Diesel Data: Automotive Repair

Overhaul

DISASSEMBLY

1. REMOVE RADIATOR GRILLE SUB-ASSEMBLY






a. Remove the 2 bolts and clip.
b. Using a screwdriver, disengage the 3 claws and remove the radiator grille sub-assembly.

HINT: Tape the screwdriver tip before use.

2. REMOVE FRONT LICENSE PLATE BRACKET (w/ Bracket)
a. Remove the 2 screws.






b. Disengage the 2 claws and remove the front license plate bracket.

3. REMOVE FRONT BUMPER BAR






a. Using a screwdriver, disengage the 12 claws and remove the 3 bumper bars.

4. REMOVE FOG LIGHT ASSEMBLY LH
5. REMOVE FOG LIGHT ASSEMBLY RH

HINT: Use the same procedure for the RH side and LH side.

6. REMOVE FOG LIGHT MOUNTING BRACKET LH






a. Remove the 2 screws and remove the fog light mounting bracket LH.

7. REMOVE FOG LIGHT MOUNTING BRACKET RH

HINT: Use the same procedure for the RH side and LH side.

8. REMOVE FRONT BUMPER SIDE SEAL LH






a. Disengage the 4 claws and remove the front bumper side seal LH.

9. REMOVE FRONT BUMPER SIDE SEAL RH

HINT: Use the same procedure for the RH side and LH side.

10. REMOVE NO. 2 FRONT BUMPER SIDE SEAL LH






a. Disengage the 4 claws and remove the No. 2 front bumper side seal LH.

11. REMOVE NO. 2 FRONT BUMPER SIDE SEAL RH

HINT: Use the same procedure for the RH side and LH side.

12. REMOVE FRONT BUMPER ENERGY ABSORBER






a. Remove the front bumper energy absorber from the front bumper reinforcement.

13. REMOVE FRONT BUMPER REINFORCEMENT






a. Disengage each clamp.
b. Remove the 6 bolts and front bumper reinforcement.

REASSEMBLY

1. INSTALL FRONT BUMPER REINFORCEMENT






a. Install the front bumper reinforcement with the 6 bolts.

Torque: 55 N.m (560 kgf.cm, 41 ft.lbf)

b. Engage each clamp.

2. INSTALL FRONT BUMPER ENERGY ABSORBER






a. Install the front bumper energy absorber to the front bumper reinforcement.

3. INSTALL NO. 2 FRONT BUMPER SIDE SEAL LH






a. Engage the 4 claws and install the No. 2 front bumper side seal LH.

4. INSTALL NO. 2 FRONT BUMPER SIDE SEAL RH

HINT: Use the same procedures for the RH side and LH side.

5. INSTALL FRONT BUMPER SIDE SEAL LH






a. Engage the 4 claws and install the front bumper side seal LH.

6. INSTALL FRONT BUMPER SIDE SEAL RH

HINT: Use the same procedures for the RH side and LH side.

7. INSTALL FOG LIGHT MOUNTING BRACKET LH






a. Install the fog light mounting bracket LH with the 2 screws.

8. INSTALL FOG LIGHT MOUNTING BRACKET RH

HINT: Use the same procedures for the RH side and LH side.

9. INSTALL FOG LIGHT ASSEMBLY LH
10. INSTALL FOG LIGHT ASSEMBLY RH

HINT: Use the same procedures for the RH side and LH side.

11. INSTALL FRONT BUMPER BAR






a. Engage the 12 claws and install the front bumper bars.

12. INSTALL FRONT LICENSE PLATE BRACKET (w/ Bracket)
a. Engage the 2 claws and install the front license plate bracket.






b. Install the 2 screws.

13. INSTALL RADIATOR GRILLE SUB-ASSEMBLY






a. Engage the 3 claws and install the radiator grille.
b. Install the 2 bolts and clip.