Heatshield - Crossbeam Front Mounting

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. Remove ignition key and engage steering column lock.
3. Open hood to service position, and fit covers to fenders.
4. Remove battery cover and disconnect ground cable from battery terminal.





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





8. 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.
9. Raise front of vehicle.





10. Remove generator cooling duct deflector.
Remove bolt.
Move deflector rearwards to release tangs from undertray.
Release deflector from rear vertical duct.





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





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





13. At each side of vehicle, remove and discard scrivet securing undertray to wheelarch liner.
14. Remove undertray from vehicle.





15. Position camber tie down special tool 204-114 on suspension.
Fully slacken tool adjuster nut.
Position tool in road spring and pass upper dowel through slot in suspension turret.
16. Lower front of vehicle.





17. Rotate stem of special tool 204-114 to locate dowel in suspension turret slot.
18. Lower front of vehicle.

19. WARNING: WHEN TIGHTENING TOOL NUT, USE LOWER DOWEL AS A GUIDE TO ENSURE THAT THE TOOL STEM DOES NOT ROTATE AND DISTURB POSITION OF DOWEL IN SUSPENSION TURRET.





Tighten nut of special tool 204-114 to full extent, to achieve suspension mid-laden position.
20. Raise front of vehicle and support on stands.
21. Remove front road wheels.





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





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





24. Slacken but do not remove crossbeam rear nuts.
Slacken crossbeam LH rear mounting nut.
Repeat procedure to slacken crossbeam RH rear mounting nut.





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





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





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





28. From engine compartment, remove crossbeam front RH bolts.





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





30. From engine compartment, remove crossbeam front LH bolts.

31. CAUTION: Slowly lower the crossbeam just sufficient to provide the required clearance. Lowering the crossbeam excessively can damage the suspension and steering pipes.





Carefully lower crossbeam to provide sufficient clearance between front mounting and body.





32. Remove and discard heatshield from front mounting.


Installation





1. Install new heatshield over front mounting.





2. 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.





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





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





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





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





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





8. 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.





9. 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.





10. 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.





11. Install Crossbeam to engine Hydramount bolts.
Install bolt securing Hydramount to crossbeam and tighten to 34 - 46 Nm.
Repeat procedure to install crossbeam opposite side bolt.





12. Tighten rear mounting bolt and nut to 131 - 185 Nm.
Repeat procedure to tighten opposite side rear mounting bolt and nut.





13. Connect steering rack transducer harness front connector.
Connect steering harness connector.
Install harness connector on body retaining clip.





14. Slacken adjuster nut and remove camber tie down tool 204-114 from suspension.
Repeat procedure to remove tie down tool from opposite side.





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





16. Using new tiestrap, secure undertray to Crossbeam brace.





17. Using new scrivets, secure undertray to each wheelarch liner.





18. Install generator cooling duct deflector.
Position deflector over rear vertical duct.
Move deflector forward to engage center tang over undertray.
Install bolt and tighten to 17 - 23 Nm.
19. Install both front road wheels.
20. Raise vehicle, remove stands and lower vehicle.
21. Remove special tool MS53 from vehicle.





22. Install both engine covers (normally aspirated vehicles only).
Position covers over engine.
Install securing pegs.
23. Install air intake tube/meter/ cleaner cover assembly.
24. Remove fender covers and close hood.
25. Connect ground cable to battery terminal and fit battery cover. Refer 86.15.19.