In this procedure, the front section of 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 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.

6. Remove radiator.

COOLING SYSTEM - K SERIES KV6,

REPAIRS, Radiator assembly.

7. Remove PAS fluid cooler.

STEERING, REPAIRS, Oil cooler -

Td4 & K1.8 models.

8. Remove headlamp.

LIGHTING, REPAIRS, Headlamp

assembly.

9. Release wiring to headlamp and position aside.

10. Remove engine bay shield.
11. Remove front wheel arch liner.

EXTERIOR FITTINGS, REPAIRS,

Liner - front wheel arch.

12. LH side: Remove front bumper LH support

bracket.

13. LH side: Remove ECM.
14. LH side: Remove battery carrier.

CHARGING AND STARTING,

REPAIRS, Carrier - battery.

15. LH side: Remove air cleaner.
16. LH side: Remove air intake hose.
17. LH side: Remove horn.

SECURITY, REPAIRS, Horn.

18. RH side: Remove front bumper RH support

bracket.

19. RH side: Remove windscreen washer

reservoir.

WIPERS AND WASHERS, REPAIRS,

Reservoir - washer.

20. RH side: Remove alternator.

CHARGING AND STARTING,

REPAIRS, Alternator - KV6.

21. RH side: Remove PAS pump.

STEERING, REPAIRS, Pump -

steering - KV6.

PANEL REPAIRS

77-2-32 REPAIRS

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. 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.

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.

18. Fit underbelly panel.

EXTERIOR FITTINGS, REPAIRS,

Panel - underbelly.

19. Connect all ECUs.
20. Connect battery earth lead.

PANEL REPAIRS

REPAIRS 77-2-33

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.

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.

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.

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.

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.

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.

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.

PANEL REPAIRS

77-2-34 REPAIRS

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.

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.

24. Fit PAS rack.

STEERING, REPAIRS, Power

steering rack.

25. Fit front damper.

FRONT SUSPENSION, REPAIRS,

Damper.

26. Fit engine and gearbox.