Page 1064 of 1529
CHASSIS AND BODY DIMENSIONS
BODY DIMENSIONS 77-1-13
Gaps and profiles
Figures shown outside brackets are metric measurements (millimetres) and those inside brackets are imperial
measurements (inches).
Front end information
Gaps
The tolerance for the above figures is ± 1.0 (0.039).
Section Gap Description Dimension
A-A a Headlamp to grille 9.5 (0.374)
B-B b Headlamp to bonnet 14.0 (0.551)
C-C c Headlamp to indicator lamp 6.0 (0.236)
D-D d Headlamp to headlamp surround panel 9.5 (0.374)
Page 1065 of 1529
CHASSIS AND BODY DIMENSIONS
77-1-14 BODY DIMENSIONS
Front end/side information
Gaps
The tolerance for gap 'e' is ± 1.0 (0.039), and for gap 'x' is ± 0.5 (0.019).
Profile
Section Gap Description Dimension
E-E e Bonnet to wing 6.0 (0.236)
x Fuel filler lid to body side panel 3.0 (0.118)
Section Description Dimension
E-E Profile of bonnet to wing +1.0 (0.039) -0.0
Page 1068 of 1529
PANEL REPAIRS
REPLACEMENT PANELS 77-2-1
PANEL REPAIRS REPLACE ME NT PA NELS
Replacement panels
Front end outer panels
1Bonnet assembly
2Front wing3Wing support bracket
Page 1069 of 1529
PANEL REPAIRS
77-2-2 REPLACEMENT PANELS
Front end inner panels
1Bonnet locking platform
2Headlamp mounting panels3Front crossmember
4Front bulkhead assembly
Page 1088 of 1529
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.
Page 1090 of 1529
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.
Page 1093 of 1529
PANEL REPAIRS
77-2-26 REPAIRS
9.Fit headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
10. Diesel models: Fit gearbox fluid cooler.
11. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
12.Fit bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
13.Connect leads/multiplug to alternator.
14.Connect battery leads, negative lead last.
Headlamp mounting panel - LH
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 headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Remove 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 air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
11.Remove 2 earth leads from LH of front
bulkhead.
12.Release and remove A/C pipes.
13.Remove crush can.
14.Remove bonnet release cable.
15.Remove 2 bolts securing front bulkhead
assembly to chassis.
16.Remove centre brace.
Page 1094 of 1529
PANEL REPAIRS
REPAIRS 77-2-27
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 bonnet release cable.
4.Fit crush can.
5. Models with A/C: Fit A/C pipes.
6.Fit 2 earth leads to LH of front bulkhead.
7.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
8.Fit battery tray.
9.Fit headlamp wiring and headlamp levelling
motors.
10.Fit repeater lamp.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
11.Fit headlamp.
+ 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 washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
