To perform this operation, the inner panel and the corresponding angles for connecting the front side member to the cross member are replaced together with the front side member.
Dismantling
1. Disconnect "negative" battery terminal.
2. Disconnect all electronic units.
3. Remove the wheel (wheels).
4. Remove the lower motor protection shield.
EXTERIOR PARTS, REPAIR WORKS, Engine lower shield.
5. Remove the front bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
6. Remove the radiator.
COOLING SYSTEM: MOD. K, KV6 engine, REPAIR WORK, Radiator assembly.
7. Remove the power steering fluid cooler.
STEERING, Steering Gear, Power Steering Fluid Cooler (for models with Td4 or K1.8 engine).
8. Remove the headlight.
LIGHTING, Headlight assembly - models up to 2004 model year, Headlight assembly - models up to 2004 model year.
9. Release the headlight wiring harness and move it aside.
10. Remove the mudguard of the engine compartment.
11. Remove the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORKS, Front fender liner.
12. Left side: Remove the left bumper bracket.
13. Left side: Remove the electronic engine control unit (ECM).
14. Left side: Remove the battery tray.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Support tray - storage battery.
15. Left side: Remove the air filter.
16. Left side: Remove the air tube.
17. Left side: Remove the horn.
SECURITY SYSTEM, REPAIR WORK, Horn.
18. Right side: Remove the right bumper bracket.
19. Right side: Remove the windshield washer reservoir.
WIPERS AND WASHERS, REPAIR WORKS, Reservoir - washer.
20. Right side: Remove the generator.
ENGINE START AND BATTERY CHARGING SYSTEM, REPAIR WORKS, Generator - KV6.
21. Right side: Remove the power steering pump.
STEERING, Steering Gear, Power Steering Pump (models with KV6 engine).
Repair work
1. Remove damaged panels, prepare joint edges and install new panels in accordance with the Body Panel Repair Code. Punch or drill holes in the panel to be installed for the cork weld as shown.
Assembly
1. Left side: Set the horn.
SECURITY SYSTEM, REPAIR WORK, Horn.
2. Left side: Install the air tube.
3. Left side: Install the air filter.
4. Left side: Replace the battery tray. Don't join "negative" battery terminal.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Support tray - storage battery.
5. Left side: Install the ECM (ECM).
6. Left side: Install the left bumper bracket.
7. Right side: Install the power steering pump.
STEERING, Steering Gear, Power Steering Pump (models with KV6 engine).
8. Right side: Replace the generator.
ENGINE START AND BATTERY CHARGING SYSTEM, REPAIR WORKS, Generator - KV6.
9. Right side: Install the windshield washer reservoir.
WIPERS AND WASHERS, REPAIR WORKS, Reservoir - washer.
10. Right side: Install the right bumper bracket.
11. Reinstall the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORKS, Front fender liner.
12. Establish a mudguard of a motor compartment.
13. Install the headlight.
LIGHTING, Headlight assembly - models up to 2004 model year, Headlight assembly - models up to 2004 model year.
14. Attach the headlight wiring harness.
15. Install the power steering fluid cooler.
STEERING, Steering Gear, Power Steering Fluid Cooler (for models with Td4 or K1.8 engine).
16. Install the heatsink.
COOLING SYSTEM: MOD. K, KV6 engine, REPAIR WORK, Radiator assembly.
17. Reinstall the front bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
18. Replace the lower engine shield.
EXTERIOR PARTS, REPAIR WORKS, Engine lower shield.
19. Connect all electronic units.
20. Attach "negative" battery terminal.
Comments on this article