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Home >> Alfa Romeo >> 2019 >> Giulia Base, AWD >> Repair and Diagnosis >> Body & Frame >> Frames, Subframes & Crossmembers >> Frame And Bumpers >> Frame >> CROSSMEMBER, Front Suspension >> Removal And Installation >> Removal And Installation >> Removal - 2.9L

Removal - 2.9L

  1. Remove the front bumper reinforcement. Refer to REINFORCEMENT, BUMPER, FRONT, REMOVAL AND INSTALLATION .
  2. Remove the air dam crossmember. Refer to AIR DAM, FRONT, REMOVAL AND INSTALLATION  or AIR DAM, FRONT CROSSMEMBER, REMOVAL AND INSTALLATION .
  3. Remove the radiator. Refer to RADIATOR, ENGINE COOLING, REMOVAL AND INSTALLATION .
  4. Remove the turbo charger heat exchangers. Refer to COOLER AND HOSES, CHARGE AIR, REMOVAL AND INSTALLATION .
  5. Remove the front steering knuckles. Refer to KNUCKLE, STEERING, REMOVAL AND INSTALLATION .
  6. Remove the front catalytic converters. Refer to CONVERTER, CATALYTIC, REMOVAL AND INSTALLATION .
    GC0198415Courtesy of CHRYSLER GROUP, LLC
  7. Using a suitable wrench, hold the pin (1a), remove the nut (1b) and disconnect the stabilizer bar link (1c) from the shock absorber.
    GC0198567Courtesy of CHRYSLER GROUP, LLC
  8. Remove the bolt (1) securing the shock absorber fork to the control arm.
    GC0197732Courtesy of CHRYSLER GROUP, LLC
  9. Disconnect the wire harness connections (1) for the steering gear.
    GC0197606Courtesy of CHRYSLER GROUP, LLC
  10. Disconnect the wire harness connection (1) for the turbo air cooling system temperature sensor.
    GC0198497Courtesy of CHRYSLER GROUP, LLC
  11. Release the retaining clip (1a) and disconnect the quick coupling (1b) of the return water pipe from the additional engine coolant radiator.
    GC0198484Courtesy of CHRYSLER GROUP, LLC
  12. Disconnect the wire harness connection (1) of the turbo air cooling system coolant electro-pump.
  13. Remove the bolt attaching the water supply line to the turbo air coolant radiator system to the crossmember.
  14. Remove the bolts (3a) and move the turbo air coolant system's water pump to one side (3b).
    GC0197807Courtesy of CHRYSLER GROUP, LLC
    15. NOTE:

    Position the steering wheel spokes in a the straight ahead position.

    NOTE:

    Avoid rotating the steering column until the steering column has been reconnected once again to the steering gear.

  15. Remove the bolt (1a) and disconnect the column (1b) from the steering gear.
    GC0198514Courtesy of CHRYSLER GROUP, LLC
  16. Remove the bolts (1a) and remove the left radiator support bracket (1b).
    GC0198560Courtesy of CHRYSLER GROUP, LLC
  17. Remove bolts (1a) and remove the right radiator support bracket (1b).
    GC0198140Courtesy of CHRYSLER GROUP, LLC
  18. Position the bumper reinforcement (1a) into place and tighten the nuts (1b) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0197686Courtesy of CHRYSLER GROUP, LLC
  19. Install the engine support tools 2000040436 or (special tool #8534C, Fixture, Driveline Support) (1).
    GC0197620Courtesy of CHRYSLER GROUP, LLC
  20. On both sides, remove the nut (1a) fastening the engine mount (1b) to the mount housing (1c).
  21. Place commercially available rubber spacer blocks, such as ROTFJ2427/J2440 or equivalent, on the (special tool #BX50-CHR, Table, Bishamon Lift) and position it under the crossmember assembly.
    GC0198180Courtesy of CHRYSLER GROUP, LLC
  22. Working on both sides, remove the front bolts attaching the front suspension crossmember to the body.
    GC0198099Courtesy of CHRYSLER GROUP, LLC
  23. Operating on both sides, remove the bolts (1a), (1b) and remove the suspension crossmember (1c).
    GC0198333Courtesy of CHRYSLER GROUP, LLC
  24. Working on both sides, remove the bolts (1a) and remove the engine mount (1b) from the crossmember.
    GC0198301Courtesy of CHRYSLER GROUP, LLC
  25. Remove bolts (1a) and remove steering gear (1b) from the crossmember.
    GC0198106Courtesy of CHRYSLER GROUP, LLC
  26. Remove the bolts (1a) and remove the stabilizer bar (1b) from the crossmember.
GC0198074Courtesy of CHRYSLER GROUP, LLC

INSTALLATION

  1. Position the stabilizer bar (1a) in its housing and tighten the bolts (1b) to the proper specification. Refer to FRONT, TECHNICAL SPECIFICATIONS .
    GC0197760Courtesy of CHRYSLER GROUP, LLC
  2. Install the steering gear (1a) and tighten the bolts (1b) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0198426Courtesy of CHRYSLER GROUP, LLC
  3. On both sides, place the isolators in their seats (1a) and tighten the bolts (1b) to the proper specification. Refer to TORQUE SPECIFICATIONS .
  4. Lift the suspension crossmember into place using the (special tool #BX50-CHR, Table, Bishamon Lift).
    GC0198007Courtesy of CHRYSLER GROUP, LLC
    GC0197666Courtesy of CHRYSLER GROUP, LLC
  5. On both sides, tighten the new bolts (1a) and (1b) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0198316Courtesy of CHRYSLER GROUP, LLC
  6. Working on both sides, tighten the new front bolts attaching the suspension crossmember to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
  7. Remove the equipment used for supporting the front suspension crossmember.
    GC0197727Courtesy of CHRYSLER GROUP, LLC
  8. On both sides, tighten the nut (1a) fastening the bracket (1b) to the isolator (1c) to the proper specification. Refer to TORQUE SPECIFICATIONS .
  9. Remove the tools used for supporting the engine.
  10. Place the radiator left mounting bracket in its housing and tighten the bolts. Proceed in the same way for the right side.
    GC0198042Courtesy of CHRYSLER GROUP, LLC
  11. Connect the steering column (1a) to the steering box pinion and tighten the new bolt (1b) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0198484Courtesy of CHRYSLER GROUP, LLC
  12. Refit the turbo air coolant system water pump in its seat and tighten the attaching bolts (3a) for the suspension crossmember to the proper specification. Refer to TORQUE SPECIFICATIONS GAS ENGINE .
  13. Refit the turbo air coolant system water pump pipe in its seat and tighten the attaching bolt (2) for the suspension crossmember to the proper specification. Refer to TORQUE SPECIFICATIONS GAS ENGINE .
  14. Connect the wire harness connector (1) of the turbo air cooling system coolant electro-pump.
    GC0198497Courtesy of CHRYSLER GROUP, LLC
  15. Connect the quick connector (1b) of the coolant inlet pipe to the additional engine coolant radiator (1a).
    GC0197606Courtesy of CHRYSLER GROUP, LLC
  16. Connect the wire harness connector (1) for the turbo air cooling system temperature sensor.
    GC0197732Courtesy of CHRYSLER GROUP, LLC
  17. Connect the wire harness connectors (1) for the steering gear.
    GC0197781Courtesy of CHRYSLER GROUP, LLC
  18. Connect the shock absorber fork to the lower rear wishbone and tighten the new attaching bolt (1) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0198458Courtesy of CHRYSLER GROUP, LLC
  19. Connect the left stabilizer bar (1a) joint to the shock absorber and tighten the new nut (1b) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
  20. Install the front catalytic converters. Refer to CONVERTER, CATALYTIC, REMOVAL AND INSTALLATION .
  21. Install the front steering knuckles. Refer to KNUCKLE, STEERING, REMOVAL AND INSTALLATION .
  22. Install the turbo charger heat exchangers. Refer to COOLER AND HOSES, CHARGE AIR, REMOVAL AND INSTALLATION .
  23. Install the radiator. Refer to RADIATOR, ENGINE COOLING, REMOVAL AND INSTALLATION .
  24. Install the air dam crossmember. Refer to AIR DAM, FRONT, REMOVAL AND INSTALLATION  or AIR DAM, FRONT CROSSMEMBER, REMOVAL AND INSTALLATION .
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