Page 2389 of 2490
Key to Plan
Long Wheelbase Body Dimensions- Side View
KeyLocation
1Front face body-bumper strut/mounting point
2Rearmost hole, vee-mount to crush tube
3Front Master Datum Plan, centre line of front crossmember rear mount ing at main floor RH longitudinal
4Rearmost hole, transmission mounting at main floor RH longitudinal
5Handbrake rear lever bracket fixings
6Rear Master Datum Plan, rear longitudinal
7Tapped boss, rear suspension 'A' frame mounting bush
8Rear suspension spring-pan damper mounting
9Rear suspension differential strut mounting
10Rear face body-bumper strut/mounting point
11Driveshaft centre bearing mounting
Page 2390 of 2490
Key to SideView
KeyLocation
1Front face body-bumper strut/mounting point
2Front Master Datum Vertical, centre line of front crossmember rear mounting
3Transmission mountings at the main floor longitudinal
4Handbrake rear lever bracket fixings
5Rear Master Datum Vertical,, rear longitudinal
6Tapped boss, rear suspensi on 'A' frame mounting bush
7Rear suspension spring-pan damper mounting
8Rear suspension differential strut mounting
9Rear face body-bumper strut/mounting point
10Wheel centre to bumper cover face
11Wheelbase
12Wheel Centre to Bumper Cover Face
13Driveshaft centre bearing mounting
Page 2421 of 2490

Uni-Body, Subframe and Mounting System - Front Axle Crossmember
Removal and Installation
Removal
CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the
vehicle. These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
Special Tool(s)
Tie-Rod-End Taper Separator
211-098 (JD 100)
Engine Support Beam
303-021 (MS 53D)
1. Position vehicle on a four-post lift.
2. Raise front of vehicle and support on stands.
3. Remove battery cover and disc onnect ground cable from
battery terminal. Refer to section 86.15.15.
4. Open hood to service position, and fit covers to fenders.
5. Remove both engine covers (nor mally aspirated vehicles only).
Release pegs.
Remove covers.
6. Remove air intake tube/meter/ cleaner cover assembly. Refer
to 19.10.30
7. Support weight of engine.
1. Position special tool 303-021 in RH and LH fender channels and tighte n beam fixings.
2. Engage hooks in the en gine front lifting eyes.
3. Tighten hook adjustment nuts until weight of engine is supported.
Page 2423 of 2490
1. Sever and discard tiestraps securing front wheel
speed sensor harness to upper wishbone.
2. Disconnect harness connector from sensor.
Repeat procedure to disconnect opposite side wheel speed
sensor harness.
16. CAUTION: Do not suspend caliper from brake hose as
this will damage the hose.
Remove brake calipers from carriers.
1. Remove caliper spring clip.
2. Remove guide pin dust caps.
3. Slacken and withdraw guide pins.
4. Remove caliper from carrier and tie to suspension mounting bracket.
Repeat procedure to remove opposite side front brake
caliper.
17. Remove filler cap from power steering fluid reservoir.
18. Disconnect steering rack transducer harness front connector.
Release harness connector from body retaining clip.
Disconnect connector.
19. Sever and discard tiestrap secu ring return pipe, harness (RHD
only) and rubber support to steering rack.
Page 2432 of 2490
10. With assistance position crossbeam/suspension assembly on
jack with protective wood under.
11. Traverse assembly into position below vehicle.
12. Ensure steering harn ess connector is positioned to avoid
damage during crossbeam lift .
13. NOTE: It may be necessary to use a hammer and drift to
finally align new mounting with body location.
Carefully raise crossbeam assembly into position.
Ensure that dowels of both crossbeam mountings are
correctly seated in body locations.
14. Ensure that both engine hydram ounts are correctly seated in
crossbeam locations.
15. Install crossbeam rear mountings.
Align rear mounting rubber with body location.
Install rear mounting securing bolt and nut and tighten
nut to 131-185 Nm.
Repeat procedure to install opposite side rear mounting
bolt and nut.
16. From engine compartment, install but do not tighten
crossbeam front RH bolts.
Page 2439 of 2490

Uni-Body, Subframe and Mounting System - Front Axle Crossmember
Front Bushing
Removal and Installation
Removal
CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the
vehicle. These devices restrict the number of times a nut or bolt can be used. See Section 100-00 for information.
Special Tool(s)
Engine Support Beam
303-021 (MS 53D)
Front Camber Tie-down Link
204-114 (JD 133)
1. Position vehicle on a four-post lift.
2. Remove ignition key and en gage steering column lock.
3. Open hood to service position, and fit covers to fenders.
4. Remove battery cover and disc onnect ground cable from
battery terminal. Refer to 86.15.19.
5. Remove both engine covers (nor mally aspirated vehicles only).
Release pegs.
Remove covers.
6. Remove air intake tube/meter/ cleaner cover assembly. Refer
to 19.10.30
7. Remove air intake tube/meter/ cleaner cover assembly. Refer
to 19.10.30
8. Support weight of engine.
1. Position special tool 303-021 in RH and LH fender channels and tighte n beam fixings.
2. Engage hooks in the en gine front lifting eyes.
3. Tighten hook adjustment nuts until weight of engine is supported.
Page 2442 of 2490
21. Remove crossbeam to engi ne Hydramount bolts.
Remove bolt securing crossbeam to Hydramount.
Fully withdraw bolt into crossbeam insert.
Repeat procedure to remove and withdraw bolt on
opposite side
22. Remove lower nut and bolt from front shock absorber.
Repeat procedure to remove bo lt from opposite side shock
absorber.
23. Slacken but do not remove crossbeam rear bolt and nuts.
Slacken crossbeam LH rear mounting bolt and nut.
Repeat procedure to slacken crossbeam RH rear mounting
nut.
24. Release lower steering column from pinion shaft.
1. Remove lower steering column nut and bolt.
Move column upwards to release it from pinion shaft.
25. Disconnect steering rack transducer harness front connector.
Release harness connector from body retaining clip.
Disconnect connector.
Page 2444 of 2490
Installation
30. CAUTION: Slowly lower the crossbeam just sufficient to
provide the required clearance. Lowering the crossbeam
excessively can damage the suspension and steering pipes.
Carefully lower crossbeam to provide sufficient clearance
between front mounting and body.
31. Remove crossbeam front mounting.
Remove front mounting heatshield.
Remove four bolts securing mounting to crossbeam.
1. Install crossbeam front mounting.
Position new mounting on crossbeam.
Install four bolts securing mounting to crossbeam and
tighten to 22-28Nm.
Install front mounting heatshield.
2. NOTE: It may be necessary to use a hammer and drift to
finally align new mounting with body location.
Carefully raise crossbeam assembly into position.
Ensure that dowels of both crossbeam mountings are