Front Subframe |Service and Repair, Removal and ... · - the control arms. Use new screws and new nut. Tighten the front screws. Tighten to 65 Nm. Angle-tighten 90°. Use bevel protractor

Sub-frame front, replacing

Special tools:999 7018 Lifting lug See: Vehicle > Electrical / Mechanical Repair > 999 7018 Lifting Lug999 5716 Reading off tool See: Vehicle > Electrical / Mechanical Repair > 999 5716 Reading Off Tool999 5460 Lifting hook See: Vehicle > Electrical / Mechanical Repair > 999 5460 Lifting Hook951 2050 Bevel Protractor See: Vehicle > Electrical / Mechanical Repair > 951 2050 Bevel Protractor999 7062 Separator See: Vehicle > Electrical / Mechanical Repair > 999 7062 Separator999 7070 Mounting See: Vehicle > Electrical / Mechanical Repair > 999 7070 Mounting

Note! As the illustrations in this service information are used for different model years and / or models, some variation mayoccur. However, the essential information in the illustrations is always correct.

Preparation

Install lifting lug 999 7018 Lifting lug See: Vehicle > Electrical / Mechanical Repair > 999 7018 Lifting Lug on the left hand side of theengine at the 2 screws.Lock the lifting lug using the snap ring.Install lifting tool 999 5716 Reading off tool See: Vehicle > Electrical / Mechanical Repair > 999 5716 Reading Off Tool converted with kit999 7070 Mounting See: Vehicle > Electrical / Mechanical Repair > 999 7070 Mounting. Install lifting hooks 999 5460 Lifting hook See:Vehicle > Electrical / Mechanical Repair > 999 5460 Lifting Hook.Lift the engine to relieve the load on the engine pads.Remove the front wheels.

Removing the clamp for the servo pressure hose

Front Subframe |Service and Repair, Removal and Replacement: Replaci... http://repair.alldata.com/alldata/article/display.action?componentId=720...

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Remove the clamp for the servo pressure line on the sub frame.

Removing the right engine mounting

Slacken off the right lower front part of the fender liner.

Remove: - the plastic nuts on the fender liner - the protective plate.Bend out the fender liner.

Remove the 4 screws for the vibration damper. Counterhold the crankshaft central nut.Remove the vibration damper.


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Remove the 2 screws for the right hand engine mounting. (1)

Removing the splash guard under engine

Remove the splash guard under the engine.

Removing the skid plate

Remove the 6 screws.


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Lift and slide the splash guard forward.Remove the protective plate.

Note! There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slidforward.

Exposing the sub-frame

Remove: - the screw for the cable duct - the screw for the ground lead.

Remove the screw for the front engine pad.


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Remove: - the oil pipe for the steering gear from the snap fasteners along the sub-frame - the screw clip for the steering gear return line - the fuel line for the engine block heater and the engine block heater (if applicable) on the left side of the sub-frame.

Remove the 4 screws holding the torque rod to the engine.

Remove the anti-roll bar links from the anti-roll bar on both sides. Counterhold using a Torx wrench so that the ball joint boot is notdamaged.

Removing the drive shaft


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Remove the screw for the drive shaft. Use a screwdriver as a counterhold on the brake disc.Knock the end of the drive shaft into the hub. Use a brass drift.

Disconnect the ball joint pinion from the control arm. Use tool 999 7062 Separator See: Vehicle > Electrical / Mechanical Repair > 9997062 Separator.Install cap nut 7062-1 on the ball joint pinion.Tighten the nut against the control arm.Then turn back one turn to form a gap between the cap nut and the control arm.Position the extractor on the control arm. Detach the ball joint from the control arm.


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Remove the 4 nuts and the screw holding the steering gear to the sub-frame.Remove the power steering line from the clips on the sub-frame.

Remove the hose for the EVAP canister in the joint by pulling apart the hose. Route the hose under the anti-roll bar.

Remove: - the screw in the mounting for the front SIPS member - the brake pipe from the snap fastener on the member - The SIPS member.

Remove the rubber mountings for the exhaust pipe.


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Remove the connector for the heated oxygen sensor (HO2S) from its mounting.

Removing the sub-frame

Position a lifting table under the sub-frame

Remove the following on both sides: - the screws holding the sub-frame brackets in the bodywork - the screw for the sub-frame mounting.Carefully lower the sub-frame.

Note! Ensure that the brake pipe clears the exhaust pipe mounting when lowering the frame.

Note! Ensure that the steering gear screws release from the sub-frame.

Transferring components


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Transfer: - the control arms. Use new screws and new nut. Tighten the front screws. Tighten to 65 Nm. Angle-tighten 90°. Use bevel protractor951 2050 BEVEL PROTRACTOR See: Vehicle > Electrical / Mechanical Repair > 951 2050 Bevel Protractor. Tighten the rear screw.Tighten to 105 Nm. Angle-tighten 90° - the anti-roll bar. Tighten to 60 Nm - the right-hand engine mounting. Tighten the screws. Tighten to 65 Nm. Angle-tighten 60° - the exhaust mounting bracket. Tighten to 50 Nm - the shock absorber Tighten to 50 Nm - lower torque rod. Tighten to 65 Nm. Angle-tighten 90°.Install new pipe / hose holders.

Installing the sub-frame

Position the sub-frame on a lifting table.Carefully lift the sub-frame.Locate the control arms to the ball joints and the steering gear to its mountings.

Hint: Lubricate the rubber coated clamp for the servo pressure pipe on the sub-frame using a soap solution. Install the screw beforeraising the sub-frame completely. Do not tighten the screw more than 2 turns as the pipe must be able to slide to the correct position in theclamp whilst raising the sub frame.

Note! Ensure that the brake pipe at the exhaust mounting is not trapped when raising the sub frame.

Lift the sub-frame up completely.Install the four screws in the sub-frame together with the sub-frame brackets and engine block heater, if applicable. 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°. Then tighten the right-hand side to thesame value.Finally tighten the screws for the brackets on both sides to 50 Nm.


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Installing removed components

Install: - the heated oxygen sensor (HO2S) connector - the rubber mountings for the exhaust pipe - SIPS (side impact protection system ) member - the four screws for the SIPS (side impact protection system) member. Tighten to 24 Nm.Route the hose for the EVAP canister to the correct position and press the joints togetherInstall 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.

Install: - the ball joints. Use new nuts. Tighten to 80 Nm. Counterhold using a Torx wrench so that the ball joint boot is not damaged - the anti-roll bar links. Use new nuts. Tighten to 50 Nm. Counterhold using a Torx wrench so that the boot is not damaged.

Install: - the lower torque rod. Tighten the two screws. Tighten to 10 Nm - the oil pipe for the steering gear from the snap fasteners along the sub-frame - the screw clip for the steering gear return line - the engine block heater and the fuel line to the engine block heater if applicable - the screw for the cable duct - the screw for the ground lead.

Installing the drive shaftInstall new screws on both sides. Use a screwdriver as a counterhold. Tighten to 35 Nm. Angle-tighten 90°. Use bevel protractor 951 2050BEVEL PROTRACTOR See: Vehicle > Electrical / Mechanical Repair > 951 2050 Bevel Protractor.

Installing the skid plateMove the skid plate up into the bumper wraparound.Press forwards until the mounting brackets engage in the sub frame.Install the screws. Tighten to 50 Nm.Install the splashguard under the engine. Tighten to 24 Nm.

Installing the right-hand engine mountingInstall the right-hand engine mounting. Use new screws. Tighten to35 Nm. Angle-tighten 90°.Fold the fender liner back into position.

Install: - the skid plate - the plastic nuts - the front wheels. See Installing wheels See: Wheels > Removal and Replacement.

Installing the clamp for the servo pressure hose

Tighten the clamp for the servo pressure pipe on the sub frame. Tighten to 10 Nm.

Removing lifting toolsRemove lifting tool 999 5716 Reading off tool See: Vehicle > Electrical / Mechanical Repair > 999 5716 Reading Off Tool , kit 999 7070


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Mounting See: Vehicle > Electrical / Mechanical Repair > 999 7070 Mounting , lifting hooks 999 5460 Lifting hook See: Vehicle >Electrical / Mechanical Repair > 999 5460 Lifting Hook and lifting lug 999 7018 Lifting lug See: Vehicle > Electrical / Mechanical Repair >999 7018 Lifting Lug.Remove

FinishingAlign the wheels. See See: Alignment > Procedures > Wheel Alignment, Checking/Adjusting

© 2017 ALLDATA, LLC. All Rights Reserved. (Version 2.0.13851)


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Steering gear, replacing

Note! As the illustrations in this service information are used for different model years and/or models, some variation mayoccur. However, the essential information in the illustrations is always correct.

PreparationSet the steering wheel to the "straight ahead" position. Remove the key so that the steering wheel lock engages.Remove the battery lead. See Battery, disconnecting See: Battery > Procedures > Battery Disconnecting.Install the lock grip pliers on the feeder hose and the return hose for the power steering pump.

Removing the screw on the lower steering shaft

Hint: If the access to the screw for the steering shaft joint mounting in the steering gear is very limited, set up the tool as illustrated.

Remove the screw on the steering shaft joint mounting in the steering gear from the engine compartment.

Removing the sub-frameRemove the sub-frame. See: Sub-frame front, replacing See: Front Subframe > Removal and Replacement.

Removing the track rod ends

Steering Gear |Service and Repair, Removal and Replacement: Steering ... http://repair.alldata.com/alldata/article/display.action?componentId=51&...

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Note! Ensure that the front wheels are pointing straight ahead.

Remove - the front wheels - the track rod ends from the steering arms.Counterhold using a fixed spanner so that the boot is not damaged.

Note! On one side, measure the length of the track rod in relation to the steering gear housing. Note the measurement.

Removing the return lines and delivery line

Place a container under the steering gear.

Remove: - the return line from the steering gear and drain the fluid - the delivery line from the steering gear and drain the fluid.


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Remove the clips holding the same lines.

Note! Note the routing of the lines / hoses.

Removing steering gearRemove the steering gear.

Installing steering gear

Measure and adjust according to the measurements made earlier between the track rod end and the steering gear housing on the newsteering gear.Install the steering gear.

Installing the return line and delivery line

Install the lines according to the noted routing.Tighten the return line and the delivery line to the steering gear. Tighten to Tightening torque See: Steering > Mechanical > TighteningTorque.

Note! Use a new O-ring on the tube at the steering gear.

Install the clips holding the same lines.


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Installing the steering arms to the wheel spindles

Install the steering arms to the wheel spindles. Use new lock nuts.Tighten, see: Tightening torque See: Steering > Mechanical > Tightening Torque. Use 951 2050 BEVEL PROTRACTOR See: Vehicle >Electrical / Mechanical Repair > 951 2050 Bevel Protractor.

Installing the sub-frameInstall the sub-frame. See: Sub-frame front, replacing See: Front Subframe > Removal and Replacement.

Installing the screw on the lower steering shaft

Note! Always check carefully that the ball joint's screw hole aligns with the cut-out in the steering gear shaft.

Expose the steering wheel lock. Turn the steering wheel so that the screw in the mounting for the steering shaft joint points straight ahead.Tighten the lower screw on the steering shaft joint mounting in the steering gear from the engine compartment. Tighten to Tighteningtorque See: Steering > Mechanical > Tightening Torque. Use a new screw.

Finishing

Install: - the fluid reservoir return hose - the clips for the cable harness along the hose - the delivery line on the power steering pump. Tighten. See: Tightening torque See: Steering > Mechanical > Tightening Torque.Use a new O-ring on the pipe at the power steering pump.

Install: - the clamp on the stay between the power steering pump / engine - the battery lead.


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Fill the reservoir with oil.

Note! Use Volvo power steering fluid, P/N 1161529-1 to ensure the correct oil quality.

Repeatedly turn the steering wheel to full lock. Check and top up oil if required.Lower the car.Apply the hand brake. Start the engine.A: Turn the steering wheel slowly to the right. Hold on full lock for 2 seconds.B: Turn the steering wheel slowly to the left, hold on full lock for 2 seconds.Repeat operations A and B approximately 10 times.

© 2017 ALLDATA, LLC. All Rights Reserved. (Version 2.0.13851)


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Documents

Front Subframe |Service and Repair, Removal and ... · - the control arms. Use new screws and new nut. Tighten the front screws. Tighten to 65 Nm. Angle-tighten 90°. Use bevel protractor