1. Disconnect battery earth lead.
2. Disconnect alternator.
3. Disconnect all ECUs.
4. Remove LH and RH engine bay shields.
5. Remove front bumper valance.

EXTERIOR FITTINGS, REPAIRS,

Bumper - assembly - front.

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. Release wiring for LH and RH headlamps and

position aside.

Repair

PANEL REPAIRS

REPAIRS 77-2-29

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. The front lower crossmember assembly
is only supplied with a limited amount of
spotwelds. Ensure that the correct amount of
plug welds are put onto the assembly as a
substitute for the spotwelds, see illustration
below.

Refit

1. Secure wiring to LH and RH headlamps.
2. Fit PAS fluid cooler.

STEERING, REPAIRS, Oil cooler -

Td4 & K1.8 models.

3. Fit radiator.

COOLING SYSTEM - K SERIES KV6,

REPAIRS, Radiator assembly.

4. Fit front bumper armature.
5. Fit front bumper valance.

EXTERIOR FITTINGS, REPAIRS,

Bumper - assembly - front.

6. Fit LH and RH engine bay shields.
7. Connect all ECUs.
8. Connect alternator.
9. Connect battery earth lead.

Front sidemember (complete)

In this procedure, the front sidemember closing
panel and the related crossmember to sidemember
gusset plate are replaced in conjunction with the front
sidemember.

Remove

1. Disconnect battery earth lead.
2. Disconnect alternator.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove underbelly panel.

EXTERIOR FITTINGS, REPAIRS,

Panel - underbelly.

6. Remove front bumper valance.

EXTERIOR FITTINGS, REPAIRS,

Bumper - assembly - front.

7. Remove front bumper armature.
8. Remove radiator.

COOLING SYSTEM - K SERIES KV6,

REPAIRS, Radiator assembly.

9. Remove PAS fluid cooler.

STEERING, REPAIRS, Oil cooler -

Td4 & K1.8 models.

10. Remove headlamp.

LIGHTING, REPAIRS, Headlamp

assembly.

11. Release wiring to headlamp and position aside.
12. Remove engine bay shield.
13. Remove front wheel arch liner.

EXTERIOR FITTINGS, REPAIRS,

Liner - front wheel arch.

14. Remove front suspension rear beam.
15. Remove engine and gearbox.

ENGINE - K SERIES KV6, REPAIRS,

Engine and automatic gearbox.

16. Remove PAS rack.

STEERING, REPAIRS, Power

steering rack.

17. Remove fascia.

INTERIOR TRIM COMPONENTS,

REPAIRS, Fascia.

18. LH side: Remove front bumper LH support

bracket.

19. LH side: Remove LH engine mounting from

body.

20. LH side: Remove battery.

CHARGING AND STARTING,

REPAIRS, Battery.

21. LH side: Remove air intake hose.
22. LH side: Remove horn.

SECURITY, REPAIRS, Horn.

23. RH side: Remove front bumper RH support

bracket.

PANEL REPAIRS

77-2-30 REPAIRS

24. RH side: Remove RH engine mounting from

body.

25. RH side: Remove windscreen washer

reservoir.

WIPERS AND WASHERS, REPAIRS,

Reservoir - washer.

26. Driver's side: Remove passenger

compartment fuse box.

27. Driver's side: Remove brake pedal box and

brake servo.

28. Driver's side: Remove clutch pedal box.
29. Remove treadplate from front door aperture.

Release front carpet and position aside.

30. 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 engine bulkhead.
2. Position front carpet and fit treadplate to front

door aperture.

3. Driver's side: Fit clutch pedal box.
4. Driver's side: Fit brake pedal box and brake

servo.

5. Driver's side: Fit passenger compartment fuse

box.

6. LH side: Fit horn.

SECURITY, REPAIRS, Horn.

7. LH side: Fit air intake hose.
8. LH side: Fit battery. Do not connect battery

earth lead.

CHARGING AND STARTING,

REPAIRS, Battery.

9. LH side: Fit LH engine mounting to body.

10. LH side: Fit front bumper LH support bracket.
11. RH side: Fit windscreen washer reservoir.

WIPERS AND WASHERS, REPAIRS,

Reservoir - washer.

12. RH side: Fit RH engine mounting to body.
13. RH side: Fit front bumper RH support bracket.
14. Fit fascia.

INTERIOR TRIM COMPONENTS,

REPAIRS, Fascia.

15. Fit PAS rack.

STEERING, REPAIRS, Power

steering rack.

16. Fit engine and gearbox.

ENGINE - K SERIES KV6, REPAIRS,

Engine and automatic gearbox.

17. Fit front suspension rear beam.
18. Fit front wheel arch liner.

EXTERIOR FITTINGS, REPAIRS,

Liner - front wheel arch.

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