Page 1985 of 3229
45.
46. NOTE: LHD il lus trati on s hown, RHD is s imil ar.46.
Releas e t he LH s ide repeat er from t he vehi cl e body anddis connect the el ect ri cal connect or.47.
Page 1986 of 3229
48. NOTE: LHD il lus trati on s hown, RHD is s imil ar.48.
Unclip the harnes s t ray from t he vehi cl e bulkhead and rout e the RHSof t he harness around the brake pipes int o t he LHS of the enginebay.
49.
50. NOTE: RHD i llus t rati on s hown, LHD is s imil ar.50.
51. NOTE: RHD i llus t rati on s hown, LHD is s imil ar.51.
Page 1987 of 3229
52. NOTE: RHD i llus t rati on s hown, LHD is s imil ar.52.
53. NOTE: LHD il lus trati on s hown, RHD is s imil ar.53.
54. NOTE: LHD il lus trati on s hown, RHD is s imil ar.54.
Page 1988 of 3229
55.
NOTE: RHD i llus t rati on s hown, LHD is s imil ar.
55. 56.
NOTE: RHD i llus t rati on s hown, LHD is s imil ar.
56.
Installation Place harnes s t o vehi cl e plenum, feed connect ors into ins ide of
vehicle and i nst all grommet. Us e as s is tance ins ide vehicl e to pul l
connectors t hrough.
1.
Secure harnes s t ray cli ps and secure rubber grommet t o vehi cl e
body.
2.
Inst all and s ecure fus ebox to body.
T orque: 10 Nm 3.
Inst all t he engi ne mounti ng plate.
T orque: M8 24 Nm M12
80 Nm 4.
Page 1989 of 3229

Secure t he engi ne harnes s to the fus ebox.
5.
Inst all and s ecure t he bat t ery l ead to t he fusebox and ins t al l the
s mall bat tery lead cover.
T orque: 10 Nm 6.
Connect t he two electrical connect ors t o t he BJB.
7.
Secure t he 3 eart h point s and s ecure t he harness cl ips t o t he vehi cl e
body.
T orque: 10 Nm 8.
Secure t he batt ery l ead to the bat tery terminal clamp.
T orque: 25 Nm 9.
Inst all t he fus e box cover.
10.
Inst all t he harness cover to the s us pens ion turret.
11.
Feed harness under t he air cleaner duct and s ecure the duct t o the
grommet.
12.
Secure headl amp and bumper harness cl ips .
13.
Connect t he height sens or elect rical connect or and s ecure t he
harnes s wit h t he cli ps .
14.
Inst all headl amp mount ing plat e.
T orque: 10 Nm 15.
Connect t he s ide repeat er el ect ri cal connector.
16.
Connect t he heat ed was her jet electrical connect ion and s ecure t he
harnes s t o the vehicl e body.
17.
Connect t he ABS s ens or and s ecure t he harness to t he vehicle body.
18.
Secure t he was her pipe to the harnes s and s ecure t he harness to the
body.
19.
Connect t he cras h s ens or electrical connect ors .
20.
Connect t he the bonnet lock electrical connect or
21.
Secure t he harness to the body and t hen secure the bonnet releas e
cabl e t o t he harness .
22.
Secure t he was her pipe to the was her bot tl e.
23.
Inst all t he washer bott le and connect t he elect rical connecti ons .
T orque: 10 Nm 24.
Page 1990 of 3229

Secure t he 3 ground cables t o t he vehi cl e body.
T orque: 10 Nm 25.
Secure t he harness to the vehicle body.
26.
Connect t he the bonnet lock electrical connect or
27.
Inst all t he RH s econdary bul khead mount ing bracket.
T orque: 10 Nm 28.
Inst all t he inner plenum plat e and s ecure t he electrical connect or to
t he plat e.
29.
Connect t he heat ed s creen RH el ect ri cal connector.
30.
Inst all t he auxi liary cool ant pump and connect the feed hos e.
T orque: 10 Nm 31.
Inst all t he FFB heat er coolant feed and ret urn pipes .
32.
Connect t he FFB heat er coolant feed and ret urn hos es to the pi pes .
33.
Connect t he A/C pres sure s wit ch and t he BBUS electrical connect ors .
Als o secure t he harnes s t o t he vehi cl e body.
34.
Secure t he engi ne compartment harnes s t o t he vehi cl e bulkhead.
35.
Secure t he harness tray to the LHS of t he vehicle bul khead.
36.
Connect t he LH heated s creen el ect ri cal connector and s ecure t he
harnes s t o the vehicl e body.
37.
Feed the harnes s i nto the LH wheel arch and s ecure t he grommet.
38.
Inst all t he ABS modulat or bracket.
T orque: 25 Nm 39.
Inst all t he LH s ide repeat er lamp and s ecure t he cli ps to the vehicle
body.
40.
Connect t he rear was her pi pe.
41.
Connect t he ABS s ens or electrical connect or and s ecure the harnes s
t o t he vehi cl e body.
42.
Connect t he two electrical connect ors t o t he CJB.
43.
Connect t he main engi ne compartment harnes s t o t he ins trument
panel harnes s and clos e t he cover.
44.
Connect t he main engi ne compartment harnes s t o t he headl amp
l evell ing ECU.
45.
Connect t he 3 floor harness el ect ri cal connect ions.
46.
Page 1991 of 3229

Inst all t he fus e cover and refi t the s ound deadening sheet.
47.
Inst all t he LH fender s pl ash s hi eld.
T orque: 6 Nm 48.
Inst all t he glove compartment l id.
Refer t o: Glove Compart ment (501-12 Ins trument Panel and
Consol e, Removal and Ins t al lat ion).
49.
Inst all t he engi ne upper s upport ins ulat or.
Refer t o: Engi ne Upper Support Ins ulat or (303-01A Engine - I6 3.2L
Petrol, Removal and Ins tall ati on).
50.
Inst all both headlamps .
Refer t o: Headl amp As sembl y (417-01 Ext eri or Li ght ing, Removal
and Inst all at ion).
51.
Inst all t he fuel fi red boos ter heater.
Refer t o: Fuel Fired Boos t er Heat er (412-02B Auxil iary Cli mate
Control, Removal and Ins tall ati on).
52.
Inst all t he ABS module.
Refer t o: Ant i-Lock Brake Sys t em (ABS) Modul e (206-09A Anti -Lock
Control, Removal and Ins tall ati on).
53.
Inst all t he brake boost er.
Refer t o: Brake Boost er (206-07 Power Brake Act uat ion, Removal
and Inst all at ion).
54.
Inst all t he s econdary bulkhead cent er panel.
Refer t o: Secondary Bulkhead Cent er Panel - TD4 2.2L Dies el (501-02 Front End Body Panel s, Removal and Ins tal lati on).
55.
Inst all t he air cleaner hous ing.
Refer t o: Air Cleaner (303-12A Intake Ai r Dis tribut ion and Fil tering -
I6 3.2L Pet rol, Removal and Ins t al lat ion).
56.
Inst all t he bumper armature.
Refer t o: Front Bumper (501-19 Bumpers , Removal and Ins tall ati on).
57.
Page 1992 of 3229

Publi s hed: 11-May-2011
Module Communications Network - Battery Junction Box (BJB)I6 3.2L
Petrol
Removal and Inst all ati on
Removal
Remove t he bumper armature.
Refer t o: Front Bumper (501-19 Bumpers , Removal and Ins tall ati on).
1.
Remove t he air cleaner hous ing.
Refer t o: Air Cleaner (303-12A Intake Ai r Dis tribut ion and Fil tering -I6 3.2L Pet rol, Removal and Ins t al lat ion).
2.
Remove t he s econdary bulkhead cent er panel.
Refer t o: Secondary Bulkhead Cent er Panel - I6 3.2L Pet rol (501-02Front End Body Panel s, Removal and Ins t al lat ion).
3.
Remove t he brake boost er.
Refer t o: Brake Boost er (206-07 Power Brake Act uat ion, Removaland Inst all at ion).
4.
Remove t he ABS module.
Refer t o: Ant i-Lock Brake Sys t em (ABS) Modul e (206-09A Anti -LockControl, Removal and Ins tall ati on).
5.
Remove both headlamps .
Refer t o: Headl amp As sembl y (417-01 Ext eri or Li ght ing, Removaland Inst all at ion).
6.
Remove t he engi ne upper s upport ins ulat or.
Refer t o: Engi ne Upper Support Ins ulat or (303-01A Engine - I6 3.2LPetrol, Removal and Ins tall ati on).
7.
Remove t he glove compartment l id.
Refer t o: Glove Compart ment (501-12 Ins trument Panel andConsol e, Removal and Ins t al lat ion).
8.