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 the generator.
3. Disconnect all electronic units.
4. Remove the wheel (wheels).
5. Remove the lower engine protection shield.
EXTERIOR PARTS, REPAIR WORKS, Engine lower shield.
6. Remove the front bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
7. Remove a beam of a forward bumper.
8. Remove the radiator.
COOLING SYSTEM: MOD. K, KV6 engine, REPAIR WORK, Radiator assembly.
9. Remove the power steering fluid cooler.
STEERING, Steering Gear, Power Steering Fluid Cooler (for models with Td4 or K1.8 engine).
10. Remove the headlight.
LIGHTING, Headlight assembly - models up to 2004 model year, Headlight assembly - models up to 2004 model year.
11. Release the headlight wiring harness and move it aside.
12. Remove the mudguard of the engine compartment.
13. Remove the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORKS, Front fender liner.
14. Remove a back beam of a forward suspension bracket.
15. Remove the engine and transmission.
KV6 ENGINE - VERSION K, Left cylinder head camshafts, Engine and automatic transmission: up to May 2003.
16. Remove the rack and pinion with power steering.
STEERING, Steering gear, Steering gear.
17. Remove the control panel.
INTERIOR TRIM PARTS, REPAIRS, Control panel - for cars up to 2004 model year.
18. Left side: Remove the left bumper bracket.
19. Left side: Remove the left engine mount from the body.
20. Left side: Remove the battery.
ENGINE START AND CHARGING SYSTEM, REPAIR WORKS, Accumulator battery.
21. Left side: Remove the air tube.
22. Left side: Remove the horn.
SECURITY SYSTEM, REPAIR WORK, Horn.
23. Right side Remove the right bumper bracket.
24. Right side: Remove the right engine mount from the body.
25. Right side: Remove the windshield washer reservoir.
WIPERS AND WASHERS, REPAIR WORKS, Reservoir - washer.
26. Driver's side: Remove the passenger compartment relay and fuse box.
27. Driver's side: Remove the brake pedal assembly and brake servo.
28. Driver's side: Remove the clutch pedal assembly.
29. Remove an overlay of a threshold of an aperture of a forward door. Loosen the front floor mat and slide it to the side.
30. Remove insulating slips from a partition of a motor compartment.
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. Restore insulating overlays of a partition of a motor compartment.
2. Replace the front carpet and install the front door sill trim.
3. Driver's side: Install the clutch pedal assembly.
4. Driver's side: Install the brake pedal assembly and brake servo.
5. Driver's side: Install the vehicle interior relay and fuse box.
6. Left side: Set the horn.
SECURITY SYSTEM, REPAIR WORK, Horn.
7. Left side: Install the air tube.
8. Left side: Install the battery. Don't join "negative" battery terminal.
ENGINE START AND CHARGING SYSTEM, REPAIR WORKS, Accumulator battery.
9. Left side: Install the left engine mount.
10. Left side: Install the right bumper bracket.
11. Right side: Install the windshield washer reservoir.
WIPERS AND WASHERS, REPAIR WORKS, Reservoir - washer.
12. Right side: Install the right engine mount.
13. Right side: Install the right bumper bracket.
14. Replace the control panel.
INTERIOR TRIM PARTS, REPAIRS, Control panel - for cars up to 2004 model year.
15. Install the power steering rack and pinion.
STEERING, Steering gear, Steering gear.
16. Install the engine and gearbox.
KV6 ENGINE - VERSION K, Left cylinder head camshafts, Engine and automatic transmission: up to May 2003.
17. Establish a back beam of a forward suspension bracket.
18. Reinstall the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORKS, Front fender liner.
19. Install the engine compartment mudguard.
20. Install the headlight.
LIGHTING, Headlight assembly - models up to 2004 model year, Headlight assembly - models up to 2004 model year.
21. Attach the headlight wiring harness.
22. Install the power steering fluid cooler.
STEERING, Steering Gear, Power Steering Fluid Cooler (for models with Td4 or K1.8 engine).
23. Install the radiator.
COOLING SYSTEM: MOD. K, KV6 engine, REPAIR WORK, Radiator assembly.
24. Establish a beam of a forward bumper.
25. Reinstall the front bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
26. Replace the lower engine shield.
EXTERIOR PARTS, REPAIR WORKS, Engine lower shield.
27. Replace the wheel (wheels) and tighten the nuts to a torque of 115 Nm.
28. Connect all electronic units.
29. Attach the generator.
30. Attach "negative" battery terminal.
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