FRONT SUSPENSION FRAME - R+R

Operation 4410D10 · FRAME AND CROSSMEMBER

1.8, 1.9 JTD 8v, 1.9 JTD 16v

Removing

- Position the vehicle on a lift.

- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.

Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R

Op. 7055A43 CENTRE FRONT GRILLE - R.R.

1. Undo the fixing bolt (1a) and disconnect the steering column (1b) from the steering box.

The bolt is the pre-treated type and it therefore cannot be reused when refitting.

- Secure the engine cooling radiator to the headlamp beam.

1. Unscrew the nuts (1a) and disconnect the steering links (1b) from the front steering knuckles using the tool (1c).

2. Undo the nuts (2a) and disconnect the front anti-roll bar rods (2b) from the anti-roll bar.

1. Undo the bolts (1a) and disconnect the front suspension lower track control arms (1b) from the steering knuckles.

1. Undo the bolt securing the lower gearbox reaction rod, on the side of the mounting bracket on the gearbox.

1. Unscrew the bolt securing the left engine support flexible mounting, front suspension frame side.

1. Disconnect the electrical connections from the power steering pump.

The version with ABS is shown in the diagram. The version with ESP comes with the three electrical connections indicated plus a fourth electrical connection with wiring for connection to the steering angle sensor.

2. Release the power steering electrical wiring (2a) from the bands (2b) securing it to the front suspension frame.

3. Undo the bolts (3a) and remove the engine cooling radiator supports (3b).

1. Position a hydraulic lift (1a) using tools (1b) and (1c) to support the front suspension frame.

Fit the guide pins (arrowed) into the front suspension frame body.

The two locating pins (1d) must be lowered onto the underbody during the dismantling.

- If the above hydraulic lift is not available, use a general hydraulic lift plus the adaptor shown in the drawing, which must be made up by the workshop to allow the use of the above frames

(*): Ensure the shank diameter of the adaptor fits the hydraulic lift used.

1. Undo the bolts (1a) and remove the underbody reinforcements (1b).

1. Undo the bolts fixing the front suspension frame to the bodyshell.

- Lower the hydraulic jack and remove the front suspension frame assembly.

1. Working at the bench, unscrew the bolts (1a) and remove the anti-roll bar (1b) from the front suspension frame.

1. Undo the nuts fixing the power steering box to the front suspension frame.

2. Remove the power steering box (2a) complete with pipes (2b) and power steering pump from the front suspension frame.

1. Undo the bolts (1a) and remove the gearbox lower reaction rod (1b).

1. Undo the bolts (1a) and remove the front suspension track control arms (1b).

Refitting

1. Refit the front suspension track control arms (1a) in their seats on the front suspension frame and secure by fitting the bolts (1b) and (1c) without tightening them.

Tighten the above bolts with the wheels on the ground and the vehicle loaded to the theoretical design load.

1. Place the gearbox lower reaction rod (1b) in its housing and secure it tightening the bolts (1b) to the recommended torque.

1. Refit the power steering box (1a) with pipes (1b) and power steering pump in its seat on the front suspension frame.

2. Tighten the new nuts fixing the power steering box to the front suspension frame to the specified torque.

1. Place the anti-roll bar (1a) in its housing in the front suspension frame and secure it by tightening the bolts (1b) to the recommended torque.

1. Refit the front suspension frame assembly using the support tools and the hydraulic lift.

During refitting, remove both locating pins (1a), which must fit into the holes in the underbody during assembly.

1. Tighten the new bolts fixing the front suspension frame to the bodyshell to the recommended torque.

1. Place the underbody reinformcements (1a) in their housing and secure them tightening the new bolts (1b) and (1c) to the recommended torque.

- Remove the tools and the hydraulic jack used to support the front suspension frame.

1. Position the engine cooling radiator supports (1a) in their housing and secure them tightening the bolts (1b) to the recommended torque.

2. Secure the power steering pump electrical wiring (2a) to the front suspension frame using the bands (2b).

3. Connect the electrical connections to the power steering pump.

1. Tighten the bolt securing the left engine support flexible mounting, front suspension frame side, to the specified torque.

1. Undo the bolt securing the lower gearbox reaction rod, on the side of the mounting bracket on the gearbox, to the specified torque.

1. Connect the front suspension lower track control arms (1a) to the front steering knuckles and secure them tightening the new bolts (1b) to the recommended torque.

1. Connect front anti-roll bar links (1a) to the anti-roll bar and tighten the nuts (1b) to the specified torque.

2. Connect the steering links (2a) to the steering knuckles and tighten the nuts (2b) to the specified torque.

1. Connect the steering column (1a) to the power steering box pinion and secure it by tightening a new bolt (1b) to the specified torque.

Op. 7055A43 CENTRE FRONT GRILLE - R.R.

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R

Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4450B12 FRONT WHEELS (TWO) - R+R

- Place the front suspension in design geometry conditions.

Op. 4450A10 FRONT WHEEL GEOMETRY - CHECK USING OPTICAL EQUIPMENT - INCLUDES ADJUSTMENT IF NECESSARY

This operation prevents torsional preloads on the front suspension flexible bushes.

- Tighten the new bolts fixing the lower track control arm to the front suspension frame to the specified torque.

- Connect the negative battery terminal.

- Remove the vehicle from the lift.