Dismantling
1. Disconnect "negative" battery terminal.
2. Disconnect the generator.
3. Disconnect all electronic units.
4. Remove the wheel (wheels).
5. Remove the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORKS, Front fender liner.
6. Remove the mudguard of the engine compartment.
7. Remove the front fender.
EXTERIOR PARTS, REPAIR WORKS, Front fender.
8. Remove the front bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
9. Remove the front bumper bracket.
10. Remove the radiator.
COOLING SYSTEM: MOD. K, KV6 engine, REPAIR WORK, Radiator assembly.
11. Remove the headlight.
LIGHTING, Headlight assembly - models up to 2004 model year, Headlight assembly - models up to 2004 model year.
12. Release the headlight wiring harness and move it aside.
13. Left side: Remove the air cleaner.
14. Left side: Remove the air tube.
15. Left side: Remove the electronic engine control unit (ECM).
16. Left side: Remove the battery tray.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Support tray - storage battery.
17. Left side: Remove the engine compartment relay and fuse box with associated wiring harnesses.
18. Left side: Remove the left front brake pipe.
19. Right side: Remove the power steering fluid reservoir.
20. Right side: Remove the right front brake pipe.
21. Right side: Remove the windshield washer reservoir.
WIPERS AND WASHERS, REPAIR WORKS, Reservoir - washer.
22. 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.
Installation
1. Left side: Install the left front brake pipe. Bleed the brake system.
BRAKING SYSTEM, ADJUSTMENTS, Bleeding of air from the brake system.
2. Left side: Install the engine compartment relay and fuse box with its respective wiring harnesses.
3. Left side: Replace the battery tray. Don't join "negative" battery terminal.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Support tray - storage battery.
4. Left side: Install the ECM (ECM).
5. Left side: Install the air tube.
6. Left side: Install the air cleaner.
7. Right side: Install the power steering fluid cooler.
STEERING, Steering Gear, Power Steering Fluid Cooler (for models with Td4 or K1.8 engine).
8. Right side: Install the windshield washer reservoir.
WIPERS AND WASHERS, REPAIR WORKS, Reservoir - washer.
9. Right side: Install the right front brake pipe. Bleed the brake system.
BRAKING SYSTEM, ADJUSTMENTS, Bleeding of air from the brake system.
10. Right side: Install the power steering fluid reservoir.
11. Install the headlight.
LIGHTING, Headlight assembly - models up to 2004 model year, Headlight assembly - models up to 2004 model year.
12. Attach the headlight wiring harness.
13. Install the power steering fluid cooler.
STEERING, Steering Gear, Power Steering Fluid Cooler (for models with Td4 or K1.8 engine).
14. Install the heatsink.
COOLING SYSTEM: MOD. K, KV6 engine, REPAIR WORK, Radiator assembly.
15. Install the front bumper bracket.
16. Reinstall the front bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
17. Reinstall the front fender.
EXTERIOR PARTS, REPAIR WORKS, Front fender.
18. Reinstall the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORKS, Front fender liner.
19. Replace the wheel (wheels) and tighten the nuts to a torque of 115 Nm.
20. Connect all electronic units.
21. Attach the generator.
22. Attach "negative" battery terminal.
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