Front Cross-Member: Service and Repair

To remove
1. Remove the cover over the intake manifold.

Part 1 Of 2:

2. Remove the bolts securing the rear engine cushion to the subframe.





3. Detach the gearbox torque arm from the subframe.
4. V6: Fit lifting eyebolts, one on the back of the cylinder head and one on the front (undo one existing bolt first). Fit holders, V6, 83 95 28.

IMPORTANT Place protection under the feet of the lifting beam to avoid damaging the paintwork.

Position lifting beam, 83 94 850 on the fenders and fit the hook in the engine's rear lifting eyebolt.
5. Hang strap 83 95 212 over the radiator assembly but do not pull it tight.
6. Unplug the front heated oxygen sensors connector and the rear heated oxygen sensor, if fitted, and remove any fixing clips, etc.
7. Raise the car and remove the front wheels.





8. Remove the air deflector.





9. Unbolt the oil cooler and allow it to hang from its hoses.
10. Pull the strap tight round the radiator member and radiator assembly.





11. Remove the reinforcement at the subframe's rear mounting point.
12. Remove the temperature sensor, if fitted, from the catalytic converter and lower away the front exhaust pipe section.
13. Remove the two steering gear retaining bolts.





14. Detach the suspension arms from the subframe.
15. Detach the anti-roll bar from the subframe.





16. Unscrew the air cleaner retaining nuts from the subframe.





17. Remove the power steering fluid pipe's rear clamp and front bracket from the subframe. Also remove the A/C pipes from their brackets.

18. Run trolley lift 83 94 793 with parent fixture 83 94 801. intermediate support 83 95 170. basic fixture 83 95 188 and jig 83 95 196 underneath the car and remove the subframe's remaining bolts.
19. Slowly lower the subframe until the remaining clamps for the power-assisted steering fluid pipe can be removed.





20. Lower the subframe and remove the radiator assembly brackets.
21. Unbolt the brackets for the A/C pipes.

To fit





1. Bolt the brackets for the A/C pipes in place.
2. Mount the brackets for the radiator assembly.
3. Raise the subframe until the center clamp for the power steering fluid pipe can be mounted.
4. Raise the subframe, guiding the tool's locating pins into the holes, and make sure that the oil cooler's hoses are correct positioned. Press the A/C pipes into their brackets.





5. Fasten the subframe at its front and center attachment points.
Tightening torque 100 Nm (75 ft. lbs. +45°.
6. Fasten the subframe at its rear attachment points together with the reinforcement.
Tightening torque 100 Nm (75 ft. lbs. +45°.
7. Tighten the reinforcement at the subframe's rear attachment point.
Tightening torque 65 Nm (50 ft. lbs.)
8. Lower the lifting table and roll it away. Remove the strap.
9. Tighten the steering gear's retaining bolts.
Tightening torque 95 Nm (70 ft. lbs.)
10. Bolt the power steering fluid pipe's rear clamp and front bracket to the subframe and tighten the bolts. The rear clamp must be fitted in such a way that the pipe is located as far away from the drive shaft as possible.





11. Tighten the anti-roll bar's retaining bolts.
Tightening torque 25 Nm (20 ft. lbs.).
12. Position the suspension arms on the subframe and fit the bolts for the front and rear attachment points.
13. Place a jack under the steering swivel member's ball joint and raise until the suspension arm is 1° below the horizontal line.
Alternatively, axle stands or similar can be placed under the steering swivel member's ball joint and the car lowered until the suspension arm is 1° below the horizontal line.
14. Tighten the bolts securing the suspension arms to the subframe.
Tightening torque 95 Nm (70 ft. lbs.).





15. Hang the oil cooler back in place and tighten its retaining bolt.





16. Tighten the air cleaner retaining nuts.
17. Raise the front exhaust pipe section and close the joint between the catalytic converter and silencer and also the connection the turbocharger. Refit the catalytic converter's temperature sensor, if previously removed (and if the car is equipped with same).
Tightening torque 25 Nm (20 ft. lbs.).
18. Refit the air deflector.
19. Refit the wheels.
Tightening torque 120 Nm (90 ft. lbs.).
Lower the car to the floor.





20. Remove the lifting beam and tighten the bolts securing the rear engine cushion to the subframe.
Tightening torque 25 Nm (20 ft. lbs.)





21. Tighten the bolts securing the gearbox torque arm to the subframe.
Tightening torque 25 Nm (20 ft. lbs.).
22. Plug in the front heated oxygen sensor's connector and that of the rear heated oxygen sensor, if fitted, and secure the cable suitable places.
23. Refit the cover over the intake manifold.
24. Check the toe-in and adjust as necessary.