Repair

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 centre braces.
2. Fit VIN plate.
3. Fit bonnet locking mechanism.
4. Fit bonnet release cable.
5. Fit RH horn. ALARM SYSTEM AND HORN, REPAIR, Vehicle horn.
6. Fit air filter assembly. ENGINE MANAGEMENT SYSTEM - Td5, REPAIRS, Air filter assembly. ENGINE MANAGEMENT SYSTEM - V8, REPAIRS, Air cleaner assembly.
7. Fit battery tray.
8. Fit battery. Do not connect leads. CHARGING AND STARTING, REPAIRS, Battery.
9. Fit headlamp wiring.
10. Fit RH and LH repeater lamps. LIGHTING, REPAIRS, Lamp - front repeater.
11. Fit RH and LH headlamps. LIGHTING, REPAIRS, Headlamp - up to 03MY.
12. Diesel models: Fit gearbox fluid cooler.
13. Models with A/C: Fit condensor. AIR CONDITIONING, REPAIRS, Condenser.
14. Fit bumper assembly. EXTERIOR FITTINGS, REPAIRS, Bumper assembly - front.
15. Connect leads/multiplug to alternator.
16. Connect battery leads, negative lead last.

Front cross member

Remove

1. Disconnect both battery leads, negative lead first.
2. Disconnect leads/multiplug from alternator.
3. Remove washer reservoir. WIPERS AND WASHERS, REPAIRS, Reservoir - washer - up to 03MY.
4. Models with A/C: Remove condensor. AIR CONDITIONING, REPAIRS, Condenser.
5. Diesel models: Remove gearbox fluid cooler.
6. Remove RH and LH headlamps. LIGHTING, REPAIRS, Headlamp - up to 03MY.
7. Release headlamp levelling motors and position aside.
8. Release headlamp wiring and position aside.
9. Remove RH horn. ALARM SYSTEM AND HORN, REPAIR, Vehicle horn.
10. Models with A/C: Release and remove A/C pipes.
11. Remove RH and LH crush cans.
12. Remove 2 bolts securing front bulkhead assembly to chassis.
13. Remove centre braces.

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.