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Subframe, diesel engine

Subframe, diesel engine

This method is used when the same subframe is to be refitted.

To remove

Important

Cables, hoses, leads, etc., are secured with cable ties made of hard plastic. After tightening, the ties are cut off, leaving more or less sharp ends that can cause cuts if not handled carefully.



1. Place the car on a lift.

2. Lay protection over the wings.

3. MAN: Undo the bolts securing the rear engine pad using a long 10 mm socket, two extensions with ball fastening (e.g. 30 17 613) and 82 93 102 Extension 500 mm, 3/8 square . Leave the bolts in place.


4. AUT: Remove the nut of the rear engine mounting and slacken the two visible bolts that hold the rear engine pad in place. Leave the bolts in place.

5. Raise the car and remove the front wheels.

6. Remove both the lower engine covers.


7. Remove the side covers in both wheel housings.


8. Cars with xenon headlamps: Undo the level sensor for the xenon headlamps from the bracket and move it to one side.


9. Remove the front section of the exhaust pipe .

10. AUT: Remove the rear engine bracket and the engine pad.


11. Remove the bolt securing the front torque arm to the subframe.


12. Remove the ball joints from the steering swivel members.


13. Remove the anti-roll bar links from the MacPherson struts.

14. Detach the air cleaner casing from the subframe.


15. Pull strap 83 95 212 Strap around the radiator assembly and radiator member to hold up the radiator assembly.

16. Undo the rubber mountings on the power steering cooling pipe.

17. Remove the bolts holding the rear support plates and the rear bolts on the subframe.


18. Remove the steering gear bolts.

19. Separate the pipe for the battery cooling.

20. Place the lifting trolley under the subframe. 83 95 311 Lifting trolley , 83 94 801 Parent fixture , 83 95 170 Intermediate piece (x4) , 83 95 188 Basic fixture and 83 95 196 Holder, front .


21. Remove the remaining bolts securing the subframe.

Note

Do not get the middle subframe bolts mixed up with the others when refitting (another size and design).


22. Open the clamps securing the power steering pipe and secure the power steering cooling pipe with a cable tie. Detach the A/C pipes from their clips.

23. Lower the subframe.

24. Move the lifting trolley out of the way.


To fit


1. Make sure the radiator guide pins are fastened correctly in the radiator crossmember.

2. Place the trolley lift and subframe underneath the car.

3. Lift the subframe carefully. Make sure the rubber dust excluders on the inner supports do not touch the centre mountings and guide the track rod ends into the steering swivel members.

4. Fit the power steering delivery pipe into the clips.


5. Guide the radiator guide pins into the subframe. Lubricate with Vaseline to facilitate fitting.

6. Guide the A/C pipes into their holders on the subframe.

7. Adjust the position of the subframe so that the bolt holes are in line with the body. There are 2 guide pins on the lifting trolley, front left and rear right, that guide the subframe into the correct position.


8. Fit the bolts to secure the subframe and the rear support plates. Tighten the bolts just enough so that the subframe does not move out of its position when the lifting trolley and fixture are removed.

Note

Do not get the middle subframe bolts mixed up with the others. The middle bolts have a thinner washer and 20mm head.


9. Move the lifting trolley out of the way.

10. Tighten the bolts on the subframe.

Tightening torque 100 Nm +45° (74 lbf ft +45°)


11. Tighten the support plate bolts.

Tightening torque: 63 Nm (46 lbf ft).

12. Fit the steering gear bolts.

Tightening torque: 90 Nm (65 lbf ft).

13. Fit and tighten the bolt securing the torque arm to the subframe.

Tightening torque 90 Nm +90° (66 lbf ft +90°) .


14. Fit the ball joint to the steering swivel member.

Warning

Make sure the ball joint journal is visible above the steering swivel member before fitting the bolt.


Tightening torque (on nut) 49 Nm (36 lbf ft).


15. Fit the anti-roll bar support to the MacPherson strut.

Tightening torque: 90 Nm (65 lbf ft).

16. Cars with automatic gearbox:

• Insert the bolts of the rear engine pad.

• Lower the car and tighten the engine pad bolts from above.

Tightening torque: 24 Nm (18 lbf ft)


• Raise the car and attach the engine bracket to the gearbox.

Tightening torque: 60 Nm (44 lbf ft).

17. Remove the strap holding up the radiator assembly.

18. Fit the rubber mountings for the power steering pipe.


19. Connect the pipe for battery cooling.

20. Fit the air cleaner casing.

21. Attach the front section of the exhaust pipe .

22. Lower the car to the floor.

23. MAN: Tighten the bolts on the rear engine pad from the engine bay side starting with the rear bolt.

Tightening torque: 24 Nm (18 lbf ft)


AUT: Fit the rear engine pad nut.

Tightening torque: 47 Nm (35 lbf ft).

24. Raise the car.

25. Undo the bolt for the front torque arm on the gearbox, centre the rubber pad in the rod and tighten.

Tightening torque: 70 Nm +90° (52 lbf ft +90°).

26. Cars with xenon headlamps: Fit the level sensor for the xenon headlamps.

27. Fit the side covers in the wheel housings.


28. Fit the rear and front lower engine covers.


29. Fit the front wheels. They must be suspended freely when tightening, see Wheels .

30. Lower the car to the floor.

31. Perform a road test. Check the position of the steering wheel on a level surface and adjust if necessary.