PANEL REPAIRS
REPAIRS 77-2-33
Refit
1. LH side: Fit horn.
+ SECURITY, REPAIRS, Horn.
2. LH side: Fit air intake hose.
3. LH side: Fit air cleaner.
4. LH side: Fit battery carrier. Do not connect
battery earth lead.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
5. LH side: Fit ECM.
6. LH side: Fit front bumper LH support bracket.
7. RH side: Fit PAS pump.
+ STEERING, REPAIRS, Pump -
steering - KV6.
8. RH side: Fit alternator.
+ CHARGING AND STARTING,
REPAIRS, Alternator - KV6.
9. RH side: Fit windscreen washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
10. RH side: Fit front bumper RH support bracket.
11.Fit front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
12.Fit engine bay shield.
13.Fit headlamp.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
14. Secure headlamp wiring.
15.Fit PAS fluid cooler.
+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
16.Fit radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
17.Fit front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
18.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
19.Connect all ECUs.
20.Connect battery earth lead.
Front valance assembly
Remove
1.Disconnect battery earth lead.
2.Disconnect all ECUs.
3.Remove road wheel(s).
4.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
6.Remove front bumper armature.
7.Remove radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
8.Remove PAS fluid cooler.
+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
9.Remove headlamp.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
10.Release wiring to headlamp and position aside.
11.Remove engine bay shield.
12.Remove front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
13.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
14.Remove front suspension rear beam.
15.Remove engine and gearbox.
+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
16.Remove front damper.
+ FRONT SUSPENSION, REPAIRS,
Damper.
17.Remove PAS rack.
+ STEERING, REPAIRS, Power
steering rack.
18.Remove fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
19. LH side: Remove front bumper LH support
bracket.
20. LH side: Remove air cleaner.
21. LH side: Remove air intake hose.
22. LH side: Remove ECM.
23. LH side: Remove engine compartment
fusebox.
24. LH side: Remove battery carrier.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
25. LH side: Remove engine compartment fuse
box and related wiring.
PANEL REPAIRS
77-2-34 REPAIRS
26. LH side: Remove LH engine mounting from
body.
27. LH side: On models with Diesel engines,
remove fuel filter.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Filter - main - up to 03MY.
28. LH side: Remove LH front brake pipe.
29. RH side: Remove front bumper RH support
bracket.
30. RH side: Remove windscreen washer
reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
31. RH side: Remove coolant expansion tank.
32. RH side: Remove RH engine mounting from
body.
33. RH side: Remove PAS fluid reservoir.
34. RH side: Remove RH front brake pipe.
35. Driver's side: Remove passenger
compartment fuse box.
36.Remove brake pedal box and brake servo.
37.Remove clutch pedal box.
38.Release vehicle harness from valance and
position aside.
39.Remove treadplate from front door aperture.
Release front carpet and position aside.
40.Remove insulation pads from engine bulkhead.
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 insulation pads to front and rear sides of
engine bulkhead.
2.Position front carpet and fit treadplate to front
door aperture.
3.Secure vehicle harness to valance.
4. Driver's side: Fit clutch pedal box.
5.Fit brake pedal box and brake servo.
6.Fit passenger compartment fuse box.
7. LH side: Fit LH front brake pipe. Bleed brake
system.
+ BRAKES, ADJUSTMENTS, Brake
bleed.
8. LH side: On models with Diesel engines, fit fuel
filter.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Filter - main - up to 03MY.
9. LH side: Fit LH engine mounting to body.
10. LH side: Fit engine compartment fuse box and
related wiring.
11. LH side: Fit battery carrier. Do not connect
battery earth lead.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
12. LH side: Fit engine compartment fusebox.
13. LH side: Fit ECM.
14. LH side: Fit air intake hose.
15. LH side: Fit air cleaner.
16. LH side: Fit front bumper LH support bracket.
17. RH side: Fit RH front brake pipe. Bleed brake
system.
+ BRAKES, ADJUSTMENTS, Brake
bleed.
18. RH side: Fit PAS fluid reservoir.
19. RH side: Fit RH engine mounting to body.
20. RH side: Fit coolant expansion tank.
21. RH side: Fit windscreen washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
22. RH side: Fit front bumper RH support bracket.
23.Fit fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
24.Fit PAS rack.
+ STEERING, REPAIRS, Power
steering rack.
25.Fit front damper.
+ FRONT SUSPENSION, REPAIRS,
Damper.
26.Fit engine and gearbox.
+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
27.Fit front suspension rear beam.
28.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
