Front
R and R front stabilizer bar
Stabilizer bar (10)
Rubber bushing for stabilizer bar mounts (21a)
Bracket for stabilizer bar mount (21b)
Left and right covers (21c and 21d)
Rubber bushing (22a)
Plate washer (22b)
Tapered washer (22c)
Hex. head bolt (22d)
Top control arm (32)
Bulkhead center section (60)
Special Tools:
Note In order to avoid distorting the support for the top control arm on the stabilizer bar during assembly, position the jackstands below the bottom control arms, not below the frame floor.
Install and tighten stabilizer bar mount on front end and support for top control arm on stabilizer bar only when they are in a position corresponding to the ready-to-drive state.
Always use new self-locking hex. nuts
Removal
1. Jack vehicle up at front. Position jackstands below bottom control arms. Remove front wheels.
2. Loosen support for top control arm (32) on stabilizer bar (10), remove hex. head bolt with tapered washer (22c), plate washer (22b) and rubber mount (22a).
3. Remove air cleaner.
4. Remove bulkhead center section (60) and bulkhead left side section.
5. Remove tandem master cylinder and brake booster.
6. Remove windshield wiper and cover.
7. Remove control unit for electronic speed control. Remove ABS control unit as well as associated bracket on firewall.
8. Remove battery and battery support.
9. Drain coolant. Remove control valve for automatic climate control.
10. Remove water hoses and pipes in area of firewall.
11. Remove bulkhead right side section.
12. Evacuate air conditioner.
13. Disconnect hoses for air conditioner on expansion valve in passenger compartment.
14. Remove mounts for brake line on left and right sides of firewall.
15. Remove mount for fuse box (arrow) at bottom of firewall.
16. Remove control linkage.
17. Remove bulkhead right bottom section.
Location on right side:
Location on left side:
18. Screw off hex. nuts for stabilizer bar mount on left and right sides of front end, remove retaining brackets (21b).
19. Remove covers on left (21c) and right (21d) of front end.
20. Press stabilizer bar out of control arm eye with suitable tool (arrow).
Right side:
Left side:
21. Remove stabilizer bar by moving to right first, then turning as required and moving upward and to left.
22. Check rubber mounts for stabilizer bar mounts on front end and support for top control arm on stabilizer bar.
The contact surface for the rubber mount on the stabilizer bar must be free of grease and oil (arrow).
Installation
23. Insert stabilizer bar so that curve in stabilizer bar arms points downward (arrow), see item 24.
24. Insert ends of stabilizer bar into mounting holes, use appropriate lever as installation aid, if required.
25. Install support for top control arm on stabilizer bar.
Caution When installing the hex. head bolt (22d) ensure that the rubber mounts are not distorted in the control arm eye.
26. Slide rubber mount for stabilizer bar mounts on front end onto stabilizer bar with separating slit toward rear.
27. Install retaining bracket. Use new self-locking hex. nuts!`
28. Install left and right covers on front end.
29. Connect coolant hoses and electrical cables.
30. Install mount for fuse box at bottom of firewall (arrow).
31. Fasten fuse box.
32. If necessary completely loosen mount for parking brake in passenger compartment to install rubber grommet.
33. Connect hoses for air conditioner to expansion valve. Connect duo valve and water hoses, fill system with coolant and perform pressure test.
34. Install bulkhead. Install engine control shaft. Install battery support.
35. Install cover for windshield wiper compartment and windshield wiper.
36. Install tandem master cylinder and brake booster.
37. Install all electrical lines, ABS control unit, control unit for speed control and battery. Install windshield washer tank with lines.
38. Install air cleaner.
39. Mount front wheels.
40. Lower vehicle.
41. Charge air conditioner. Install cover on left side of instrument panel.
42. Check vehicle level, adjust, if required.