41 33 039 Removing and installing front panel

Special tools required:

Necessary preliminary tasks:

Clamp off BATTERY
Drain COOLANT
Remove COOLANT EXPANSION TANK
Remove UNDERBODY PROTECTION
Remove FRONT BUMPER PANEL
Remove BOTH WHEEL ARCH LINERS
Vehicles with A/C system only:
Drain AIR CONDITIONER

Bottom left side:

Release screw (1).

Tightening torque 51 11 9AZ

Release clamp (3) for cooling water hose with special tool 17 2 052 .

Vehicles with A/C system only:

Loosen screws (2) for A/C lines and pull off lines.

Close open lines.

Installation note:

Fig 1: Identifying Screws And Cooling Water Hose Clamp

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Replace O-rings on both connections and coat with refrigerant oil.

Tightening torque 64 53 1AZ

IMPORTANT: If air conditioner has been opened for more than 24 hours, dryer flask must be replaced

Release screws (1).

Tightening torque 51 11 4AZ .

Slacken nut (2).

Tightening torque 51 11 3AZ .

Fig 2: Identifying Screws And Nut

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Bottom right side:

Release screw (1).

Tightening torque 51 11 9AZ .

Release wiring harness (2) from front panel and side member.

Release screws (3).

Tightening torque 51 11 4AZ .

Slacken nut (4).

Tightening torque 51 11 3AZ .

Fig 3: Identifying Wiring Harness, Nut, And Screws

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Unlock connector (1) and remove.

Fig 4: Identifying Connector

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Unlock connector (1) and remove.

Disconnect hoses (2).

Release wiring harness (3) from container.

Detach hose (4) for window washer system at the attachment points.

Fig 5: Identifying Window Washer System Hose

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Unlock connector (1) for horn and disconnect.

Release wiring harness at attachment point (2).

Fig 6: Identifying Horn Connector

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Unlock connector (1) for temperature sensor (1) and disconnect.

Pull wiring harness (2) off of air duct.

Fig 7: Identifying Temperature Sensor Connector

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Release screw (1) on side wall.

Tightening torque 41 35 2AZ .

Repeat operation on other side.

Fig 8: Identifying Screw On Side Panel

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Unscrew nuts (1).

Tightening torque 51 11 3 AZ .

Repeat above step on left side.

Fig 9: Identifying Nuts

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Vehicles with A/C system only:

Unclip line for air conditioning (1) from holder.

Fig 10: Identifying Air Conditioning Line

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Vehicles with turbocharger only:

Release hose clamp (1) and detach hose (2).

Fig 11: Identifying Hose Clamp

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Unlock plug connection (1) for fan and disconnect.

Detach wiring harness at attachment points (2).

Fig 12: Identifying Wiring Harness Attachment Points And Fan Plug Connection

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Release clamp (1) using special tool 17 2 051 and disconnect the coolant hose.

Vehicles with turbocharger only:

Release clamp (2) using special tool 17 2 051 and disconnect the coolant hose.

Fig 13: Identifying Coolant Hose Clamps

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Open clutch (1) and detach Bowden cable for hood/bonnet release.

Unlock plug connection (2) for headlight and disconnect.

Release screw (3).

Tightening torque 63 12 1AZ .

Release screws (4).

Tightening torque 51 11 7 AZ .

Fig 14: Identifying Headlight Plug Connection, Clutch, And Screws

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Unlock plug connection (1) for headlight and disconnect.

Vehicles with turbocharger only:

Unlock plug connection (2) for charge air pressure sensor and disconnect.

Release clamp (3) and pull off charge air hose.

Release screw (4).

Tightening torque 63 12 1AZ .

Release screws (5).

Tightening torque 51 11 7 AZ .

Remove front panel.

Fig 15: Identifying Clamp, Plug Connections, And Screws

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