Page 2537 of 3229
SectionDescriptionGapProfile
A-AHood t o bumper cover gap5.0 +2.0 -0.0N/AB-BFront bumper cover t o headl amp gap5.0 ±2.5 (maximum taper 2.0)N/A
C-CHood t o headlamp gap5.0 +2.0 -0.0N/A
D-DHeadlamp to bumper cover4.0 ±2.0N/AE-EFender to headlamp3.0 ±1.01.0 ±1.5
F-FFender to bumper cover2.0 +1.0 -0.01.5 ±1.0
G-G5.0 ±1.7N/A
Page 2538 of 3229
SectionDescriptionGapProfile
H-HFender t o front door5.0 ±1.00.7 ±1.0J-JFront door t o A-Pill ar4.5 ±1.0-2.5 ±1.2
K-KFront door fini sher t o door0.0 +1.0 -0.0-2.0 ±1.0
L-LFront door t o rear door5.0 ±1.00.8 ±1.0M-MFront door t o rear door5.0 ±1.01.0 ±1.0
Page 2539 of 3229
SectionDescriptionGapProfile
N-NRear door fini sher t o door0.0 +1.0 -0.0-2.0 ±1.0O-ORear door to s i de panel4.5 ±1.0-2.5 ±1.2
P-PRear door to s i de panel4.5 ±1.01.0 ±1.0
Q-QRear door to s i de panel5.0 ±1.00.5 ±0.5R-RSi de panel t o bumper cover2.0 +1.0 -0.01.5 ±1.0
S-SSi de panel t o rear l amp3.0 ±1.51.0 ±1.2
Page 2540 of 3229
SectionDescriptionGapProfile
T-TRear l amp t o bumper cover3.0 ±2.0N/AU-URear l amp t o li ft gate5.0 ±1.53.0 ±1.3
V-VD-Pil lar t ri m panel to liftgat e glas s5.0 ±2.02.5 ±1.3
W -WSi de panel t o l iftgate5.0 ±1.52.0 ±1.5X-XLi ft gate t o bumper cover6.0 ±2.7N/A
Page 2541 of 3229

Publi s hed: 11-May-2011
Front End Sheet Metal Repairs - Front End Sheet Metal
Des cript ion and Operat ion
Front end s ervice panels
ItemDescription
1Hood l atch panel2Fender apron upper panel
3Fender apron panel front ext ensi on
4Fender apron panel rei nforcement5Sus pens ion top mount
6Fender apron panel
7Front s ide member and sus pens i on top mount as s embly8Front s ide member cl osi ng panel
9Front s ide member secti on
10Fender apron lower panel11Front s ide member
12Fender apron panel front reinforcement
13Front bumper mounti ng14Front bumper
Time schedules, front end
The fol lowing schedul es s how the tot al t ime t aken t o repl ace si ngl e panels and als o combi nat ions of panel s. The publi s hedt imes i ncl ude the removal of Mechani cal , El ect ri cal and Trim, (MET), i tems , plus paint t imes bas ed on Met all ic Clear OverBase Pai nt, (blends to adjacent panels are not included). A corrosi on prot ect ion t ime is included where appropriate.
The t imes were generated by That cham, (the Mot or Ins urance Repai r Research Cent re), and are t o be us ed as a gui de onl y,based on new undamaged panels . Job al lowances are not included, as a guide Thatcham recommend 0.3 hours to be addedt o s ingle panel ti mes and 0.5 hours t o be added to combi nat ion t imes.
Single panel timesPanel DescriptionT imes
Hood5.6
Front bumper cover5.5Front fender5.5
Hood l at ch panel6.2
Engine and Sus pens ion as s embly remove and ins tal l8.5Inst rument panel remove and ins t al l6.2
Combination panel replacement times
C ombination panel times
Page 2542 of 3229

Panel DescriptionT imes
Hood
Front bumper coverFront bumper
Hood l at ch panel
Front fenderFender mount ing bracket, (front )
T otal T imeL/H 16.5R/H 16.5
C ombination panel times
Panel DescriptionT imes
HoodFront bumper cover
Front bumper
Hood l at ch panelFront fender L/H and R/H
Front fender mounti ng bracket , (front ) L/H and R/H
T otal T ime17.2
C ombination panel timesPanel DescriptionT imes
Hood
Front bumper coverFront bumper
Hood l at ch panel
Front fenderFront fender mounti ng bracket , (front )
Front bumper mount ing
Front s ide memberFront s ide member and s us pens ion top mount as s embl y
Fender apron upper panel
Engine and s us pens ion as s embly remove and ins tal lInst rument panel remove and ins t al l
T otal T imeL/H 42.2R /H 43.6
C ombination panel times
Panel DescriptionT imes
HoodFront bumper cover
Front bumper
Hood l at ch panelFront fender L/H and R/H
Front fender mounti ng bracket , (front ) L/H and R/H
Front bumper mount ing L/H and R/HFront s ide member L/H and R/H
Front s ide member and s us pens ion top mount as s embl y L/H and R/H
Fender apron upper panel L/H and R/HEngine and s us pens ion as s embly remove and ins tal l
Inst rument panel remove and ins t al l
T otal T ime57.6
C ombination panel timesPanel DescriptionT imes
Hood
Front bumper coverFront bumper
Hood l at ch panel
Front fenderFront fender mounti ng bracket , (front )
Front bumper mount ing
Front s ide member s ecti onFender apron lower panel
Fender apron panel front reinforcement
Engine and s us pens ion as s embly remove and ins tal l
T otal T imeL/H 29.9R/H 30.0
Page 2543 of 3229

Publi s hed: 11-May-2011
Front End Sheet Metal Repairs - Front Bumper Mounting
Removal and Inst all ati on
Removal
• NOTE: The front bumper mount ing i s s erviced as a s eparat e weld-on panel .
• NOTE: Due t o t he combi ned thi cknes s of the panels , it i s recommended t hat s pot welds are repl aced wi th MIG plug wel dsin thi s repair.
1. The front bumper mounti ng is replaced in conjuncti on wit h:
Front bumper cover
Front bumper
Hood lat ch panel
Both front fenders
2. For addit ional informati on rel at ing to this repair procedurepleas e s ee t he foll owing:For addi ti onal informat ion, refer t o: Body and Frame (501-26Body Repai rs - Vehi cl e Speci fic Informat ion and ToleranceChecks , Descripti on and Operat ion) /Standard W orks hop Practi ces (100-00 General Informat ion,Des cript ion and Operat ion).
3. Remove the hood l at ch panel .For addi ti onal informat ion, refer t o: Hood Latch Panel (501-27,Removal and Ins tall ati on).
4. Remove the radi ator cool ing pack.For addi ti onal informat ion, refer t o: Radiator (303-03A Engi neCooling - I6 3.2L Petrol, Removal and Ins tall ati on).
5. LH Side: Remove the ai r int ake pi pe.
6. RH Side: Remove t he winds hi eld was her res ervoir.For addi ti onal informat ion, refer t o: W i nds hiel d W as herRes ervoi r (501-16 W i pers and W as hers , Removal andIns t allat ion).
7. Rel eas e and lay as ide t he wiring harnes s .
8. Mil l out t he s pot wel ds.
Page 2544 of 3229
9. Mil l out t he s pot welds .
10. Separat e t he joi nt s and remove the panel.
Installation
1. Prepare t he old and new panel joi nt s urfaces.
2. Dri ll holes in the new panel ready for pl ug weldi ng.
3. Offer up the new panel and clamp i nto pos it ion. Checkali gnment , if correct , proceed to next s tep, i f not , recti fy andrecheck before proceeding.
4. Plug weld to the front s ide member.