Page 2349 of 2490

Bumpers - Front Bumper Cover
Removal and Installation
Removal
WARNING: ENSURE THAT ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF AREA BEFORE OPERATING RAMP.
1. Position vehicle on 4-post ramp.
2. Remove battery cover and disc onnect ground cable from
battery terminal. Refer to 86.15.19.
3. Remove radiator surround and grill. Refer to 76.55.15 and
76.55.03.
4. Raise ramp to working height.
5. Using wheel-free lifts, remove front wheels.
6. Remove wheelarch liners for access.
7. Remove undertray. Refer to 76.22.90.
8. At each side of vehicle:
Disconnect fog lamp, directio n indicator and sidemarker
lamp (where fitted) harness multiplugs.
If headlamp powerwash is fitted, remove and discard
plastic clip from hose and disconnect hose on RH side of
bumper.
9. Remove bolts securing bumper assembly to mounting struts.
10. Lower 4-post ramp.
11. Carefully withdraw bumper casing and beam assembly
forward to clear guide blocks and remove assembly from
vehicle.
12. Remove three bolts securing each fog lamp to bumper cover
and remove both lamps from cover.
Page 2352 of 2490
16.
Install wheelarch liners.
17. Install undertray. Refer to 76.22.90.
18. Lower 4-post ramp.
19. Install road wheels and lower wheel-free lifts.
20. Position number plate plinth on bumper and install securing
screws.
21. Install number plate.
22. Connect ground cable to batter y terminal and install battery
cover. Refer to 86.15.15.
Page 2353 of 2490
Bumpers - Front Bumper Isolator
Removal and Installation
Removal
Installation
1.
Remove front bumper asse mbly. Refer to 76.22.08.
2. Slacken and remove three bolts securing strut to front lower
cross-member, remove strut from vehicle and discard gasket.
1. Position strut and new gasket on cross-member and fit and
tighten securing bolts.
2. Fit bumper assembly to struts. Refer to 76.22.08.
Page 2359 of 2490
Safety Belt System -
Torques
ComponentNm
Screws, front seat belt height adjuster to B/C post LH and RH24 - 26
Nut, seat belt upper anchor to height adjuster LH and RH30 - 40
Bolt, LH and RH rear seat belt lower anchor to BIW30 - 40
Bolt, centre rear seat belt lower anchor to BIW30 - 40
Bolts, rear seat belt automatic locking re tractor LH, RH and centre to squab panel30 - 40
Bolt, rear seat belt buckle LH, RH and centre to BIW30 - 40
Bolt, front seat belt buckle LH and RH to seat rail30 - 40
Bolt, front seat belt lower an chor LH and RH to seat rail30 - 40
Bolts, front seat belt automatic lock ing retractor/pretensioner to B post30 - 40
Bolts, side airbag to seat frame9 - 11
Screws, front seat belt guide to B/C post8 - 10
Screws, single point sensor to tunnel5 - 7
Screws, side impact sens ing module to 'B' post5 - 7
Page 2360 of 2490

Safety Belt System - Safety Belt System
Description and Operation
Front Seat Belts
Each front seat belt has three anchorage points, and a height adjuster installed in each 'B' post provides four shoulder strap
positions. The belts are left and right ha nded and have plastic moulding on the r unning loop and tongue. A pyrotechnic pre-
tensioning device installed at the lower mounting point in each 'B' post, removes excess slack from the seat belt in the event
of a heavy frontal impact.
Rear Seat Belts
A standard inertia reel type belt is installed at each rear seat position. Each of these belts has three anchorage points. The
lower end of each outer belt is bolted to the front lower section of the inner wheelarch, whilst the lower end of the centre
belt is bolted to the seat pan. All thr ee inertia reel assemblies are bolted to the upper section of the squab panel. Two
buckle assemblies serving the three belts, are each bolted to the seat pan. A cable mounted single buckle provides for
fastening of the RH outer belt and a twin buckle assembly mounted on two cables serves the centre and LH outer belts.
Pyrotechnic Seatbelt Pre-tensioning
Page 2362 of 2490

Safety Belt System - Front Safety Belt Retractor
Removal and Installation
Removal
• WARNINGS:
IF A SEAT BELT PRETENSIONING UNIT IS INADVERTENTLY RUPTURED AND INGESTION AND/OR INHALATION
OCCURS, FIRST AID MUST BE APPLIED AND MEDICAL ADVICE SOUGHT.
NO ATTEMPT MUST BE MADE TO DISMANTLE A PRETENSIONING RETRACTOR UNIT. THERE ARE NO SERVICEABLE
PARTS.
WHEN HANDLING A RETRACTOR UNIT PISTON HOUSING, THE PISTON MUST ALWAYS BE POINTED DOWNWARDS
AND AWAY FROM ONE'S SELF AND OTHER PERSONNEL AND FINGERS MUST BE KEPT AWAY FOM THE TAKE-UP SPOOL
MECHANISM.
ANY PRETENSIONING UNIT DROPPED FROM A HEIGHT GREA TER THAN 0.3M (12 INCHES) MUST NOT BE FITTED TO A
VEHICLE.
UNACTIVATED PRE-TENSIONING UNIT COMPONENTS CONTAIN A SOLID, FLAMMABLE MATERIAL.
1. Position seat fully forward for access.
2. Remove battery cover and disc onnect ground cable from
battery terminal. Refer to 86.15.19.
3. Remove front seat belt upper anchor and trim.
1. Unclip front seat belt upper anchor plastic cover
and position for access to securing nut.
2. Slacken and remove se at belt upper anchor
securing nut.
3. Remove seat belt upper anchor and plastic cover. Remove and discard felt washer from slider stud.
4. Remove front seat belt escutcheon.
5. Slacken seat belt lower anchor securing bolt and remove with
wavy washer, spacer and card washer.
Page 2365 of 2490
Safety Belt System - Rear Safety Belt Retractor
Removal and Installation
Removal
1. Remove rear seat cushion. Refer to 76.70.37.
2. Remove rear headrests.
3. Slacken and remove bolt securi ng lower anchor to front of
inner wheel arch.
4. Slacken and remove bolt securing belt buckle cable to seat
pan and remove belt buckle assembly from vehicle.
5. Remove escutcheon.
1. Using a flat-bladed screwdriver in the two rectangular apertures, carefully withdraw
escutcheon from top of seat squab.
2. Remove escutcheon from belt via split in moulding.
6. Pass seat belt lower anchor plate and tongue through squab
aperture.
Page 2366 of 2490
Installation
7. Remove seat squab for access using extension of undisturbed
belts to achieve clearance from inertia reels. Refer to 76.70.38.
8. Slacken and remove two bolts and washer securing inertia reel
assembly to top of squab panel and remove belt assembly from
vehicle.
1. Position inertia reel assembly at top of squab panel and fit and
tighten securing bolts.
2. Pass belt tongue and lower anchor plate through aperture at
top of seat.
3. Fit escutcheon over seat belt an d fit and firmly seat in squab
aperture.
4. Position lower anchor plate at inner wheelarch (seat pan for
centre seat belt) and fit and tighte n securing bolt.
5. Position buckle assembly (and lo wer anchor plate if centre belt)
on seat pan and fit and tighten cable securing bolt.
6. Position and secure rear se at squab. Refer to 76.70.38.
7. Fit rear seat cushion. Refer to 76.70.37