Front Crossmember

Front Crossmember

Removal

NOTE:
This is a category 'B' repair.

NOTE:
In this procedure the front crossmember is removed and installed without the need to remove any other body panels.
1 Before commencing this procedure ensure that you are aware of all Health and Safety requirements. For additional information, refer to Health and Safety Precautions Health and Safety Precautions
2 For further information on the methods, tools and fixings used in this procedure refer to the body repairs - general information section. For additional information, refer to Body Repairs
3 Disconnect the battery. For additional information, refer to Battery Disconnect
4 Remove the fan cowl.
5 Release the air intake duct and position it aside.
6 Release the PAS reservoir and position it aside.
7 Remove the LH & RH radiator upper mountings, this also releases the support braces. If the crossmember is being renewed, completely remove the mountings and save for fitment to the new panel.
8 Release the crossmember wiring harness and position it aside.
9 If the panel is being renewed, remove the RH & LH SRS front impact severity sensors and save for installation to the new panel. For additional information, refer to Front Impact Severity Sensor Front Impact Severity Sensor





10 Remove the 2 headlamp mounting brackets, 2 10mm Bolts on each side.





11 Remove 4 13mm bolts, 2 each side, to the fender apron panel front extension.





12 Remove 4 13mm bolts, 2 each side, to the fender apron panel reinforcement.





13 Remove 2 10mm bolts, 1 each side, to the front side member extension.

Installation
1 Install is the reversal of removal.




2 Tighten the crossmember to fender apron panel front extension bolts to: 20 Nm (15 lb.ft).




3 Tighten the crossmember to fender apron panel reinforcement bolts to: 30 Nm (22 lb.ft).




4 Tighten the crossmember to front side member extension bolts to: 25 Nm (18 lb.ft).




5 Tighten the headlamp mounting bracket to crossmember bolts to: 9 Nm (7 lb.ft).
6 Check headlamp alignment, adjust as necessary. For additional information, refer to Headlamp Adjustment Adjustments