Page 2742 of 3039
A Front seat belt retractor fixing hole Front seat belt anchorage fixing hole 1684.37
Page 2760 of 3039
10.
11.
12. NOTE: If the hood strut mounting bracket is to be
replaced, it is not necessary to remove it.
Drill out the spot welds to remove the hood strut mounting
bracket.
NOTE: If the fender mounting plate is damaged it is
not necessary to remove it from the fender apron panel.
Drill out the spot welds to release the fender mounting
plate.
NOTE: If the fender mounting plate is undamaged it
can be reused by releasing it from the fender apron panel,
leaving it attached to the suspension top mount. Drill out
from underneath to allow spot welds to be used in
installation.
Drill out the spot welds, from underneath, to release the
fender mounting plate.
13.
NOTE: Use a belt sander where there is no access to drill.
Drill out the spot welds.
Page 2767 of 3039
11. NOTE: Spot welds must be drilled from underneath,
this will make sure the new panel can be spot welded on
installation. Use a belt sander where there is no access to
drill.
Drill out the spot welds.
12. Separate the joints and remove the old panel.
Installation
1. Drill holes in the new panel ready for MAG plug welding.
2. Prepare the old and new panel joint surfaces.
3. Offer up the new panel and clamp into position. Check alignment, if
correct, proceed to next step, if not rectify and recheck before
proceeding.
4. NOTE: Spot welds must be installed 5mm away from the
originals and in the same quantities, whenever this is
possible. Where this is not possible, spot welds should be
installed adjacent to the original.
Spot weld.
Page 2782 of 3039
8. NOTE: If the front fender lower mounting is
undamaged it should be retained for reuse.
Remove the front fender lower mounting retaining bolt.
9. drill.
NOTE: Use a belt sander where there is no access to
Drill out the spot welds.
10. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.
2. Offer up the new panel and clamp into position. Check alignment, if
correct, proceed to next step, if not rectify and recheck before
proceeding.
3. NOTE: Spot welds must be installed 5mm away from the
originals and in the same quantities, whenever this is
possible. Where this is not possible spot welds should be
installed adjacent to the original.
Spot weld.
Page 2798 of 3039

Actuation, Removal and Installation).
12. Remove the left-hand and right-hand front seats.
For additional information, refer to: Front Seat (501-10 Seating, Removal and Installation).
13. Remove the heater core and evaporator core housing.
For additional information, refer to: Heater Core and Evaporator Core Housing (412-01 Climate Control, Removal and Installation).
14. Remove the front safety belt retractor.
For additional information, refer to: Front Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
15. Remove the B-pillar side impact sensor.
For additional information, refer to: B-Pillar Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).
16. Remove the left-hand and right-hand front floor covering.
17. Remove the rear floor covering.
18. If the left-hand front side member and suspension top mount assembly
is to be repaired, remove the left-hand rear foot well duct.
19. If the right-hand front side member and suspension top mount assembly
is to be repaired, remove the right-hand rear foot well duct.
20. If the drivers side front side member and suspension top mount is being
repaired, remove the pedal box.
21. Release and position the insulating material at the inner bulkhead to
one side.
22. Release and position the inner bulkhead and floor panel wiring harness
to one side.
23. Drain the fuel tank.
For additional information, refer to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).
24. If the left-hand front side member and suspension top mount assembly
is to be repaired, remove the left-hand under shield.
25. If the right-hand front side member and suspension top mount assembly
is to be repaired, remove the right-hand under shield.
26. If the left-hand front side member and suspension top mount assembly
is to be repaired, remove the fuel supply and return pipes.
27. For diesel engine vehicles only, if the left-hand front side member and
suspension top mount assembly is to be repaired, remove the fuel
cooler.
28. If the right-hand front side member and suspension top mount assembly
is to be repaired, release and position the underfloor wiring harness to
Page 2799 of 3039
one side.
29. If the right-hand front side member and suspension top mount assembly
is to be repaired, remove the front to rear brake pipes.
30. Remove the exhaust heat shields.
31. Release and position the front side member and suspension top mount
wiring harness to one side.
32. Remove any remaining miscellaneous components from the repair area
as necessary.
33. NOTE: Remove the sealer to expose the spot welds.
Drill out the spot welds as indicated.
34. NOTES:
Remove the sealer to expose the spot welds.
Use a belt sander where there is no access to drill. The three spot
welds at the rocker panel should be drilled from outside and right
through, to allow MAG plug welding on installation
Drill out the spot welds as indicated. www.JagDocs.com
Page 2825 of 3039
6. drill. NOTE: Use a belt sander where there is no access to
Drill out the spot welds.
7. Separate the joints and remove the old panel.
Installation
1. Drill holes in the new panel ready for MAG plug welding.
2. Prepare the old and new panel joint surfaces.
3. Offer up the new panel and clamp into position. Check alignment, if
correct, proceed to next step, if not rectify and recheck before
proceeding.
Page 2829 of 3039

(414-01 Battery, Mounting and Cables, General Procedures).
6. Disconnect the generator electrical connectors.
7. Remove the windshield glass.
For additional information, refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
8. Remove the rear window glass.
For additional information, refer to: Rear Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
9. Remove the roof opening panel frame.
For additional information, refer to: Roof Opening Panel Frame (501-17 Roof Opening Panel, Removal and Installation).
10. Remove the driver and passenger side front scuff plate trim panels.
For additional information, refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
11. Remove the driver and passenger side rear scuff plate trim panels.
For additional information, refer to: Rear Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
12. Remove the driver and passenger side air curtain modules.
For additional information, refer to: Side Air Curtain Module (501-20B Supplemental Restraint System, Removal and Installation).
13. Remove the rear seat backrest.
14. Remove the driver and passenger side rear safety belt retractors.
For additional information, refer to: Rear Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
15. Remove the rear center safety belt retractor.
For additional information, refer to: Rear Center Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
16. Remove the driver and passenger side RF filters.
17. Remove the diversity antenna module.
18. Remove the antenna.
For additional information, refer to: Navigation System Antenna (419-07 Navigation System, Removal and Installation).
19. Release and position the roof wiring harnesses to one side
20. Position the roof opening panel front and rear drain hoses to one side.
21. Remove the driver and passenger side roof mouldings.
22. Drill out the spot welds.
www.JagDocs.com