Repair

Repair

Headlamp mounting panel - LH

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 headlamp. LIGHTING, REPAIRS, Headlamp - up to 03MY.
7. Remove repeater lamp. LIGHTING, REPAIRS, Lamp - front repeater.
8. Release headlamp levelling motor and position aside.
9. Release headlamp wiring and position aside.
10. Remove air filter assembly. ENGINE MANAGEMENT SYSTEM - Td5, REPAIRS, Air filter assembly. ENGINE MANAGEMENT SYSTEM - V8, REPAIRS, Air cleaner assembly.
11. Remove 2 earth leads from LH of front bulkhead.
12. Release and remove A/C pipes.
13. Remove crush can.
14. Remove bonnet release cable.
15. Remove 2 bolts securing front bulkhead assembly to chassis.
16. Remove centre brace.

Refit

10. Fit repeater lamp.

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.
1. Fit centre brace.
2. Fit 2 bolts securing bulkhead to chassis and tighten bolts to 45 Nm (33 lbf.ft).
3. Fit bonnet release cable.
4. Fit crush can.
5. Models with A/C: Fit A/C pipes.
6. Fit 2 earth leads to LH of front bulkhead.
7. Fit air filter assembly. ENGINE MANAGEMENT SYSTEM - Td5, REPAIRS, Air filter assembly. ENGINE MANAGEMENT SYSTEM - V8, REPAIRS, Air cleaner assembly.
8. Fit battery tray.
9. Fit headlamp wiring and headlamp levelling motors.

LIGHTING, REPAIRS, Lamp - front

repeater.