
17
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Return to the “Expanded Functions” function and this time click on “delete” to save the settings (Fig.34).
Fig.34
Now you can take the CD out of the drive (Fig.35).
Fig.35
18
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At this point, the Lamborghini VAS PC software is correctly installed and ready for use.
To exit the VAS PC software, select the GO TO / EXIT menu at the bottom (Fig.36).
Fig.36
9$6GLDJQRVLVLQWHUIDFH
To connect the Lamborghini VAS PC software to the vehicle, it is necessary to use the VAS 5054 diagnosis interface
code: 69190203 (A-Fig. 37).
This interface can be used via Bluetooth connection (B-Fig.37) or by simply using the USB connector (&)LJ) ' & B A
inside the package (')LJ).
Fig.37
19
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Connect the VAS5054 to the vehicle in the OBD outlet and to the computer with the USB cable. Then follow the
automatic hardware installation prompted by Windows (Fig.38).
Press “Next” to continue the automatic installation of the VAS5054 (Fig.38).
Fig.38
To verify that this interface is operating correctly, it is necessary to check the following setting after having connected
the interface both to the vehicle and to the laptop using the USB cable.
/DXQFKWKH($&RQ¿JH[HDSSOLFDWLRQLQVLGHWKHIROGHU&?6,',6?KRPH?'%DVH6\V?(,'%66Fig.39).
The setting in the main window must be “All Applications” (Fig.39).
Fig.39
20
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If the setting in the main window does not correspond to “All Applications”, select the interface by clicking on “Any
EDIC” one time. Select the function “Assign application” to extend the setting to “All Applications” (Fig.40).
Fig.40
,IWKH9$6LQWHUIDFHLVEHLQJFRQQHFWHGWKH¿UVWWLPHLWPXVWEHFRQQHFWHGWRWKHODSWRSE\WKH86%FDEOHDQG
to the vehicle in the OBD outlet so that the software is able to acquire the interface serial code (Fig.41).
The VAS 5054 must be connected to the OBD outlet of the vehicle in order for the interface serial code to
be acquired.
Fig.41
21
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The VAS5054 interface will operate correctly only if the previous setting has been performed correctly.
The VAS 5054 also works via Bluetooth connection. The new Panasonic laptops are already equipped with
a compatible Bluetooth. If your laptop does not have it, it is possible to order a Bluetooth USB stick (code
69190204).
To connect the VAS5054 interface using the Bluetooth, it is in any case necessary to power it by connecting
it to the OBD outlet in the vehicle.
*XLGHG)XQFWLRQVIRUWKH,PPRELOL]HUFRGH
To access the Lamborghini guided functions for the Immobilizer code, select the “Guided Functions” menu on the
main screen (Fig.42).
Fig.42
22
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The Immobilizer code for a replaced control unit can be managed simply by following the instructions displayed on
the screen after the right function has been selected.
There are 8 main functions inside the “Guided Functions”, 5 of which are dedicated only to the Immobilizer code
(Fig.43):
1 Kombi - enable immobilizer / new identity

2 Kombi - vehicle key adaptation, immobilizer IV
3 ECU 01 Master - engine control unit 01 enable immobilizer
4 ECU 11 Slave - engine control unit 11 enable immobilizer
5 ECU 01-11 Engine control units regeneration
6 Kombi - Read measurement value blocks
7 RNSE Interrogate Anti-theft PIN code
Fig.43
1 Kombi - enable immobilizer / new identity
The “1 Kombi – enable immobilizer / new identity” function (Fig.43) must be used if a new identity has to be given
to the immobilizer because a complete keys & locks kit is replaced or if only the “Kombi 17” has to be replaced (see
example on page 27 “Immobilizer code for Kombi 17 replacement”), so the latter has to be simply adapted to the
existing immobilizer.
It is only when the “New Identity” function is selected that you have to get a new complete keys & locks kit
(Fig.44).
Fig.44
23
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2 Kombi - vehicle key adaptation, immobilizer IV
The function “2 Kombi – vehicle key adaptation, immobilizer IV” (Fig.43) is instead used only when the existing keys
have to be adapted to the immobilizer currently in the vehicle. Example: when a customer requests an additional
key.
Only those keys that will be adapted using this procedure can later be used to start the engine. If one of the customer
keys is forgotten, function 2 (key adaptation) must be subsequently launched again and the procedure has to be
repeated for all of the keys again.
If the entire complete locks kit has been replaced, it is necessary to give the immobilizer a new identity by
instead selecting “1 Kombi – enable immobilizer / new identity” as indicated in the note (Fig.45).
The number of keys available will be asked during the key learning procedure (default: 2). Insert each key
in sequence when the tester makes the request.
3 ECU 01 Master - engine control unit 01 enable immobilizer / Fig.45

4 ECU 11 Slave - engine control unit 01 enable immobilizer
The “3 ECU 01 Master – engine control unit 01 enable immobilizer” and “4 ECU 11 Slave – engine control unit
11 enable immobilizer” functions (Fig.43) are instead used for replacing engine control units. Carefully follow the
instructions on the screen to complete the procedure.
Exchanging components between one vehicle and another similar vehicle is possible.
:DUQLQJLWLVQRWSRVVLEOHWRH[FKDQJHWKH0$67(5DQG6/$9(FRQWUROXQLWVHYHQEHWZHHQWZR
GLIIHUHQWYHKLFOHV,IRQHFRQWUROXQLWKDVEHHQFRGHGDV0DVWHUIRUWKHLPPRELOL]HULWLVQRORQJHU
SRVVLEOHWRXVHLWDV6ODYHLQDQ\FDVHZKDWVRHYHURWKHUZLVHERWKHQJLQHFRQWUROXQLWVZLOOKDYHWR
be replaced.
24
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5 ECU 01-11 Engine control units regeneration
The function “5 ECU 01-11 Engine control units regeneration” (Fig. 43) has to be used only when there is an
interruption of communication while assigning a new immobilizer identity to the engine control units. In this case, it
is possible to launch a regeneration to align the engine ECUs with the Kombi.
6 Kombi - Read measurement value block
To check the measurements displaying the correct code of the control units / keys, there is the guided function “Read
measurement value block” in the Kombi (Fig.43).
This displays whether or not the control units have been correctly coded, if the keys have been adapted and the total
number of keys recognised. If Immo status displays status 6, the immobilizer is coded correctly.
The measurements to strictly take into consideration are on the Kombi (Fig.46):
• channel 21 column 1 and 2

• channel 22 column 1,2,3 and 4
• channel 23 column 1,3 and 4
Fig.46
25
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7 RNSE - Interrogate Anti-theft PIN code
The last function, “RNSE – Interrogate Anti-theft PIN code” (Fig.43), is used to request the radio PIN code should
the RNSE request it.
By launching the function, the tester directly acquires the VIN and serial code of the Radio from the vehicle and queries
the main database. The radio PIN will be displayed on the tester, and it can be entered on the radio manually.
The radio PIN code request function also works without being connected to the vehicle. In fact, the program
asks if the tester is connected to the vehicle (Fig.47). If you answer no, it is in any case possible to proceed
with the PIN request procedure, but the AUZB… serial code of the radio and the vehicle VIN, in addition to
the usual customer data, have to be entered manually.
• enter the VIN correctly with all 17 digits

• enter the radio serial correctly with all 14 digits
• LI\RXGRQRWKDYHWKHUDGLRVHULDOFRGH\RXFDQJHWLWYLDDQ(&8LGHQWL¿FDWLRQRIWKH516(WKHFRGHDOZD\V
starts with AUZ… and has a total of 14 digits.
Fig.47
26
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:$51,1*
$OORIWKHIXQFWLRQVSUHYLRXVO\GHVFULEHGUHTXLUHVSHFLDOUHTXHVWVWREH¿OOHGLQVXFKDV
1DPHDQGVXUQDPHRIWKHFXVWRPHU)LJ
ZRUNVKRSMRERUGHU)LJ
QDWLRQDOLW\RIWKHFXVWRPHU)LJ
7KHVH GDWD ZLOO EH VWRUHG LQ WKH GDWDEDVH WR WUDFN WKH RSHUDWLRQV KLVWRULFDOO\ FDUULHG RXW RQ WKH
YHKLFOH
Fig.48
Fig.49
Fig.50
27
L714 10 92 00
Access to the main database by way of user name and password is strictly personal as the data processed are
VHQVLWLYH7RJHWHQDEOLQJWRGDWDEDVHDFFHVVLWLVQHFHVVDU\WR¿OOLQDQGVHQGWKHVSHFLDO*(.2DFFHVVIRUPWR
tania.gonzato@lamborghini.com .
Connection must be made with the database by means of a standard Internet connection with use of user name and
password, the latter being provided by the Lamborghini Token reserved for Geko service (Fig.51).
Remember to enter the secret pin 1324 before the code provided by Token.
$IWHURQH¶VFUHGHQWLDOVDUHDXWKHQWLFDWHGWKHWHVWHUZLOODXWRPDWLFDOO\H[FKDQJHWKHGDWDEHWZHHQWKHYHKLFOHDQGWKH
database, and the newly assembled components will be enabled or the requested information will be furnished.
Carefully follow the instructions on the tester screen to execute the control unit code operations.
Fig.51
28
L714 10 92 00
2QFHWKHSURFHGXUHLV¿QLVKHGLWLVSRVVLEOHWRSULQWDGLDJQRVLVSURWRFROLQ;0/¿OHIRUPDWLIWKHUHDUHSUREOHPV
The protocol contains the operations carried out on the vehicle (Fig.52).
It is advisable to save this protocol on the desktop and send it with a request for assistance to service.department@
lamborghini.com .
Fig.52
%HIRUH\RXFDQVDYHWKH¿OH\RXKDYHWRHQWHUWKHYHKLFOH9,1DQGFDUUHJLVWUDWLRQQXPEHUWKHGHDOHUFRGH
ZLOOVXI¿FHDVDQDOWHUQDWLYHFig.53).
Fig.53
29
L714 10 92 00
1HWZRUN6HWWLQJV
A control function is available in the ADMINISTRATION / Network Settings / Application Test menu in order to check
that the tester is correctly connected to reach the database (Fig.54).
By running this function, it will be possible to verify that the connection works and that your user name is properly
enabled.
It is not necessary to connect to a vehicle in order to run the Application Test.

User name and Token code will be requested
Fig.54
Then select Geko test and launch the application after having correctly entered your credentials.
If the test is positive, namely “Application test OK” (Fig.55), this means that the tester is able to communicate with
the database correctly and that your credentials have been accepted.
,IWKHWHVWLVQRWSRVLWLYHFOLFNRQWKH³SURWRFRO¿OH´VHFWLRQRIWKHHUURUPHVVDJHVR\RXFDQUXQDSULQWVFUHHQDQG
send it to Lamborghini to request assistance.
Fig.55
30
L714 10 92 00
,PPRELOL]HUFRGHIRU.RPELUHSODFHPHQW
In the case of Kombi 17 instrument cluster replacement, assign the immobilizer the code as described in the following
example:
1. Go to the screen (Fig.56) by clicking on guided functions in the main menu. A
2. Select the Lamborghini brand (A-Fig.56).
Fig.56
3. Select the model (B-Fig.57).
Fig.57
31
L714 10 92 00
4. Select the MY (&)LJ).
&
Fig.58
5. Select the body (')LJ).
'
Fig.59
32
L714 10 92 00
6. Select the engine (()LJ).
Fig.60
7. &RQ¿UPWKHSUHYLRXVVHOHFWLRQVFig.61).
Fig.61
33
L714 10 92 00
8. Select Body equipment (F-Fig.62).
Fig.62
9. If the Kombi is replaced, select the function: “Kombi: Enable immobilizer” (Fig.63).
Fig.63
34
L714 10 92 00
10. Continue (Fig.64).
Fig.64
11. The explanations about program operation are displayed (Fig.65SUHVV'21(WRFRQWLQXH
Fig.65
35
L714 10 92 00
12. Ensure that the tester is connected to the vehicle (Fig.66SUHVV'21(WRFRQWLQXH
Fig.66
13. Make sure that the injection key is turned to ON (Fig.67SUHVV'21(WRFRQWLQXH
Fig.67
36
L714 10 92 00
14. Select function 1 for Kombi replacement (Fig.68).
Function 2, on the other hand, must be used if a complete keys + locks kit is replaced to give the
immobilizer a new identity. Function 3 ends the test.
Fig.68
15. Enter customer name/surname (Fig.69).
Fig.69
37
L714 10 92 00
16. Enter the workshop job order (Fig.70).
Fig.70
17. Enter the nationality (Fig.71).
Fig.71
38
L714 10 92 00
18. Enter user name and password (Fig.72) supplied by the Token (remember PIN 1324).
Fig.72
19. Never turn the key to OFF during data transmission. Do that only when the tester requests it. Press DONE to
continue (Fig.73).
Fig.73
39
L714 10 92 00
20. Select the number of keys to adapt to the new Kombi (default: 2).
It is possible to increase the number of keys up to a maximum of 8 (clicking on “Increase”) or to

reduce the number of keys to a minimum of 1 (clicking on “Decrease”).
After making the selection, press “Accept” to continue (Fig.74).
Fig.74
21. &RQ¿UPWKHQXPEHURINH\VE\FOLFNLQJRQ³<HV´Fig.75).
Fig.75
40
L714 10 92 00
22. 7KH.RPELZLOOVZLWFKVWDWXVDIWHUKDYLQJDGDSWHGWKH¿UVWNH\ZKHQWKHWHVWHUPDNHVWKHUHTXHVWLWZLOOEH
QHFHVVDU\WRSUHVV.H\2))DQGSXWWKHQH[WNH\LQVLGHFOLFNLQJRQ.H\21DJDLQWKHVWDWXVRQWKH.20%,
display will be 7: 2-2 (Fig.76).
Fig.76
23. ,IHYHU\WKLQJZDVVXFFHVVIXOFRQ¿UP<(6Fig.77).
Fig.77
41
L714 10 92 00
24. Press Key OFF/ON and try ignition (Fig.78).
Fig.78
25. 7KHV\VWHPSURYLGHVFRQ¿UPDWLRQRIVXFFHVVIXORSHUDWLRQFig.79).
Fig.79
42
L714 70 01 00
Use of battery charger and maintainer
This accessory allow to charger the battery and to maintainer the charge level when the car is stopped for a long
time. For this reason, the product can connect to the car and leave there for a long time, in order to always maintain
the battery in a perfect condition.
Before use this accessory, read carefully the user’s manual that you can find in the package.
Connection to the car:

This battery charger and maintainer can be connected to the car in three different way:
1. using the proper connector present in the package, connect the battery charger to the 12V connection (lighter)
in the car’s interior;
2. connect the battery pole clamps directly to the car’s battery;
3. assemble the small harness, with the eyelet terminals, on the battery’s poles and fix it on a rigid rest; in this
way you can always have a predisposition to connect the battery charger and maintainer to the car.
A When the battery charger and maintainer works, it can arrive at high temperature. For this reason,
it is necessary don’t leave this accessory in the car’s interior. We suggest to leave always this
product out of the car; when the red-black cable is between the car’s doors (or bonnet) and the body,
the door (or bonnet) can be closed without damage the cable or the car.
Program of battery charger and maintainer:

This accessory can work in three different automatic program:
Low power: this program is right to charger and maintain the battery smaller than car’s one. For
example the battery of motorcycle.
Normal power: this program is right to Lamborghini’s car; it allow to charger and maintain the perfect
condition of the battery when the car is stopped for a long time.
High power: this program is right to charger the battery when the car is in very cold environment.
This program is suggested also to charger the battery that is very discharger.
1
L140 76 07 05
&DUERQ&HUDPLF%UDNH.LW,QVWDOODWLRQ
3URYLGHWKH9,1RIWKHFDURQZKLFKWKHFDUERQFHUDPLFEUDNHVZLOOEHLQVWDOOHGLIQRWVXSSOLHGZKHQ
ordered).
Lift the vehicle on the car liftSDJH.
Remove the 4 wheels .
Remove the brake calipers .
Remove the parking brake.
Remove the brake disks .
Remove the brake boosterUHIHUHQFH$.
$VVHPEOLQJWKHIURQWDQGUHDUEUDNHVRIWKH³&DUERQ&HUDPLF%UDNH.LW´
1. Assemble the new brake disks in carbon-ceramic that are supplied with the kit.
Assemble the new brake calipers supplied with the kit.
In the rear axle, assemble the parking brake using the same material that was orginally present in the
car.
%HYHU\FDUHIXOZKHQKDQGOLQJWKHFDUERQFHUDPLFEUDNHGLVNV7KH\DUHYHU\IUDJLOH$OVREHDZDUH
WKDWWKHGLVNVDQGFDOLSHUVGLIIHUDFFRUGLQJWRWKHD[OHDQGVLGHRIWKHFDUWKHNLWFRQWDLQVDULJKW
GLVNDQGDOHIWGLVNDULJKWFDOLSHUDQGDOHIWFDOLSHUIRUWKHIURQWD[OH
$VVHPEOLQJWKHQHZEUDNHERRVWHUV
4. Assemble the new brake boosters UHIHUHQFH$ supplied with the kit.
1
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)LQDORSHUDWLRQV
Use the parking brake’s control lever several times to activate the automatic backlash device .
7RSXSWKHEUDNHV\VWHPZLWKEUDNHÀXLG.
Bleed the brake system .
7RSXSWKHQHZEUDNHV\VWHPZLWKEUDNHÀXLG.
Assemble the 4 wheels on the car .
7KHFDU¶VSUHYLRXV]LS¿OHFDQQRWEHXVHGWRVHWXSWKH$%6(63V\VWHP¶V(&82QO\DIWHUWKH6SDUH
3DUWV6DOHV2I¿FHKDVFRQ¿UPHGWKH]LS¿OH¶VXSGDWLQJIRUWKHFDULQTXHVWLRQFDQWKH$%6(63(&8
EHVHWXSZLWKWKHQHZ]LS¿OH
$%6(63(&8VHWXS
1. 8VLQJWKH/D5D'RZQORDG0DQDJHUGRZQORDGWKHQHZ]LS¿OHDVVRFLDWHGZLWKWKHFDU¶V9,17RGRVRUHIHUWR
pages 1 through 8 of document in the workshop manual.
8VLQJWKHQHZ]LS¿OHDQG/D5DVHWXSWKH(63$%6(&8IROORZLQJWKHLQVWUXFWLRQVRQSDJHVDQGRI
document in the workshop manual.
$IWHUVHWXSZLWKWKHQHZ]LS¿OHWKHV\VWHPZLOODXWRPDWLFDOO\UHZULWHWKH$%6(63(&8FRGLQJSURJUDPPLQJ
it to use the carbon-ceramic brakes.
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L714 78 07 05
)UDPHVWR¿[WKHWZR
screws with rubber head
)URQWSDUWWR¿[
the license plate
Installation of the license plate support
Using this new license plate support it is no longer necessary to drill the front bumper or use adhesive tape
WR¿WWKHOLFHQVHSODWHRQIURQWEXPSHU7KLVSURGXFWDOORZWRPDLQWDLQWKHIURQWEXPSHUDVLQWDFWDQGFOHDQDV )L[LQJEDUWR¿[WKH
ZKHQWKHFDUKDVFRPHRXWIURPWKHIDFWRU\ license plate to the
bumper.
Fig.1
2SHUD]LRQLSUHOLPLQDUL A
Disassemble the water radiator (front central) grid (080703).
Disassemble the front spoiler (080703)
Disassemble the lock cover (080603 - Reference B2)
$VVHPEOHWKH¿[LQJEXVK Fig.2
1. Position the license plate support (A-Fig.2) as show in the picture beside (Fig.2); over the front central grid in
the horizontal surface of the bumper, mark with a indelible marker (pen) the points (B-Fig.3) where there are the
WKUHHKROHVWKDWDUHSUHVHQWRQWKH¿[LQJEDURIWKHOLFHQVHSODWH
B
Fig.3
1
L714 78 07 05
2. Over the front central grid, in the horizontal surface of the bumper, make three holes (diameter 12,5mm) (C-Fig.4);
it is necessaryGULOOWKHVXUIDFHRIWKHEXPSHUDQGDOVRWKHEODFNIUDPHXQGHULW
C
,QRUGHUWRFDUU\RXWDSHUIHFW¿[LQJRIWKHOLFHQVHSODWHWKHEXVKHVKDYHWREHLQVHUWLQERWKEXPSHU¶VVXUIDFH
and the black frame under the bumper itself; in order to check if this operation is carried out, verify from the
KROHZKHUHWKHORFNFRYHUZDV¿WLWZDVUHPRYHGZLWKWKHSUHOLPLQDU\RSHUDWLRQ
:KHQ\RXDUHPDNLQJWKHKROHVLW¶VLPSRUWDQWWRSRVLWLRQWKHGULOOLQSHUIHFWDVZHOODV\RXFDQ
YHUWLFDOSRVLWLRQVRDVWKHGULOOPDNHDDQJOHRI90° with the bumper surface.
3. Insert in the three holes (C-Fig.4), that was carried out with the previous operation, three bushes (')LJ)
Fig.4
supplied with the kit; as shown in the picture beside (()LJ), the bushes have to be push in the hole to the end,
VRDVWKHUXEEHUHGJHWRXFKWKHH[WHUQDOVXUIDFHRIWKHEXPSHU
'
Installation of the new license plate support

4. As show in the picture 1, on the two front ends of the license plate support there are two frames where there is
DKROHLQVHUWLQWKHVHWZRKROHVWKHWZRVFUHZZLWKUXEEHUKHDGWKDWDUHVXSSOLHGLQWKHNLWDQG¿[WKHPZLWKWKH
two 0VHOIORFNLQJQXWVWKDWDUHVXSSOLHG7KHWZRVFUHZVZLWKUXEEHUKHDGDUHXVHIXOLQRUGHUWRDYRLGGDPDJH
RQWKHEXPSHUZKHUHWKHOLFHQVHSODWHVXSSRUWWRXFKLW
5. Fit the license plate on the license plate support; to carry out this operation drill the front part of the support or
XVHDGKHVLYHWDSH Fig.5
6. Position the OLFHQVHSODWHVXSSRUWVRWKDWWKHWKUHHKROHVRQLWV¿[LQJEDUSHUIHFWO\FRLQFLGHZLWKWKHKROHLQWKH

KRUL]RQWDOVXUIDFHRIWKHEXPSHURYHUWKHIURQWFHQWUDOJULG
(
7. Using the M6 screws (()LJ)VXSSOLHGZLWKWKHNLW¿[WKHOLFHQVHSODWHVXSSRUWon the three bushes (')LJ)
that was installed in the KRUL]RQWDOVXUIDFHRIWKHEXPSHURYHUWKHIURQWFHQWUDOJULG
&KHFNLIWKH¿[LQJRIWKHOLFHQVHSODWHVXSSRUWZDVFDUULHGRXWLQDSHUIHFWZD\WRYHULI\LW¶VQHFHVVDU\
PRYHOLJKWO\WKHVXSSRUWDQGWKHQYHULI\IURPWKHKROHZKHUHWKHORFNFRYHUZDV¿WLWZDVUHPRYHG
ZLWKWKHSUHOLPLQDU\RSHUDWLRQLIWKHEXVKHVDUH¿WWHGLQWKHFRrrect way.
Final operation
Assemble the front spoiler (080705)
Assemble the water radiator (front central) grid (080705).
Assemble the lock cover (080605 - Reference B2) Fig.3
2
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$ L3RGNLWLQVWDOODWLRQ
'LVDVVHPEOHWKHSDVVHQJHUVLGHORZHUGDVKERDUG (086803 – reference R).
'LVDVVHPEOHWKHULJKWVLGHWXQQHOHQGSDQHO(086303 – reference A). %
A
'LVDVVHPEOHWKH%-$SXVKEXWWRQSDQHO(086803 – reference O).
'LVDVVHPEOHWKHPXOWLPHGLDV\VWHP±UHIHUHQFH%
'LVDVVHPEOHWKHEHQFKEHKLQGWKHVHDWV(086803 ±UHIHUHQFH%.
7KHLQVWDOODWLRQRIWKHL3RGLQWHUIDFHVWRSVWKHZRUNLQJRIWKH86%LQWHUIDFHRUWKH&'&KDQJHUWKH
one installed in the car); if the car is equipped with one of these two options then this equipment
ZLOOQRWZRUNDIWHUWKHLQVWDOODWLRQRIWKHL3RGLQWHUIDFH
'LVFRQQHFWWKH86%LQWHUIDFHRUWKH&'&KDQJHU
2QWKHEHQFKEHKLQGWKHVHDWVDWWKHHQGRIWKHFHQWUDOWXQQHOWKHUHLVWKH86%LQWHIDFHRUWKH&'&KDQJHU
$)LJ'LVFRQQHFWWKHFRQQHFWRU%)LJSUHVHQWEHKLQGWKH86%LQWHIDFHRUWKH&'&KDQJHUWKDWFRQQHFW )LJ
WKHV\VWHPWRWKHFDU¶VZLULQJKDUQHVVHV
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5HPRYHWKH86%LQWHIDFHRUWKH&'&KDQJHUIURPLWVEUDFNHW&)LJWKDW¿[LWRQWKHUHDUEHQFK '
$IWHUGLVFRQQHFWLQJVHFXUHWKHZLULQJKDUQHVVHVZLWKWDSHWRDVWDEOHVXSSRUWWRSUHYHQWYLEUDWLRQZKLOH
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Disassemble the bench behind the seats – reference B).
Disassemble the central tunnel – reference C).
Disassemble the passenger sun visors±UHIHUHQFH:operations 5-6).
Release (don’t remove) the front part of the roof liner ±ULIHULPHQWR:.
Disassemble the roof lamp .
Disassemble the passenger side lower dashboard assembly UHIHUHQFH5.
Disassemble the dashboard ±UHIHUHQFH6.
A
The Kenwood multimedia system include the navigation and the Bluetooth functions. If the car is equipped
B
with the Bluetooth optional as original equipment, the Bluetooth ECU has to be removed from the car because
it will be not useful with the new Kenwood multimedia system.
The Kenwood multimedia system include the iPod and USB connections; these connections completely
replace the original ones that are present in the car if it is equipped with these optional. If the car has the
CD-Changer, this element has to be removed because it is incompatible with the new multimedia system.
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Remove the iPod interface 2° 3° 1°
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1. Behind the multimedia system RNS-E of the car, there is a sponge sleeve that contain ($)LJ) the
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2. Open (cut) the sponge sleeve and disconnect the two black connectors (%)LJ) that are present inside it.
3. Remove the green connector (')LJWKDWLV¿[HGLQWKHEODFNRQH&)LJ) that was connected to the
multimedia system RNS-E.
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5. On the H[WHUQDOVXSHULRUVXUIDFHRIWKHJORYHER[WKHUHLVWKHL3RGLQWHUIDFH ())LJ); disconnect all the

wiring harnesses that are connected with it. F G
Remove the iPod connection wiring harness (*)LJWKDWJRHVLQVLGHWKHJORYHER[WKURXJKWKHsmall foam
rubber; remove also the small foam rubber.
7. :KHQWKHVHVL[RSHUDWLRQZDVEHFDUULHGRXWLWLVSRVVLEOHUHPRYHDOOWKHFRPSRQHQWRIWKHL3RGLQWHUIDFH
system that is present on the car. Remove the iPod interface ())LJ) and the iPod interface wiring harness
(+)LJ) that connect the iPod interface to the multimedia system RNS-E.
H
Fig.3
I L
2SHUDWLRQHIIHFWLYHIRUDOOFDUV 1
In order to install the Kenwood multimedia system it’s necessary to replace the original multimedia harness
of the car with the new one supplied with the kit. The new multimedia harness has to be installed as the
original one was positioned in the car; the main difference between the two harness is that the new one has
less connection with the car than the original one.
2
M
Removing the original multimedia harness (infotainment harness) of the car.

1. Disconnect the original infotainment harness from the multimedia system (RNS-E) of the car; to carry out this Fig.4
operation it’s necessary to remove the green (,)LJ) and the blue (/)LJ) connector from the main black
connector (0)LJ) of the RNS-E and to remove the grey/pink connector (1)LJ) that is connected directly to
the RNS-E (only if the vehicle is equipped with rear view camera or TV-tuner).
Q
2. If the car is equipped with the Bluetooth system as original equipment, disconnect the little black connector
(2)LJ) of the multimedia wiring harness from the black connector of the dashboard wiring harness.
3. 5HPRYHQRWFRPSOHWHO\WKHFRYHULQJLQVRXODWLRQVRXQGSURR¿QJRQWKHGULYHUVLGHRIWKHFHQWUDOWXQQHOLQWKH

car interior (see the Fig.5).
3
4. Remove the multimedia harness (3)LJ) that is positioned on the driver side of the central tunnel; to carry out
WKLVRSHUDWLRQLW¶VQHFHVVDU\UHPRYHWKH¿[LQJFOLS (4)LJWKDW¿[WKHKDUQHVVWRWKHFKDVVLV Fig.5
2
L714 79 74 05
5. Disconnect the original multimedia harness of the car from the kit to the connections on rear bench:
1. If the car is equipped with the Bluetooth system, disconnect the black connector (1)LJ) from the Bluetooth
4 1 3
ECU. 5
2. Remove the little loop (2)LJ)RIWKHRULJLQDOPXOWLPHGLDKDUQHVVWKDWLV¿[HGXVLQJWKHSURSHUVFUHZLQWKH
bushing (2)LJ) that is present on the rear bench in front of the ECU with the white cap (Bosch ECU). 2
3. Disconnect the black connector (3)LJ) of the original multimedia harness to the black one of the central
harness (3)LJ) that is present on the rear bench on the left of the ECU with the white cap (Bosch ECU).
4. Remove the connector to the CD-Changer or to the USB interface (4)LJ).
5. If the vehicle is equipped with the rear view camera, remove the yellow connector (5)LJ) of the original
multimedia harness from the rear view camera’s ECU.
5
The connections that are described in the operations 1 and 5 are the all link that could be present on the
car; all these connections are present only if the car is equipped with all the possible multimedia optional. It’s )LJ
necessary disconnect only the link that are present; if something that is described here is missing , it’s only
S
because the proper optional is not present on the car.
Remove the black connector (5)LJ) of the car’s wiring harness that is connected to the RVC control unit.
T
Removing the multimedia elements that are not compatible with the Kenwood system.
7. On the rear bench, remove the USB interface (6)LJ) or the CD-Changer, if the car is equipped with it.
5HPRYHWKHEUDFNHWWKDW¿[HGWKH86%LQWHUIDFHRUWKH&'&KDQJHUWRFDUU\RXWWKLVRSHUDWLRQLWLVQHFHVVDU\
to remove the three screws (7)LJWKDW¿[WKHEUDFNHWWRWKHEHQFK U
Fig.7
9. 5HPRYHWKHEUDFNHWWKDW¿[WKH%OXHWRRWKFRQWUROXQLW (8)LJ) on the rear bench; to do this it’s necessay to
disassemble the two screw on the rear bench and release the joint present in the front part of the bracket.
:
10. Remove the Bluetooth control unit (8)LJ) from the rear bench.
Installation of the new multimedia harness (infotainment harness) on the car.

11. Lay the new multimedia harness (9)LJVXSSOLHGZLWKWKHNLWRQWKHGULYHUVLGHRIWKHFHQWUDOWXQQHODQG¿[LW 9
XVLQJWKHEXVKLQWKHFKDVVLVDQGWKH¿[LQJFOLSV(:)LJ) that are present in the new harness. The new harness
has to be positioned so that the the black/yellow jack (video connection) will be placed behind the multimedia
system, while the other connections have to be placed on the rear bench.
)LJ
3
L714 79 74 05
12. The following connections have to be carry out on the rear bench:
1. Put to ground the little loop (1)LJ)SUHVHQWRQDZLUHRIWKHQHZPXOWLPHGLDKDUQHVV¿[LWXVLQJWKHSURSHU
screw that have to be insert in the bushing (1)LJ) that is present on the rear bench in front of the ECU with 1 2
the white cap (Bosch ECU).
2. Link the black connector (2)LJ) of the new multimedia harness to the black connector of the central
harness (2)LJ) that is present on the rear bench on the left of the ECU with the white cap (Bosch ECU).
Fig.9
6SHFL¿FRSHUDWLRQVIRUFDUHTXLSSHGZLWKUHDUYLHZFDPHUD.
1. The following connections have to be carry out on the rear bench:
5
3. Connect the brown connector (3)LJ) of the new multimedia harness to the rear view camera’s
4
control unit (=)LJ).
4. Insert the black male connector of the new infotainment harness in the proper connection (4)LJ)
of the rear view camera’s control unit (=)LJ).
5. Connect the black female connector (5)LJ) of the new multimedia wiring harness to the black
male connector (5)LJ) of the car wiring harness that was previously inserted in the rear view
camera’s control unit (removed with the operation 6 (5)LJ)).
Z
3
Fig.10
2. Connect the yellow/black video connector (A)LJ11) to the Kenwood multimedia system (B)LJ11); this
connector has to be connected to the yellow connector (B)LJ11) that has the label “rear view camera”
on its own cable.
A
2QWKHFDUHTXLSSHGZLWKWKHUHDUYLHZFDPHUDWKHEXWWRQRQWKHFHQWUDOWXQQHOFRQVROHWKDWLV
XVHGIRUWKHPDQXDODFWLYDWLRQRIWKHFDPHUDZLOOEHQRORQJHUXVHIXOWKHPDQXDODFWLYDWLRQRI B
WKHFDPHUDZLOOEHQRORQJHUSRVVLEOHEXWWKHFDPHUDZLOODXWRPDWLFDOO\VWDUWZKHQWKHUHYHUVH
gear will be engaged.
Fig.11
4
L714 79 74 05
2SHUDWLRQHIIHFWLYHIRUDOOFDUV
2QWKHFDUVZLWKRXWUHDUYLHZFDPHUDWKHIUHHFRQQHFWLRQVKDYHWREH¿[HGWRVRPHVXSSRUWVXVLQJWKH
black clamps that are supplied with the kit.
D
$VVHPEO\RIWKHQHZVSHFL¿FEUDFNHWRIWKHQHZ.HQZRRGPXOWLPHGLDV\VWHP E
13. Remove the supporting bracket (C)LJ12) of the RNS-E multimedia system. To carry out this operation, in the
internal side of the dashboard it is necessary to remove the 6 screws, 2 upside the bracket (D)LJ12) and 2 on C
each lateral side (E)LJ12) RIWKHEDFNHWWKDW¿[WKHEUDFNHWWRWKHGDVKERDUG
Fig.12
14. As shown in the picture beside (Fig.13), assemble the rubber buffer (G)LJ13) supplied with the kit on the rear
part of the new supporting bracket ()Fig.13) (supplied with the kit) of the Kenwood multimedia system. G H
15. Insert in the new supporting bracket ()Fig.13)WKHVSHFL¿FVOLGH(H)LJ13) supplied with the kit that is useful
WR¿[WKH.HQZRRGV\VWHP; this slide (H)LJ13) has to be inserted frontally in the bracket and then it has to be
pushed (as showed by the yellow arrows in the picture beside) until it will be blocked in the supporting bracket.
Assemble the new supporting bracket, with the slide and the buffer, on the central console of the car’s dashboard.
7KLVQHZVXSSRUWLQJEUDFNHWKDVWREH¿[HGLQWKHVDPHZD\RIRULJLQDORQHWRFDUU\RXWWKLVRSHUDWLRQLWLV
F
QHFHVVDU\WRZRUNLQVLGHWKHGDVKERDUGDQGWRXVHWKHVDPHVFUHZVDQG¿[LQJSRLQWVRQWKHGDVKERDUG2
upside and 2 on each lateral side of the bracketWKDWZDVXVHGWR¿[WKHRULJLQDOEUDFNHW,ILWLVQHFHVVDU\XVH
Fig.13
also the 6 clips supplied with the kit.
Assembly of the new GPS antenna. L

17. In the area behind the kombi, remove the original GPS antenna of the multimedia system RNS-E (/Fig.14) from
the proper bracket (,Fig.14). I
Assemble the new GPS antenna (0Fig.14) supplied with the kit (it is inside the Kenwood package) on the same
bracket (,Fig.14). The new GPS antenna (0Fig.14KDVWREH¿[HGXVLQJWKHPDJQHWSUHVHQWRQLWDQGLWKDV
to be placed so that its own cable come out from the side that is turned to the front of the car (as shown in the
picture beside Fig.14) .
M
19. /D\WKH*36DQWHQQDFDEOHIURPWKHDQWHQQDWRWKHDUHDEHKLQGWKHPXOWLPHGLDV\VWHP5ROOXSWKHH[FHVV
FDEOHDQG¿[WKHFDEOHDWWKHGDVKERDUGZLULQJKDUQHVVXVLQJWKHFODPSVXSSOLHGZLWKWKHNLW Fig.14
5
L714 79 74 05
Assembly of the microphone of the Bluetooth system.
The Bluetooth function of the Kenwood system can not use the same microphone that is used by the original
bluetooth system of the car. For this reason it is necessary to install a new microphone (supplied inside the
Kenwood package) in the roof lamp; this new microphone has to replace the one that can be present on the
car (if it has the Bluetooth opiton).
20. Lay the cable of the microphone (that is supplied inside the Kenwood package) from the multimedia system (in the 2
central console of the dashboard) to the roof lamp following the red path that is shown in the picture(Fig.15).
1
To pass the wiring harness under the roof liner, remove the screw underneath the roof lamp (1)LJ) so
that the front part of the roof liner can be lowered and the wire can be passed under it. On the lower part of
the door side the wiring harness can be passed under the coverings without removing them (2)LJ.
$OZD\VWDNHWKHXWPRVWFDUHQRWWRGDPDJHWKHOHDWKHUXSKROVWHU\ZKLOHLQVHUWLQJWKHFDEOHXQGHU Fig.15
WKHJDVNHWVDQGFRYHULQJV
21. 7KH OLWWOH EUDFNHW WKDW LV ¿[HG DW WKH PLFURSKRQH KDV WR EH VWXFN EHWZHHQ WKH URRI ODPS DQG URRI OLQHU WKH
microphone has to be placed turned to the driver headrest in the position that is shown in the picture beside
(3)LJ). 3
Assembly of the new iPod and USB connection.

22. Drill a hole of 20 mm of diameter 4)LJEHKLQGWKHJORYHER[RIWKHSDVVHQJHUVLGH,I\RXVHHWKHJORYHER[
IURPEHKLQGWKHKROHPXVWEHLQWKHULJKWVLGHRIYHUWLFDOSRVWHULRUZDOORIJORYHER[WKHULJKWSRVLWLRQLVZKHUH
WKHUHLVWKH³WULDQJXODU´GHSUHVVLRQRQWKHJORYHER[¶ZDOO)LJ
)LJ
If the car is equipped with the iPod interface as original optional, this hole is already present and it is not
necessary to be done again. Q
23. On the cable for the iPod’s connection, assemble one of the black clamp that are supplied in the kit. This black
FODPSPXVWEH¿[HGDWPPIURPWKHFRQQHFWRUWKDWZLOOEHFRQQHFWHGWRWKHL3RG
24. 5HSHDWWKHVDPHRSHUDWLRQRQWKHFDEOHRIWKH86%FRQQHFWLRQDVVHPEOLQJDEODFNFODPSDWPPIURPWKH
USB connector.
Fig.17

L714 79 74 05
25. Insert the iPod cable and then the USB cable into the small foam rubber 5)LJ supplied with the kit.
S
5
Assemble the small foam rubber 5)LJVXSSOLHGZLWKWKHNLWLQWKHKROHEHKLQGWKHJORYHER[VRWKDWWKH
L3RGDQG86%FRQQHFWLRQVJRLQVLGHWKHJORYHER[LWVHOI
27. 3XOOWKHWZRFDEOHVIURPWKHLQWHUQDOVLGHRIWKHJORYHER[SXOOWLOOWKHEODFNFODPSVDVVHPEOHZLWKWKHRSHUDWLRQ

DQG6)LJ have arrived to touch the foam rubber on the its esternal side.
Lay the two cables (iPod and USB) starting from the small foam rubber 5)LJ to the rear part of the
PXOWLPHGLDV\VWHPVHFXUHLWDORQJWKH$&SLSHXVLQJWKHFODPSVVXSSOLHGZLWKWKHNLW5ROOXSWKHH[FHVVFDEOH
LQVHUWLWLQDVSRQJHVOHHYHDQG¿[WKHZKROHXVLQJ a clamp. )LJ
Assembly of the iPod brackets

U
$VVKRZQLQWKH¿JXUHFig.19WZREUDFNHWVDUHSUHVHQWLQWKHNLWWKH¿UVW7)LJ) useful for the iPod T
Nano, the second (8)LJ) useful for iPod of 80gb and the all other using the proper support. These
EUDFNHWVPXVWEH¿[HGLQWKHLQWHUQDOVLGHRIWKHJORYHER[FRYHU7KLVRSHUDWLRQLVQRWQHFHVVDU\LIWKHFDULV
equipped with the iPod connection as original equipment.
29. The picture (Fig.19) show the right position of the two iPod’s brackets. Position the brackets and drill two little
KROHWZRIRUHDFKEUDFNHWZKHUHWKHUHDUHWKHEUDFNHWV¶¿[LQJSRLQWVWKDWLVWKHKROHZKHUHLWLVQHFFHVVDU\
LQVHUWWKHVFUHZVWR¿[WKHEDFNHW
:KLOH\RXGULOOWKHLQWHUQDOVLGHRIJORYHER[¶FRYHU\RXPXVWEHHVSHFLDOO\FDUHIXOLQRUGHUWRGRQ¶W
GDPDJHWKHIURQWDOVLGHRIWKHJORYHER[DUHODSDUWHIURQWDOHGHOORVSRUWHOORVWHVVR)RUWKLVUHDVRQ
WKHKROHPXVWEHVKDOORZFRQVHTXHQWO\\RXPXVWGULOORQO\WKHLQWHUQDOVLGHRIWKHJORYHER[DQG\RX Fig.19
PXVWGRQ¶WWRXFKWKHIURQWSDUWRIWKHFRYHU
30. Using the little screws supplied with the kit and the hole, assembly the iPod’s brackets on the internal side of the 9
JORYHER[¶FRYHU
Assembly of the new Kenwood multimedia system.

Z
Assemble the dashboard ±UHIHUHQFH6
31. As shown in the picture beside (Fig.20), using the screw and the washer supplied with the kit, assemble the
black stud (9)LJ) that is supplied with the kit in the hole (=)LJ) that is present behind the Kenwood
Fig.20
multimedia system.
7
L714 79 74 05
32. The table down here show all the connections that have to be carry out behind the Kenwood multimedia system.
3
Each line is equivalent to a connection that have to be done between the two connector that are shown on the 1
line itself. All the involved connectors are shown in the picture beside (Fig.21WKH\DUHLGHQWL¿HGE\DQXPEHU
FODVVLFRUURPDQDQGE\DFRORUWKHWZRFRQQHFWRUVLGHQWL¿HGE\WKHVDPHQXPEHUDQGWKHVDPHFRORUKDYH
to be connected together. 2 II
Interface wiring harness Car's wiring harness 4

N° Description N° Description I
1 Radio antenna connector - antenna side > I Radio antenna wiring harness connector
2 CAN line connector - car side > II RNS-E main connector 9
.HQZRRGPXOWLPHGLDV\VWHP
7
N° Descrizione
3 Radio antenna connector - system side > III Radio antenna connection
4 CAN line connector - system side > IV Main Kenwood connection
Accessories connections
N° Description 10
5 GPS antenna connector > V GPS antenna connection
iPod video jack (yellow) > VI iPod video connection (yellow) X VI VII
> 5
7 iPod audio jack (black) VII iPod audio connection (black)
iPod USB connector > VIII USB connection iPod (see the label on the cable)
9 USB connector > IX USB connection
10 Microphone jack (Bluetooth system) > X Microphone plug (Bluetooth system)
V
The white connector (IFig.21KDVFRQQHFWLRQSRLQWVZLWKRQHFDEOHHDFKWKH¿UVWFDEOHKDVDELJGLDPHWHU

while the other one is lesser thick. The green connector (1 Fig.21) has to be connect to the connection point IV
ZKHUHWKHUHLVWKHELJJHVWFDEOHLQWKLVFRQQHFWLRQSRLQWWKHUHDUHWZROLWWOHKRRNVWKDW¿[WKHMRLQLQJEHWZHHQ
the two connectors.
IX
If the car is equipped with rear view camera: behind the new Kenwood multimedia system, verify that there
is the connection between the video jack of the rear view camera (multimedia harness) and the connection
of the Kenwood system; this connection had to be carried out with the operation 2 at page 4 (B)LJ11). III VIII
Fig.21

L714 79 74 05
33. Place the new Kenwood multimedia system ($)LJ) in the central console of the dashboard and insert it in the
VSHFL¿FEUDFNHWDQGVOLGHWKDWDUHDVVHPEOHGZLWKWKHSUHYLRXVRSHUDWLRQVRSHUDWLRQVIURPWR
34. )L[WKHQHZVSHFL¿FIUDPH%)LJ) that is supplied with the kit on the central console around the Kenwood
system ($)LJ7RFDUU\RXWWKLVRSHUDWLRQLWLVQHFHVVDU\WR¿WWKHWZRVWXGWKDWDUH¿[HGEHKLQGWKHIUDPHLQ
the hole that are present in the supportion bracket.
B
A
Vehicle setting up.

Fig.22
7KHFDU¶VSUHYLRXV]LS¿OHFDQQRWEHXVHGWRVHWXSWKHV\VWHPRIWKHFDU2QO\DIWHUWKH6SDUH3DUWV
6DOHV2I¿FHKDVFRQ¿UPHGWKH]LS¿OH¶VXSGDWLQJIRUWKHFDULQTXHVWLRQFDQWKH.RPELLQVWUXPHQW
FOXVWHU(&8EHVHWXSZLWKWKHQHZ]LS¿OH
35. 8VLQJWKH/D5DV\VWHPGRZQORDGWKHQHZ]LS¿OHDVVRFLDWHGZLWKWKHFDU¶V9,1.
8VLQJWKHQHZ]LS¿OHDQGWKH/D5D$6V\VWHPVHWXSWKH.RPELLQVWUXPHQWFOXVWHU(&8.
Final operations
Assemble the central tunnel – reference C).
Assemble the new (supplied with the kit) bench behind the seats – reference B)
)L[GRQ¶WUHPRYHWKHIURQWSDUWRIWKHURRIOLQHU±ULIHULPHQWR:.
Assemble the roof lamp .
Assemble the passenger sun visors±UHIHUHQFH:operations 5-6).
Assemble the passenger side lower dashboard assembly UHIHUHQFH5.
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WKHQHZ]LS¿OHUHTXLUHGIRUWKHFDU,IWKLVSURFHGXUHLVQRWIROORZHGWKHPXOWLPHGLDV\VWHP516(
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'LVDVVHPEOHWKHWXQQHORUQDPHQW±UHIHUHQFH%)
'LVDVVHPEOHWKHFHQWUDOWXQQHO – reference C).
'LVDVVHPEOHWKHGULYHUVLGHWXQQHOHQGSDQHO – reference A).
'LVDVVHPEOHWKH%-$SXVKEXWWRQSDQHO±UHIHUHQFH2).
'LVDVVHPEOHWKHPXOWLPHGLDV\VWHP±UHIHUHQFH%).
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)UHHWKHZDWHUFRROLQJFLUFXLW¶VWDQNIURPWKHVXSSRUWV – reference A).
'LVDVVHPEOHWKHUHDUHQJLQHKRRG – reference C).
'LVDVVHPEOHWKHHQJLQHKRRGLQVLGHFRYHUV – reference A).
'LVDVVHPEOHWKHVSRLOHU – reference G).
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,QWKH]RQHEHKLQGWKHIRRWUHVWRIWKHSDVVHQJHUVLGHORFDWHWKHELJEODFNFRQQHFWRU(1)LJ) present behind
WKHIXVHER[LW¶VWKHFRQQHFWRURIWKHKDUQHVVWKDWJRHVLQWRWKHIXVHER[
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'R QRW GLVFRQQHFW ZLUHV SUHVHQW LQ WKH FDU IURP WKH FRQQHFWRU 6LPSO\ FRQQHFW WR WKHP ZLWKRXW
cutting them. All connections between wires must be soft soldered and must then be protected with
insulating tape (as shown in Fig.10$IWHUPDNLQJDOORIWKHFRQQHFWLRQVSURWHFWWKHYLVLEOHSDUWRI
WKHZLULQJKDUQHVVZLWKEODFNÀRFNWDSH%HFDUHIXOQRWWRGDPDJHWKHFDU¶VLQWHULRUZKHQFUHDWLQJ 1
these connections.
Fig.10
,W¶V QHFHVVDU\ FRQQHFW WKH ZLUHV RI WKH 976 KDUQHVV WR WKH FDU¶V ZLUHV WKRVH DUH FRQQHFWHG ZLWK WKH EODFN
connector (1)LJRIWKHIXVHER[7RFDUU\RXWWKLVRSHUDWLRQIROORZWKHLQVWUXFWLRQVWKRVHDUHSUHVHQWLQWKH
IROORZLQJWDEOH
976:LUHV:KLWHFRQQHFWRU %ODFNFRQQHFWRUQ459 3LFWXUH10

3,1 Colour Sign 3,1 Colour Number Description
%ODFN GND ĺ % 1%ODFN ,QJ*1'
%ODFN ĺ % %5:KLWH5HG ,QJIRUHOHFWURQLFV
8 %ODFN ĺ % +5*UH\5HG 385
Protect the VRIWVROGHULQJXVLQJinsulating tape as shown in the picture beside (2)LJ)
Using EODFNÀRFNWDSHFRYHUWKHKDUQHVVRIWKHEODFNFRQQHFWRULQRUGHUWRSURWHFWLWDVLWZDVSURWHFWEHIRUH O

start these operations
Fig.11
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8QLWDQGFRYHUZLWKWKHEODFNÀRFNWDSHWKHWZREODFNZLUHVWKRVHDUHQHFHVVDU\WRFDUU\RXWWKHFUDQNLQKLELWLRQ
Q
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/D\WKHWZRZLUHVRIWKHFUDQNLQKLELWLRQWKRVHZDVFRYHUHGE\WKHSUHYLRXVRSHUDWLRQIURPWKH]RQHRIWKHIXVH
ER[WRWKHFRQQHFWRURIWKHLJQLWLRQNH\NH\¶VEORFNWRFDUU\RXWWKLVRSHUDWLRQWKHZLUHVPXVWSDVVEHKLQGWKH
8VLQJWKHEODFNFDEOHWLHVVXSSOLHGZLWKWKHNLW¿[WKHZLUHVSRVLWLRQHGE\WKHSUHYLRXVRSHUDWLRQDWVRPH¿[HG
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/RFDWHWKHEODFNYLROHWFRQQHFWRU3)LJRIWKHLJQLWLRQNH\DQGGLVFRQQHFWLWIURPWKHNH\¶VEORFNRIWKHFDU

3
Fig.12
&XWWKHWZREOXHZLUHVFRQQHFWHGWRWKHSLQRIWKHEODFNYLROHWFRQQHFWRU3)LJDQGDIWHUZDUGVXQFRYHU
WKHWZRFRXSOHRIH[WUHPHV4)LJWKRVHDUHGHULYHGIURPWKHFXWWLQJ7KHUHVXOWRIWKLVRSHUDWLRQPXVWEHD
FRXSOHRIEOXHZLUHVWKDWOHDYHVWKHEODFNYLROHWFRQQHFWRU3)LJDQGDQRWKHUFRXSOHRIEOXHZLUHVWKDWFRPH
IURPWKHFHQWUDOZLULQJKDUQHVVRIWKHFDU
,W¶VSRVVLEOHWKDWWKHUHLVRQO\RQHEOXHZLUHFRQQHFWHGLQWKHSLQRIWKHEODFNYLROHWFRQQHFWRU3)LJ
,Q WKLV FDVH QRW IDU IURP WKH EODFNYLROHW FRQQHFWRU WKLV EOXH ZLUH LV VSOLW LQ WZR GLIIHUHQW EOXH ZLUHV LW¶V
necessary to cut the blue wire near the blackYLROHWFRQQHFWRUEHIRUHWKHVSOLWEHFDXVHLQWKLVZD\LWLV
SRVVLEOHWREORFNERWKWKHVLJQDORIWKLVZLUH
As showed in the picture beside (5)LJLW¶VQHFHVVDU\WRXQLWHWKHWZREOXHZLUHVRIHDFKFRXSOHVDQGVROGHU

WKHLUVRIWVROGHUZLWKRQHRIWKHWZR976ZLUHVRIWKHFUDQNLQKLELWLRQWKRVHDUHSRVLWLRQHE\WKHRSHUDWLRQ
RIWKLVSDJH7KHUHVXOWRIWKLVRSHUDWLRQPXVWEHDFRXSOHRIEOXHZLUHVVROGHUHGZLWKDEODFN976ZLUHDQG
WKHRWKHUFRXSOHRIEOXHZLUHVVROGHUHGZLWKWKHRWKHUEODFN976ZLUH,QWKLVZD\WKH976FRQWUROXQLWLVVHULDO
FRQQHFWHGZLWKWKHWZREOXHZLUHVWKRVHDUHQHFHVVDU\WRWUDQVIHUWKHLJQLWLRQVHJQDOIURPWKHNH\¶VEORFNWRWKH
HQJLQHVWDUWHU
Protect the VRIWVROGHULQJXVLQJinsulating tape as shown in the picture beside (5)LJ) and, using EODFNÀRFN
WDSHFRYHUWKHKDUQHVVRIWKHEODFNYLROHWFRQQHFWRULQRUGHUWRSURWHFWLWDVLWZDVSURWHFWEHIRUHVWDUWWKHVH R
operations
&RQQHFWWKHEODFNYLROHWFRQQHFWRU3)LJWRWKHNH\¶VEORFNRIWKHFDU
Fig.13
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As show in the picture beside ($)LJDVVHPEOHWKHHQGRIWKH*60DQWHQQD¶VZLUH)LJLQWKHYLROHW
FRQQHFWRUVXSSOLHGZLWKWKHNLW A
(
&RQQHFWWRWKH976(&8%)LJDOOWKHQHFHVVDU\KDUQHVVHV,QWKHIURQWVLGHFRQQHFWWKHFRQQHFWRURI
WKH976KDUQHVV&)LJWKHFRQQHFWRURIWKH*36DQWHQQD')LJDQGWKHRQHRIWKH*60DQWHQQD
($)LJ,QWKHUHDUSDUWRIWKH(&8LQVHUWWKHFRQQHFWRURIWKH'ULYHU&DUGVDQWHQQD()LJ
%
M
Assemble the kombi (Workshop Manual ±UHIHUHQFH1
'
C
$VVHPEOHWKHVWHHULQJZKHHOFRYHU (Workshop Manual ±UHIHUHQFH%
Fig.19
Assemble the steering wheel (Workshop Manual 087505 – reference A).
&RQQHFWWKHYHKLFOH¶VEDWWHU\:RUNVKRS0DQXDO091504)
&RQ¿JXUHDQGDFWLYDWHWKH*60*367UDFNLQJ6\VWHPV
,QRUGHUWRFRQ¿JXUHDQGDFWLYDWHWKH976LW¶VQHFHVVDU\WRFDOOWKH³1DWLRQDO6HUYLFH3URYLGHU´163DQG

DWWKHVDPHWLPHFDUU\RXWVRPHRSHUDWLRQRQWKHFDUIRUWKLVUHDVRQZHVXJJHVWWRXVHDSRUWDEOHPRELOH
SKRQH
6WDUWWKHFDU¶VHQJLQHLQRUGHUWRYHULI\WKDWWKHYHKLFOHZRUNV¿QH,IWKHUHLVDQ\SUREOHPEHIRUHJRRQZLWKWKH
other operations, consult the ³*XLGHWRUHVROYHWKHSUREOHP´LQWKHODVWSDJHRIWKLVPDQXDO
9HULI\WKDWWKHRSHUDWLRQDQGDWWKHSDJHRIWKLVPDQXDODUHGRQHYHULI\WKHFRPPXQLFDWLRQRIWKHGDWD

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)ROORZ WKH SURFHGXUH GHVFULEHG LQ WKH WDEOH “,QLWLDOLVDWLRQ SURFHGXUH RI WKH *60*36 7UDFNLQJ 6\VWHP´
that is present in the QH[WSDJHRIWKLVPDQXDO
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Requirements
Step Ignition 'ULYHU 'ULYHU 6HUYLFH Action
card 1 card 2
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2II 2II 2II Standard
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2Q2II 2II 2II Standard ,QVHUWIXVHVWRSRZHURQ,&'6ZLWFK,JQLWLRQ2QIRUVHFDQGWKHQ2II

3 On 2II 2II Standard 'ULYHWKHYHKLFOHRXWVLGHDQGSDUNRXWLQWKHRSHQDLUQRFDQRS\HWF
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4 On 2II 2II Standard :KHQWKHGLDJQRVWLFZRUNLVFRPSOHWHWKHSURYLGHUFDOOVWKHGHDOHU
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Press Press
5 On Standard RI'ULYHU&DUGVRQHDIWHUWKHRWKHUIRURQHVHFRQG'RQRWVZLWFKRIIWKH'ULYHU&DUGV3URYLGHU
button button
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7 2II 2II 2II Standard 6ZLWFKRIILJQLWLRQZDLWVHFRQGV
8 2II 2II 2II Standard 3URYLGHUFDUULHVRXWLQWHUQDOQGWHVWPRGHDVNLI976LVDUPHG
9 2II On 2II Standard 6ZLWFKRQGULYHUFDUG
2II On 2II Standard 3URYLGHUFDUULHVRXWLQWHUQDOUGWHVWPRGHDVNLI976LVGLVDUPHG
2II On 2II Standard $VNWKHSURYLGHUWRDFWLYDWHWKHFUDQNLQKLELWLRQ
2II On 2II Standard $IWHUFRQ¿UPDWLRQZDLWVHFRQGV
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On On 2II Standard $IWHUFRQ¿UPDWLRQWU\WRVWDUWWKHHQJLQHDJDLQ5HPDUNHQJLQHVKRXOGVWDUW
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2II On 2II Standard
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As shown in the picture beside (Fig.20SODFHWKH976&RQWURO8QLW)LJ) (with all harnesses connected) on
the ERWWRPSDUWRIWKHPHWDOFDJH()LJVXSSOLHGZLWKWKHNLW
Fig.20
Using the WRSSDUWRIWKHPHWDOFDJH()LJ)FORVHWKH976(&8ZLWKDOOKDUQHVVHVFRQQHFWHGLQWRLWVPHWDO
protection cage as shown in the picture beside (Fig.21 7KH SLFWXUH EHVLGH ))LJ) shows also how the
ERWWRPSDUWDQGWKHWRSRQHKDYHWREHSHUIHFWO\MDPPHGEHWZHHQWKHP7KHKDUQHVVHVFRQQHFWHGDWWKH976
(&8KDYHWRFRPHRXWWKURXJKWKHVSHFLDOKROH*)LJSUHVHQWLQWKHVLGHRIWKHPHWDOSURWHFWLRQFDJH
Fig.21
Place metal bracket ()LJ) supplied with the kit on (+)LJWKHZKROH976(&8DQGPHWDOSURWHFWLRQFDJH
VRWKDWWKHKROHRIWKHPHWDOEUDFNHWFRLQFLGHZLWKWKHWZR¿[LQJKROHRIWKHZKROH,)LJ/)LJ7KHPHWDO
SURWHFWLRQFDJHKDYHWRVWRSRQWKHÀDWIDFHRIWKHPHWDOEUDFNHWDVDFRQVHTXHQFHWKHEHQGHGHGJHRIWKH
EUDFNHWKDYHWREHGLUHFWXSZDUGVDVVKRZQLQWKHSLFWXUHEHVLGHFig.22
8VLQJRQH0WRU[VFUHZ)LJ) and the proper M5 nut ()LJVXSSOLHGZLWKWKHNLW¿[WKHPHWDOEUDFNHW

(+)LJRQWKHZKROH976(&8DQGPHWDOFDJHDWWKLVSRLQW¿[WKHFRPSRQHQWXVLQJRQO\WKHKROH,)LJ)
SODFHDWWKHHQGRIWKHPHWDOEUDFNHWDVVKRZQLQWKHSLFWXUHEHVLGHFig.22
I M
H
L
Fig.22
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VLGH
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below the black metal support (1)LJORFDWHGDWWKHSUHYLRXVSRLQW7KHPHWDOEUDFNHWKDYHWREHSRVLWLRQHG
so that its two nearest hole (/)LJ 0)LJ SHUIHFWO\ FRLQFLGH ZLWK WKH KROH SUHVHQW RQ WKH EODFN PHWDO 1
VXSSRUWRIWKHFDU¶VFKDVVLV
Fig.23
39. Using one M6 screw ()LJ) and the proper M6 nut ()LJ¿[WKHEUDFNHW+)LJ) at the black metal
support (1)LJXVLQJRQO\WKHKROHQHDUHVWWKHFDU¶VFKDVVLV2)LJ
,QVHUWWKHVHFRQG0VFUHZ)LJLQWKHRWKHUKROHRIWKHEODFNPHWDOVXSSRUW3)LJ) and pass it also O

WKURXJKWKHKROHRIWKHEUDFNHWDQGWKHPHWDOFDJH8VLQJWKHSURSHU0QXW)LJ¿[WKHEUDFNHWWKHFDJH
at the black metal support (3)LJRIWKHFDU¶VFKDVVLV,QWKLVZD\WKHPHWDOSURWHFWLRQFDJHWKDWFRQWDLQWKH
976(&8DQGWKHPHWDOEUDFNHWVXSSOLHGZLWKWKHNLWDUH¿[HGDWWKHFDU¶VFKDVVLV 3
)RUVHFXULW\UHDVRQVLW¶VQHFHVVDU\WRORFDWHWKHKDUQHVVHVXVHGWRLQVWDOOWKHV\VWHPLQDZD\WKDW
WKH\DUHKLGGHQZKHQWKHFDUZLOOEHFRPSOHWHO\DVVHPEOHQRRQHZLOOKDYHWREHDEOHWRVHHWKH
KDUQHVVHVRIWKH976RUWKHDQWHQQDVRQHVZKHQKHVHHWKHSDVVHQJHUIRRWUHVW]RQHRIWKHFDU)RU
WKLVUHDVRQZHVXJJHVWWRKLGHWKHKDQHVVHVDERYHWKH976(&8RUEHKLQGWKHFDU¶VPDWV Fig.24
Final operations
Assemble the multimedia system ±UHIHUHQFH%
)L[DWWKHSURSHUEUDFNHWWKHIXVHER[SUHVHQWEHKLQGWKHSDVVHQJHUIRRWUHVW
$VVHPEOHWKHSDVVHQJHUVLGHORZHUGDVKERDUG (086803 – reference R)
$VVHPEOHWKHIRRWUHVWRIWKHSDVVHQJHUVLGH
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6WDUWWKHFDU¶VHQJLQHWRYHULI\LIWKHYHKLFOHZRUNV¿QHLIWKHUHLVDQ\SUREOHPSURFHHGWRFDUU\RXWWKHIROORZLQJ
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11

Lamborghinni Manual

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Lamborghinni Manual

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L714 00 00 00

® Automobili Lamborghini S.p.A.

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A. Earmuffs must be worn

M. Danger of hot surfaces

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The manufacturer’s liability

Raising the car

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Airbag unit replacement after an accident

Recommendations for the operator

23a 23b 16a 23c 4c

26b 26a 24b

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&RGH 'HVFULSWLRQ ' 0 * 3KRWR

961295014 L 507 V4 Valve adjustment tool

009007087 Carburation Check Tool

961595002 Oil pump oil seal installation tool

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65195098 Torx T80 wrench

65395009 Wheel centering pin

62495152 Engine lifting tool

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961295015 Jalpa valve adjustment tool

961195002 Oil pump oil seal installation tool

961295035 Wrench for gear tooth coupling

&RGH 'HVFULSWLRQ ' 0 * 3KRWR

961295038 Phase variator wrench

961195023 Camshaft gear locking tool

961195024 Camshaft Dowel Extractor

&RGH 'HVFULSWLRQ ' 0 * 3KRWR

962095003 Idle Speed Adjustment Wrench

961195042 Camshaft gear locking tool

961695013 TDC brush positioning jig

&RGH 'HVFULSWLRQ ' 0 * 3KRWR

009008019 Wrench for cylinder head tightening

961195026 Base for dial gauge

961195027 Liner stop

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