Front Bulkhead Assembly

Front Bulkhead Assembly

In this procedure, the headlamp mounting panels and the bonnet locking platform are removed.

Remove

1. Disconnect battery earth lead.

CAUTION: After switching off the ignition, wait 2 minutes before disconnecting the battery. Failure to wait two minutes will damage the navigation computer.

2. Remove both headlamp assemblies.
3. Remove front bumper.
4. Release 4 cable ties securing washer hose to armature and move hose aside.
5. Disconnect the headlamp, headlamp wash/wiper and horn multiplugs from the bonnet locking platform assembly.
6. Remove 2 screws securing armature extension and remove extension from armature.
7. Remove scrivets securing radiator intake ducts to bumper support brackets.
8. Remove 3 bolts securing LH bumper support bracket. Repeat for RH bracket and remove.
9. Diesel models: Remove 2 bolts securing fuel cooler intake duct to bonnet locking platform.
10. Move duct aside.
11. Remove radiator assembly retaining bolts from bonnet locking platform.
12. Remove 4 bolts securing bonnet locking platform to inner wings.
13. Cut and discard cable tie securing radiator expansion pipe to bonnet locking platform.
14. LH side only: Remove bolt securing washer bottle to headlamp mounting panel.
15. Remove 4 bolts securing lower outer edge of the bonnet locking platform assembly to inner wings.
16. With assistance carefully release and remove the bonnet locking platform assembly.

Refit

1. With assistance position the bonnet locking platform assembly to body.
2. Fit and finger tighten bolts securing bonnet locking platform assembly to body, align and tighten M8 bolts to 25 Nm (18 lbf.ft), tighten the M6 bolts to 10 Nm (7 lbf.ft).
3. Position radiator assembly to bonnet locking platform and secure with bolts.
4. Position armature to body fit nuts and bolts, tighten bolts to 10 Nm (7 lbf.ft), tighten nuts to 45 Nm (33 lbf.ft).
5. Fit bolt securing washer bottle to the headlamp mounting bracket and tighten to 3 Nm (2.2 lbf.ft).
6. Secure harness with cable ties.
7. Fit and secure bumper support brackets, tighten bolts to 3 Nm (2.2 lbf.ft), fit scrivets.
8. Connect multiplugs.
9. Fit armature extension and tighten bolts to 10 Nm (7 lbf.ft).
10. Position washer hose to armature and secure with new cable ties.
11. Diesel models: Position fuel cooler intake duct to bonnet locking platform, fit and tighten bolts to 3 Nm (2.2 lbf.ft)
12. Position radiator expansion hose and cable tie to bonnet locking platform.
13. Fit front bumper.
14. Fit both headlamp assemblies.
15. Connect the battery earth lead.

CAUTION: After re-connecting the battery, the steering wheel must be turned to full LH and RH lock (with engine running). This allows the DSC system to re-learn the steering wheel position. Failure to do so will result in a variety of instrument warning lights been illuminated.