199003029 - 7210A02 FRONT END ASSEMBLY - R.R.

Removing ( Refitting )     Op. 5530B10 BATTERY - R+R     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     Op. 7210E10 R.R. FRONT BUMPER     Op. 7210A18 R.R FRONT CROSSMEMBER     Op. 5540B07 LEFT FRONT HEADLAMP - R.R     Op. 5540B08 RIGHT FRONT HEADLAMP - R.R 1. Remove the engine coolant system expansion reservoir cap.
1. Insert a rubber pipe (1a) on the engine coolant drainage tap (1b), then open the tap (1c) and allow the fluid to flow out into a container.
1. Loosen the band (1a) and disconnect the end (1b) of the lower hose from the radiator.2. Loosen the band (2a) and disconnect the end (2b) of the air outlet hose from the intercooler.3. Loosen the band (3a) and disconnect the end (3b) of the flexible hose from the turbine to the rigid pipe.
- Lower the vehicle.1. Undo the retainers and remove the cover of the junction box in the engine compartment.2. Slightly turn the box to gain access to the underlying electrical connections.3. Detach the electrical connections (3a, 3b).
DescriptionConnector
1bREAR/CROSSMEMBER COUPLING    See D106 REAR/CROSSMEMBER COUPLING
1bJUNCTION UNIT    See B001 JUNCTION UNIT
1. Disconnect the electrical earth lead on the front left side of the side panel.
DescriptionConnector
1LEFT FRONT EARTH    See C010 LEFT FRONT EARTH
1. Disconnect the electrical connection from the air conditioning system multi-stage linear sensor.
DescriptionConnector
1LINEAR SENSOR FOR FANS    See K120 LINEAR SENSOR FOR FANS
1. Undo the bolt (1a) and disconnect the pipe (1b) from the air conditioner condenser (1c).- Release the pipes from the retainers.
Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.
1. Disconnect the bonnet release cable from the lock.
1. Loosen the band and disconnect the sleeve from the engine cooling system thermostat.
1. Loosen the band and disconnect the sleeve from the engine cooling system expansion tank.
1. Undo the bolt (1a) and move the cold air intake (1b) slightly aside.
1. Unscrew the bolts (1a) and remove the front end unit (1b) complete with:- expansion tank- heat exchanger- bonnet lid lock- fans- crossmember wiring- sleeves and rigid pipes
- If necessary, strip the front end, remove the following parts with reference to the appropriate procedures:- expansion tank- heat exchanger- bonnet lid lock- fans- crossmember wiring- sleeves and rigid pipes Refitting ( Removing ) - Check that the front end is not damaged.- If necessary, refit the various components on the front end.1. Position the front end (1a) and secure it using the bolts (1b).
ComponentFasteningdia  Value (daNm)Validity
Front end to bodyBoltM10x1.5x28.53.2 ÷ 3.8
- Fit the cold air intake.- Connect the hose to the expansion tank and secure it using the band.- Connect the hose to the thermostat and secure it using the band.- Connect the bonnet release cable.1. Position pipe (1a) on air conditioner compressor (1b) and secure with bolt (1c).
ComponentFasteningdia  Value (daNm)Validity
Pipe connector on condenserBoltM81.8 ÷ 2.2
- Connect the electrical connection of the linear sensor, of the side panel earth and of the intermediate junctions.- Refit the engine compartment junction unit and fit the bonnet lid.- Connect the intercooler and radiator pipes.- Close the screw plug and keep the coolant drainage pipe.- Refill the cooling circuit and tighten the cap on the expansion reservoir.    Op. 5540B08 RIGHT FRONT HEADLAMP - R.R     Op. 5540B07 LEFT FRONT HEADLAMP - R.R     Op. 7210A18 R.R FRONT CROSSMEMBER     Op. 7210E10 R.R. FRONT BUMPER     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     Op. 5530B10 BATTERY - R+R