PANEL REPAIRS
REPAIRS 77-2-27
Bonnet locking platform
In this procedure the bonnet locking platform
reinforcement is also replaced in conjunction with the
bonnet locking platform.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Remove radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
6.Remove both headlamp assemblies.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Remove horn.
+ SECURITY, REPAIRS, Horn.
8.Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
9.Remove air intake hose.
10.Remove bonnet lock.
11.Support bonnet in open position.
12.Remove bonnet stay.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Refit
1.Fit bonnet stay.
2.Fit bonnet lock.
3.Fit air intake hose.
4.Fit battery. Do not connect earth lead.
+ CHARGING AND STARTING,
REPAIRS, Battery.
5.Fit horn.
+ SECURITY, REPAIRS, Horn.
6.Fit both headlamp assemblies.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Fit radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
8.Fit front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
9.Connect all ECUs.
10.Connect alternator.
11.Connect battery earth lead.
HEATING AND VENTILATION
80-16REPAIRS
Relay - power - positive temperature co-
efficient (PTC) - Td4 models
$% 80.20.34
Remove
1.Disconnect battery earth lead.
2.Release and open under bonnet fuse box lid.
3.Remove 3 nuts securing fuse box and release
fuse box from studs.
4.Remove fixing and release PTC power relay
bracket from studs.
5.Remove cover from PTC power relay.6.Remove cable ties securing PTC power relay.
7.Remove PTC power relay.
Refit
1.Fit PTC power relay.
2.Fit cable ties to secure PTC power relay.
3.Fit cover over PTC power relay.
4.Fit PTC power relay bracket to studs and
secure with fixing.
5.Fit fuse box to studs, fit nuts and tighten to 8
Nm (6 lbf.ft).
6.Close fuse box lid.
M80 0576
M80 0577
