Front Crossmember

Front End Sheet Metal Repairs - Front Crossmember

Removal and Installation

Removal

- NOTE:
- This is a category 'B' repair.
- 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.
2. For further information on the methods, tools and fixings used in this procedure refer to the body repairs - general information section.
3. Disconnect the battery.
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.







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.