Release the fasteners (x2) that secure the fuse box to the front
crossmember (torque 6 Nm).
Release the clip that secures the wheel speed sensor harness, then remove
the nut that secures the high pressure A/C pipe to the body.
Release the bolts (x4) that secure the coolant reservoir to the front
crossmember (torque 6 Nm). Do not remove the reservoir at this time.
Carefully lift up the coolant reservoir and disconnect the coolant level
sensor harness.
Release all clips that secure the coolant hose to the bottom of the front
crossmember.
Release the clip that secures the RH body harness to the bottom of the
front crossmember.
Release the nut that secures the front drive unit ground stap to the body
(torque 6 Nm), then release the clip that secures the intelligent battery
sensor (IBS) harness to the body.
Release the clip that secures the 4-way valve hose to the
body.
Disconnect the harness from coolant pump 1, then slide the pump outboard to
remove it from the subframe. Move the pump out of the way to gain acccess to
the brake lines.
Note: The coolant hoses do not need to be disconnected from the pump.
Remove the bolt that secures the A/C pipe bracket to the cross-brace
(torque 6 Nm).
Remove the bolts (x2) that secrure the TXV to evaporator (torque 6
Nm).
Remove the nut that secures the high pressure A/C pipe to the compressor
(torque 10 Nm). Release the pipe and remove the seal. Plug the hole.
Caution: The hole
must be plugged to prevent contamination.
Caution: Remove and discard O-rings.
Remove the brake fluid from the reservoir.
Release the clips (x3) that secure the brake lines to the LH frame
rail.
Release the clips (x2) that secure the brake lines to the front
crossmember.
Place suitable absorbent material underneath the ABS module and brake
lines.
Release the front brake lines from the ABS module (torque 23 Nm).
Caution: If brake fluid is spilled on a painted surface, wash
off immediately with clean water.
Plug the brake line connections to prevent contamination.
Place suitable absorbent material underneath the booster and brake
lines.
Release the front brake lines from the booster (torque 18 Nm).
Caution: If brake fluid is spilled on a painted surface, wash
off immediately with clean water.
Plug the brake line connections to prevent ingress of moisture or
dirt.
Remove the brake line bundle from the vehicle.
Installation
Installation procedure is the reverse of removal, except
for the following: