INTERIOR TRIM COMPONENTS
REPAIRS 76-3-21
11.Remove access panel from front edge of front
stowage pocket.
12.Remove screw securing front stowage pocket
to headlining.
13.Remove lens from front interior lamp.
14.Remove 2 nuts securing front interior lamp to
headlining.
15.Disconnect multiplug from front interior lamp.
16.Remove front interior lamp.
17.Remove 10 screws securing front stowage
pocket to headlining.
18.Disconnect 3 multiplugs from sunroof switches.
19.Remove front stowage pocket.
20.Remove caps from sun visor clips.
21.Remove screws and release both sun visor
clips.
22.Remove tail door aperture upper trim casing.
23.Remove rear sunroof aperture trim. 24.Remove front sunroof aperture trim.
25.Release end caps from all grab handles.
26.Remove 2 bolts securing each grab handle to
roof.
27.Remove all 4 grab handles.
28. Models with volumetric alarm: Release front
volumetric sensor from headlining and
disconnect multiplug.
29. Models with rear A/C:
aRelease rear A/C control panel from
headlining.
bDisconnect 2 multiplugs and 2 Lucar
connectors from rear A/C control panel.
cRemove rear A/C control panel.
30.Release rear interior lamp from headlining and
disconnect multiplug.
31.Remove rear interior lamp.
INTERIOR TRIM COMPONENTS
REPAIRS 76-3-23
11.Position rear interior lamp to headlining and
connect multiplug.
12.Fit rear interior lamp to headlining.
13. Models with rear A/C:
aPosition rear A/C control panel to headlining
and connect multiplugs and Lucar
connectors.
bFit rear A/C control panel to headlining.
14. Models with volumetric alarm: Connect
multiplug to front volumetric sensor and fit
sensor to headlining.
15.Fit grab handles to headlining and secure with
bolts.
16.Fit end caps to grab handles.
17.Fit front sunroof aperture trim.
18.Fit rear sunroof aperture trim.
19.Fit tail door aperture upper trim casing.
20.Fit sun visor clips to headlining and secure with
screws.
21.Fit caps to sun visor clips.
22.Position front stowage pocket to headlining and
connect multiplugs to sunroof switches.
23.Fit and tighten 10 screws securing front
stowage pocket to headlining.
24.Connect multiplug to front interior lamp.
25.Fit front interior lamp to headlining and secure
with nuts.
26.Fit lens to front interior lamp.
27.Fit and tighten screw securing front stowage
pocket to headlining.
28.Fit access panel to front edge of front stowage
pocket.
29.Position sun visor to headlining and secure to
clip.
30.Connect multiplug to sun visor.
31.Fit and tighten screws securing sun visor to
headlining.
32.Repeat process for second sun visor.
33. Models with premium ICE: Position both 'A'
post trim casings and connect multiplugs to
speakers.
34.Fit both trim casings to 'A' posts and secure
with clips.
35.Fit both 'B' post upper trim casings.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - upper - 'B' post.
36.Fit both 'D' post trim casings.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - 'D' post.
PANEL REPAIRS
REPAIRS 77-2-21
REPAIRS
Front bulkhead assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
4.Remove washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
5. Models with A/C: Remove condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
6. Diesel models: Remove gearbox fluid cooler.
7.Remove RH and LH headlamps.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
8.Release headlamp levelling motors and
position aside.
9.Release headlamp wiring and position aside.
10.Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
11.Remove battery tray.
12.Remove air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
13.Remove 2 earth leads from LH of front
bulkhead.
14.Remove RH horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
15. Models with A/C: Release and remove A/C
pipes.
16.Remove RH and LH crush cans.
17.Remove bonnet release cable.
18.Support bonnet in open position
19.Remove bonnet locking mechanism.
20.Remove VIN plate.
21.Remove 2 bolts securing front bulkhead
assembly to chassis.
22.Remove centre braces.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit centre braces.
2.Fit 2 bolts securing bulkhead to chassis and
tighten to 45 Nm (33 lbf.ft).
3.Fit VIN plate.
4.Fit bonnet locking mechanism.
5.Fit bonnet release cable.
6.Fit crush cans.
7. Models with A/C: Fit A/C pipes.
8.Fit RH horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
9.Fit 2 earth leads to LH of front bulkhead.
10.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
11.Fit battery tray.
12.Fit battery. Do not connect leads.
+ CHARGING AND STARTING,
REPAIRS, Battery.
13.Fit headlamp wiring and headlamp levelling
motors.
14.Fit RH and LH headlamps.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
15. Diesel models: Fit gearbox fluid cooler.
16. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
17.Fit washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
PANEL REPAIRS
REPAIRS 77-2-23
Bonnet locking platform
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
4. Models with A/C: Remove condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
5. Diesel models: Remove gearbox fluid cooler.
6.Remove RH and LH headlamps.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Remove RH and LH repeater lamps.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
8.Release headlamp wiring and position aside.
9.Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
10.Remove battery tray.
11.Remove air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
12.Remove RH horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
13.Remove bonnet release cable.
14.Support bonnet in open position
15.Remove bonnet locking mechanism.
16.Remove VIN plate.
17.Remove centre braces.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit centre braces.
2.Fit VIN plate.
3.Fit bonnet locking mechanism.
4.Fit bonnet release cable.
5.Fit RH horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
6.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
7.Fit battery tray.
8.Fit battery. Do not connect leads.
+ CHARGING AND STARTING,
REPAIRS, Battery.
9.Fit headlamp wiring.
10.Fit RH and LH repeater lamps.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
11.Fit RH and LH headlamps.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
12. Diesel models: Fit gearbox fluid cooler.
13. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
14.Fit bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
PANEL REPAIRS
77-2-24 REPAIRS
Front cross member
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
4. Models with A/C: Remove condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
5. Diesel models: Remove gearbox fluid cooler.
6.Remove RH and LH headlamps.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Release headlamp levelling motors and
position aside.
8.Release headlamp wiring and position aside.
9.Remove RH horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
10. Models with A/C: Release and remove A/C
pipes.
11.Remove RH and LH crush cans.
12.Remove 2 bolts securing front bulkhead
assembly to chassis.
13.Remove centre braces.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.Refit
1.Fit centre braces.
2.Fit 2 bolts securing bulkhead to chassis and
tighten bolts to 45 Nm (33 lbf.ft).
3.Fit crush cans.
4. Models with A/C: Fit A/C pipes.
5.Fit RH horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
6.Fit headlamp wiring and headlamp levelling
motors.
7.Fit RH and LH headlamps.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
8. Diesel models: Fit gearbox fluid cooler.
9. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
10.Fit washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
11.Connect leads/multiplug to alternator.
12.Connect battery leads, negative lead last.
PANEL REPAIRS
REPAIRS 77-2-25
Headlamp mounting panel - RH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
4. Models with A/C: Remove condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
5. Diesel models: Remove gearbox fluid cooler.
6.Remove RH headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Remove RH repeater lamp.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
8.Release headlamp levelling motor and position
aside.
9.Release headlamp wiring and position aside.
10.Remove battery and battery tray.
+ CHARGING AND STARTING,
REPAIRS, Battery.
11.Remove horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
12.Remove RH crush can.
13.Remove 2 bolts securing front bulkhead
assembly to chassis.
14.Remove RH centre brace.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit centre brace.
2.Fit 2 bolts securing bulkhead to chassis and
tighten bolts to 45 Nm (33 lbf.ft).
3.Fit crush can.
4. Models with A/C: Fit A/C pipes.
5.Fit horn.
+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
6.Fit battery and battery tray. Do not connect
leads.
+ CHARGING AND STARTING,
REPAIRS, Battery.
7.Fit headlamp wiring and headlamp levelling
motors.
8.Fit repeater lamp.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
M77 1741A
PANEL REPAIRS
77-2-28 REPAIRS
Valance upper assembly - LH
In this procedure, the front wing, the valance outer
reinforcement and the bonnet alarm switch mounting
bracket are replaced in conjunction with the LH
valance upper assembly.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
4.Remove air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
5.Remove PAS/ACE reservoir.
6.Remove ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
7.Remove brake pipes from valance.
8.Release harness from valance and position
aside.
9. Models with A/C: Depressurise A/C system
and remove pipes from valance.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
M77 1743
M77 1690A
PANEL REPAIRS
77-2-30 REPAIRS
Refit
1.Fit harness to valance.
2.Fit and secure expansion tank to fixings.
3.Fit fuse box.
4.Fit battery tray.
5.Fit battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
6.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
Valance upper assembly (front section) -
LH
In this procedure, the front wing, the valance outer
reinforcement (front section) and the bonnet alarm
switch mounting bracket are replaced in conjunction
with the LH valance upper assembly (front section).
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
4.Remove air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
5.Remove PAS/ACE reservoir.
6.Remove ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
7.Release harness from valance and position
aside.
8. Models with A/C: Depressurise A/C system
and remove pipes from valance.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.