Technical Change front end on 09 ducato x250 to 2015

[Seanwinder22]

Has anyone got any advice or help on changing the front end on my Fiat Ducato maxi 2009 to a facelift 2015

I was told to buy the bonnet full bumper & grill
Both wings
Slam panel
Headlights & brackets
Radiator
Scuttle tray and pipes
But is this a case of taking old of and fitting new parts or will it need any welding ext ? Will the bonnet arms on the brackets be in the right place ?
I can see the coolant bottle and power steering will need relocating also
Possibly even the new shape and bracket purchase even the screen washer bottle ??
Any help appreciated please before I begin to take everything off

 

[the green vanper]

Hello,

It is doable, but costs a lot of money (I've seen complete 'sets' for around 2200 - 2500 EUR) and will take time.

I was considering such 'tuning' at some time, but quit due to the above.

It's only a facelifting, so body parts should fit plug and play (without any welding). There might be also some electrical things to sort out, especially if you're planning to fit the 'full' LED lights (and not only the ones with LED DRL).

 

[Seanwinder22]

Hello,

It is doable, but costs a lot of money (I've seen complete 'sets' for around 2200 - 2500 EUR) and will take time.

I was considering such 'tuning' at some time, but quit due to the above.

It's only a facelifting, so body parts should fit plug and play (without any welding). There might be also some electrical things to sort out, especially if you're planning to fit the 'full' LED lights (and not only the ones with LED DRL).

Hi thanks mate I have the facelift already
As in parts
But the bonnet brackets are actually in a different location then the pre lift
New scuttle tray gets swapped out
Now I’m seeing the front panel brace needs changing because too short so that’s welding too along with welding new bonnet bracket supports

 

[Seanwinder22]

Hello,

It is doable, but costs a lot of money (I've seen complete 'sets' for around 2200 - 2500 EUR) and will take time.

I was considering such 'tuning' at some time, but quit due to the above.

It's only a facelifting, so body parts should fit plug and play (without any welding). There might be also some electrical things to sort out, especially if you're planning to fit the 'full' LED lights (and not only the ones with LED DRL).

A video here but in polish showing the actual changes needed
It’s not just a panel swap buddy

 

[the green vanper]

Great find

He explains in the very beginning of the part 2 that he wasn't able to find anywhere on the internet those information that welding (and how much) is required. Those were exactly the same information I got when I was thinking about such a 'tuning'. That it should be 'plug and play'. And everyone saw that such modifications were done.

There is also another thing: both the x250 and the x290 had faceliftings. And those can also make things more difficult. He mentions it only once: the color of the plastic cover on the fender changed with the x290 facelifting in 2016. But there could be also other 'small' things.

 

[Seanwinder22]

Yes mate I have had so much translated he also gives a list

1. You do all the work on your own responsibility!
2. When welding the hinges to the shaft, you should:dismantle the entire upholstery and dashboard,the butyl may ignite from the inside.3. Assist line from pump totank, you need to buy a new one with part number
3. 1374621080, the pre-lit one will be too short.4. The headlight installation was pre-litetwo types of plugs, soldering plugs should be done by comparing 1 to 1 staggeredlamp bulbs in pre-facelift and facelift.

It does look very simple after you get the bonnet brackets welded
But it’s finding someone that can make some and weld them on

I literally have everything ready to go even the brace panels for the bumper and light brackets
But finding a fabrication guy is hard

 

[the green vanper]

About the headlights plugs, he also explains that the same plugs are used in 2008 - 2009 FIAT Croma, but they have 2 pins connected less. And they are almost 2 times cheaper, so one can buy the 3 Croma plugs (and use the missing pins from the third plug) instead of the 2 Ducato plugs. I'd also check if they are spare pins available at the dealership, it will be much more cheaper. For my non-FIAT daily I've bought 3 of them with a plug for like 3 EUR last week. They also had pins with cables (also a repair kit), but they were much more expensive (like 5 EUR per piece).

He also explains the positioning of the hinge base (but included the dimensions on the video). As far as I remember, 63 mm from the side and 370 mm from the bottom. It can be seen on the video.

The holes for the coolant and power steering liquid reservoirs' support are there, but the support is completely different. Same for the reservoirs. And the access is completely different (through the black plastic below the windscreen and not from under the bonnet).

If you would like me to check and translate a precise moment in the video, I'll try to do it in the evening

 

[Seanwinder22]

About the headlights plugs, he also explains that the same plugs are used in FIAT Croma, but they have 2 pins connected less. And they are almost 2 times cheaper, so one can buy the 3 Croma plugs (and use the missing pins from the third plug) instead of the 2 Ducato plugs. I'd also check if they are spare pins available at the dealership, it will be much more cheaper. For my non-FIAT daily I've bought 3 of them with a plug for like 3 EUR last week. They also had pins with cables (also a repair kit), but they were much more expensive (like 5 EUR per piece).

He also explains the positioning of the hinge base (but included the dimensions on the video). As far as I remember, 63 mm from the side and 370 mm from the bottom. It can be seen on the video.

The holes for the coolant and power steering liquid reservoirs' support are there, but the support is completely different. Same for the reservoirs. And the access is completely different (through the black plastic below the windscreen and not from under the bonnet).

If you would like me to check and translate a precise moment in the video, I'll try to do it in the evening

Wow thanks buddy massive help
And yes mate I’m wanting to know what he’s saying when he’s changing the front brace panel that the bumper and headlight bolt too
I’ve had to also buy these

Good news tho I have found someone today to do the welding which he did say yes very easy job welding the brackets
Just tricky with the butyl can catch fire

Also I’m sure he welds some other fixings on those front panels
Maybe because the bumper torx screws don’t align

 

[Seanwinder22]

About the headlights plugs, he also explains that the same plugs are used in FIAT Croma, but they have 2 pins connected less. And they are almost 2 times cheaper, so one can buy the 3 Croma plugs (and use the missing pins from the third plug) instead of the 2 Ducato plugs. I'd also check if they are spare pins available at the dealership, it will be much more cheaper. For my non-FIAT daily I've bought 3 of them with a plug for like 3 EUR last week. They also had pins with cables (also a repair kit), but they were much more expensive (like 5 EUR per piece).

He also explains the positioning of the hinge base (but included the dimensions on the video). As far as I remember, 63 mm from the side and 370 mm from the bottom. It can be seen on the video.

The holes for the coolant and power steering liquid reservoirs' support are there, but the support is completely different. Same for the reservoirs. And the access is completely different (through the black plastic below the windscreen and not from under the bonnet).

If you would like me to check and translate a precise moment in the video, I'll try to do it in the evening

If you find a ducato someone is breaking this is a great deal to buy and do which I got everything off one van at the scrapyard from a 2017
Or a pergeot boxer or relay they all work the work
Bonnet /grill/ wings/ headlights and brackets plus the small bracket for bumper
Slam panel
Scuttle tray and drain hoses
Coolant and power steering bottles and bracket to hold
Bonnet hinges
Bonnet bulkhead brackets if can find
Brace panel lhs & rhs
And the front bumper plate
And I think I may need to buy some screws he holds up in a bag and welds some nuts on the brace panel ?
But I think it’s very worth it to get this and fit
It looks amazing

 

[the green vanper]

The screws he had in the bag were the screws for the dust / mud covers that go underneath the van. They are generally rusted. Or missing.

The part he's holding at around 6:40 is I assume the front brace panel. It is different than in the x250, as it has side parts that the headlights are bolted to.
The upper rubber mounts of the cooler are the same (6:50), so no need to change them (nor the coolers). He changed those because they had more or less 10 years and thought it's a good moment. Same for the reinforcement which is behind the bumper, it was also rusted and that's why he changed it.

At 7:20 he's explaining the reservoirs and their mounts - the new ones have to get much further back. And as mentionned in the previous post - the new mount is galvanized and is using the existing holes in the frame. Access to the reservoirs is explained at 15:20.

At around 8:50 he's explaining I assume the side brace panels. The old one is different, they are spot welded, so need some work to be removed. Then, the new one has a different shape, so the part remaining on the van has to be cut to shape (9:55). It also needed some rust to be removed (10:20). At 11:03 he shows where the front brace panel should be attached.

At around 12:50 he's explaining that first the front brace needs to be attached to the cooler rubber mounts and levelled. Then, the side braces are bolted to the front one. At 13:24 he explains to align the new side brace to the signs of how the old one was welded. But (which he doesn't mention) it also needs to be aligned in the place shown in the bottom right on the video! He's working on that at 24:57.

Around 22:15 he explains the bolts and nuts - they are all the same

Around 24:45 he explains the colour difference of the plastic wheel arch (?). SEVEL changed the colour of the plastics (probably the supplier) in 2016, so in order to have the same colour, you need to get those from a 2015 - 2016 van.

 

[Seanwinder22]

The screws he had in the bag were the screws for the dust / mud covers that go underneath the van. They are generally rusted. Or missing.

The part he's holding at around 6:40 is I assume the front brace panel. It is different than in the x250, as it has side parts that the headlights are bolted to.
The upper rubber mounts of the cooler are the same (6:50), so no need to change them (nor the coolers). He changed those because they had more or less 10 years and thought it's a good moment. Same for the reinforcement which is behind the bumper, it was also rusted and that's why he changed it.

At 7:20 he's explaining the reservoirs and their mounts - the new ones have to get much further back. And as mentionned in the previous post - the new mount is galvanized and is using the existing holes in the frame. Access to the reservoirs is explained at 15:20.

At around 8:50 he's explaining I assume the side brace panels. The old one is different, they are spot welded, so need some work to be removed. Then, the new one has a different shape, so the part remaining on the van has to be cut to shape (9:55). It also needed some rust to be removed (10:20). At 11:03 he shows where the front brace panel should be attached.

At around 12:50 he's explaining that first the front brace needs to be attached to the cooler rubber mounts and levelled. Then, the side braces are bolted to the front one. At 13:24 he explains to align the new side brace to the signs of how the old one was welded. But (which he doesn't mention) it also needs to be aligned in the place shown in the bottom right on the video! He's working on that at 24:57.

Around 22:15 he explains the bolts and nuts - they are all the same

Around 24:45 he explains the colour difference of the plastic wheel arch (?). SEVEL changed the colour of the plastics (probably the supplier) in 2016, so in order to have the same colour, you need to get those from a 2015 - 2016 van.

You sir have really helped
Thank you so much
I have been trying to post the video and get subtitles on it
A kid at work told me little parts but not much help
You have told me just about what’s needed

I’m thinking about the bonnet brackets on the bulkhead
He must have made them from the old ones ?
They do look like he turned them over and cut in half compared them to those on the x250

But great news then about screws etc because I have them all from taking the old front end off

 

[Seanwinder22]

About the headlights plugs, he also explains that the same plugs are used in 2008 - 2009 FIAT Croma, but they have 2 pins connected less. And they are almost 2 times cheaper, so one can buy the 3 Croma plugs (and use the missing pins from the third plug) instead of the 2 Ducato plugs. I'd also check if they are spare pins available at the dealership, it will be much more cheaper. For my non-FIAT daily I've bought 3 of them with a plug for like 3 EUR last week. They also had pins with cables (also a repair kit), but they were much more expensive (like 5 EUR per piece).

He also explains the positioning of the hinge base (but included the dimensions on the video). As far as I remember, 63 mm from the side and 370 mm from the bottom. It can be seen on the video.

The holes for the coolant and power steering liquid reservoirs' support are there, but the support is completely different. Same for the reservoirs. And the access is completely different (through the black plastic below the windscreen and not from under the bonnet).

If you would like me to check and translate a precise moment in the video, I'll try to do it in the evening

Just replying to the plugs
When I got the new headlights the owner had already taken them out for me
I’ve noticed he’s left the plugs in the back of the headlight and just cut the wires
I was thinking about just soldering the wires together and heat shrink

 

[Seanwinder22]

I will do a video on this myself in English so at least one is online
From start to finish
Taking the pre lift off
Doing the welding on the bonnet brackets to the bulkhead
To pinning the brace panel etc
Everything else is pretty simple
The coolant bottle/steering bottle just moves to the back on a new galv bracket that’s about it
Take out old scuttle tray
Can leave old bonnet brackets on with rhd drive because no bracket is in the way of the window on the new scuttle tray to get to coolant
Only left hand drive because of air box on the bonnet

Brace panel needs to be spotted on the leg and a little grinder cut to shape under the panel ready for the headlight bracket

I would say start to finish 2 hours to 3 max
Hardest part is welding new bracket location for bonnet
Once they are on
Good to go
I will take photos and videos of the fix

 

[the green vanper]

I was thinking about just soldering the wires together and heat shrink

Yes, go for cutting the old loom and soldering the wires. Hope the colours are the same If the pins are the same, you could also dismantle the plug and put the old wires with pins in the new plug.

You sir have really helped
Thank you so much
I have been trying to post the video and get subtitles on it
A kid at work told me little parts but not much help
You have told me just about what’s needed

I’m thinking about the bonnet brackets on the bulkhead
He must have made them from the old ones ?
They do look like he turned them over and cut in half compared them to those on the x250

But great news then about screws etc because I have them all from taking the old front end off

You are welcome
It looks to me too like he used the old bonnet brackets.

I will do a video on this myself in English so at least one is online
I will take photos and videos of the fix

Great idea!

 

[Seanwinder22]

Looking at the brace repair panel you have to buy it’s definitely not got the amount of holes in it and same location
So he must have drilled all those holes ?
But I can’t understand why if it’s a straight swap but gets welded at the leg
Here’s a pic of the repair panel and his on his van

 

[Seanwinder22]

Looking at the brace repair panel you have to buy it’s definitely not got the amount of holes in it and same location
So he must have drilled all those holes ?
But I can’t understand why if it’s a straight swap but gets welded at the leg
Here’s a pic of the repair panel and his on his van

He’s got 4 holes at the top left
And 5 bottom left
But these plates don’t come with them like this

 

[the green vanper]

He doesn't have a spot welder, so he drilled the holes to make a standard weld.

 

[Seanwinder22]

On the grill I have purchased they have left some drl lights on it
Just cut the wires
They are 6 in total
How would I go about re wiring these ?
Will I need to buy a controller?
Never fitted them before so this I’ve no idea about
Thanks

 

[the green vanper]

Strange, the x290 has DRL in the headlights. The earlier (cheaper) had tungstene bulbs, the newer (more expensive) had LED strings + full LED were available later on.

A relay is needed to wire them.

 

[Seanwinder22]

Strange, the x290 has DRL in the headlights. The earlier (cheaper) had tungstene bulbs, the newer (more expensive) had LED strings + full LED were available later on.

A relay is needed to wire them.

I’ve honestly no idea what they are
They are on the grill let me take some better images