Instructions
Body Structures / Front Structures / Front Crash Structure / DA-RM-01A001-01-001 - Remove/Install crash structure - Front - Right
Preparation work
1.     
Care Point: Only remove components if replacing the corresponding crash structure.
2.     
Care Point: Remove both sides.
3.     
Care Point: Remove both sides.
4.     
5.     
6.     
7.     
8.     
Care Point: Remove both sides.
9.     
10.    
11.    
12.    
Care Point: Detach gas struts from both ends and remove from vehicle.
13.    
14.    
15.    
Care Point: Disconnect electrical connector and detach manual release cable only.
16.    
Care Point: Remove both sides.
17.    
Care Point: Disconnect Headlamps, side markers/side repeaters and signal lamps, remove bumper with lights attached.
18.    
19.    
20.    
21.    
Care Point: Detach coolant hoses only.
22.    
Care Point: Disconnect Horn/Alarm control unit/Ambient temperature sensor/homelink unit. Remove duct as an assembly.
23.    
24.    
25.    
Care Point: Driver side only.
26.    
Care Point: Disconnect only.
27.    
Care Point: Remove wishbone to actuator bolt only.
28.    

WARNING!
 
Risk of poisoning and injury when handling brake fluid!
Swallowing brake fluid can cause symptoms of poisoning such as headaches, dizziness, stomach pains, vomiting, diarrhoea, cramps and unconsciousness.
A dose of more than 100 cm3 can have fatal consequences.
Contact with brake fluid can cause serious skin damage to unprotected skin.
Wear safety glasses and protective clothing such as rubber gloves.
Ensure that brake fluid is only accessible to authorized personnel.
Store brake fluid in original containers only.
Only store brake fluid in suitable, appropriately marked containers.
Never put brake fluid in beverage containers.
 

WARNING!
 
Risk of injury and poisoning working with hydraulic fluid!
Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure. When disengaging hydraulic lines without depressurising the system, dangerous skin or eye injuries can occur due to the very high pressures (in excess of 200 bar). If hydraulic fluid, particularly central hydraulic fluid (especially harmful), comes into contact with unprotected skin, this can cause damage to the skin.
If hydraulic fluid is swallowed, this can lead to poisoning symptoms such as headache, dizziness, nausea, vomiting, diarrhoea, cramps and unconsciousness.
Wear protective gloves, protective clothing and eye protection.
Depressurise and drain the system if necessary when commencing work on hydraulic systems.
Never put hydraulic fluid into beverage containers.
Ensure sufficient ventilation, especially in the case of central hydraulic fluid.
Ensure that only authorised persons have access to hydraulic fluid.
Immediately seal disconnected leads and hoses and the connections to the assembly with blind plugs.
 

WARNING!
 
Risk of injury and poisoning working with hydraulic fluid!
Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure. When disengaging hydraulic lines without depressurising the system, dangerous skin or eye injuries can occur due to the very high pressures (in excess of 200 bar). If hydraulic fluid, particularly central hydraulic fluid (especially harmful), comes into contact with unprotected skin, this can cause damage to the skin.
If hydraulic fluid is swallowed, this can lead to poisoning symptoms such as headache, dizziness, nausea, vomiting, diarrhoea, cramps and unconsciousness.
Wear protective gloves, protective clothing and eye protection.
Depressurise and drain the system if necessary when commencing work on hydraulic systems.
Never put hydraulic fluid into beverage containers.
Ensure sufficient ventilation, especially in the case of central hydraulic fluid.
Ensure that only authorised persons have access to hydraulic fluid.
Immediately seal disconnected leads and hoses and the connections to the assembly with blind plugs.
 

WARNING!
 
Risk of injury and poisoning working with hydraulic fluid under pressure!
Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure. If any part of the hydraulic circuit has failed, a possibility of the system not depressurising can occur. Extra precaution is required in this event. If hydraulic fluid is swallowed, this can lead to poisoning symptoms such as headache, dizziness, nausea, vomiting, diarrhoea, cramps and unconsciousness.
Always wear skin protection cream, protective gloves and safety glasses when working on a potentially pressurised system.
 

Depressurise Suspension System
 
Care Point:
The suspension system must be depressurised before any work on the hydraulic system can begin.

 
1.  
Connect McLaren Diagnostic System (MDS), proceed to Diagnostic Toolbox within Chassis Control Unit (CCU).
 
2.  
Access Sequences section.
 
3.  
Carry out APMU Maintenance Start.
 

Remove crash structure - Front
 
Care Point:
Harness completely removed from all graphics for clarity.

 
1.  
Working along fender brackets, detach electrical harnesses.
 
2.  
Working along crash structure, detach electrical harnesses and suspension pipe clips.
 

 
Care Point:
Vehicles fitted with nose lift option only.

 
3.  
Detach nose lift pressure line (1) from clips.
 
4.  
Remove bolts (2). (M8x20) 25 Nm
 
5.  
Remove bolts (3). (M8x25) 38 Nm
 

6.  
Detach brake system fluid line (4) from clips.
 
7.  
Remove bolts (5). (M8x20) 25 Nm
 
8.  
Remove bolt (6). (M12x25) 50 Nm
 
9.  
Remove crash structure (7) from vehicle.
 


Install crash structure - Front
1.   
Set up vehicle on celette bench.
 
2.   
Install crash structure to vehicle and hand tighten bolts.
 

3.   
Torque bolts in sequence (1 - 10).
 
4.   
Using celette bench, install replacement fender brackets.
 
5.   
Install remaining components in reverse order.
 
6.    
7.    
8.    
9.    
10.   


   
   
   Note