Installing Front-Axle Cross Member

1. Install front-axle cross member.
   1. 1.1 Position front-axle cross member in installation position using >VAS 6931 - Transmission and Engine Jack  .
   2. 1.2 Tighten screws on the front-axle cross member in the sequence -4, 2, 3, 5-  .

      Threaded joint securing front-axle cross member to the body -4-  (stud): >Tightening torque 25 Nm (19 ftlb.) 

      Threaded joint securing front-axle cross member to the body -4-  (nut): >Initial tightening 70 Nm (52 ftlb.)  > Final tightening + 90° 

      Threaded joint securing vertical strut to front-axle cross member -2-  : >Tightening torque 30 Nm (22 ftlb.) 

      Threaded joint securing control arm with front-axle cross member to the body -3-  : >Initial tightening 70 Nm (52 ftlb.)  > Final tightening + 180° 

      Threaded joint securing front-axle cross member to the body -5-  : >Initial tightening 70 Nm (52 ftlb.)  >Final tightening + 90° 

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      Front-axle cross member

   3. 1.3 Fit longitudinal struts -1-  .

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      Longitudinal struts

      1. 1.3.1 Tighten screws -2 to 4-  .

         Longitudinal strut with front-axle cross member to the body -2-  : >Tightening torque 100 Nm (74 ftlb.) 

         Longitudinal strut to body -3-  : >Tightening torque 100 Nm (74 ftlb.) 

         Longitudinal strut to body -4-  : >Tightening torque 40 Nm (30 ftlb.) 

2. Applies only to all-wheel drive vehicles  : Fit bracket for all-wheel final drive -1-  on the front-axle cross member.

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   Bracket for all-wheel final drive

   1. 2.1 Tighten studs -3-  . >Tightening torque 17 Nm (13 ftlb.) 
   2. 2.2 Unscrew nuts -2-  . >Initial tightening 30 Nm (22 ftlb.)  > Torque angle 90° 
3. Secure wire harness at the right -1-  .

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   Right wire harness

   1. 3.1 For TPM (Tyre Pressure Monitoring) 315 MHz (M-no. 7K4)  : Secure wire harness in bracket -4-  .

      For TPM (Tyre Pressure Monitoring) 433 MHz (M-no. 7K3)  : Secure wire harness in bracket -5-  .

   2. 3.2 Connect electric plug connection -2-  from the TPM control unit -3-  and lock it.
4. Secure wire harness at the left -1-  .

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   Left wire harness

   1. 4.1 Secure wire harness in brackets -3-  .
   2. 4.2 Connect and lock electric plug connection -2-  .
5. Push on and lock electric plug connection -1-  from angle sensor for headlight beam adjustment on both sides of the vehicle.

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   Electric plug connection

6. Secure coolant lines -1-  and vent line -2-  on both sides of the vehicle at the connection point in front of the tunnel.

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   Coolant lines/vent line (connection point in tunnel)

   1. 6.1 Push on and lock quick connectors -3 and 4-  .
7. Secure wire harness in left wheel housing -1-  .

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   Wire harness (connection point in wheel housing)

   1. 7.1 Connect and lock electric plug connection -4-  .
   2. 7.2 Secure electric plug connection and line -4-  in the brackets.
   3. 7.3 Connect and lock electric plug connection -3-  .
   4. 7.4 Secure electric plug connection -3-  in bracket.
   5. 7.5 Tighten nut -2-  on ground line. >Tightening torque 8 Nm (6 ftlb.) 
8. Secure coolant lines -1-  and vent line -2-  on both sides of the vehicle at the connection point in the wheel housing.

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   Coolant lines/vent line (connection point in wheel housing)

   1. 8.1 Push on and lock quick connectors -5 and 6-  .
   2. 8.2 Fit holder -3-  and tighten screw -4-  . >Tightening torque 8 Nm (6 ftlb.) 
9. Applies only to all-wheel drive vehicles  : Fit coolant lines -1-  on the all-wheel final drive.

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   Coolant lines for all-wheel final drive

   1. 9.1 Push on and lock quick connectors -2-  .
10. Fit restraining straps -1-  .

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    Restraining straps

    1. 10.1 Engage restraining straps on the front-axle cross member -5-  .
    2. 10.2 Tighten the screws -2-  .

       Vehicles with all-wheel drive: >Tightening torque 23 Nm (17 ftlb.) 

       Vehicles without all-wheel drive: >Tightening torque 23 Nm (17 ftlb.) 

    3. 10.3 Applies only to all-wheel drive vehicles  : Push on and lock electric plug connection -4-  on additional coolant pump.
    4. 10.4 Applies only to all-wheel drive vehicles  : Secure bracket -3-  for electric wire harness.
11. Check that the steering column pin is offset. The center position marking on the sensor cover -1-  must be aligned with the marking on the protection cap -2-  .

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    Power-steering gear in center position

12. Fit bottom joint -1-  on power-steering gear -2-  .

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    Bottom joint on power-steering gear

    1. 12.1 Tighten screw -3-  . >Pre-tightening 20 Nm (14.8 ftlb.)  > Final tightening + 90° 
13. Fit connecting link for anti-roll bar -1-  on both sides of the vehicle on the anti-roll bar.

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    Mounting for connecting link

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    Mounting for connecting link for anti-roll bar (PDCC)

    1. 13.1 Tighten nut -2-  .

       Conventional anti-roll bar: >Initial tightening 40 Nm (29.5 ftlb.)  > Final tightening + 30° 

       PDCC anti-roll bar: >Initial tightening 50 Nm (37 ftlb.)  > Final tightening + 50° 

14. Fit lower trailing arm -1-  on the wheel bearing housing.

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    Mounting for lower trailing arm on wheel bearing housing

    1. 14.1 Tighten nut -2-  . >Tightening torque 100 Nm (74 ftlb.) 
    2. 14.2 Seal the threaded joint securing lower trailing arm to wheel bearing housing with wax as shown in -Illustration-  . Use Pfinder AP14/4 for this.

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Applying wax on marked area