Front Cross-Member: Service and Repair
Sub-frame front, replacingSpecial tools: 999 7018 999 5716 999 5460, 951 2050, 999 7062, 999 7070
Note: As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.
Preparation
Install lifting lug 999 7018 on the left hand side of the engine at the 2 screws.
Lock the lifting lug using the snap ring.
Install lifting tool 999 5716 converted with kit 999 70770. Install lifting hooks 999 5460.
Lift the engine to relieve the load on the engine pads.
Remove the front wheels.
Removing the clamp for the servo pressure hose
Remove the clamp for the servo pressure line on the sub frame.
Removing the right engine mounting
Slacken off the right lower front part of the fender liner.
Remove:
- the plastic nuts on the fender liner
- the protective plate.
Bend out the fender liner.
Remove the 4 screws for the vibration damper.
Counterhold the crankshaft central nut.
Remove the vibration damper.
Remove the 2 screws for the right hand engine mounting. (1)
Removing the splash guard under engine
Remove the splash guard under the engine.
Removing the skid plate
Remove the 6 screws.
Lift and slide the splash guard forward.
Remove the protective plate.
Note: There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.
Exposing the sub-frame
Remove:
- the screw for the cable duct
- the screw for the ground lead.
Remove the screw for the front engine pad.
Remove:
- the oil pipe for the steering gear from the snap fasteners along the sub-frame
- the screw clip for the steering gear return line
- the fuel line for the engine block heater and the engine block heater (if applicable) on the left side of the sub-frame.
Remove the 4 screws holding the torque rod to the engine.
Remove the anti-roll bar links from the anti-roll bar on both sides. Counterhold using a Torx wrench so that the ball joint boot is not damaged.
Removing the drive shaft
Remove the screw for the drive shaft. Use a screwdriver as a counterhold on the brake disc. Knock the end of the drive shaft into the hub. Use a brass drift.
Disconnect the ball joint pinion from the control arm. Use tool 999 7062
Install cap nut 7062-1 on the ball joint pinion.
Tighten the nut against the control arm.
Then turn back one turn to form a gap between the cap nut and the control arm.
Position the extractor on the control arm. Detach the ball joint from the control arm.
Remove the 4 nuts and the screw holding the steering gear to the sub-frame.
Remove the power steering line from the clips on the sub-frame.
Remove the hose for the EVAP canister in the joint by pulling apart the hose. Route the hose under the anti-roll bar.
Remove:
- the screw in the mounting for the front SIPS member
- the brake pipe from the snap fastener on the member
- The SIPS member.
Remove the rubber mountings for the exhaust pipe.
Remove the connector for the heated oxygen sensor (HO2S) from its mounting.
Removing the sub-frame
Position a lifting table under the sub-frame
Remove the following on both sides:
- the screws holding the sub-frame brackets in the bodywork
- the screw for the sub-frame mounting.
Carefully lower the sub-frame.
Note: Ensure that the brake pipe clears the exhaust pipe mounting when lowering the frame.
Note: Ensure that the steering gear screws release from the sub-frame.
Transferring components
Transfer:
- the control arms. Use new screws and new nut. Tighten the front screws. Tighten to 65 Nm. Angle-tighten 90°. Use bevel protractor 951 2050. Tighten the rear screw. Tighten to 105 Nm. Angle-tighten 90°
- the anti-roll bar. Tighten to 60 Nm
- the right-hand engine mounting. Tighten the screws. Tighten to 65 Nm. Angle-tighten 60°
- the exhaust mounting bracket. Tighten to 50 Nm
- the shock absorber Tighten to 50 Nm
- lower torque rod. Tighten to 65 Nm. Angle tighten 90°.
Install new pipe/hose holders.
Installing the sub-frame
Position the sub-frame on a lifting table.
Carefully lift the sub-frame.
Locate the control arms to the ball joints and the steering gear to its mountings.
Hint: Lubricate the rubber coated clamp for the servo pressure pipe on the sub-frame using a soap solution. Install the screw before raising the sub-frame completely. Do not tighten the screw more than 2 turns as the pipe must be able to slide to the correct position in the clamp whilst raising the sub frame.
Note: Ensure that the brake pipe at the exhaust mounting is not trapped when raising the sub frame.
Lift the sub-frame up completely.
Install the four screws in the sub-frame together with the sub-frame brackets and engine block heater, if applicable. Use new screws. Lubricate the screws.
First tighten the screws on the left side of the subframe. Tighten to 105 Nm. Angle tighten to 120°.
Then tighten the right-hand side to the same value.
Finally tighten the screws for the brackets on both sides to 50 Nm.
Installing removed components
Install:
- the heated oxygen sensor (HO2S) connector
- the rubber mountings for the exhaust pipe
- SIPS (side impact protection system ) member
- the four screws for the SIPS (side impact protection system) member. Tighten to 24 Nm.
Route the hose for the EVAP canister to the correct position and press the joints together Install the four nuts and the screw holding the steering gear. Use new nuts and a new screw.
Tighten to 50 Nm.
Clip the cable in position.
Install:
- the ball joints. Use new nuts. Tighten to 80 Nm. Counterhold using a Torx wrench so that the ball joint boot is not damaged
- the anti-roll bar links. Use new nuts. Tighten to 50 Nm. Counterhold using a Torx wrench so that the boot is not damaged.
Install:
- the lower torque rod. Tighten the two screws. Tighten to 10 Nm
- the oil pipe for the steering gear from the snap fasteners along the sub-frame
- the screw clip for the steering gear return line
- the engine block heater and the fuel line to the engine block heater if applicable
- the screw for the cable duct
- the screw for the ground lead.
Installing the drive shaft
Install new screws on both sides. Use a screwdriver as a counterhold. Tighten to 35 Nm.
Angle-tighten 90°. Use bevel protractor 951 2050.
Installing the skid plate
Move the skid plate up into the bumper wraparound.
Press forwards until the mounting brackets engage in the subframe.
Install the screws. Tighten to 50 Nm.
Install the splashguard under the engine. Tighten to 24 Nm.
Installing the right-hand engine mounting
Install the right-hand engine mounting. Use new screws. Tighten to 35 Nm. Angle-tighten 90°.
Fold the fender liner back into position.
Install:
- the skid plate
- the plastic nuts
- the front wheels.
Installing the clamp for the servo pressure hose
Tighten the clamp for the servo pressure pipe on the subframe. Tighten to 10 Nm.
Removing lifting tools
Remove lifting tool 999 5716, kit 999 7070, lifting hooks 999 5460 and lifting lug 999 7018.
Remove
Finishing
Align the wheels.