Workshop Manuals Factory service & repair Fiat
01 General information02 Specifications03 Manufacturing data and tolerances04 Tightening torques05 Fluids and lubricants06 Maintenance07 Diagnostic checks08 Engine09 Clutch10 Gearbox and differential11 Axles and driveshafts12 Brakes13 Steering14 Suspension and wheels15 Heating, air conditioning and auxiliary units16 Electrical equipment17 Body fittings18 Body panels and frame19 Wiring diagrams and electrical functions20 Wiring harnesses21 Connectors and pin-outs22 Fault diagnosis23 Special tools
Fiat 500 Factory Service Manual (2007-2024)18 · Body panels and frame
18 · Body & interior

R r facia support beam

Make
Fiat
Model
500 Factory Service Manual
Year
2007–2024
Section
Removing-refitting › R r facia support beam
Body panels and frameR r facia support beam

R R FACIA SUPPORT BEAM

Operation 7210A74 · STRUCTURAL ELEMENTS (FRONT PART)

1.2 8v

Removing

Before working on the Air Bag system, follow the safety instructions for working on the system very carefully.

Op. 5580C AIR BAG SYSTEM

- Disconnect the negative battery terminal.

DescriptionConnector
BatterySee A001 BATTERY

- Remove both running board connections

Op. 7040L42

- Remove both front doors.

Op. 7210E36 R.R. FRONT SIDE DOOR

- For vehicles fitted with a knee air bag carry out the following procedure:

Op. 5580C23 DRIVER'S KNEE BAG - R.R.

- For vehicles not fitted a knee air bag carry out the following procedure:

Op. 7040A30

- For all vehicles carry out the following procedure:

Op. 7040A26 STEERING COLUMN TRIM - R+R

Op. 5580E08 AERIAL FOR ELECTRONIC KEY (CODE) - R.R

Op. 5580C18 AIR BAG MODULE - R+R

Op. 4110A10 STEERING WHEEL - R+R FOR REPLACEMENT OR CHECKS

Op. 5550A10 STALK UNIT ASSEMBLY - R+R

Op. 7040A23 INSTRUMENT PANEL FRAME IN DASHBOARD - R.R

Op. 5560B10 CONTROL PANEL - R+R

Op. 5520A14 IGNITION KEY LOCK BARREL - R+R

Op. 2125C24 GEAR LEVER KNOB - R + R

Op. 2125C02 GEAR CONTROL LEVER OUTER BOOT - R.R.

Op. 7040A28 TRIM ON GEARBOX CONTROL PANEL - R.R.

- Remove both centre console side trims.

Op. 7040A65 CONSOLE SIDE CLOSING (ONE) - R.R.

- Remove both electronic window switches:

Op. 7005M10 ELECTRIC WINDOW CONTROL SWITCH (ONE) FOR ONE FRONT DOOR - R.R.

Op. 7040L20 TUNNEL COVER - R.R

Op. 7040A56 SWITCH UNIT IN DASHBOARD - R.R.

Op. 7040A41 SPEAKER GRILLE (ONE) LH OR RH ON INSTRUMENT FACIA - R R

Op. 7040A49 CONNECTOR HOLDER TRIM FOR EOBD - R.R.

Op. 7040A44 LEFT DASHBOARD SIDE TRIM - R.R.

Op. 5570T80 CAR RADIO EQUIPMENT - R+R

Op. 5010C30 CENTRAL AIR VENT IN DASHBOARD - R.R.

Op. 5010C12 WINDSCREEN DEMISTER DIFFUSER - R+R

- Remove both diffusers:

Op. 5010C26 FRONT SIDE PANEL AIR DIFFUSER, L.H. OR R.H. - R R

Op. 7040A10 DASHBOARD TRIM - R+R

- Remove both pillar trims.

Op. 7040H30 FRONT PILLAR TRIM (ONE), LEFT OR RIGHT - R.R.

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5010A12 HEATER WATER SUPPLY PIPE - R.R.

- Position a suitable container for collecting the coolant.

1. Open the retaining band and disconnect the heater water return pipe, heater side.

R R FACIA SUPPORT BEAM

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 1056B15 THROTTLE BODY INTERGRAL WITH MDS - R.R.

1. Undo nut (1a) from pipe (1b), expansion valve side.

R R FACIA SUPPORT BEAM

1. Undo nut (1a) and disconnect pipe (1b), expansion valve side.

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

R R FACIA SUPPORT BEAM

Op. 4110D20 STEERING ELECTRICAL CONTROL DEVICE - R R

Op. 5010C55 RIGHT LOWER AIR DIFFUSER - R+R

1. On both sides, undo the bolts securing the crossmember.

R R FACIA SUPPORT BEAM

1. Detach the electrical connection for the front door coupling.

DescriptionConnector
1Dashboard/rear couplingSee D020 DASHBOARD/REAR COUPLING
R R FACIA SUPPORT BEAM

- Disconnect the aerial.

DescriptionConnector
Coaxial cable for radio aerial couplingSee D168 COAXIAL CABLE FOR RADIO AERIAL COUPLING

1. Detach the electrical connection.

DescriptionConnector
1Dashboard braid couplingSee D259 INSTRUMENT PANEL BRIDGE COUPLING

2. Disconnect the connection for the Air Bag control unit.

DescriptionConnector
2Air Bag control unitSee M060 AIR BAG CONTROL UNIT

3. Undo nut (3a) and disconnect earth connection (3b).

DescriptionConnector
3bAir Bag system earthSee C050 AIR BAG SYSTEM EARTH
R R FACIA SUPPORT BEAM

1. Detach the electrical connection.

DescriptionConnector
1Front/dashboard couplingSee D001 FRONT/DASHBOARD COUPLING
R R FACIA SUPPORT BEAM

1. Undo nut (1a) and disconnect earth connection (1b).

DescriptionConnector
1bDriver''s dashboard earthSee C015 DASHBOARD EARTH, DRIVER'S SIDE
R R FACIA SUPPORT BEAM

1. Disconnect the Body Computer electrical connections.

DescriptionConnector
1Body computerSee M001 BODY COMPUTER
R R FACIA SUPPORT BEAM

1. Unscrew nuts (1a) and bolt (1b) securing the gearbox lever mount.

R R FACIA SUPPORT BEAM

1. Unscrew the bolts securing the gear lever support bracket.

R R FACIA SUPPORT BEAM

1. Undo the bolts on the windscreen base.

2. Remove the entire air conditioning unit crossmember.

R R FACIA SUPPORT BEAM

Refitting

- Place the entire air conditioning unit crossmember in position.

- Tighten the bolts on the windscreen base.

- Tighten the bolts securing the gearbox lever support bracket.

- Tighten the bolts securing the gearbox lever support.

- Tighten the nuts securing the gearbox lever support.

1. Connect the Body computer electrical connections.

DescriptionConnector
1Body computerSee M001 BODY COMPUTER
R R FACIA SUPPORT BEAM

1. Secure the electrical connection.

DescriptionConnector
1Front/dashboard couplingSee D001 FRONT/DASHBOARD COUPLING
R R FACIA SUPPORT BEAM

1. Connect earth connection (1a) and tighten nut (1b).

DescriptionConnector
1Driver''s dashboard earthSee C015 DASHBOARD EARTH, DRIVER'S SIDE
R R FACIA SUPPORT BEAM

1. Secure the electrical connection.

DescriptionConnector
1Dashboard braid couplingSee D259 INSTRUMENT PANEL BRIDGE COUPLING

2. Connect the connection for the Air Bag control unit.

DescriptionConnector
2Air Bag control unitSee M060 AIR BAG CONTROL UNIT

3. Connect earth connection (3a) and tighten nut (3b).

DescriptionConnector
3aAir Bag system earthSee C050 AIR BAG SYSTEM EARTH
R R FACIA SUPPORT BEAM

1. Secure the electrical connection.

DescriptionConnector
Dashboard/rear couplingSee D020 DASHBOARD/REAR COUPLING
R R FACIA SUPPORT BEAM

- Connect the aerial.

DescriptionConnector
Coaxial cable for radio aerial couplingSee D168 COAXIAL CABLE FOR RADIO AERIAL COUPLING

1. Tighten the bolts securing the crossmember on both sides to the recommended torque.

ComponentFasteningdiaValue (daNm)Validity
Instrument panel (on side panels)BoltM82.0all versions
R R FACIA SUPPORT BEAM

Op. 5010C55 RIGHT LOWER AIR DIFFUSER - R+R

Op. 4110D20 STEERING ELECTRICAL CONTROL DEVICE - R R

- Remove the protective caps from the rigid air conditioning coolant hose.

- Replace the O-rings from the rigid air conditioning coolant hose connectors using rings resistant to R134A coolant.

1. Connect pipe (1a) to the expansion valve and tighten nut (1b) to the recommended torque.

ComponentFasteningdiaValue (daNm)Validity
Supply/return pipes (on condenser)BoltM82.0all versions
R R FACIA SUPPORT BEAM

1. Connect pipe (1a), expansion valve side, and tighten nut (1b) to the recommended torque.

ComponentFasteningdiaValue (daNm)Validity
Supply/return pipes (on condenser)BoltM82.0all versions
R R FACIA SUPPORT BEAM

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 1056B15 THROTTLE BODY INTERGRAL WITH MDS - R.R.

- Connect the heater water return pipe, heater side and close the retaining band.

Op. 5010A12 HEATER WATER SUPPLY PIPE - R.R.

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

- Remove both pillar trims.

Op. 7040H30 FRONT PILLAR TRIM (ONE), LEFT OR RIGHT - R.R.

Op. 7040A10 DASHBOARD TRIM - R+R

- Remove both diffusers:

Op. 5010C26 FRONT SIDE PANEL AIR DIFFUSER, L.H. OR R.H. - R R

Op. 5010C12 WINDSCREEN DEMISTER DIFFUSER - R+R

Op. 5010C30 CENTRAL AIR VENT IN DASHBOARD - R.R.

Op. 5570T80 CAR RADIO EQUIPMENT - R+R

Op. 7040A44 LEFT DASHBOARD SIDE TRIM - R.R.

Op. 7040A49 CONNECTOR HOLDER TRIM FOR EOBD - R.R.

Op. 7040A41 SPEAKER GRILLE (ONE) LH OR RH ON INSTRUMENT FACIA - R R

Op. 7040A56 SWITCH UNIT IN DASHBOARD - R.R.

Op. 7040L20 TUNNEL COVER - R.R

- Remove both electronic window switches:

Op. 7005M10 ELECTRIC WINDOW CONTROL SWITCH (ONE) FOR ONE FRONT DOOR - R.R.

- Remove both centre console side trims:

Op. 7040A65 CONSOLE SIDE CLOSING (ONE) - R.R.

Op. 7040A28 TRIM ON GEARBOX CONTROL PANEL - R.R.

Op. 2125C02 GEAR CONTROL LEVER OUTER BOOT - R.R.

Op. 2125C24 GEAR LEVER KNOB - R + R

Op. 5520A14 IGNITION KEY LOCK BARREL - R+R

Op. 5560B10 CONTROL PANEL - R+R

Op. 7040A23 INSTRUMENT PANEL FRAME IN DASHBOARD - R.R

Op. 5550A10 STALK UNIT ASSEMBLY - R+R

Op. 4110A10 STEERING WHEEL - R+R FOR REPLACEMENT OR CHECKS

Op. 5580C18 AIR BAG MODULE - R+R

Op. 5580E08 AERIAL FOR ELECTRONIC KEY (CODE) - R.R

Op. 7040A26 STEERING COLUMN TRIM - R+R

- For vehicles fitted with a knee air bag carry out the following procedure:

Op. 5580C23 DRIVER'S KNEE BAG - R.R.

- For vehicles not fitted a knee air bag carry out the following procedure:

Op. 7040A30

- Refit both front doors.

Op. 7210E36 R.R. FRONT SIDE DOOR

- Refit both running board connections

Op. 7040L42

Op. 0010T21 ENGINE COOLANT - CHECK DENSITY AND TOP UP, IF NECESSARY

- Connect the negative battery terminal.

DescriptionConnector
BatterySee A001 BATTERY

1.3 Multijet

Removing

Before working on the Air Bag system, follow the safety instructions for working on the system very carefully.

Op. 5580C AIR BAG SYSTEM

- Disconnect the negative battery terminal.

DescriptionConnector
BatterySee A001 BATTERY

- Remove both running board connectors.

Op. 7040L42

- Remove both the front doors:

Op. 7210E36 R.R. FRONT SIDE DOOR

- For vehicles with knee Air Bag carry out the following operation:

Op. 5580C23 DRIVER'S KNEE BAG - R.R.

- For vehicles without knee Air Bag carry out the following operation:

Op. 7040A30

- For all vehicles carry out the following operations:

Op. 7040A26 STEERING COLUMN TRIM - R+R

Op. 5580E08 AERIAL FOR ELECTRONIC KEY (CODE) - R.R

Op. 5580C18 AIR BAG MODULE - R+R

Op. 4110A10 STEERING WHEEL - R+R FOR REPLACEMENT OR CHECKS

Op. 5550A10 STALK UNIT ASSEMBLY - R+R

Op. 7040A23 INSTRUMENT PANEL FRAME IN DASHBOARD - R.R

Op. 5560B10 CONTROL PANEL - R+R

Op. 5520A14 IGNITION KEY LOCK BARREL - R+R

Op. 2125C24 GEAR LEVER KNOB - R + R

Op. 2125C02 GEAR CONTROL LEVER OUTER BOOT - R.R.

Op. 7040A28 TRIM ON GEARBOX CONTROL PANEL - R.R.

- Remove both centre console side trims:

Op. 7040A65 CONSOLE SIDE CLOSING (ONE) - R.R.

- Remove both the electric window switches:

Op. 7005M10 ELECTRIC WINDOW CONTROL SWITCH (ONE) FOR ONE FRONT DOOR - R.R.

Op. 7040L20 TUNNEL COVER - R.R

Op. 7040A56 SWITCH UNIT IN DASHBOARD - R.R.

Op. 7040A41 SPEAKER GRILLE (ONE) LH OR RH ON INSTRUMENT FACIA - R R

Op. 7040A49 CONNECTOR HOLDER TRIM FOR EOBD - R.R.

Op. 7040A44 LEFT DASHBOARD SIDE TRIM - R.R.

Op. 5570T80 CAR RADIO EQUIPMENT - R+R

Op. 5010C30 CENTRAL AIR VENT IN DASHBOARD - R.R.

Op. 5010C12 WINDSCREEN DEMISTER DIFFUSER - R+R

- Remove both diffusers:

Op. 5010C26 FRONT SIDE PANEL AIR DIFFUSER, L.H. OR R.H. - R R

Op. 7040A10 DASHBOARD TRIM - R+R

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 5530B10 BATTERY - R+R

Op. 1048B44 RIGID AIR SUPPLY PIPE BETWEEN HEAT EXCHANGER AND INTAKE MANIFOLD - R.R.

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5010A12 HEATER WATER SUPPLY PIPE - R.R.

- Position a suitable container for collecting the coolant.

1. Open securing band (1a) and disconnect return pipe (1b).

R R FACIA SUPPORT BEAM

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 1056B15 THROTTLE BODY INTERGRAL WITH MDS - R.R.

1. Undo nut (1a) from pipe (1b), expansion valve side.

2. Release the pipe from the retaining clip.

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

R R FACIA SUPPORT BEAM

1. Undo nut (1a) and disconnect pipe (1b), expansion valve side.

2. Release the pipe from the retaining clip.

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

R R FACIA SUPPORT BEAM

Op. 4110D20 STEERING ELECTRICAL CONTROL DEVICE - R R

Op. 5010C55 RIGHT LOWER AIR DIFFUSER - R+R

1. Unscrew the bolts securing the crossmember on both sides.

R R FACIA SUPPORT BEAM

1. Detach the electrical connection.

DescriptionConnector
1Dashboard/rear couplingSee D020 DASHBOARD/REAR COUPLING
R R FACIA SUPPORT BEAM

- Disconnect the aerial.

DescriptionConnector
Coaxial cable for radio aerial couplingSee D168 COAXIAL CABLE FOR RADIO AERIAL COUPLING

1. Detach the electrical connection.

DescriptionConnector
1Dashboard braid junctionSee D259 INSTRUMENT PANEL BRIDGE COUPLING

2. Disconnect the electrical connection for the Air Bag control unit.

DescriptionConnector
2Air Bag control unitSee M060 AIR BAG CONTROL UNIT

3. Undo nut (3a) and disconnect earth connection (3b).

DescriptionConnector
3bAir Bag system earthSee C050 AIR BAG SYSTEM EARTH
R R FACIA SUPPORT BEAM

1. Detach the electrical connection.

DescriptionConnector
1Front/dashboard couplingSee D001 FRONT/DASHBOARD COUPLING
R R FACIA SUPPORT BEAM

1. Undo nut (1a) and disconnect earth connection (1b).

DescriptionConnector
1Driver''s dashboard earthSee C015 DASHBOARD EARTH, DRIVER'S SIDE
R R FACIA SUPPORT BEAM

1. Disconnect the Body Computer electrical connections.

DescriptionConnector
1Body computerSee M001 BODY COMPUTER
R R FACIA SUPPORT BEAM

1. Unscrew nuts (1a) and bolt (1b) securing the gearbox lever mount.

R R FACIA SUPPORT BEAM

1. Unscrew the bolts securing the gear lever mount bracket.

R R FACIA SUPPORT BEAM

1. Undo the bolts on the windscreen base.

2. Remove the cross member complete with air conditioning unit.

R R FACIA SUPPORT BEAM

Refitting

- Position the cross member in its housing complete with air conditioning unit.

- Tighten the bolts on the windscreen base.

- Tighten the bolts securing the gear lever mount bracket.

- Tighten the bolt securing the gear lever support.

- Tighten the nuts securing the gear lever support.

1. Connect the Body Computer electrical connections.

DescriptionConnector
1Body computerSee M001 BODY COMPUTER
R R FACIA SUPPORT BEAM

1. Secure the electrical connection.

DescriptionConnector
1Front/dashboard couplingSee D001 FRONT/DASHBOARD COUPLING
R R FACIA SUPPORT BEAM

1. Connect earth connection (1a) and tighten nut (1b).

DescriptionConnector
1aDriver''s dashboard earthSee C015 DASHBOARD EARTH, DRIVER'S SIDE
R R FACIA SUPPORT BEAM

1. Secure the electrical connection.

DescriptionConnector
1Dashboard braid junctionSee D259 INSTRUMENT PANEL BRIDGE COUPLING

2. Connect the connection for the Air Bag control unit.

DescriptionConnector
2Air Bag control unitSee M060 AIR BAG CONTROL UNIT

3. Connect earth connection (3a) and tighten nut (3b).

DescriptionConnector
3aAir Bag system earthSee C050 AIR BAG SYSTEM EARTH
R R FACIA SUPPORT BEAM

1. Secure the electrical connection.

DescriptionConnector
1Dashboard/rear couplingSee D020 DASHBOARD/REAR COUPLING
R R FACIA SUPPORT BEAM

- Connect the aerial.

DescriptionConnector
Coaxial cable for radio aerial couplingSee D168 COAXIAL CABLE FOR RADIO AERIAL COUPLING

1. Tighten the bolts securing the cross member on both sides to the recommended torque.

ComponentFasteningdiaValue (daNm)Validity
Instrument panel (on side panels)BoltM82.0all versions
R R FACIA SUPPORT BEAM

Op. 5010C55 RIGHT LOWER AIR DIFFUSER - R+R

Op. 4110D20 STEERING ELECTRICAL CONTROL DEVICE - R R

- Remove the protective caps from the air conditioner coolant rigid pipes.

- Replace the O-rings for the connector on the air conditioner coolant rigid pipes, using rings that are resistant to R134A refrigerant fluid.

1. Secure the pipe to the retaining clip.

2. Connect pipe (2a) to the expansion valve and tighten nut (2b) to the specified torque.

ComponentFasteningdiaValue (daNm)Validity
Supply/return pipes (on expansion valve)NutM10x1.253.5all versions
R R FACIA SUPPORT BEAM

1. Secure the pipe to the retaining clip.

2. Connect pipe (2a), expansion valve side, and tighten nut (2b) to the recommended torque.

ComponentFasteningdiaValue (daNm)Validity
Supply/return pipes (on expansion valve)NutM10x1.253.5all versions
R R FACIA SUPPORT BEAM

Op. 1056B15 THROTTLE BODY INTERGRAL WITH MDS - R.R.

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

- Connect the water return pipe from the heater, heater side and close the retaining band.

Op. 5010A12 HEATER WATER SUPPLY PIPE - R.R.

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

Op. 0010T21 ENGINE COOLANT - CHECK DENSITY AND TOP UP, IF NECESSARY

Op. 1048B44 RIGID AIR SUPPLY PIPE BETWEEN HEAT EXCHANGER AND INTAKE MANIFOLD - R.R.

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

Op. 7040A10 DASHBOARD TRIM - R+R

- Refit both diffusers:

Op. 5010C26 FRONT SIDE PANEL AIR DIFFUSER, L.H. OR R.H. - R R

Op. 5010C12 WINDSCREEN DEMISTER DIFFUSER - R+R

Op. 5010C30 CENTRAL AIR VENT IN DASHBOARD - R.R.

Op. 5570T80 CAR RADIO EQUIPMENT - R+R

Op. 7040A44 LEFT DASHBOARD SIDE TRIM - R.R.

Op. 7040A49 CONNECTOR HOLDER TRIM FOR EOBD - R.R.

Op. 7040A41 SPEAKER GRILLE (ONE) LH OR RH ON INSTRUMENT FACIA - R R

Op. 7040A56 SWITCH UNIT IN DASHBOARD - R.R.

Op. 7040L20 TUNNEL COVER - R.R

- Refit both the electric window switches:

Op. 7005M10 ELECTRIC WINDOW CONTROL SWITCH (ONE) FOR ONE FRONT DOOR - R.R.

- Refit both centre console side trims:

Op. 7040A65 CONSOLE SIDE CLOSING (ONE) - R.R.

Op. 7040A28 TRIM ON GEARBOX CONTROL PANEL - R.R.

Op. 2125C02 GEAR CONTROL LEVER OUTER BOOT - R.R.

Op. 2125C24 GEAR LEVER KNOB - R + R

Op. 5520A14 IGNITION KEY LOCK BARREL - R+R

Op. 5560B10 CONTROL PANEL - R+R

Op. 7040A23 INSTRUMENT PANEL FRAME IN DASHBOARD - R.R

Op. 5550A10 STALK UNIT ASSEMBLY - R+R

Op. 4110A10 STEERING WHEEL - R+R FOR REPLACEMENT OR CHECKS

Op. 5580C18 AIR BAG MODULE - R+R

Op. 5580E08 AERIAL FOR ELECTRONIC KEY (CODE) - R.R

Op. 7040A26 STEERING COLUMN TRIM - R+R

- For vehicles with knee Air Bag carry out the following operation:

Op. 5580C23 DRIVER'S KNEE BAG - R.R.

- For vehicles without knee Air Bag carry out the following operation:

Op. 7040A30

- Refit both the front doors:

Op. 7210E36 R.R. FRONT SIDE DOOR

- Refit both running board connectors:

Op. 7040L42

- Connect the negative battery terminal.

DescriptionConnector
BatterySee A001 BATTERY

1.4 16v

Removing

Before working on the Air Bag system, follow the safety instructions for working on the system very carefully.

Op. 5580C AIR BAG SYSTEM

- Disconnect the negative battery terminal.

DescriptionConnector
BatterySee A001 BATTERY

- Remove both running board connectors

Op. 7040L42

- Remove both the front doors:

Op. 7210E36 R.R. FRONT SIDE DOOR

- For vehicles with knee bags, carry out the following operation:

Op. 5580C23 DRIVER'S KNEE BAG - R.R.

- For vehicles without knee bags, carry out the following operation:

Op. 7040A30

- Carry out the following operations on all vehicles:

Op. 7040A26 STEERING COLUMN TRIM - R+R

Op. 5580E08 AERIAL FOR ELECTRONIC KEY (CODE) - R.R

Op. 5580C18 AIR BAG MODULE - R+R

Op. 4110A10 STEERING WHEEL - R+R FOR REPLACEMENT OR CHECKS

Op. 5550A10 STALK UNIT ASSEMBLY - R+R

Op. 7040A23 INSTRUMENT PANEL FRAME IN DASHBOARD - R.R

Op. 5560B10 CONTROL PANEL - R+R

Op. 5520A14 IGNITION KEY LOCK BARREL - R+R

Op. 2125C24 GEAR LEVER KNOB - R + R

Op. 2125C02 GEAR CONTROL LEVER OUTER BOOT - R.R.

Op. 7040A28 TRIM ON GEARBOX CONTROL PANEL - R.R.

- Remove both centre console side trims:

Op. 7040A65 CONSOLE SIDE CLOSING (ONE) - R.R.

- Remove both electric window switches:

Op. 7005M10 ELECTRIC WINDOW CONTROL SWITCH (ONE) FOR ONE FRONT DOOR - R.R.

Op. 7040L20 TUNNEL COVER - R.R

Op. 7040A56 SWITCH UNIT IN DASHBOARD - R.R.

Op. 7040A41 SPEAKER GRILLE (ONE) LH OR RH ON INSTRUMENT FACIA - R R

Op. 7040A49 CONNECTOR HOLDER TRIM FOR EOBD - R.R.

Op. 7040A44 LEFT DASHBOARD SIDE TRIM - R.R.

Op. 5570T80 CAR RADIO EQUIPMENT - R+R

Op. 5010C30 CENTRAL AIR VENT IN DASHBOARD - R.R.

Op. 5010C12 WINDSCREEN DEMISTER DIFFUSER - R+R

- Remove both vents:

Op. 5010C26 FRONT SIDE PANEL AIR DIFFUSER, L.H. OR R.H. - R R

Op. 7040A10 DASHBOARD TRIM - R+R

- Remove both the pillar trims:

Op. 7040H30 FRONT PILLAR TRIM (ONE), LEFT OR RIGHT - R.R.

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 5530B10 BATTERY - R+R

Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5010A12 HEATER WATER SUPPLY PIPE - R.R.

- Position a suitable container for collecting the refrigerant fluid.

1. Open the retaining band (1a) and disconnect the water return pipe (1b), heater side.

R R FACIA SUPPORT BEAM

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 1056B15 THROTTLE BODY INTERGRAL WITH MDS - R.R.

2. Undo the fixing nut (2a) and disconnect the high pressure pipe (2b), expansion valve side.

1. Undo the nut (1a) securing the pipe (1b), expansion valve side.

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

R R FACIA SUPPORT BEAM

Op. 4110D20 STEERING ELECTRICAL CONTROL DEVICE - R R

Op. 5010C55 RIGHT LOWER AIR DIFFUSER - R+R

1. Undo the bolts securing the crossmember on both sides.

R R FACIA SUPPORT BEAM

1. Detach the electrical connection.

DescriptionConnector
1Dashboard/rear couplingSee D020 DASHBOARD/REAR COUPLING
R R FACIA SUPPORT BEAM

- Disconnect the aerial.

DescriptionConnector
Coaxial cable for radio aerial couplingSee D168 COAXIAL CABLE FOR RADIO AERIAL COUPLING

1. Detach the electrical connection.

DescriptionConnector
1Dashboard bridge couplingSee D259 INSTRUMENT PANEL BRIDGE COUPLING

2. Disconnect the electrical connection for the Air Bag control unit.

DescriptionConnector
2Air Bag control unitSee M060 AIR BAG CONTROL UNIT

3. Undo the fixing nut (3a) and disconnect the earth connection (3b).

DescriptionConnector
3bAir Bag system earthSee C050 AIR BAG SYSTEM EARTH
R R FACIA SUPPORT BEAM

1. Detach the electrical connection.

DescriptionConnector
1Front/dashboard couplingSee D001 FRONT/DASHBOARD COUPLING
R R FACIA SUPPORT BEAM

1. Undo the fixing nut (1a) and disconnect the earth connection (1b).

DescriptionConnector
1bDriver''s dashboard earthSee C015 DASHBOARD EARTH, DRIVER'S SIDE
R R FACIA SUPPORT BEAM

1. Disconnect the electrical connections for the Body Computer.

DescriptionConnector
1Body computerSee M001 BODY COMPUTER
R R FACIA SUPPORT BEAM

1. Undo the nuts (1a) and the bolt (1b) fixing the gear lever support.

R R FACIA SUPPORT BEAM

1. Undo the bolts fixing the gear lever mounting bracket.

R R FACIA SUPPORT BEAM

1. Undo the fixing bolts at the base of the windscreen.

2. Remove the crossmember complete with climate control unit.

R R FACIA SUPPORT BEAM

Refitting

- Place the crossmember complete with climate control unit in position.

- Tighten the fixing bolts at the base of the windscreen.

- Tighten the bolts fixing the gear lever mounting bracket.

- Tighten the bolt fixing the gear lever support.

- Tighten the nuts fixing the gear lever support.

1. Connect the electrical connections for the Body Computer.

DescriptionConnector
1Body computerSee M001 BODY COMPUTER
R R FACIA SUPPORT BEAM

1. Secure the electrical connection.

DescriptionConnector
1Front/dashboard couplingSee D001 FRONT/DASHBOARD COUPLING
R R FACIA SUPPORT BEAM

1. Connect the earth connection (1a) and tighten the fixing nut (1b).

DescriptionConnector
1Driver''s dashboard earthSee C015 DASHBOARD EARTH, DRIVER'S SIDE
R R FACIA SUPPORT BEAM

1. Secure the electrical connection.

DescriptionConnector
1Dashboard bridge couplingSee D259 INSTRUMENT PANEL BRIDGE COUPLING

2. Connect the electrical connection for the Air Bag control unit.

DescriptionConnector
2Air Bag control unitSee M060 AIR BAG CONTROL UNIT

3. Connect the earth connection (3a) and tighten the fixing nut (3b).

DescriptionConnector
3aAir Bag system earthSee C050 AIR BAG SYSTEM EARTH
R R FACIA SUPPORT BEAM

1. Secure the electrical connection.

DescriptionConnector
1Dashboard/rear couplingSee D020 DASHBOARD/REAR COUPLING
R R FACIA SUPPORT BEAM

- Connect the aerial.

DescriptionConnector
Coaxial cable for radio aerial couplingSee D168 COAXIAL CABLE FOR RADIO AERIAL COUPLING

1. Tighten the bolts securing the crossmember on both sides to the recommended torque.

ComponentFasteningdiaValue (daNm)Validity
Instrument panel (on side panels)BoltM82.0all versions
R R FACIA SUPPORT BEAM

Op. 5010C55 RIGHT LOWER AIR DIFFUSER - R+R

Op. 4110D20 STEERING ELECTRICAL CONTROL DEVICE - R R

- Remove the protective plugs from the air conditioning refrigerant rigid pipes.

- Replace the o-rings for the air conditioning refrigerant fluid rigid pipe connectors using seals resistant to R134A refrigerant fluid.

1. Connect the high pressure (1a) and low pressure (1b) pipes, expansion valve side and tighten the fixing nuts (1c) to the recommended torque.

ComponentFasteningdiaValue (daNm)Validity
Supply/return pipes (on expansion valve)NutM10x1.253.5all versions
R R FACIA SUPPORT BEAM

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 1056B15 THROTTLE BODY INTERGRAL WITH MDS - R.R.

- Connect the heater water return pipe, heater side and close the retaining band.

Op. 5010A12 HEATER WATER SUPPLY PIPE - R.R.

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

Op. 5530B10 BATTERY - R+R

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R

- Refit both the pillar trims:

Op. 7040H30 FRONT PILLAR TRIM (ONE), LEFT OR RIGHT - R.R.

Op. 7040A10 DASHBOARD TRIM - R+R

- Refit both vents:

Op. 5010C26 FRONT SIDE PANEL AIR DIFFUSER, L.H. OR R.H. - R R

Op. 5010C12 WINDSCREEN DEMISTER DIFFUSER - R+R

Op. 5010C30 CENTRAL AIR VENT IN DASHBOARD - R.R.

Op. 5570T80 CAR RADIO EQUIPMENT - R+R

Op. 7040A44 LEFT DASHBOARD SIDE TRIM - R.R.

Op. 7040A49 CONNECTOR HOLDER TRIM FOR EOBD - R.R.

Op. 7040A41 SPEAKER GRILLE (ONE) LH OR RH ON INSTRUMENT FACIA - R R

Op. 7040A56 SWITCH UNIT IN DASHBOARD - R.R.

Op. 7040L20 TUNNEL COVER - R.R

- Refit both electric window switches:

Op. 7005M10 ELECTRIC WINDOW CONTROL SWITCH (ONE) FOR ONE FRONT DOOR - R.R.

- Refit both centre console side trims:

Op. 7040A65 CONSOLE SIDE CLOSING (ONE) - R.R.

Op. 7040A28 TRIM ON GEARBOX CONTROL PANEL - R.R.

Op. 2125C02 GEAR CONTROL LEVER OUTER BOOT - R.R.

Op. 2125C24 GEAR LEVER KNOB - R + R

Op. 5520A14 IGNITION KEY LOCK BARREL - R+R

Op. 5560B10 CONTROL PANEL - R+R

Op. 7040A23 INSTRUMENT PANEL FRAME IN DASHBOARD - R.R

Op. 5550A10 STALK UNIT ASSEMBLY - R+R

Op. 4110A10 STEERING WHEEL - R+R FOR REPLACEMENT OR CHECKS

Op. 5580C18 AIR BAG MODULE - R+R

Op. 5580E08 AERIAL FOR ELECTRONIC KEY (CODE) - R.R

Op. 7040A26 STEERING COLUMN TRIM - R+R

- For vehicles with knee bags, carry out the following operation:

Op. 5580C23 DRIVER'S KNEE BAG - R.R.

- For vehicles without knee bags, carry out the following operation:

Op. 7040A30

- Refit both the front doors:

Op. 7210E36 R.R. FRONT SIDE DOOR

- Refit both running board connectors:

Op. 7040L42

Op. 0010T21 ENGINE COOLANT - CHECK DENSITY AND TOP UP, IF NECESSARY

- Connect the negative battery terminal.

DescriptionConnector
BatterySee A001 BATTERY

Parts & tools for this job For 2007 Fiat 500

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