Contents: Dismantling ⇩ Assembly ⇩
Before disconnecting the battery, make sure that all requirements and conditions contained in the section on disconnecting the battery are met.
GENERAL INFORMATION, Precautions when working with electrical equipment.
Dismantling
1. Disconnect the negative terminal from the battery.
2. Remove the air duct.
HEATING AND VENTILATION, REPAIR WORK, Air filter - air intake.
3. Raise the front of the vehicle and support it with stands.
4. Remove the protective shield.
EXTERIOR PARTS, REPAIR WORK, Engine protection - front.
5. Remove the 4 screws securing the lower aerodynamic panel and remove the panel.
6. Remove the front wheels.
7. Remove the right drive shaft.
DRIVE SHAFTS, REPAIR WORK, Drive shaft - front - right.
8. Remove the left drive shaft.
DRIVE SHAFTS, REPAIR WORK, Drive shaft - front - left.
9. Place a suitable container under the power steering pump.
10. Loosen the union nut, disconnect the high pressure line from the power steering pump, remove and discard the sealing ring.
CAUTION: Before disconnecting or removing steering components, make sure that the adjacent surfaces are free of dirt. Install plugs in the openings of fittings and pipes to protect the system from dirt ingress.
11. Remove the 2 strips securing the power steering low pressure line to the subframe.
12. Loosen the fasteners and disconnect the low pressure line from the working fluid cooler.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
13. Remove the container from under the power steering pump.
14. Remove the screw securing the fan shroud to the radiator.
15. Remove the fan shroud fasteners.
16. Remove the fan shroud from the radiator.
17. Install the LRT-12-216 tool onto the engine mounting tabs.
18. Attach the chain to the engine mounting brackets and tighten the chain by loading it with the weight of the engine.
19. Remove the left engine mount nut.
20. Remove the right engine mount nut.
21. Raise the engine, separating it from the supports.
CAUTION: To avoid damaging the radiator, support and keep the fan shroud away from the radiator as it will rise with the engine.
22. Remove the steering angle sensor connector block.
23. Mark the position of the lower part of the steering column. Remove the screw of the lower steering column joint and disconnect the steering column from the steering gear. Discard the mounting screw.
CAUTION: Do not turn the steering wheel when the intermediate shaft or universal joint is disconnected, as this will damage the rotating slip ring and steering wheel controls.
24. Mark the position of the fasteners and remove the fasteners securing the front body position sensor cable to the vehicle subframe and remove the sensors. Disconnect the front body position sensor connector blocks.
25. Remove the 2 nuts securing each anti-roll bar heat shield to the body and the 2 bolts securing each heat shield to the subframe. Remove the heat shields.
26. Support the subframe using a jack.
27. Remove the 2 subframe-to-crossmember screws and the 6 subframe-to-car body screws. Discard the screws.
28. With the help of an assistant, lower and remove the subframe assembly.
29. Note the position of the pressure and drain pipes, unscrew the fitting mounting bolts and remove the pipes. Remove the sealing rings.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
30. Remove the 2 bolts and 2 nuts securing the steering gear assembly and discard the bolts and nuts.
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NOTE: Do not perform further disassembly if the component is removed only for ease of access.
31. Loosen the locknuts of the steering rod ends and remove the ends with the ball joints. Remember the number of thread turns to avoid mistakes during assembly. Discard the retaining rings.
32. Remove the tie rod end locknuts.
Assembly
1. Screw the locknuts onto the ends of the steering rods.
2. Place the retaining rings on the ends of the steering rods so that the conical part of the ring faces the conical belt of the rod.
3. Screw the tie rod ends onto the rods, turning them to the number of turns recorded during removal.
4. Install the steering gear assembly and tighten the new bolts and nuts to a tightening torque of 100 N·m, then tighten the nuts by 90°.
5. Clean the fittings and connection surfaces from dirt.
6. Install new sealing rings and connect the pipe fittings, tightening the M16 screw to 40 Nm and the M14 screw to 36 Nm.
7. Clean the mating surfaces of the subframe and the car body.
8. Together with an assistant, install the subframe assembly.
9. Install new screws and tighten the 6 subframe-to-body mounting screws to 165 Nm, then tighten the two rear screws another 90°. Tighten the subframe-to-crossmember mounting bolts to 132.5 Nm.
10. Install the anti-roll bar heat shields and tighten the fasteners.
11. Lower the engine onto the supports.
NOTE: When lowering the engine, guide the fan shroud into place.
12. Attach the fan shroud to the radiator by installing the fasteners.
13. Tighten the screw securing the fan shroud to the radiator.
14. Tighten the 2 engine mounting nuts on the supports and tighten them to a torque of 100 Nm.
15. Disconnect the lift chain.
16. Remove the engine mounting tabs.
17. Attach the lower end of the steering shaft to the steering gear shaft, making sure that the mounting marks match.
18. Install the new steering shaft joint mounting bolt and tighten it to 24 N·m.
19. Connect the connector to the steering angle sensor connector.
20. Connect the electrical connector blocks of the front vertical body position sensors.
21. Route the sensor cables and secure them with clamps in their original position.
22. Wipe off any dirt from the mating surfaces of the pump and high pressure pipeline.
23. Install a new sealing ring on the end of the pipe, connect the pipe to the pump and tighten the high pressure nipple nut to a torque of 25 Nm.
24. Connect the low pressure line to the power steering fluid cooler.
25. Install 2 strips securing the power steering low pressure line to the subframe.
26. Install the right drive shaft.
DRIVE SHAFTS, REPAIR WORK, Drive shaft - front - right.
27. Install the left drive shaft.
DRIVE SHAFTS, REPAIR WORK, Drive shaft - front - left.
28. Reinstall the wheels and tighten the nuts to a torque of 140 Nm.
29. Replace the lower aerodynamic panel and tighten the screws to 45 Nm.
30. Replace the protective shield.
EXTERIOR PARTS, REPAIR WORK, Engine protection - front.
31. Remove the safety stands and lower the front of the vehicle.
32. Check the oil level in the front axle differential.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, ADJUSTMENTS, Front main gear and differential housing - oil drain and filling.
33. Reinstall the air duct.
HEATING AND VENTILATION, REPAIR WORK, Air filter - air intake.
34. Connect the negative terminal to the battery.
35. Remove air from the system and add working fluid to the power steering reservoir.
STEERING, ADJUSTMENTS, Power assisted steering (PAS) - bleeding.
36. Check and, if necessary, adjust the front wheel alignment angles.
STEERING, ADJUSTMENTS, Front wheel alignment angles - checking and adjustment.
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