Dismantling
1. Disconnect "negative" battery terminal.
2. Disconnect the generator.
3. Disconnect all electronic units.
4. Remove the front bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
5. Remove a beam of a forward bumper.
6. Remove the radiator.
COOLING SYSTEM: MOD. K, KV6 engine, REPAIR WORK, Radiator assembly.
7. Remove the headlamp assembly.
LIGHTING, Headlight assembly - models up to 2004 model year, Headlight assembly - models up to 2004 model year.
8. Release the headlight wiring harness and move it aside.
9. Left side: Remove the left bumper bracket.
10. Left side: Remove the battery.
ENGINE START AND CHARGING SYSTEM, REPAIR WORKS, Accumulator battery.
11. Left side: Remove the horn.
SECURITY SYSTEM, REPAIR WORK, Horn.
12. Left side: Remove the air tube.
13. Right side: Remove the right bumper bracket.
14. Right side: Remove the windshield washer reservoir.
WIPERS AND WASHERS, REPAIR WORKS, Reservoir - washer.
15. Right side Remove the power steering fluid cooler.
STEERING, Steering Gear, Power Steering Fluid Cooler (for models with Td4 or K1.8 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: Install the air tube.
2. Left side: Set the horn.
3. Left side: Install the battery. Don't join "negative" battery terminal.
ENGINE START AND CHARGING SYSTEM, REPAIR WORKS, Accumulator battery.
4. Left side: Install the left bumper bracket.
5. Right side: Install the power steering fluid cooler.
STEERING, Steering Gear, Power Steering Fluid Cooler (for models with Td4 or K1.8 engine).
6. Right side: Install the windshield washer reservoir.
WIPERS AND WASHERS, REPAIR WORKS, Reservoir - washer.
7. Right side: Install the right bumper bracket.
8. Install the headlamp assembly.
LIGHTING, Headlight assembly - models up to 2004 model year, Headlight assembly - models up to 2004 model year. Attach the headlight wiring harness.
9. Install the heatsink.
COOLING SYSTEM: MOD. K, KV6 engine, REPAIR WORK, Radiator assembly.
10. Establish a beam of a forward bumper.
11. Install the front bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
12. Connect all electronic units.
13. Attach the generator.
14. Attach "negative" battery terminal.
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