Removal
NOTES:
Removal steps in this procedure may contain installation details.
Some variation in the illustrations may occur, but the essential information is always correct.
All vehicles
1. Refer to: Specifications (414-01 Battery, Mounting and Cables, Specifications).
2. Refer to: Central Junction Box (CJB) (418-00 Module Communications Network, Removal and Installation).
3. Refer to: Instrument Panel Upper Section (501-12 Instrument Panel and Console, Removal and Installation).
4.

5.

6. Torque: 10 Nm

7.

8.

9.

10. Torque: 10 Nm

11.

Vehicles with auxiliary heating
12.

13.

All vehicles
14.

15.

16. Refer to: Anti-Theft Alarm Horn with Integral Battery (419-01A Anti-Theft - Active, Removal and Installation).
17.

18. Torque: 10 Nm

19. WARNING: Be prepared to collect escaping fluid.

20.

21. NOTE: LH illustration shown, RH is similar. Remove the front RH wheel arch liner.
Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
Vehicles with fuel fired booster heater
22. Refer to: Fuel Fired Booster Heater - TD4 2.2L Diesel (412-02 Auxiliary Climate Control, Removal and Installation).
All vehicles
23.

24.

25. WARNING: Be prepared to collect escaping fluid.

26.

27. Refer to: Secondary Bulkhead Center Panel - TD4 2.2L Diesel (501-02 Front End Body Panels, Removal and Installation).
28. Refer to: Anti-Lock Brake System (ABS) Module (206-09A Anti-Lock Control, Removal and Installation).
29. Refer to: Brake Booster (206-07 Power Brake Actuation, Removal and Installation).
30.

31. Torque: 10 Nm

32.

33. Torque: 25 Nm

34. Torque: 10 Nm

35.

36. Torque: 10 Nm

37. Torque: 10 Nm

38.

39.

40. Torque: 10 Nm

41.

42. WARNING: Be prepared to collect escaping fluid.
CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
Torque: 14 Nm

43. WARNING: Be prepared to collect escaping fluid.
CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
Torque: 14 Nm

Vehicles with manual transmission
44. WARNING: Be prepared to collect escaping fluid.
CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.

45. WARNING: Be prepared to collect escaping fluid.
CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.

All vehicles
46. Torque: 25 Nm

Vehicles with manual transmission
47.

All vehicles
48.

49. WARNING: Be prepared to collect escaping fluid.

50.

51.

52. Refer to: Coolant Expansion Tank (303-03A Engine Cooling - TD4 2.2L Diesel, Removal and Installation).
53.

54. Torque: 7 Nm

55. Torque: 10 Nm

56.

57. Torque:
Bolt 10 Nm

Right-hand drive vehicles
58. WARNING: Be prepared to collect escaping fluid.

Vehicles with fuel fired booster heater
59.

All vehicles
60.

Installation
1. To install, reverse the removal procedure.
Battery Junction Box (BJB) GTDi 2.0L
Communications Network - Overview, System
Operation and Component Description
Communications Network - Diagnosis and Testing
Inner Quarter Panel
Fuel Fired Booster Heater FWD