Dismantling
1. Disconnect the negative battery terminal.
2. Disconnect the generator.
3. Disconnect all electronic units.
4. Remove the wheel(s).
5. Remove the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORK, Front mudguard.
6. Remove the engine compartment splash guard.
7. Remove the front fender.
EXTERIOR PARTS, REPAIR WORK, Front wing.
8. Remove the front bumper.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly - for cars up to model year 2004.
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 Before 2004 Model Year, Headlight Assembly - Models Before 2004 Model Year.
12. Release the headlight wiring harness and move it to the side.
13. Left side: Remove the air cleaner.
14. Left side: Remove the air duct.
15. Left side: Remove the engine control module (ECM).
16. Left side: Remove the battery tray.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Support tray - battery.
17. Left side: Remove the engine compartment fuse/relay 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.
WINDSHIELD WIPERS AND WASHERS, REPAIR WORK, 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 works
(The article was copied from the website: lrman.ru)
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.
Installation
1. Left side: Install the left front brake pipe. Bleed the brake system.
BRAKE SYSTEM, ADJUSTMENTS, Bleeding the brake system.
2. Left side: Install the engine compartment fuse/relay box with its associated wiring harnesses.
3. Left side: Install the battery tray. Do not connect the negative battery terminal.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Support tray - battery.
4. Left side: Install the Engine Control Module (ECM).
5. Left side: Install the air duct.
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.
WINDSHIELD WIPERS AND WASHERS, REPAIR WORK, Reservoir - washer.
9. Right side: Install the right front brake pipe. Bleed the brake system.
BRAKE SYSTEM, ADJUSTMENTS, Bleeding the brake system.
10. Right side: Install the power steering fluid reservoir.
11. Install the headlight.
LIGHTING, Headlight Assembly - Models Before 2004 Model Year, Headlight Assembly - Models Before 2004 Model Year.
12. Secure 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 radiator.
COOLING SYSTEM: MOD. K, KV6 engine, REPAIR WORK, Radiator assembly.
15. Install the front bumper bracket.
16. Reinstall the front bumper.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly - for cars up to model year 2004.
17. Install the front fender in place.
EXTERIOR PARTS, REPAIR WORK, Front wing.
18. Reinstall the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORK, Front mudguard.
19. Reinstall the wheel(s) and tighten the nuts to 115 Nm.
20. Connect all electronic units.
21. Connect the generator.
22. Connect the negative battery terminal.
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