Front sidemember (complete)

FRONT SIDEMEMBER (COMPLETE)

NOTE: 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 all ECUs.
3. Remove road wheel(s).
4. Remove underbelly panel. See BODY, Exterior fittings.
5. Remove front bumper valance. See BODY, Exterior fittings.
6. Remove front bumper armature.
7. Remove radiator. See COOLING SYSTEM, Repairs.
8. Remove PAS fluid cooler. See STEERING, Repairs.
9. Remove headlamp. See ELECTRICAL, Repairs.
10. Release wiring to headlamp and position aside.
11. Remove engine bay shield.
12. Remove front wheel arch liner. See BODY, Exterior fittings.
13. Remove front suspension rear beam.
14. Remove engine and gearbox. See ENGINE, Repairs.
15. Remove PAS rack. See STEERING, Repairs.
16. Remove fascia. See BODY, Interior trim components.

For LH side

17. Remove front bumper LH support bracket.
18. Remove LH engine mounting from body.
19. Remove battery. See ELECTRICAL, Repairs.
20. Remove air intake hose.
21. Remove horn. See ELECTRICAL, Repairs.

For RH side

22. Remove front bumper RH support bracket.
23. Remove RH engine mounting from body.
24. Remove windscreen washer reservoir. See WIPERS & WASHERS, Repairs.

For driver’s side

25. Remove passenger compartment fuse box.
26. Remove brake pedal box and brake servo. See BRAKES, Repairs.
27. Remove clutch pedal box. See CLUTCH, Repairs.

For both sides

28. Remove treadplate from front door aperture. Release front carpet and position aside.
29. 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.