198003124 - 7205A02 STRIPPING FRONT END ASSEMBLY

Removing ( Refitting )

The operation should be carried out with the front end detached.

1. Working on the top right side of the front end, undo the bolt (1a) and remove the horn and bracket (1b). 1. Undo the nuts (1a) and remove the crossmember (1b). 1. Undo the bolts (1a) and remove the upper crossmember (1b). - For 1.9 JTD engines only Working on both sides of the front end, undo the bolts (1a) and remove the intercooler radiator (1b). - For 1.9 JTD engines only Working on the left side of the front end, disconnect the bands (1a) for the electrical wiring (1b). Undo the bolts (2a) and remove the valve and pipes (2b). 1. Undo the bolts (1a) and remove the lower crossmember (1b).2. Undo the radiator assembly fixing bolts.3. Remove the front end (3a) separating it from the radiator assembly (3b). 1. If necessary, working on both sides of the front end, undo the bolts (1a) and remove the connecting brackets (1b). 1. If necessary, working on both sides of the front end, undo the bolts (1a) and remove the brackets (1b). Refitting ( Removing ) - Check that the front end is not damaged.- If removed, working on both sides of the front end, position the brackets and tighten the bolts.- If removed, working on both sides of the front end, position the connecting brackets and tighten the bolts.- Position the front end on the radiator assembly.- Tighten the radiator assembly fixing bolts.- Position the lower crossmember and tighten the bolts.- For 1.9 JTD engines only Position the valve and pipes and tighten the bolts. Connect the electrical wiring bands to the front end.- For 1.9 JTD engines only Position the intercooler radiator and tighten the fixing bolts.- Position the upper crossmember and tighten the bolts.- Position the crossmember and tighten the nuts.- Position the horn and bracket and tighten the bolt.