Repair Procedures

REMOVAL

1. Remove the front wheel & tire.
2. Disconnect the power steering pressure tube from the pump by loosening the eye bolt and loosen pressure hose bracket bolt.
3. Loosen the bolt (A) and then disconnect the universal joint assembly (B) from the pinion of the steering gear box.




4. Disconnect the power steering return hose (A).




5. Loosen the nut (B) and then disconnect the stabilizer link (A) with the mounting fork.




6. Remove the split pin and castle nut (A).




7. Disconnect the tie-rod end from the knuckle by using SST (09568-34000).




8. Disconnect the lower arm with knuckle by loosening the mounting bolts (A).




9. Remove the through bolt (C) and nut and then disconnect the mounting fork (A) with the lower arm (B).




10. Remove the muffler rubber hanger (A).




11. Remove the front roll stopper through bolt (A) and nut.




12. Loosen the rear roll stopper mounting bolts (A).




13. Remove the sub-frame (A) from the body by loosening the mounting bolts and nuts.




14. Remove stabilizer from the sub-frame by loosening the bracket mounting bolts (A).




15. Disconnect the stabilizer link (A) with the stabilizer bar by loosening the nut.




16. Remove the bushing (A) and the bracket (B) from the stabilizer bar.






INSTALLATION

1. Install the bushing (A) and the bracket (B) to the stabilizer bar.




2. Connect the stabilizer link (A) with the stabilizer bar by tightening the nut.

Tightening torque Nm (kgf.m, lb-ft):
100 - 120 (10.0 - 12.0, 72 - 87)






3. Install the stabilizer to the sub-frame by tightening the bracket mounting bolts (A).

Tightening torque Nm (kgf.m, lb-ft):
45 - 55 (4.5 - 5.5, 33 - 40)






4. Install the-sub frame (A) and the sub-frame stay by tightening the mounting bolts and nuts.

Tightening torque Nm (kgf.m, lb-ft):
Sub-frame mounting bolts:
100 - 120 (10.0 - 12.0, 72 - 87)
Sub-frame stay mounting bolt & nut:
45 - 55 (4.5 - 5.5, 33 - 40)






5. Tighten the rear roll stopper mounting bolts (A).

Tightening torque Nm (kgf.m, lb-ft):
50 - 65 (5.0 - 6.5, 40 - 47)






6. Install the front roll stopper through bolt (A) and nut.

Tightening torque Nm (kgf.m, lb-ft):
50 - 65 (5.0 - 6.5, 40 - 47)






7. Install the muffler rubber hanger (A).




8. Connect the mounting fork (A) with the lower arm (B) and tighten the through bolt (C) and nut.

Tightening torque Nm (kgf.m, lb-ft):
140 - 160 (14.0 - 16.0, 101 - 116)






9. Connect the lower arm with the knuckle by tightening the bolts (A).

Tightening torque Nm (kgf.m, lb-ft):
100 - 120 (10.0 - 12.0, 72 - 87)






10. Connect the tie-rod end with the knuckle and then install the castle nut (A) and split pin.

Tightening torque Nm (kgf.m, lb-ft):
24 - 34 (2.4 - 3.4, 19 - 31)






11. Connect the stabilizer link (A) with the mounting fork and tighten the nut (B).

Tightening torque Nm (kgf.m, lb-ft):
100 - 120 (10.0 - 12.0, 72 - 87)






12. Connect the universal joint assembly (B) with the pinion of the steering gear box and then tighten the bolt (A).

Tightening torque Nm (kgf.m, lb-ft):
30 - 35 (3.0 - 3.5, 22 - 25)






13. Connect the power steering return hose (A).




14. Connect the power steering pressure tube with the power steering pump by tightening the eye bolt.

Tightening torque Nm (kgf.m, lb-ft):
55 - 65 (5.5 - 6.5, 40 - 47)


15. Install the front wheel & tire

Tightening torque Nm (kgf.m, lb-ft):
90 - 110 (9.0 - 11.0, 65 - 80)


16. Bleed power steering system.