Front Cross-Member: Service and Repair

Sub-Frame Front, Replacing

Special Tools: 999 5716, 999 5460, 999 5045, 951 2050

Preparation







- Install lifting beam 999 5716. Install lifting hooks 999 5460
- Lift the engine to relieve the load on the engine pads.

Remove







- the front wheels
- the splash guard under the engine.







- the air duct cover.







- the cable duct screw.

Remove







- the oil pipes from the steering gear from the snap fasteners on the sub-frame
- the hose for the EVAP canister along the subframe
- the fuel line for the engine block heater and the engine block heater (if applicable) on the left side of the subframe.







- the hose for the EVAP canister in the joint by pulling apart the hose. Pull it forwards under the anti-roll bar and remove it from the snap fastener on the sub-frame.

Remove







- the mounting for the exhaust pipe on the bracket
- the screws holding the bracket for the exhaust pipe. Release the brake pipe from the snap fastener on the bracket
- the bracket.







- Remove the heated oxygen sensor (HO2S) wiring from the mounting.







- Remove the anti-roll bar links from the antiroll bar. Counterhold using a Torx wrench so that the ball joint boot is not damaged.







- Remove both the nuts retaining the lower torque rod
- Remove the screw and bend up the bushing with the holder towards the torque rod.







- Remove the front engine pad screw.







- Slacken off the right lower front section of the fender liner
- Remove the plastic nuts on the fender liner
- Remove the splash guard
- Bend out the fender liner.







- Remove both the right hand engine mounting screws.







- Remove the four nuts and the screw holding the steering gear to the sub-frame
- Remove the delivery line from the clips on the sub-frame







- Remove the nuts from the ball joints. Counterhold with a Torx wrench so that the ball joint boot is not damaged.

Removing the subframe







- Remove and hang up the engine block heater (if applicable) on the left front mounting for the sub-frame
- Position a lifting table under the sub-frame
- Remove the screws holding the sub-frame brackets to the bodywork on both sides
- Remove the four screws from the subframe
- Carefully lower the sub-frame.

NOTE: Ensure that the steering gear screws release from the subframe.







Hang the steering gear from a hook 999 5045 so that the lower steering shaft does not come apart.

Transferring components

Transfer







- the control arms. Use new screws and new nut. Tighten the front screws. Tighten to 65 Nm. Angle tighten 90 degrees. Use bevel protractor 951 2050. Tighten the rear screw. Tighten to 105 Nm. Angle-tighten 90 degrees
- the anti-roll bar. Tighten to 60 Nm
- the right-hand engine mounting. Tighten the screws. Tighten to 65 Nm. Angle-tighten 60 degrees
- the mounting for the heated oxygen sensor (HO2S) wiring
- the engine pad.

Install new pipe/hose holders.

Installing the subframe
- Position the sub-frame on a lifting table
- Carefully lift the subframe
- Locate the control arms on the ball joints and the steering gear on its mountings
- Remove the hook (999 5045) that is holding the steering gear
- Lift the sub-frame up completely
- Reinstall the engine block heater (if applicable).







- Install the engine block heater (if applicable) on the left front mounting for the sub-frame
- Install the four screws in the sub-frame together with the subframe brackets. Use new screws. Lubricate the screws
- First tighten the screws on the left side of the sub-frame. Tighten to 105 Nm. Angle-tighten to 120 degrees. Then tighten the righthand side to the same value
- Finally tighten the screws for the brackets on both sides to 50 Nm.

Finishing







Install
- the right-hand engine mounting. Use new screws. Tighten to 35 Nm. Angle-tighten 90 degrees.







- the front engine pad. Tighten to 50 Nm.







- lower torque rod. Tighten the screw and nut. Tighten to 35 Nm. Angle-tighten 90 degrees.

The lower torque rod must be tightened last to avoid tension being introduced.

Tighten the front nuts. Tighten to 65 Nm. Angle-tighten 90 degrees. Use bevel protractor 951 2050.

NOTE: Use new screws and nuts.







- the fender liner and the splash guard with both the plastic nuts.







- the four nuts and the screw holding the steering gear. Use new nuts and a new screw. Tighten to 50 Nm

Clip the cable in position.







- the wiring for the heated oxygen sensor (HO2S) in its mounting.







- the mountings for the exhaust pipe on the bracket. Tighten to 10 Nm
- the brake pipe on the bracket for the exhaust pipe
- the bracket for the exhaust pipe. Tighten the bracket screws. Tighten to 25 Nm.







- EVAP canister hose. Press the joint together.







- oil pipes to steering gear
- any fuel line for engine block heater
- any engine block heater.







- new nuts on the ball joints. Tighten. Counterhold using a Torx wrench to prevent damaging the ball joint boot.







- the anti-roll bar links. Use new nuts. Tighten to 50 Nm. Counterhold with a Torx wrench so that the boot is not damaged.







- the cable duct screw.







- the air duct cover.







- the splash guard under the engine. Tighten to 20 Nm
- Lower the car.
- Install the wheels.
- Remove the lifting tools for the engine