Body repair

BODY REPAIR

The following panel repair operations itemize components which must be removed for access during repair of a base model vehicle.

Because of the unpredictable nature of accident damage, the items listed make no allowance for any difficulties which may be found in removal and only apply to an undamaged vehicle. All damaged components should be renewed following panel repairs.

FRONT BULKHEAD ASSEMBLY

NOTE: In this procedure, the crossmember to sidemember gusset plates are replaced in conjunction with the front bulkhead assembly.

Remove

1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL, Repairs.
3. Disconnect all ECUs.
4. Remove front bumper valance. See BODY, Exterior fittings.
5. Remove front bumper armature.
6. Remove radiator. See COOLING SYSTEM, Repairs.
7. Remove PAS fluid cooler. See STEERING, Repairs.
8. Remove LH and RH headlamps. See ELECTRICAL, Repairs.
9. Release wiring to headlamps and position aside.
10. Remove LH and RH engine bay shields.
11. Remove bumper valance LH and RH attachment brackets.
12. Remove battery. See ELECTRICAL, Repairs.
13. Remove air intake hose.
14. Remove horn. See ELECTRICAL, Repairs.
15. Remove windscreen washer reservoir. See WIPERS & WASHERS, Repairs.
16. Remove bonnet lock.
17. Support bonnet in open position.
18. Remove bonnet stay.

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.