| Removal and Installation Special Tool(s) | | Remover/Installer, coolant hose clamp 303-397 | General Equipment Hose clamp - coolant hose Vehicles with fuel powered booster heater | | -
Drain the cooling system. For additional information, refer to: Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften (303-03A, General Procedures), Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften (303-03B, General Procedures), Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften (303-03C, General Procedures), Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften (303-03D, General Procedures), Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften (303-03E, General Procedures). | | | -
NOTE:Mark installation position of front engine mounting bracket with respect to the wheelhouse. Remove the front engine mounting bracket bolts. - Pull the engine forwards.
| All vehicles | | -
Remove the engine cover (2.0L diesel shown). | | | -
Remove the left and right front wheels.
For additional information, refer to: Rad und Reifen (204-04, Removal and Installation).
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Remove the left and right front wheelhouse covers. | | | -
Remove the wheelhouse insulation. | | | -
Remove the front bumper cover.
For additional information, refer to: Abdeckung – Stoßfänger vorn (501-19, Removal and Installation).
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Empty the windshield washer reservoir. | | | -
Remove the front scuff plate - passenger side.
For additional information, refer to: Vordere Einstiegsverkleidung (501-05, Removal and Installation).
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Remove the right and left-hand direction indicators. - Pull turn indicators out of wing, turn bayonet type socket and pull out.
| Vehicles with anti-lock brake system | | -
Remove the hydraulic control unit (HCU). For additional information, refer to: Antiblockierbremssystem (206-09A, Diagnosis and Testing), Hydraulische Regeleinheit (HCU) (206-09C, Removal and Installation). | Vehicles without anti-lock brake system | | -
Remove the battery tray. For additional information, refer to: (414-01 ) Batteriekonsole - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (Removal and Installation), Batteriekonsole - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (Removal and Installation). | Vehicles with manual transaxle | | -
CAUTION:If brake fluid comes into contact with the paintwork, the affected area must be washed down immediately with cold water. CAUTION:Close off lines to prevent loss of brake fluid and dirt from entering. Detach the supply hose of the clutch master cylinder and the supply line of the clutch slave cylinder from the clutch master cylinder. - Release the clutch master cylinder supply hose clip.
- Release the clutch slave cylinder supply line clip.
| 14. Remove the components in the order indicated in the following illustration(s) and table(s). CAUTION:Make sure that the windshield wiper motor is in the park position. 1 - Windshield wiper arm nuts 3 - Clips, cowl panel grille 5 - Bolts for windshield wiper motor with linkage 6 - Windshield wiper motor with linkage 7 - Windshield wiper motor connector 8 - Connector - heated windshield (if fitted) 9 - Connector - heated windshield washer jets (if fitted) 10 - Clips - engine compartment wiring harness NOTE:Only vehicles with anti-theft alarm horn with integral battery 11 - Nuts - anti-theft alarm system horn 12 - Anti-theft alarm system horn 13 - Connector - anti-theft alarm system horn CAUTION:Close off the coolant hoses, fuel hose and fuel fired booster heater to stop dirt from entering. NOTE:Only vehicles with fuel fired booster heater 15 - Exhaust pipe - fuel fired booster heater 17 - Left-hand coolant hose - fuel fired booster heater 18 - Fuel hose - fuel fired booster heater 19 - Right-hand coolant hose - fuel fired booster heater 20 - Bolt - fuel fired booster heater NOTE:Only vehicles with fuel fired booster heater 22 - Nuts - fuel fired booster heater bracket 23 - Bracket - fuel fired booster heater (secure to one side) 25 - Windshield washer upper reservoir upper retaining bolt 26 - Windshield washer pump connector 28 - Clips - engine compartment wiring harness 29 - Connector - anti-lock brake system wheel sensor 30 - Connector - headlamp range control front sensor (if fitted) 33 - Clips - engine compartment wiring harness 34 - Connector - anti-lock brake system wheel sensor 40 - High pressure switch connector 41 - Bracket - evaporator refrigerant lines (unclip) 42 - Clips - engine compartment wiring harness 44 - Connector - brake fluid level warning light switch 45 - Battery junction box (BJB) cover 47 - Engine wiring harness connector 50 - Connector - power steering pump (if fitted) 52 - Ambient Air Temperature (AAT) connector 53 - Connector - pre-glow relay (if fitted) 54 - Clips - engine compartment wiring harness 56 - Connector - bonnet lock 57 - Connector - anti-theft alarm system sensor 58 - Connector - cooling fan 59 - Connector - park position sensor 60 - Clips - engine compartment wiring harness 65 - Connector - audio input 66 - Passenger air bag deactivation (PAD) switch electrical connector (if equipped) 67 - Opening damper, glove compartment cover (unhook) 68 - Glove compartment cover 73 - Clips - engine compartment wiring harness 74 - Connector - electric booster heater (if equipped) 15. To install, reverse the removal procedure. CAUTION:Ensure that the front engine mounting bracket is in the original installation position. | | -
Bleed the clutch system.
For additional information, refer to: Kupplungssystem entlüften (308-00, General Procedures).
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Check the angle of the windshield wiper arms in relation to the windshield.
For additional information, refer to: Vorderen Wischerarm einstellen (501-16, General Procedures).
| Removal Details Item 14 : Intake hose - fuel fired booster heater | | -
Raise the vehicle.
For additional information, refer to: Anheben mit Hebebühne (100-02, Description and Operation).
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Disconnect the additional coolant pump electrical connector (if fitted). | Item 16 : Connector - fuel fired booster heater Item 21 : Fuel fired booster heater | | -
Unclip the fuel fired booster heater from the bracket. | Item 24 : Windshield washer upper reservoir lower retaining bolt | | -
Raise the vehicle.
For additional information, refer to: Anheben mit Hebebühne (100-02, Description and Operation).
| Item 27 : Windshield washer upper reservoir (secure to one side) | | -
Pull the connecting piece of the lower reservoir from the upper reservoir. | | | -
Pull the reservoir from the filler neck. | Item 32 : Engine compartment wiring harness | | -
Slide the wiring harness into the engine compartment. | Item 36 : Engine compartment wiring harness | | -
Slide the wiring harness into the engine compartment. | Item 37 : Coolant hose, coolant expansion tank (only 1.6L diesel engine) | | -
Empty the coolant expansion tank. | | | -
CAUTION:Close off the coolant hose from the expansion tank using a hose clamp, so that coolant is prevented from escaping from the coolant hose. Clamp the coolant hose shut. | Item 38 : Coolant expansion tank | | -
Unclip the coolant expansion tank and place to one side. | Item 39 : Low pressure switch connector | | -
CAUTION:If brake fluid comes into contact with the paintwork, the affected area must be washed down immediately with cold water. Detach the brake fluid reservoir from the bulkhead extension and tie it back to one side. | | | -
Remove the bulkhead extension. - Pull the bulkhead extension out of the clips.
| Item 43 : Engine compartment wiring harness | | -
Pull out the wiring harness under the refrigerant lines. | Item 55 : Engine compartment wiring harness | | -
Slide the wiring harness into the engine compartment. | Item 62 : Glove compartment screws | | -
Fold down the covering caps of the screws for the glove compartment. | | | -
Detach the central junction box (CJB) from the reinforcing element. | | | -
Detach the CJB from the CJB bracket. - Turn the CJB downwards.
- Pull out the CJB.
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Detach the wiring harness from the CJB bracket (if fitted). | Item 63 : Hose, glove compartment cooling (if equipped) | | -
Detach the glove compartment cooling hose from the glove compartment. | Item 64 : Glove compartment | | -
Remove the access flap for the DVD drive (if equipped). | Item 69 : Lower connector - dashboard wiring harness | | -
Detach the connector housing from the A-pillar. | Item 70 : Upper connector - dashboard wiring harness | | -
Push the bulkhead insulation matting to one side. | | | -
Detach the connector housing from the bulkhead. | Item 71 : Connector - engine compartment wiring harness | | -
Disconnect the engine wiring harness connector from the CJB. | Item 72 : Ground cable bolts | | -
Detach the wiring harness from the bulkhead. | Item 75 : Engine compartment wiring harness | | -
Slide the engine compartment wiring harness, together with the rubber grommet, into the engine compartment. | Item 76 : Engine compartment wiring harness | | -
NOTE:Only vehicles with electrohydraulic power steering Disconnect the steer angle sensor electrical connector (if fitted). | | | -
Unclip the supply line of the clutch slave cylinder from the bracket. | | | -
Unclip the brake pipe and remove the clip. | | | -
Pull out the wiring harness under the refrigerant lines and the coolant lines. | Installation Details Item 2 : Windshield wiper arms CAUTION:Move the windshield wiper motor to the parked position before installing the wiper arms. |
