This operation replaces the crossmember side panels along with the bulkhead panel assembly.
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 power steering fluid cooler.
STEERING, Steering Gear, Power Steering Fluid Cooler (for models with Td4 or K1.8 engine).
8. Remove the left and right headlights.
LIGHTING, Headlight assembly - models up to 2004 model year, Headlight assembly - models up to 2004 model year.
9. Release the headlight wiring harnesses and move them aside.
10. Remove the left and right mudguards of a motor compartment.
11. Remove the left and right bumper amplifier brackets.
12. Remove the battery.
ENGINE START AND CHARGING SYSTEM, REPAIR WORKS, Accumulator battery.
13. Remove the air tube.
14. Remove the horn
SECURITY SYSTEM, REPAIR WORK, Horn.
15. Remove the windshield washer reservoir.
WIPERS AND WASHERS, REPAIR WORKS, Reservoir - washer.
16. Remove the hood latch.
17. Secure the hood in the raised position.
18. Remove the hood pillar.
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. Establish a rack of a cowl.
2. Install the hood latch.
3. Install the windshield washer reservoir.
WIPERS AND WASHERS, REPAIR WORKS, Reservoir - washer.
4. Set the horn.
SECURITY SYSTEM, REPAIR WORK, Horn.
5. Install the air tube.
6. Install the battery. Don't join "negative" battery terminal.
ENGINE START AND CHARGING SYSTEM, REPAIR WORKS, Accumulator battery.
7. Install the left and right bumper amplifier brackets.
8. Establish the left and right mudguards of a motor compartment.
9. Install the left and right headlights.
LIGHTING, Headlight assembly - models up to 2004 model year, Headlight assembly - models up to 2004 model year. Attach the headlight harnesses.
10. Install the power steering fluid cooler.
STEERING, Steering Gear, Power Steering Fluid Cooler (for models with Td4 or K1.8 engine).
11. Install the heatsink.
COOLING SYSTEM: MOD. K, KV6 engine, REPAIR WORK, Radiator assembly.
12. Establish a beam of a forward bumper.
13. Reinstall the front bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
14. Connect all electronic units.
15. Connect the generator.
16. Attach "negative" battery terminal.
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