Dismantling and assembling front cover

No.

Designation

Removal

Installation

1

Cover

1

Adjust cover at hinges according to fender contours and front spoiler

2

Ear clamp 10/6

8

Remove

Replace

3

Hose

1

Separate from valve and pull out of cover frame complete with grommet

Push through cover frame complete with grommet, push onto valve and fit with ear clamp

4

Retaining clip

2

Unclip from cover hinge and separate from hose

Push onto hose and clip into cover hinge

5

Valve

2

Check, replace if required

6

Retaining clip

9

Unclip from cover frame and hose

Clip onto hose and cover frame

7

Damper

1

Push off the connector

Push onto the connector

8

Connector

1

Unclip wire

Clip wire into place according to wiring diagram

9

Heated windshield washer nozzle

2

Unclip from cover in upward direction

Clip into cover from above

10

Wiring harness

1

Remove from engine compartment light and pull out of cover frame complete with grommet

Route in cover frame and clip to engine compartment light

11

Retaining lip

9

Unclip from cover frame and wiring harness

Clip into wiring harness and cover frame

12

Protective cap

1

Pull off engine compartment light

Push onto engine compartment light

13

Engine compartment light

1

14

Cap

1

No.

Designation

Removal

Installation

15

Combination screw 4.2 x 13

1

16

Retaining clip

2

Unclip from cover hinge and pull off the wiring harness

Push onto wiring harness and clip onto cover hinge

17

Wiring harness

1

Pull out of cover frame complete with grommet

Engage into cover frame complete with grommet

18

Hexagon head bolt M 8 x 18

4

19

Retainer

2

Unclip from ball socket of gas strut and pull out

Engage into ball socket of gas strut and clip into place

20

Retainer

2

Push down on ball socket of gas strut

Push up on ball socket of gas strut

21

Gas strut

2

Unclip from ball pin

Clip back into ball pins

22

Ball pin

2

23

Hexagon head bolts

4

24

Cover hinge

2

25

Combination screw 4.2 x 13

4

26

Tab washer

1

27

Tapping nut

2

Replace

28

Grommet

2

Replace

29

Backing

1

Check, replace if required

30

Ornament

1

31

Rubber buffer

2

Remove from cover frame with a rotary motion

Turn back into cover frame and adjust in such a manner that the cover is flush with the fender contours and the front spoiler

32

Bracket

2

Unclip

Clip into place

No.

Designation

Removal

Installation

33

Hexagon head bolt M 6 x 12

2

34

Washer A 6.4

2

35

Cover lock upper section

1

Adjust to allow the catch to engage correctly in the support and to engage the riveted pin correctly into the cover lock

36

Hexagon head bolt M 6 x 16

2

37

Support

1

Adjust to allow the catch to engage correctly

38

Hexagon head bolt M 6 x 35

2

39

Washer A 6.4

2

40

Cover lock lower section

1

Adjust to allow the riveted pin to engage correctly

41

Support

1

Fit with lower cover lock section to body

42

Spring clip

1

Unclip from seat

Clip back into seat

43

Bimetallic-element switch

1

Unclip spring clip and disconnect connector

Clip spring clip into place and reconnect connector

44

Emergency operation

1

Remove lateral front trim (carpet) in the cover and bearing cup area

Refit lateral front trim (carpet) in the cover and bearing cup area

45

Cover

1

Unclip from bearing cup in upward direction

Clip into bearing cup from above

46

Pull handle

1

Remove from bearing cup complete with bowden cable

Insert into bearing cup complete with bowden cable

47

Countersunk head bolt M 6 x 15

2

No.

Designation

Removal

Installation

48

Bearing cup

1

Unscrew countersunk head bolts and unclip from below

Clip into body from below and tighten with countersunk head bolts

49

Roll pin 4 x 12

1

Drive out

Replace

50

Bowden cable

1

Drive out roll pin, unclip clamp and bracket and open tie-wrap. Undo clamping screw from cover lock. Unclip from support

Insert roll pin, clip stay, retainer clip and bracket back Into place. Clip into support. Tighten clamping screw on cover lock

51

Retainer clip

1

Unclip

Clip into place (replace if required)

52

Tie-wrap

1

Open

Replace, close

53

Filler pad

2

Remove

Bond into place

54

Gasket

1

Lift off in upward direction

Push into place

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