Page 2350 of 2490
13. Release sidemarker lamp/refle ctor clips and remove both
lamps/reflectors from bumper cover.
14. Remove direction indicators fr om bumper assembly. Refer to
Section 417.
15. Release tangs securing brake cooling ducts to bumper cover
and remove ducts.
16. Remove powerwash jet assemb lies and hoses from top of
bumper assembly. Refer to 84.20.08.
17. Remove bumper blades.
1. Remove three screws secu ring each blade to bumper
cover.
2. Slide each blade forward to release two side tangs from cover and remove blades from bumper.
18. Rotate three splitter vane fasteners 1/4 turn counter-
clockwise and remove splitter vane from air intake.
19. Remove number plate and plinth.
20. Remove and discard four scrive ts securing upper section of
Page 2387 of 2490
Key to Plan
Standard Wheelbase Body Dimensions- Side View
KeyLocation
1Front face body-bumper strut/mounting point
2Rearmost hole, vee-mount to crush tube
3Front Master Datum Plan, centre li ne of front crossmember rear mount ing at main floor RH longitudinal
4Rearmost hole, transmission mounting at main floor RH longitudinal
5Handbrake rear lever bracket fixings
6Rear Master Datum Plan, rear longitudinal
7Tapped boss, rear suspension 'A' frame mounting bush
8Rear suspension spring-pan damper mounting
9Rear suspension differential strut mounting
10Rear face body-bumper strut/mounting point
11Driveshaft centre bearing mounting
Page 2388 of 2490
Key to SideView
Long Wheelbase Body Dimensions-Plan
KeyLocation
1Front face body-bumper strut/mounting point
2Front Master Datum Vertical, centre line of front crossmember rear mounting
3Transmission mountings at the main floor longitudinal
4Handbrake rear lever bracket fixings
5Rear Master Datum Vertical,, rear longitudinal
6Tapped boss, rear suspensi on 'A' frame mounting bush
7Rear suspension spring-pan damper mounting
8Rear suspension differential strut mounting
9Rear face body-bumper strut/mounting point
10Wheel centre to bumper cover face
11Wheelbase
12Wheel Centre to Bumper Cover Face
13Driveshaft centre bearing mounting
Page 2389 of 2490
Key to Plan
Long Wheelbase Body Dimensions- Side View
KeyLocation
1Front face body-bumper strut/mounting point
2Rearmost hole, vee-mount to crush tube
3Front Master Datum Plan, centre line of front crossmember rear mount ing at main floor RH longitudinal
4Rearmost hole, transmission mounting at main floor RH longitudinal
5Handbrake rear lever bracket fixings
6Rear Master Datum Plan, rear longitudinal
7Tapped boss, rear suspension 'A' frame mounting bush
8Rear suspension spring-pan damper mounting
9Rear suspension differential strut mounting
10Rear face body-bumper strut/mounting point
11Driveshaft centre bearing mounting
Page 2390 of 2490
Key to SideView
KeyLocation
1Front face body-bumper strut/mounting point
2Front Master Datum Vertical, centre line of front crossmember rear mounting
3Transmission mountings at the main floor longitudinal
4Handbrake rear lever bracket fixings
5Rear Master Datum Vertical,, rear longitudinal
6Tapped boss, rear suspensi on 'A' frame mounting bush
7Rear suspension spring-pan damper mounting
8Rear suspension differential strut mounting
9Rear face body-bumper strut/mounting point
10Wheel centre to bumper cover face
11Wheelbase
12Wheel Centre to Bumper Cover Face
13Driveshaft centre bearing mounting
Page 2411 of 2490

illustration and is positioned along the edge of the rubber.
• NOTE: The depth of the glass and thus the thickness of the ad hesive, is controlled by the screen rubber contacting the
body flange.
Adhesive Application
Key to Adhesive Application Drawing
Adhesive Curing
The specified adhesive cures by exposure to moisture (not by heat). Cure times may vary considerably dependent upon
ambient humidity levels. Initial 'chill off' will occur within 1 to 4 minutes ( dependent upon the application temperature and
rate of cooling), after which the screen must not be moved.
BUMPER REPAIR\RENEWAL
Bumper Description
Each bumper comprises a beam mounte d to the body via two strut assemblies and a moulded polypropylene cover
incorporating side armatures and chrome plated plastic upper trims. The front bumper cover which is moulded to form a
lower air intake for the cooling pack, also incorporates twin fog lamps, brake cooling ducts and side marker lamps or
reflectors (dependent upon market). A plastic undertray secured to the lower edge of the front bumper and the BIW
improves airflow and minimises the ingres s of road grime in that area. Standard bumpers have glass mat thermoplastic
(GMT) beams mounted on GMT struts. For certain markets, aluminium bumper beams are installed on menasco energy
absorbing struts.
Bumper Cover Repair
1Fitted condition
2Bead application
Page 2423 of 2490
1. Sever and discard tiestraps securing front wheel
speed sensor harness to upper wishbone.
2. Disconnect harness connector from sensor.
Repeat procedure to disconnect opposite side wheel speed
sensor harness.
16. CAUTION: Do not suspend caliper from brake hose as
this will damage the hose.
Remove brake calipers from carriers.
1. Remove caliper spring clip.
2. Remove guide pin dust caps.
3. Slacken and withdraw guide pins.
4. Remove caliper from carrier and tie to suspension mounting bracket.
Repeat procedure to remove opposite side front brake
caliper.
17. Remove filler cap from power steering fluid reservoir.
18. Disconnect steering rack transducer harness front connector.
Release harness connector from body retaining clip.
Disconnect connector.
19. Sever and discard tiestrap secu ring return pipe, harness (RHD
only) and rubber support to steering rack.
Page 2436 of 2490
30. Connect steering harness.
Route harness connector to body front location.
Connect steering ha rness connector.
Install connector in body retaining clip.
31. Connect wheel speed sensor harness.
1. Connect wheel speed sensor harness to sensor.
2. Using new tiestraps secure wheel speed sensor harness to upper wishbone.
Repeat procedure to connect opposite side wheel speed
sensor.
32. Install brake calipers.
1. Install caliper on carrier.
2. Install guide pins.
3. Install guide pin dust caps.
4. Install caliper spring clip.
Repeat procedure to install opposite side front brake
caliper.
33. Install both front road sp rings. Refer to 60. 20.02.
34. Using screws or new scrivets , secure undertray to front
bumper cover.