Page 2025 of 2490
The B and C posts and closing pane ls of both models are extensively reinforced to satisfy all forthcoming global legislation
on side impact protection.
Plenum Braces
Braces bolted to welded brackets on th e upper toeboard and plenum at each side of the BIW, achieve high structural
integrity and frontal crash performance.
Centre Bearing Support
Page 2026 of 2490
Drive shaft centre bearing support mounted in forward position, minimises NVH an d further increases floor stiffness.
Page 2027 of 2490
Front End Body Panels - Front End Body Panels
Description and Operation
The front body structure is de signed to satisfy bumper impact requiremen ts. The front bumper assembly forms a major
front structure component and is fully desc ribed in Section 501-19. The front fenders which are bolted to the front valances,
are fully described in the Body and Paint Repair manual.
Left and right hand false bulkheads together with insulation covers, installed between the engine compartment and the BIW
front bulkhead, provide optimum insulation against noise and heat intrusion. Two plenum braces bolted between the BIW
upper toeboard and the plenum, increa se bodyshell structural integrity.
The plastic radiator grill and vane block achieve weight reductions over steel components and provide high resistance to
front end corrosion.
Page 2028 of 2490
Front End Body Panels - Cowl Panel Grille
Removal and Installation
Installation
1.
Open the hood and fit fender covers.
2. Remove the wiper arm and blade assembly. Refer to
84.15.44.90.
3. Slacken and remove the five pl enum cover securing screws.
4. Position the plenum cover for access and disconnect windshield
washer pump tube from pl enum cover connector.
5. Remove plenum cover from vehicle.
6. Remove screenwasher conne ctor from plenum cover.
7. Remove plenum cover spacers,
1. Fit washer hose connector to plenum cover.
2. Fit and fully seat plenum cover spacers.
3. Position plenum cover for access and fit windshield washer
pump to plenum connector hose.
4. Fit plenum cover ensuring that it seats correctly in upper seal.
5. Fit and tighten securing screws.
6. Fit washer hose to plenum connector.
7. Fit wiper arm and blade. Refer to 84.15.44.90.
8. Close hood and remove fender covers.
Page 2029 of 2490
Front End Body Panels - Driver Side Bulkhead Cover
Removal and Installation
Removal
Installation
1. CAUTION: Make sure the driver side bulkhead cover
locating peg is not damaged during removal. Failure to follow this
instruction may result in damage to the vehicle.
Remove the driver side bulkhead cover.
1. To install, reverse the removal procedure.
Page 2030 of 2490
Front End Body Panels - Passenger Side Bulkhead Cover
Removal and Installation
Removal
Installation
1. Lift and withdraw tool tray cover, and remove tools.
2. CAUTION: Make sure the pass enger side bulkhead cover
locating peg is not damaged during removal. Failure to follow this
instruction may result in damage to the vehicle.
Remove the passenger si de bulkhead cover.
1. To install, reverse the removal procedure.
Page 2031 of 2490
Front End Body Panels - Radiator Grille Opening Panel
Removal and Installation
Removal
Installation
1.
Open hood and fit fender covers.
2. Slacken and remove the ten cl osing panel securing bolts.
3. Position closing panel for access and disconnect hood switch
harness multiplug.
4. Remove closing panel from vehicle.
5. Remove and discard the two rubbe r grommets locating top of
radiator.
1. Fit and secure hood switch to closing panel.
2. Fit new rubber grommets to closing panel.
3. Position closing panel for access and connect hood harness
multiplug.
4. Fully seat closing panel and fit and tighten securing bolts.
5. Close hood and remove fender covers.
Page 2032 of 2490
Front End Body Panels - Radiator Grille Opening Panel Reinforcement Removal and Installation
Removal
Installation
1.
Remove radiator grilles. Refer to 76.55.03.
2. Remove radiator grille surround. (Refer to 76.55.15)
3. Open hood.
4. Fit front fender cover.
5. Slacken headlamp trim panel to headlamp securing screw.
6. Carefully release headlamp trim panel fir tree fastener from BIW
and remove panel from vehicle.
7. Remove securing screw from trim panel and remove and discard fir
tree fastener.
1. Fit new fir tree fastener to headlamp trim panel.
2. Fit but do not tighten securing screw to headlamp trim panel.
3. Position headlamp trim panel on BIW front panel, locating securing
screw in headlamp slot.
4. Fully seat fir tree fastener in BIW front panel.
5. Finally tighten headlamp trim panel securing screw.
6. Close hood and remove fender cover.
7. Fit radiator grill surround. Refer to 76.55.15
8. Fit radiator grilles. Refer to 76.55.03.