SHEET METAL 1B-1

SECTION 18
SHEET METAL
INDEX
Ref. Subject Page Ref. Subject Page
1. GENERAL DESCRIPTION .............................. 1B-1 2.4 PILOT PIN, HOOD LOCK .............................. 1B-9
2. SERVICE NOTES ............................................ 1B-2 Remove .................................................... 18-9
2.1 FRONT END PANEL ASSEMBLY ................ 1B-2 Reinstall .................................................. 18-9
Remove .................................................... 1B-2 2.5 HOOD LOCK SECONDARY CATCH ............ 1B-10
Reinstall .................................................. 1B-2 Remove .................................................... 1B-10
2.2 FRONT FENDER ASSEMBLY........................ 1B-5 Reinstall .................................................. 1B-10
Remove.................................................... 1B-5 2.6 ENGINE HOOD RELEASE CABLE
Reinstall .................................................. 1B-6 ASSEMBLY ...................................................... 1B-10
2.3 ENGINE HOOD ASSEMBLY .......................... 1B-7 Remove.................................................... 1B-10
Remove .................................................... 1B-7 Reinstall .................................................. 1B-10
Reinstall .................................................. 1B-8
Adjust ...................................................... 1B-9

1. GENERAL DESCRIPTION
'VL' series front end sheetmetal consists of a new front end panel assembly to suit the homofocal headlamps featured
on the Berlina and SL models. On the Calais, a front end panel assembly houses electrically operated hinged covers for
the partly concealed headlamps featured on that model. Front end panels which align with the outer ends of the front
end panel assembly also blend in with the front fenders on Calais.
New front fenders which house modified front fender liners are included on all 'VL' models.
II
:·
An island type engine hood assembly with full width air vent louvres is hinged at its rear end and is supported in its open
position by a support rod attached to the front panel assembly.

C)
An engine hood lock release lever mounted beneath the right hand side of the instrument panel, controls a hood lock
release spring which engages the head of an adjustable pilot pin attached to the engine hood assembly. The engine
hood, when released from its locked position, engages a secondary catch. This secondary catch can be released by
inserting ones fingers beneath the leading edge of the engine hood and raising the horizontal tab on the safety catch.
The engine hood can then be raised and supported in its open position.
18-2 SHEET METAL

2. SERVICE NOTES
2.1 FRONT END PANEL ASSEMBLV

REMOVE
1. Disconnect battery ground cable.
2. Remove radiator grille (refer 2.1 'Radiator Grille -
Remove' Section 1C in this Volume).
3. On Berlina and SL models, remove headlamp
assemblies (refer Section 128, Volume 5 of this
Supplement). On Calais model, disconnect the
headlamp cover motor electrical connector (refer
Section 128, Volume 5 of this Supplement).
4. On Berlina and SL models, remove the screw and
washer assemblies securing the front end panel
assembly to the front panel assembly and front
fenders illustrated in Fig. 18-1, View 'A' and remove
the assembly.
5. On Calais models, remove the screw and washer
assemblies securing the front end panel assembly to
the front panel assembly illustrated in Fig. 18-2, and
remove the assembly.
6. Prise off radiator front shroud from the front end
panel assembly.

REINSTALL
Reverse removal operations.

)
 /-----,,,
(I\
,_________-

&scREW A FRONT END PANEL ASM.

WASHER ��M
\
7 PLACES \
--------- FENDER ASM. RH
,______--
'�
BRACE ASM.

& FENDER

SCREW AND
WASHER ASM.
2PLACES R/L 'J' NUT
2PLACES
SECTION A-A
7

ffiSCREW AND
WASHER ASM.
2PLACES R/L
�
'U' NUT SECTION C-C
2PLACES

WHEELHOUS
INNER
7
en
t==>ffii :c
rn
B-B � ,, rn
-5 -I
SECTION
BRACE,
HEADLAMP SUPPORT

I
3::
& SCREW AND -....._... c:2)
---
rn
WASHER ASM.
-I
6'£ -------lLJ &
2PLACES R/L
l>
,________ SCREW AND
WASHER ASM.
r
2PLACES R/L

Figure 1B-1
 ..
PANEL ASM. FRONT END
ffi SCREW AND WASHER ASM.
5 PLACES

7 en
:I:
'J' NUT
t m
2 PLACES R/L rn
SECTION A-A -f
i::
FOR INSTALLATION
m
REFER SECTION 128
-I
l>
r-

�
SECTION G-G

G
.dl
��
�
--------SCREW
2 PLACES R/L

&scREW AND
WASHER ASM.
2 PLACES R/L

SECTION C-C

BRACKET HEADLAMP
SUPPORT

Figure 1B-2
 SHEET METAL 18-5

2.2 FRONT FENDER ASSEMBLY

REMOVE
1 . Remove front end panel assembly (refer 2.1 in this
Section).
2. Remove the front bumper bar assembly (refer 2.2
'Front Bumper Bar - Remove', in Section 1 D of this
Volume).
3. Remove the front fender liner illustrated in Fig. 1 8-3,
Section A-A, from side on which fender is to be
removed.

\SCREW FASTENER
4 PLACES R & L SIDE

SECTION A-A
'SCREW
4 PLACES R/L SIDE

Figure 18-3

4. From inside vehicle, remove the rocker panel cover

and the front lower end of the front door opening
finishing lace illustrated in Fig. 1 B-4, Sections C-C,
D-D and F-F.

SECTION F-F SECTION C-C

FRONT DOOR OPENING

FINISHING LACE

FRONT DOOR OPENING

FINISHING LACE

SHROUD LOWER
TRIM ASM.

( )
__ __
8VL, 8VX

SECTION D-D SECTION C-C

Figure 18-4
1 B-6 SHEET METAL

If the right hand fender is being removed, remove

the right hand shroud lower trim assembly by prising G
out the trim fastener illustrated in Fig. 18-5, Section
G-G.
5. Removal of the left hand shroud lower trim assembly
necessitates removal of the E.C.C.S. module moun­
ting bracket illustrated in Fig. 18-5, Section A-A.

avL, avx
SECTION G-G avL, avx
8VK

SECTION A-A

Figure 18-5

6. On Calais models, it is necessary to remove the front

rocker panel moulding, refer 2.1 O 'Exterior
Ornamentation', Section 1 A in this Volume.
7. Remove the radio antenna. Refer Fig. 18-5a, for
electric antenna installation details. The manual &_ 8-11 Nm
antenna is removed by detaching the nut at the
upper end of the assembly. & 3.5 Nm

_& 12 - 16 Nm

8. Remove screw and washer assemblies and screws

securing the rear of the fender to the front end
assembly illustrated in Fig. 18-6.
9. Remove screw and washer assemblies securing the
lower and upper part of the fender to the front end
assembly and the engine inner skirt panel illustrated
in Fig. 1 8-6, removing the fender. NUT

REINSTALL BRACE
Reverse removal operations. BOLT &
-- APPLY HN1044 AROUND
HOLE IN LH DOOR OPENING
(". j
FRAME ASM. TO OBTAIN
A WATERTIGHT SEAL

Figure 1 B-Sa
 SHEET METAL 1B-7

SCREW
/

( ) SECTION C-C

& B
SCREW AND
WASHER ASM.
2 PLACES L/R

SCREW AND
6, WASHER ASM.
/.5 2 PLACES R/L

8-11 Nm
4.0-5.0 Nm

(J
Figure 1B-6

2.3 ENGINE HOOD ASSEMBLV

REMOVE
1. With the engine hood assembly raised and sup­
ported, carefully ease the rubber bumpers from the
surfaces of the engine hood inner panel and hinges
illustrated in Fig. 1B-7, View 'B'.
2. Pencil mark location of the hinges on the engine
hood inner panel to facilitate installation.
 SHEET METAL

f
ii
, GINE HOOD
��ATHERSTRIP

COAT MATIN SURFACES

SE CTION A-A ' �
WITH NEOPR NE CEMENT

Figure 1B-7

3. 1 the engine
W'th . hood adequatelys�h�orted, remove
the scr�ws securing. the hinges to rear sides. of
the engine hood inner paneI (refer F'g
1 • 1 8-8, View
.
'C'), removing the assembly.

RE INSTALL
Reverse removal operations.

i.1
,
 SHEET METAL 1B-9

' ."
( )

VIEWIAJ

SET PILOT PIN TO NOMINAL AND THEN

ADJUST Pl LOT PIN AND BUFFER TO
VIEW� ACHIEVE EVEN FRONT END BODY
CLEARANCES AND FLUSHNESS
PILOT PIN
18- 24 Nm

Figure 1B-8

ADJUST
When adjusting the engine hood assembly, uniform
spacing and alignment between the engine hood and
adjacent parts is important.
Slotted holes in the hinge arms provide horizontal
adjustment, whilst floating anchor nuts mounted inside
the engine hood inner panel provide vertical adjustment
for the rear end of the engine hood.
Vertical adjustment for the front end of the engine hood
is achieved by adjustment of the pilot pin and hood lock
nut in conjunction with the hood buffers located on the
front of the engine hood inner panel (refer Fig. 18-8,
Views '8' and 'D', Section A-A).

2.4 PILOT PIN, HOOD LOCK

REMOVE
1. Raise and support the engine hood assembly.
2. Slacken off the hood lock nut, then still retaining the
nut, unscrew the pilot pin in an anti clockwise
direction (refer Fig. 18-8, View '8', Section A-A).

REINSTALL
Reverse removal operations.
1B-10 SHEET METAL

2.5 HOOD LOCK SECONDARY CATCH

REMOVE
1. Raise and support the engine hood assembly.
2. Remove rivet illustrated in Fig. 18-8, View 'A',
securing hood lock spring and secondary catch to
engine hood assembly bracket, removing catch and
spring.

REINSTALL
Reverse removal operations.

2.6 ENGINE HOOD RELEASE CABLE

ASSEMBLY

REMOVE
1. Raise and support the engine hood assembly.
2. Depress the hood lock release spring and disengage
the nipple at the front end of the release cable from
the release spring, illustrated in Fig. 18-9, View 'D'.
3. Disengage clips securing cable assembly to front end
panel assembly and right hand engine skirt panel
(refer Fig. 18-9, Sections 8-8 and E-E.
4. From inside the vehicle, slide the cable, bracket and
lever assembly illustrated in Fig. 18-9, View '8'
Section D-D, from the right hand shroud panel lower,
rearwards; then pull the complete assembly into the
vehicle.

REINSTALL
)
Reverse removal operations.
 SHEET METAL 1B-11

ENGINE HOOD NO CLEARANCE PERMISSIBLE

HOOD RELEASE RELEASE .SPRING BETWEEN HOOD RELEAS E
CABLE ASM. APPLY LITHIUM GREAS E TO SPRIN.G & NIPPLE ON ASS EMBLY
COILS OF RELEASE SPRING

RELEASE EFFORT NOT TO EXCEED

40 Nm AT HOOD RELEASE HANDLE
LOWER EDGE
HOOD SUPPORT
ENGINE
HOOD SUPPORT

J/ -vi:::- �
CREW&_
- !ID-+�
S
-iLIP -""- � .@,,

CLIP
VIEW[§]
RETAINER -
ENGINE HOOD SECTION A-A
S ECTION E-E ECTION
S C-C S ECTION B-B SUPPORT

,& ..3.6 - 4.6 Nm

( J
Figure 1B-9

�---··/