To perform this operation, the inner panel and the corresponding brackets for connecting the front side member to the cross member are replaced together with the front side member.
Dismantling
1. Disconnect the negative battery terminal.
2. Disconnect the generator.
3. Disconnect all electronic units.
4. Remove the wheel(s).
5. Remove the lower engine protection shield.
EXTERIOR PARTS, REPAIR WORK, Lower engine protection shield.
6. Remove the front bumper.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly - for cars up to model year 2004.
7. Remove the front bumper beam.
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 Before 2004 Model Year, Headlight Assembly - Models Before 2004 Model Year.
11. Release the headlight wiring harness and move it to the side.
12. Remove the engine compartment splash guard.
13. Remove the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORK, Front mudguard.
14. Remove the rear beam of the front suspension.
15. Remove the engine and gearbox.
ENGINE KV6 - MODIFICATION K, Left cylinder head camshafts, Engine and automatic transmission: up to May 2003.
16. Remove the rack and pinion mechanism with power steering.
STEERING, Steering gear, Steering gear.
17. Remove the control panel.
INTERIOR TRIM PARTS, REPAIR WORK, Control Panel - for vehicles up to model year 2004.
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 STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Battery.
21. Left side: Remove the air duct.
22. Left side: Remove the horn.
SECURITY SYSTEM, REPAIR WORK, Sound signal.
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.
WINDSHIELD WIPERS AND WASHERS, REPAIR WORK, Reservoir - washer.
26. Driver's side: Remove the passenger compartment fuse/relay box.
27. Driver's side: Remove the brake pedal assembly and brake servo.
28. Driver's side: Remove the clutch pedal assembly.
29. Remove the front door sill trim. Release the front floor mat and move it to the side.
30. Remove the insulating pads from the engine compartment bulkhead.
Repair works
1. Remove damaged panels, prepare joint edges and install new panels in accordance with the Body Panel Repair Rules. Punch or drill holes in the panel to be installed for the plug weld, as shown in the figure.
Assembly
1. Restore the insulating pads of the engine compartment partition.
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 passenger compartment fuse/relay box.
6. Left side: Set the horn.
SECURITY SYSTEM, REPAIR WORK, Sound signal.
7. Left side: Install the air duct.
8. Left side: Install the battery. Do not connect the negative terminal of the battery.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, 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.
WINDSHIELD WIPERS AND WASHERS, REPAIR WORK, 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, REPAIR WORK, Control Panel - for vehicles up to model year 2004.
15. Install the rack and pinion mechanism with power steering.
STEERING, Steering gear, Steering gear.
16. Install the engine and gearbox.
ENGINE KV6 - MODIFICATION K, Left cylinder head camshafts, Engine and automatic transmission: up to May 2003.
17. Install the rear beam of the front suspension.
18. Reinstall the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORK, Front mudguard.
19. Install the engine compartment splash guard.
20. Install the headlight.
LIGHTING, Headlight Assembly - Models Before 2004 Model Year, Headlight Assembly - Models Before 2004 Model Year.
21. Secure 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. Install the front bumper beam.
25. Reinstall the front bumper.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly - for cars up to model year 2004.
26. Reinstall the lower engine protection shield.
EXTERIOR PARTS, REPAIR WORK, Lower engine protection shield.
27. Reinstall the wheel(s) and tighten the nuts to 115 Nm.
28. Connect all electronic units.
29. Connect the generator.
30. Connect the negative battery terminal.
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