Subframe

Subframe

To remove





1. Remove the cover over the intake manifold.
Remove the two upper nuts from the exhaust flange.
2. Remove the bolts securing the rear engine cushion to the subframe.

3. V6: Fit the lifting eyes, one on the rear of the cylinder head and one on the front of the cylinder head (first undo an existing screw). Attach holder, V6, 83 95 287

IMPORTANT: Put some protection under the feet for the lifting beam in order to avoid damage to the paintwork.

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





7. Remove the air shields.
8. R4 engine: Unbolt the engine oil cooler and allow it to hang from it's hoses.





9. Remove the retaining bolts from the power steering cooling coil.
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 two steering gear retaining bolts.
13. Remove the front exhaust pipe section.
14. Detach the gearbox torque arm from the subframe.





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





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





18. Remove the A/C pipes from their brackets.
19. Detach the power steering fluid pipe from the clips.
20. Run trolley lift 83 95 311 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 remaining subframe bolts.
21. Lower the subframe.





22. 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. Lift up the subframe carefully. Make sure the rubber boots on the inner drivers do not knock against the middle brackets on the subframe before the subframe is firmly against the body.
4. Fasten the power steering pipe in the clip.





5. Guide the radiator guide pins into the subframe. Lubricate with petroleum jelly to make fitting easier.
6. Guide the A/C pipes into their holders on the subframe.
7. Fit the power steering cooling pipe.
8. Adjust the subframe so that the bolt holes are alligned with the body. There are two guide pins front left and rear right on the lifting trolley that will guide the subframe to its correct position.
9. Fit the bolts to secure the subframe and the rear support plates. Tighten the bolts enough to ensure the subframe does not move when the lifting trolley and fixture are removed.

Note: The middle bolts on the subframe must not get mixed up with the others. The middle bolts have a smaller washer and 20 mm head.

10. Lower the lifting trolley and move it away.
11. Tighten the bolts on the subframe.
Tightening torque: 100 Nm +45� (74 lbf ft +45�)
12. Tighten the reinforcement at the subframe's rear attachment point.
Tightening torque: 65 Nm (50 lbf ft)
13. Remove the strap.
14. Tighten the steering gear's retaining bolts.
Tightening torque: 95 Nm (70 lbf ft)
15. 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.
16. Tighten the anti-roll bar's retaining bolts.
Tightening torque: 25 Nm (20 lbf ft)





17. Position the suspension arms on the subframe and fit the bolts for the front and rear attachment points.
18. Place a jack under the steering swivel member's ball joint and raise sit 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.
19. Tighten the bolts securing the suspension arms to the subframe.
Tightening torque, front: 110 Nm +90�(81 lbf ft +90�)
Tightening torque, rear: 120 Nm +90�(88 lbf ft +90�)
20. Hang the oil cooler back in place and tighten its retaining bolts.





21. Tighten the air cleaner retaining nuts.





22. 4-cyl: Raise the front exhaust pipe section and tighten the joint between the catalytic converter and the silencer as well as the connection to the turbocharger. Refit the temperature sensor where appropriate.
Tightening torque: 25 Nm (20 lbf ft)
V6: Fit the exhaust pipe to the rear exhaust manifold.
Fit the exhaust pipe to the catalytic converter and the silencer.
Tightening torque: 40 Nm (30 lbf ft)





23. Fit the air shields.
24. Fit the wheels, see Wheels.
Tightening torques:
- aluminium rim: 110 Nm (81 lbf ft)
- pressed steel rim: 50 Nm +2x90�, max. 110 Nm (37 lbf ft +2x90�, max. 81 lbf ft)
Lower the car to the floor.
25. Remove the lifting beam and tighten the bolts securing the rear engine cushion to the subframe.
Tightening torque: 25 Nm (20 lbf ft)





26. Tighten the bolts securing the gearbox torque arm to the subframe.
Tightening torque: 90 Nm +90� (66 lbf ft +90�).


27. Fit the exhaust pipe to the turbocharger.
Tightening torque: 25 Nm (18 lbf ft)
28. Plug in the front heated oxygen sensor's connector and that of the rear heated oxygen sensor, if fitted, and secure the cable at suitable places.
29. Refit the cover over the intake manifold.
30. Check the toe-in and adjust as necessary, see Wheel alignment in the Steering linkage section. k the toe-in and adjust as necessary, see Wheel alignment in the Steering linkage section.