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PANEL REPAIRS REPAIRS 77-2-21 REPAIRS Front bulkhead assembly Remove 1. Disconnect both battery leads, negative lead first. 2. Disconnect leads/multiplug from alternator. 4. Remove washer reservoir. Reservoir - washer - up to 03MY. 5. Models with A/C: Remove condensor. 6. Diesel models: Remove gearbox fluid cooler. LIGHTING, REPAIRS, Headlamp - up 8. Release headlamp levelling motors and position aside. 9. Release headlamp wiring and position aside. 10. Remove battery. 11. Remove battery tray. Td5, REPAIRS, Air filter assembly. V8, REPAIRS, Air cleaner assembly. 13. Remove 2 earth leads from LH of front bulkhead. 14. Remove RH horn. 15. Models with A/C: Release and remove A/C pipes. 16. Remove RH and LH crush cans. assembly to chassis. 22. Remove centre braces. Repair 1. Remove existing panel(s), prepare panel joint faces and install new panel(s) in accordance Refit 1. Fit centre braces. tighten to 45 Nm (33 lbf.ft). 3. Fit VIN plate. 9. Fit 2 earth leads to LH of front bulkhead. 10. Fit air filter assembly. Td5, REPAIRS, Air filter assembly. V8, REPAIRS, Air cleaner assembly. 11. Fit battery tray. 13. Fit headlamp wiring and headlamp levelling motors. 14. Fit RH and LH headlamps. LIGHTING, REPAIRS, Headlamp - up 15. Diesel models: Fit gearbox fluid cooler. 17. Fit washer reservoir. |