Removal

Removal

CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used.

1. Position vehicle on a four-post lift.
2. Raise front of vehicle and support on stands.
3. Remove battery cover and disconnect ground cable from battery terminal.
4. Open hood to service position. and fit covers to fenders.





5. Remove both engine covers (normally aspirated vehicles only).
Release pegs.
Remove covers.
6. Remove air intake tube/meter/ cleaner cover assembly.





7. Support weight of engine.
Position special tool 303-021 in RH and LH fender channels and tighten beam fixings.
Engage hooks in the engine front lifting eyes.
Tighten hook adjustment nuts until weight of engine is supported.





8. Remove generator front cooling duct.
Remove bolt.
Move duct rearwards to release tang from undertray.
Release front duct from rear vertical duct.





9. Remove scrivets or screws securing undertray to bumper cover. Discard scrivets.





10. Remove and discard tiestrap securing undertray to body brace.





11. At each side of vehicle, remove and discard scrivet securing undertray to wheelarch liner.
12. Remove undertray from vehicle.
13. Remove both front road wheels.
14. Remove both front road springs.





15. Disconnect wheel speed sensor harness connectors.
Sever and discard tiestraps securing front wheel speed sensor harness to upper wishbone.
Disconnect harness connector from sensor.
Repeat procedure to disconnect opposite side wheel speed sensor harness.

16. CAUTION: Do not suspend caliper from brake hose as this will damage the hose.





Remove brake calipers from carriers.
Remove caliper spring clip.
Remove guide pin dust caps.
Slacken and withdraw guide pins.
Remove caliper from carrier and tie to suspension mounting bracket.
Repeat procedure to remove opposite side front brake caliper.





17. Remove filler cap from power steering fluid reservoir.





18. Disconnect steering rack transducer harness front connector.
Release harness connector from body retaining clip.
Disconnect connector.





19. Sever and discard tiestrap securing return pipe, harness (RHD only) and rubber support to steering rack.





20. RHD vehicles. Sever and discard tiestrap securing harness to steering rack.
21. Route harness from behind steering return pipe.
22. Position a drain receptacle below pinion housing.





23. Remove pipe retaining plate securing bolt and withdraw plate.





24. Drain power steering fluid.
Disconnect pipes and allow fluid to drain.
Remove and discard O-ring seals from pipe connectors.
Fit blanking plugs to pipe connectors and pinion housing ports.
25. Remove drain receptacle.





26. Remove pipe support from steering rack.
Release return pipe from support.
Remove support from rack.
27. Ensure that steering is in central position.





28. Release lower steering column from pinion shaft.
Remove lower steering column securing nut and bolt.
Move column upwards to release it from pinion shaft.





29. Support weight of crossbeam.
Position a jack under crossbeam.
Place a piece of wood between jack and crossbeam.
Raise jack to just support crossbeam.





30. From engine compartment, remove Crossbeam front RH securing bolts.





31. Remove power steering fluid reservoir for access.
Remove reservoir securing nuts and bolts.
Position reservoir for access.





32. From engine compartment, remove Crossbeam front LH securing bolts.





33. Remove crossbeam to engine Hydramount securing bolts.
Remove bolt securing crossmember to Hydramount.
Fully withdraw bolt into crossmember insert.
Repeat procedure to remove and withdraw bolt on opposite side

34. CAUTION: To prevent damage to ball joints, secure each hub assembly to suspension turret using strong wire.





Remove lower nut and bolt from front shock absorber.
Repeat procedure to remove bolt from opposite side shock absorber.





35. Remove crossbeam rear securing bolts.
Remove bolt from crossbeam LH rear mounting.
Repeat procedure to remove bolt from crossbeam RH rear mounting.
36. Ensure that steering transducer harness is clear of return pipe and LH side body.
37. Lower and traverse front suspension assembly clear of vehicle.
38. With assistance, lift front suspension assembly onto bench.





39. Remove nut securing each tie rod outer ball joint to steering arm.





40. Release tie rod ball joint from steering arm.
Install special tool 211-098 on tie rod outer ball joint.
Tighten tool bolt to release ball joint taper pin.
Remove tool and release tie rod from steering arm.
Repeat procedure to release opposite side tie rod ball joint.





41. Remove steering harness from LH suspension turret.
Release harness securing clips from suspension turret.
Mark position of clips on harness.
Remove tape securing clips to harness and discard clips.





42. Disconnect and remove steering harness.
Disconnect harness connector from transducer.
Remove harness from suspension assembly.





43. Remove steering rack from crossbeam.
Remove steering rack securing bolts.
Remove steering rack and mounting brackets.





44. Release stabilizer bar from link arms.
Remove link arm to stabilizer bar securing nut.
Release link arm from stabilizer bar.
Repeat procedure to release opposite end of stabilizer bar from link arm.





45. Remove stabilizer bar from crossbeam.
Remove stabilizer bar securing bolts.
Remove stabilizer bar mounting brackets and remove bar from crossbeam.





46. Remove wishbone securing nuts.
Remove lower wishbone front arm eccentric bolt securing nut.
Remove lower wishbone rear arm eccentric bolt securing nut.
Repeat procedure to remove wishbone securing nuts from opposite side.





47. Remove upper wishbone fulcrum shaft securing nut.
Repeat procedure to remove securing nut from opposite side fulcrum shaft.
48. Remove wire temporarily supporting hub assembly.





49. Remove wishbone/hub assembly from crossbeam.
Supporting hub assembly, withdraw lower wishbone eccentric bolts.
Supporting hub assembly, withdraw fulcrum shaft from upper wishbone.
Remove wishbone/hub assembly from crossbeam.
Repeat procedure to remove wishbone/hub assembly on opposite side.





50. Remove crossbeam front mountings.
Remove front mounting heatshield.
Remove four bolts securing mounting to crossbeam.
Repeat procedure to remove mounting on opposite side.