Front suspension beam - r r

Operation 4410D13 · Frame and cross beam

Removal

Position the vehicle on the ramp.

Proceed with the removal See Op. 1016A40 Ignition coil cover on cylinder head- r+r .

1 Undo nuts 1a and move bonnet lid catch 1b aside without disconnecting the bonnet opening cable.

1 Fit two brackets to the engine to support the power unit the power unit safely as shown in the figure.

1 Fit the tool 1a, complete with support mountings 1b.

Special tool 1.820.581.000 – Crossmember 1a

Special tool 1.870.650.000 – Support pads 1b

2 Fit the tools 2a and 2b, then connect them using links 2c to the brackets fitted previously.

Special tool 1.860.851.002 – Crossmember 2a

Special tool 1.870.748.000 – Vertical support 2b

Proceed with the removal See Op. 1072C44 Exhaust manifold heat shield on bulkhead - r+r .

Proceed with the removal See Op. 4450B12 Front or rear wheels (two) - r+r .

Proceed with the removal See Op. 7055B64 Engine bay dust protection in rear wheel arch (one), lh or rh - r r (Right and left sides).

Proceed with the removal See Op. 7055B54 Under-engine guard - r r .

1 Unscrew the bolts securing the drive shafts to the internal differential/drive shaft

1 Undo the nuts 1a and disconnect the front anti-roll bar joints 1b from the front damper forks.

1 Undo the bolts fixing the front shock absorber forks to the lower track control arms. 2 Undo the nut for the bolts securing the fronts suspension lower wishbones to the the knuckles.

3 Use the tool to disconnect the front suspension lower wishbone from the steering knuckles.

Special tool 1.821.169.000 – Extractor 3

Proceed with the removal See Op. 1080B62 Catalytic converter - r + r .

Proceed with the removal See Op. 1080B40 Catalytic pre-converter - r r .

Proceed with the removal See Op. 1080B40 Catalytic pre-converter - r r .

Proceed with the removal See Op. 1080B40 Catalytic pre-converter - r r .

Proceed with the removal See Op. 1008A44 Rear rigid mount - r r .

1 Undo bolts 1a and nuts 1b fixing the manual gear lever mounting.

2 Recover the plates.

3 Slacken the rear bolts fixing the manual gear lever mounting.

4 Lower the gearlever mount as necessary.

1 Fit the tool 1a on the hydraulic jack 1b to support the front suspension frame.

Special tool 1.860.978.000 – Flange 1a

2 Undo the bolts securing the power steering box to the front suspension crossmember.

3 Undo the rear bolts fixing the front suspension crossmember to the bodyshell.

4 Undo the side bolts fixing the front suspension crossmember to the bodyshell.

1 Release the power assisted steering system pipes from the front suspension beam bracket.

1 Slowly lower the hydraulic jack and remove the front suspension crossmember 1a complete with lower track control arms 1b and anti-roll bar 1c.

1 Working at the bench, undo the bolts 1a and remove the anti-roll bar 1b with joints.

2 Undo bolts 2a and remove power steering system pipe bracket 2b.

1 Undo the bolts 1a and remove the front suspension lower wishbones 1b.

Refitting

1 Refit the front suspension lower wishbones 1a and secure to the front suspension beam by tightening bolts 1b to the specified torque.

Screw M10 – Front suspension lower lever 1b: (Front suspension crossmember side) 7.1 ÷ 7.9 daNm

1 Refit power steering system pipe bracket 1a and secure to the front suspension beam with bolt 1b.

2 Refit antiroll bar 2a with joints and secure to the front suspension beam by tightening bolts 2b to the specified torque.

Bolt M8 – Front anti-roll bar 2b: (Front suspension crossmember side) 3.6 ÷ 4.4 daNm

Use a hydraulic jack with mounting tool to refit the front suspension beam with lower wishbones and anti-roll bar.

Special tool 1.860.978.000 – Flange

Secure the power steering system pipes to the bracket on the front suspension beam.

1 Tighten the side bolts securing the front suspension crossmember to the bodyshell to the recommended torque.

Side bolt M12 – Engine or rod anchorage beam 1: (Bodyshell side) 10.8 ÷ 13.2 daNm

2 Tighten the rear bolts securing the front suspension crossmember to the bodyshell to the recommended torque.

Rear bolts M12 – Engine or rod anchorage beam 2: (Bodyshell side) 10.8 ÷ 13.2 daNm

Rear bolt M10 – Engine or rod anchorage beam 2: (Bodyshell side) 7.2 ÷ 8.8 daNm

3 Tighten the bolts securing the power steering box to the front suspension crossmember to the specified torque.

Bolt M14 – Power steering box 3: (Front suspension crossmember side) 11.7 ÷ 14.3 daNm

Remove the hydraulic jack with mounting tool from the front suspension beam.

Refit the handbrake control mount and secure with bolts and nuts.

Proceed with the refitting See Op. 1008A44 Rear rigid mount - r r .

Proceed with the refitting See Op. 1080B40 Catalytic pre-converter - r r .

Proceed with the refitting See Op. 1080B40 Catalytic pre-converter - r r .

Proceed with the refitting See Op. 1080B62 Catalytic converter - r + r .

Connect the front suspension lower wishbones to the knuckles.

1 Connect the front suspension lower wishbones to the knuckles and secure by tightening the nuts to the required torque.

Nut M14 – Front suspension lower lever 1: (Steering knuckle side) 8.6 ÷ 9.5 daNm

2 Tighten the bolts securing the front damper forks to the lower wishbones to the specified torque.

Bolt M12 – Front damper fork on wishbone 2: (Lower track control arm side) 10.8 ÷ 13.2 daNm

1 Connect the front anti-roll bar joints 1a to the front damper brackets and secure them by tightening the nuts 1b to the specified torque.

Nut M10 – Front anti-roll bar joints 1b: (Front shock absorber fork side) 4.1 ÷ 5.0 daNm

1 Tighten the bolts securing the drive shafts to the intermediate differential/drive shaft internal drive shaft to the specified torque.

Bolt M8 – Driveshaft 1: (Differential. internal. driveshaft./side..) 3.5 ÷ 4.3 daNm

Proceed with the refitting See Op. 7055B54 Under-engine guard - r r .

Proceed with the refitting See Op. 7055B64 Engine bay dust protection in rear wheel arch (one), lh or rh - r r (Right and left sides).

Proceed with the refitting See Op. 4450B12 Front or rear wheels (two) - r+r .

Proceed with the refitting See Op. 1072C44 Exhaust manifold heat shield on bulkhead - r+r .

Remove the safety tools used for supporting the power unit.

Special tool 1.860.851.002 – Crossmember

Special tool 1.870.748.000 – Vertical support

Special tool 1.820.581.000 – Crossmember

Special tool 1.870.650.000 – Support pads

Refit the bonnet lid catch and secure with nuts.

Proceed with the refitting See Op. 1016A40 Ignition coil cover on cylinder head- r+r .

Remove the car from the ramp.

Proceed with the refitting See Op. 4450A10 Front wheel geometry - check using optical equipment - includes front wheel tow-in adjustment if necessary .