Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Models with Td4 or KV6 engine: Remove the engine soundproofing cover, if equipped.
ENGINE - Td4, Inlet and outlet camshafts, Engine soundproofing casing, models produced before May 2002.
2. Models with Td4 or KV6 engine: Loosen and remove the intake manifold.
3. Models with Td4 or KV6 engine: Loosen the clamp securing the electrical cable and air intake to the body.
4. Models with Td4 or KV6 engine: Raise the air intake and release the washer reservoir hose clamp.
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5. Models with Td4 or KV6 engine: Loosen and remove the air intake.
6. Td4 engine models: Loosen the 2 clamps and remove the intercooler outlet hose.
7. Unscrew the 2 bolts securing the power steering fluid cooler pipes.
8. Remove the power steering fluid reservoir from the support bracket and set it aside.
9. Release the retainer and disconnect the ABS pressure regulator connector block.
10. Place a cloth under the pressure regulator to prevent brake fluid from splashing out.
CAUTION: Brake fluid can damage paintwork. If brake fluid comes into contact with painted surfaces, remove any traces of the fluid immediately and rinse the area with water.
11. Disconnect the 2 inlet brake pipes from the ABS pressure regulator.
12. Disconnect the 4 brake outlet pipes from the ABS pressure regulator.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
13. Unscrew the 3 bolts securing the ABS pressure regulator to the support bracket.
14. Loosen and remove the ABS pressure regulator from the support bracket.
Installation
1. Install the ABS pressure regulator on the support bracket. Install the bolts and tighten them to 9 Nm.
2. Clean the brake line connections and line ends.
3. Connect the brake lines to the pressure regulator, ensuring that the lines are properly connected to the corresponding holes in the regulator.
4. Tighten the couplings to a torque of 17 Nm.
5. Connect the electrical connector to the ABS pressure regulator and fasten the connector retainer.
6. Models with Td4 or KV6 engine: Install the air intake on the body.
7. Models with Td4 or KV6 engine: Secure the air intake to the washer reservoir filler neck and the electrical cable clamp.
8. Models with Td4 or KV6 engine: Install the air duct.
9. Install the power steering fluid reservoir onto the support bracket.
10. Tighten the power steering fluid cooler line mounting bolts to a torque of 10 Nm.
11. Models with Td4 engine: Connect the intercooler outlet hose and tighten the hose clamps.
12. Models with Td4 or KV6 engine: Install the engine soundproofing cover, if equipped.
ENGINE - Td4, Inlet and outlet camshafts, Engine soundproofing casing, models produced before May 2002.
13. Remove air from the brake system.
BRAKE SYSTEM, ADJUSTMENTS, Bleeding the brake system.
14. To ensure that the ABS is working properly, diagnostics MUST be performed using the TestBook/T4 device.
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