Installation

Installation





1. Install front mounting brackets.
Position and fully seat mounting bracket on crossbeam.
Install the four bolts and tighten to 22 - 28 Nm.
Install heatshield.
Repeat procedure to install mounting bracket on opposite side of crossbeam.





2. Install upper wishbone/hub assemblies on crossbeam.
Position upper wishbone on crossbeam.
Install fulcrum shaft threaded end facing rearward.
Install fulcrum shaft securing nut and tighten to 60 - 80 Nm.
Repeat procedure to install opposite side upper wishbone/hub assembly.





3. Install lower wishbone assemblies.
Position lower wishbone on crossbeam.
Install but do not tighten wishbone front and rear arm eccentric bolts and nuts.
Rotate each eccentric bolt to position largest graduation mark vertically.
Ensuring that eccentric bolts do not rotate out of position, partially tighten securing nuts.
Repeat procedure to install opposite side upper wishbone/hub assembly.





4. Install stabilizer bar to link arms.
Position stabilizer bar and install link arm pin in bar.
Install but do not tighten link arm pin to stabilizer bar securing nut.
Repeat procedure to install link arm at opposite end of stabilizer bar.





5. Install stabilizer bar to crossbeam.
Ensure bushes are correctly positioned on stabilizer bar.
Install support brackets over bushes.
Position stabilizer bar on crossbeam.
Install and tighten bolts to 30 - 40 Nm.
Repeat procedure at opposite end of stabilizer bar.





6. Tighten link arm to stabilizer bar securing nut to 60 - 80 Nm.
Repeat procedure at opposite end of stabilizer bar.





7. Install steering rack on crossbeam.
Ensure that bushes are correctly positioned on steering rack.
Position steering rack on crossbeam.
Position support brackets over bushes.
Install mounting bracket bolts and tighten to 40 - 54 Nm.





8. Install tie rods on steering arms.
Position and fully seat tie rod ball joint taper pin on steering arm.
Install tie rod ball joint nut and tighten to 71 - 85 Nm.
Repeat procedure to install opposite side tie rod ball joint.





9. Install harness on suspension turret.
Noting positions marked during removal, tape new securing clips to steering harness.
Install securing clips/harness on LH turret.
10. With assistance position Crossbeam1suspension assembly on jack with protective wood under.
11. Traverse assembly into position below vehicle.
12. Ensure steering harness connector is positioned to avoid damage during crossbeam lift.

13. NOTE: It may be necessary to use a hammer and drift to finally align new mounting with body location.





Carefully raise crossbeam assembly into position.
Ensure that dowels of both Crossbeam mountings are correctly seated in body locations.





14. Ensure that both engine hydramounts are correctly seated in crossbeam locations.





15. Install crossbeam rear mountings.
Align rear mounting rubber with body location.
Install rear mounting securing bolt and nut and tighten nut to 131 - 185 Nm.
Repeat procedure to install opposite side rear mounting bolt and nut.





16. From engine compartment, install but do not tighten crossbeam front RH bolts.





17. From engine compartment, install crossbeam front LH bolts and tighten to 22 - 28 Nm.





18. Install power steering fluid reservoir.
Position reservoir on mounting bracket.
Install reservoir securing nuts and bolts.





19. From engine compartment, tighten crossbeam front RH bolts to 22 - 28 Nm.





20. Install shock absorber on lower wishbone.
Lift lower wishbone to align shock absorber lower mounting.
Install bolt and nut and tighten nut to 43 - 57 Nm.
Repeat procedure to install opposite side shock absorber.





21. Install lower steering column on pinion shaft.
Move column downwards to engage coupling splines on pinion shaft.
Install nut and bolt and tighten to 22 - 28 Nm.
22. Lower and withdraw jack from crossbeam.





23. Release engine from support tool.
Slacken hook adjustment nuts until weight of engine is released.
Remove hooks from engine front lifting eyes.
Remove special tool 303-021 from fender channel.





24. Install crossbeam to engine Hydramount securing bolts.
Install bolt securing Hydramount to crossmember and tighten to 22 - 28 Nm.
Repeat procedure to install crossmember opposite side securing bolt.





25. Position and connect harness to steering transducer.
RHD vehicles. Position steering harness behind return pipe.
Connect harness to transducer.





26. Install power steering pipes on pinion housing.
Remove blanks and install new O-ring seals in pipe connectors.
Apply power steering fluid to O-ring seals.
Remove blanking plugs from pinion housing ports.
Position pipes on pinion ports and seat O-rings.





27. Secure pipes to pinion housing.
Ensure pipes and retaining plate are correctly seated.
Install bolt and tighten to 9 - 12 Nm.





28. Secure return pipe on steering rack.
Position pipe rubber support on steering rack.
Position pipe on support.
RHD vehicles. Position harness on pipe support rubber.
Secure pipe and harness to support with new tiestrap.





29. RHD vehicles. Using new tiestrap, secure harness to steering rack.





30. Connect steering harness.
Route harness connector to body front location.
Connect steering harness connector.
Install connector in body retaining clip.





31. Connect wheel speed sensor harness.
Connect wheel speed sensor harness to sensor.
Using new tiestraps secure wheel speed sensor harness to upper wishbone Repeat procedure to connect opposite side wheel speed sensor.





32. Install brake calipers.
Install caliper on carrier.
Install guide pins.
Install guide pin dust caps.
Install caliper spring clip.
Repeat procedure to install opposite side front brake caliper.
33. Install both front road springs.





34. Using screws or new scrivets, secure undertray to front bumper cover.





35. Using new tiestrap, secure undertray to crossbeam brace.





36. Install generator cooling duct deflector.
Position deflector over rear vertical duct.
Slide deflector forward to engage center tang over undertray.
Install bolt and tighten to 17 - 23 Nm.





37. Using new scrivets, secure undertray to each wheelarch liner.
38. Install both front road wheels.
39. Raise vehicle, remove stands and lower vehicle.





40. Ensuring graduation mark remains aligned, finally tighten wishbone rear eccentric bolt to 113 - 153 Nm.





41. Ensuring graduation mark remains aligned, finally tighten wishbone front eccentric bolt to 113 - 153 Nm.
42. Install air intake tube/meter/ cleaner cover assembly.





43. Install both engine covers (normally aspirated vehicles only).
Position covers over engine.
Install securing pegs.
44. Fill power steering system.
45. Remove fender covers and close hood.
46. Connect ground cable to battery terminal and fit battery cover. Refer 86.15.19.
47. Carry out steering geometry and wheel alignment checks and adjust as necessary.