Front Cross-Member: Service and Repair

Replacing the cross member

Preparations




Remove the air baffle.

Remove the lateral strut




Removing the screws and the strut.

Removing the central front-rear member





Remove:
- the four screws in the ends of the member
- the heat deflector plate from the rear engine mounting
- the screws for the engine mountings. Remove the member.

Removing the front exhaust pipe




Remove the mounting for the heated oxygen sensor (HO2S) in the pipe bracket.

Note! Do not damage the wiring for the front and rear heated oxygen sensors (HO2S).





Remove:
- the two front rubber mountings for the exhaust pipe
- the nuts on the flange for the manifold
- the exhaust pipe. Leave the exhaust pipe hanging from its mountings.

Removing the steering gear housing from the cross member





Remove:
- the rear engine mounting from the transmission
- the screw from the heat deflector plate for the steering gear housing
- the two screws from the pipe bracket on the cross member
- the heat deflector plate
- the four screws from the steering gear housing
- the brackets. Lift the steering gear housing from the cross member.

Removing the anti-roll bar from the control arms





Remove:
- the nut. First lock the ball joint using a Torx wrench (TX30)
- the control arms.

Removing the cross member








Support the cross member.

Remove:
- the screws
- the cross member.

Transferring the anti-roll bar
Transfer the anti-roll bar to the new cross member.

Installing the cross member








Clean the mating surfaces thoroughly.

Install:
- the cross member. Install the two front (long) screws. Tighten these two screws by hand
- the control arms on the cross member. Tighten by hand
- the lock nut for the front pin bolt for the control arm.

Tighten the screwed joint:
- the long screws at the front edge. Tighten to 90 Nm
- the short screws at the rear edge. Tighten to 90 Nm.
Remove the support and rock the car a few times so that the bushings come into the correct position.
Tighten the front pin bolt for the control arms. Tighten to 90 Nm + 60°.

Installing the steering gear housing





Install:
- the steering gear in its mountings
- the brackets and the screws. Tighten to 80 Nm.

Installing the pipe bracket





Install:
- the pipe bracket. Tighten to 25 Nm
- the heat deflector plate. Tighten to 10 Nm
- The rear mounting on the transmission. Tighten to 60 Nm.

Installing the exhaust pipe





Install:
- the exhaust pipe on the manifold flange. Tighten to 25 Nm
- the front rubber mountings for the exhaust pipe. Tighten to 13 Nm
- the cable mounting for the front heated oxygen sensor (HO2S) in the pipe mounting.

Note! Use new gaskets.

Installing the central front-rear member





Install:
- the member on the front and rear engine mountings
- the four screws for the central front-rear member.

Note! Note the positions of the rubber element and washers.

Tighten to 70 Nm.

Tighten:
- the screws in the engine mountings. Tighten to 55 Nm
- the heat deflector plate for the rear engine mounting. Tighten to 10 Nm.

Installing the anti-roll bar on the control arms





Install:
- the anti-roll bar on the control arms
- new nuts for the ball joints.
Tighten the nut. First lock the ball joint using a Torx wrench (TX30). Then tighten the nut. Tighten to 50 Nm.

Installing the lateral strut




Install the strut. Tighten to 40 Nm.

Installing the air baffle
Install the air baffle.