05/10/2023 09:06:13

Subframe Assembly - Front (1st Generation) (RWD) (Remove and Install)

Correction Code 30010301

This procedure is for RWD vehicles built through April 10, 2016.

For other generation front subframe assemblies, see also:

Special tools required for this procedure:

  • 1021241-00-B - Subframe Fixture, Rear, MDLS
  • 1021242-00-C - Subframe Fixture, Front Jig - MDLS

    or

  • 1063646-00-A - Model S/X Legacy Subframe Lift Fixture
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
If the vehicle has air suspension, activate "Jack" mode on the touchscreen before raising and supporting the vehicle.
  • 2023-10-05: Added alternative special tool.

Removal

  1. Center the steering wheel, and then install the steering wheel holder. Make sure that the front road wheels are in a straight ahead position.
  2. Remove the underhood storage unit (refer to procedure).
  3. Disconnect 12V power (refer to procedure)..
  4. Remove the front wheels (refer to procedure).
  5. Remove the HV battery (refer to procedure).
  6. Remove the front skid plate (refer to procedure).
  7. Remove the front skid bar from the front subframe (refer to procedure).
  8. Remove the bolts (x2) that attach the battery chiller to the subframe (torque 5 Nm).
  9. Remove the nuts (x2) and bolts (x2) that attach the A/C compressor bracket to the subframe (torque 10 Nm).
  10. Partially lower the vehicle to a comfortable working height.
  11. Remove battery coolant pump 1 from the subframe bracket (refer to procedure).
    Informational PurposesAn informational icon, calling your attention
    Note
    The coolant hose is still between the subframe and the stabilizer bar.
  12. Remove battery coolant pump 2 from the subframe bracket (refer to procedure).
  13. Release the bolts (x2) that attach the center 3 way valve, and then remove the connector.
  14. Disconnect the steering rack connectors (x2) from the steering rack.
  15. Remove the bolts (x2) that attach the vacuum pump to the subframe (refer to procedure).
  16. Remove the bolts (x2) that attach the air suspension pump bracket to the subframe (torque 5.5 Nm).
  17. Release the rear bolt that attaches the radiator bypass 3 way coolant valve to the subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    The forward bolt that attaches the radiator bypass 3 way coolant valve is removed in a later step, as it is only accessible from under the vehicle.
  18. On both sides of the vehicle, release the clips (x2) that attach the coolant hose to the subframe brackets.
  19. Place a metal rod or similar across the top of the front frame rails.
  20. Partially raise the vehicle to a comfortable working height.
  21. On both sides of the vehicle, loosen but do not remove the tie rod ends (refer to procedure).
  22. Fully raise the vehicle to a comfortable working height.
  23. On each side of the vehicle, release the bolts (x2) that attach the stay bar, and then remove the stay bar (torque 11 Nm).
  24. Remove the bolts (x3) that attach the air valve block to the subframe (torque 5.5 Nm).
  25. Remove the nuts (x2) that attach the ABS modulator pump to the subframe, and then release the ABS modulator pump from the rubber mounting (refer to procedure).
  26. Remove the forward bolt that attaches the radiator bypass 3 way coolant valve to the subframe bracket (torque 5 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    The rear bolt was removed from above the vehicle in a prior step.
  27. On each side of the vehicle, remove and discard the nut (x1) that attaches the stabilizer bar to the stabilizer bar end links (refer to procedure).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the stabilizer bar at this time.
  28. On both sides of the vehicle, remove the bolt (x1) and nut (x1) that attach the front shock absorber to the rear lower control arm (torque 140 Nm).
  29. Remove and discard the LH and RH lower control arm nuts (x2) and washers (x2) (torque 196 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    To prevent ball joint damage, always hold the ball joint pin with a wrench while loosening or tightening the lock nut.
  30. Remove the bolt that attaches the lower intermediate shaft to the steering rack, and then slide the shaft off of the rack (refer to procedure).
  31. Remove the bolts (x4) that attach the front subframe to the bumper carrier:
    • Composite carrier: 7.5 Nm
    • Magnesium carrier: 11 Nm
  32. Install the front subframe jig onto the subframe fixture.
  33. Install the locating pins in the appropriate location.
    1 Rear wheel drive
    2 Dual motor
  34. Have an assistant lower the vehicle. Guide the front subframe onto the fixture.
  35. On each side of the vehicle, remove the bolts that attach the subframe to the chassis:
    • Forward bolt (x2) (torque 140 Nm)
    • Rear bolt (x2) (Torque 76 Nm)
  36. Lower and tilt the subframe back to remove it from the carrier, and then move the subframe away from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Protect coolant hoses and the chiller by feeding them past the stabilizer bar.
  37. On both sides of the vehicle, remove the bolt (x1) that attaches the subframe brace to the subframe (torque 26 Nm).
  38. Remove the stabilizer bar from the subframe.
  39. Noting the number of turns required, unscrew the LH and RH tie rod ends that were loosened in a previous step, and then remove them from the vehicle.
  40. Remove the bolts (x2) that attach the steering rack assembly to the subframe, and then remove the steering rack assembly from the subframe (torque 175 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    A washer might be located between the steering rack and the subframe. Retain and use this washer during reinstallation of the steering rack.

Installation

Installation procedure is the reverse of removal, except for the following:
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Only use cleaning agents and solvents in a well-ventilated area.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Replace all patchbolt(s).
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Replace all nylon-insert locknuts.
Informational PurposesAn informational icon, calling your attention
Note
Clean the affected areas before installation.

Observe the following:

  • Align the witness marks on the chassis and subframe.
  • Make sure that all subframe fixing bolts are started before attempting to tighten.
  • Align the suspension components to the subframe and set the cams to the previously marked positions. Do not fully tighten at this time.
  • Remove the suspension from "Jack" mode, and then set to "Standard" and allow the suspension to settle.

Perform the following:

  1. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  2. Unlock the vehicle gateway. See Gateway Unlock.
  3. In Toolbox 3, click the Actions tab, type "Calibrate-Steering-Column" into the search field, click PROC_EPAS_X_CALIBRATIONSearch for routine in ToolboxBosch EPAS Calibration, click Run, and allow the routine to complete.
  4. In Toolbox 3, click the Actions tab, type "ESP-CONFIG" into the search field, click PROC_ESP_X_ESP-CONFIGSearch for routine in ToolboxESP ConfigurationChassis / Brakes - ESP Config, click Run, and allow the routine to complete.
  5. Transfer the vehicle to a 4 post lift (refer to procedure).
  6. Perform a Lock To Lock-Angle test. See Lock To Lock-Angle Test.
  7. Fully torque all suspension components at ride height.
  8. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  9. Refer to the Alignment Requirement tables to determine whether an EPAS alignment check (EC) or four wheel alignment check (AC) is necessary. If performed, add the alignment check/adjust as a separate activity. See Alignment Requirement - Suspension.