Page 2569 of 3229
2. Drill holes in the new panel ready for MIG plug welding.
3. Offer up the new panel and clamp into position. Check
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
4. MIG P l ug we l d.
5. Sp o t w e l d .6. Install weld stud.
7. Dress all welded joints.
8. The installation of associated panels and mechanical
components is the reverse of removal.
Page 2570 of 3229

Publ is hed: 11-May-2011
Front End Sheet Metal Repairs - Fender Apron Upper Panel
Removal and Installation
Removal
• NOTE: The fender apron upper panel is s erviced as a s eparat e weld-on panel.
• NOTE: The service panel is not fully welded.
• NOTE: There is an NVH element attached inside this panel, it is not serviced on the new panel. Therefore, if damaged, a
new element will be required.
1. The fender apron upper panel is replaced in conjunct ion wit h:
Front bumper cover
Hood
Hood lat ch panel
Both front fenders
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Remove t he hood l at ch panel.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : H o o d L a t ch P a ne l (501-27,
Removal and Installation).
4. Remove the hood.
5. Remove the plenum chamber panel.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Plenum Chamber
(412-01
Climate Control, Removal and Installation).
6. LH Side: Remove the air intake pipe.
7. RH Side: Release and lay aside the wiring harness.
8. Remove t he hood hi nge, 2 x 13mm headed bol t s .
9. Mill out the spot welds.
Page 2571 of 3229
10. Separate the joints and remove the old panel, including its
NVH element.
Installation
1. Prepare and spot weld the new panel in the areas
illustrated, where it is not fully welded.
2. Prepare the old and new panel joint surfaces.
Page 2572 of 3229
3. Drill holes in the new panel ready for MIG plug welding.
4. Offer up the new panel and clamp into position. Check
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
5. Re move t he pa ne l a nd a ppl y a dhe s i ve t o t he a re a s
illustrated.
6. If necessary, renew the NVH element.
7. Apply sealer adhesive to the NVH element.
8. Offer up the new panel and clamp into position.
Page 2573 of 3229
9. Spot weld at the points illustrated.
10. MIG Pl ug we l d.
11. Dress all welded joints.
12. The installation of associated panels and mechanical
components is the reverse of removal.
Page 2574 of 3229

Publ is hed: 11-May-2011
Front End Sheet Metal Repairs - Front Side Member Closing Panel
Removal and Installation
Removal
• NOTE: The front side member closing panel must be unpicked from the front side member and suspension top mount
assembly, it is not serviced separately.
• NOTE: The panel is serviced less its weld studs
1. The front side member closing panel is replaced in conjunction
with:
Front bumper cover
Front bumper
Hood lat ch panel
Both front fenders
Front bumpe r mount i ng
Fender apron l ower panel
Fender apron panel front reinforcement
Front s i de me mbe r
• NOTE: It is also necessary to remove the engine and suspension as an assembly.
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Re move t he f ront s i de me mbe r.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Side Member
(501-27
Front End Sheet Metal Repairs, Removal and Installation).
4. Mill out the spot welds.
5. Saw cut the old panel at the point illustrated.
6. Separate the joints and remove the old panel.
Page 2575 of 3229
Installation
1. Remove the panel from the service panel.
1. Mill out the spot welds.
2. Saw cut, ensuring the cut aligns with the one
a l re a dy ma de o n t he ve hi cl e .
2. Prepare the old and new panel joint surfaces.
3. Drill holes in the new panel ready for MIG plug welding.
4. Offer up the new panel and clamp into position. Check
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
5. W ith panels clamped into position:
1. Tack weld the butt joint.
2. MIG pl ug wel d.
6. Dress the tack welds.
Page 2576 of 3229
7. MIG weld the butt joint.
8. Install weld stud.
9. Dress all welded joints.
10. The installation of associated panels and mechanical
components is the reverse of removal.