PANEL REPAIRS
REPAIRS 77-2-39
Valance outer reinforcement
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
6.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
7.Remove front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
8.Remove headlamp.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
9.Release wiring from valance and position
aside.
10. LH side: Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
11. LH side: Remove ECM.
12. LH side: Remove relay module.
13. LH side: Remove battery carrier.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
14. LH side: Remove engine compartment fuse
box and related wiring.
15. RH side: Remove PAS fluid reservoir.
16. RH side: Remove brake pipes from valance. 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. LH side: Fit engine compartment fuse box and
related wiring.
2. LH side: Fit battery carrier.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
3. LH side: Fit relay module.
4. LH side: Fit ECM.
5. LH side: Fit battery. Do not connect earth lead.
+ CHARGING AND STARTING,
REPAIRS, Battery.
6. RH side: Fit PAS fluid reservoir.
7. RH side: Fit brake pipes to valance. Bleed
brakes.
+ BRAKES, ADJUSTMENTS, Brake
bleed.
8.Secure wiring to valance.
9.Fit headlamp.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
10.Fit front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
11.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
12.Fit front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
13.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
14.Connect all ECUs.
15.Connect alternator.
16.Connect battery earth lead.
HARNESSES
86-7-6 REPAIRS
53.Release fuse box, disconnect 11 multiplugs
and remove fuse box.
54.Disconnect multiplug from steering column
switch.
55.Release harness clip from steering column.
56.Disconnect multiplug from throttle position
sensor.
57.Disconnect multiplugs from brake light switch
and brake pedal position switch.58.Disconnect multiplug from airbag ECU.
59.Remove airbag ECU securing bolt and release
earth lead.
60.Remove nut from earth header and release
header from floor tunnel.
HARNESSES
86-7-10 REPAIRS
90.Remove 4 screws from rear bumper lamps,
release lamps and disconnect multiplugs.
91.Release harness clips and pull harness into
luggage compartment.
92.Release main harness retaining clips and pull
harness into vehicle interior.
93.Remove main harness.Refit
1.Lay main harness in vehicle.
2.Locate rear section and secure in retaining
clips.
3.Feed harness to rear bumper lamps, secure in
clips and grommets.
4.Connect multiplugs to rear bumper lamps, fit
rear lamps and secure with screws.
5.Fit LH rear earth header and secure with nut.
6.Connect multiplugs to LH tail lamp.
7.Position RH tail lamp and connect multiplugs.
8.Fit RH tail lamp and secure with Torx screws.
9.Fit RH rear earth header and secure with nut.
10.Connect multiplug to towing electrics.
11.Connect rear screen washer tube.
12.Connect tail door harness multiplugs.
13.Connect and fit rear window lift and wash/wipe
relays.
14.Position harness into luggage compartment.
15.Connect both rear ABS speed sensor
multiplugs and secure harness grommets.
16.Connect multiplug to fuel pump.
17.Fit fuel pump access cover and secure with
screws.
18.Fit luggage compartment carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
19.Connect multiplugs at the base of 'B/C' Posts.
20.Fit all harness clips to interior of vehicle.
21.Fit multiplugs and earth header to LH lower 'A'
post.
22.Fit earth header to RH lower 'A' post.
23.Connect multiplug to window lift ECU.
24.Fit face level vent ducting.
25.Fit steering column to bracket and secure with
nuts.
26.Fit rear heater ducting and secure with nut.
27.Secure harness to rear heater ducting with
clips.
28.Position mounting bracket and secure relays.
29.Connect Lucar to handbrake switch.
30. Manual gearbox only: Connect multiplug to
gear lever hill descent switch.
31.Connect multiplug to accelerometer.
32. Automatic gearbox only: Connect multiplugs
to gear selector.
33.Connect heated oxygen sensor multiplug.
34.Fit earth header to floor tunnel and secure with
nut.
35.Fit earth lead to airbag ECU and secure with
bolt.
36.Connect multiplug to airbag ECU.
37.Connect multiplugs to brake light switch and
brake pedal position switch.
38.Connect multiplug to throttle position sensor.
39.Fit harness clip to steering column.
40.Connect multiplug to steering column switch.
