Radiator Support: Service and Repair

Front Bulkhead Assembly

View:

Remove

1. Disconnect both battery leads, negative lead first.
2. Disconnect leads/multiplug from alternator.
3. Remove front wing.
4. Remove washer reservoir.
5. Models with A/C: Remove condenser.
6. Diesel models: Remove gearbox fluid cooler.
7. Remove RH and LH headlamps.
8. Release headlamp levelling motors and position aside.
9. Release headlamp wiring and position aside.
10. Remove battery.
11. Remove battery tray.
12. Remove air filter 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.
17. Remove bonnet release cable.
18. Support bonnet in open position
19. Remove bonnet locking mechanism.
20. Remove VIN plate.
21. Remove 2 bolts securing front bulkhead assembly to chassis.
22. Remove centre braces.

Repair







1. Remove existing panel(s), prepare panel joint faces and install new panel(s) in accordance with Panel Replacement Procedure. Punch or drill holes in new panel for plug welding as shown.

Refit

1. Fit centre braces.
2. Fit 2 bolts securing bulkhead to chassis and tighten to 45 Nm (33 lbf.ft).
3. Fit VIN plate.
4. Fit bonnet locking mechanism.
5. Fit bonnet release cable.
6. Fit crush cans.
7. Models with A/C: Fit A/C pipes.
8. Fit RH horn.
9. Fit 2 earth leads to LH of front bulkhead.
10. Fit air filter assembly.
11. Fit battery tray.
12. Fit battery. Do not connect leads.
13. Fit headlamp wiring and headlamp levelling motors.
14. Fit RH and LH headlamps.
15. Diesel models: Fit gearbox fluid cooler.
16. Models with A/C: Fit condenser.
17. Fit washer reservoir.
18. Fit front wing.
19. Connect leads/multiplug to alternator.
20. Connect battery leads, negative lead last.