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- Disconnect both battery cables. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
- Remove the front fender. For additional information, refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
- Remove the hood latch panel. For additional information, refer to: Hood Latch Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
- Remove the radiator. For additional information, refer to: Radiator (303-03C Engine Cooling - TDV6 2.7L Diesel, Removal and Installation).
- Remove the radiator coolant expansion tank. For additional information, refer to: Coolant Expansion Tank (303-03C Engine Cooling - TDV6 2.7L Diesel, Removal and Installation).
- L/H side: Remove the power steering fluid reservoir. For additional information, refer to: (211-02 Power Steering)
- Remove the hood.
- Remove both hood support struts.
- Remove the hood wiring harness.
- Remove both wiper arms and blades.
- Remove the plenum chamber panel. For additional information, refer to: Plenum Chamber (412-01 Air Distribution and Filtering, Removal and Installation).
- L/H side: Remove the battery.
- Remove the battery wiring harness.
- R/H side: Release the ABS modulator.
- Remove the air cleaner. For additional information, refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - V8 S/C 4.2L Petrol, Removal and Installation).
- Remove the insulation from the outer bulkhead.
- L/H side: Remove the fuel fired booster heater. For additional information, refer to: Fuel Fired Booster Heater (412-02B Auxiliary Heating, Removal and Installation).
- L/H side: Remove the battery junction box. For additional information, refer to: (418-00 Module Communications Network)
Battery Junction Box - V8 S/C 4.2L Petrol (Removal and Installation),
- Remove the front wheelhouse wiring harness.
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| Item | Description |
| 1 | 14 spot welds. |
| 2 | 2 mig welds. |
| 3 | 11 plug welds |
| 4 | 19 plug welds. |
| 5 | 5 plug welds. |
| 6 | 3 spot welds |
- For additional information:
- Welding. For additional information, refer to: Body Repairs (501-25A Body Repairs - General Information -, Description and Operation).Corrosion protection. For additional information, refer to: Corrosion Protection (501-25B Body Repairs - Corrosion Protection -, Description and Operation).Tolerance checks. For additional information, refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
- Install is the reversal of removal.
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