Repair Procedures

REMOVAL

1. Remove the both front wheels.
2. Drain the power steering fluid by disconnecting the return hose (A).




3. Disconnect the pressure tube (A) from the power steering pump by loosening the eye bolt.








4. Disconnect the stabilizer link (A) with the strut assembly by loosening the nut.




5. Remove the split pin and castle nut and then disconnect the tie-rod end (A) with the knuckle using a SST (09568-34000).




6. Separate the knuckle with the lower arm by loosening the mounting bolts (A).




7. Loosen the bolt (A) and then disconnect the universal joint assembly (B) with the pinion of the steering gear.




8. Remove the muffler rubber hanger (A).




9. Remove the front and rear roll stopper through bolts & nuts (A, B).








10. Remove the sub-frame (A) and stay by loosening mounting bolts.




11. Loosen the return hose mounting bracket bolt (A).




12. Remove the rear roll stopper (A) from the sub-frame by loosening the mounting bolts.




13. Remove the heat protector (A).




14. Remove the pressure (A) and return tube (B) from the steering gear box.




15. Remove the steering gear box from the sub-frame by loosening the mounting bolts.






INSTALLATION

1. Install the steering gear box (A) to the sub frame by tightening the mounting bolts.

Tightening torque Nm (kgf.m, lb-ft):
60 - 80 (6.0 - 8.0, 43 - 58)




2. Install the pressure tube (A) and return tube (B) to the steering gear box and then tighten the flare nut.

Tightening torque Nm (kgf.m, lb-ft):
12 - 18 (1.2 - 1.8, 9 - 13)




3. Install the heat protector (A).




4. Install the rear roll stopper (A) to the sub-frame by tightening the mounting bolts.

Tightening torque Nm (kgf.m, lb-ft):
50 - 65 (5.0 - 6.5, 36 - 47)




5. Install the return hose mounting bracket (A) to rear roll stopper.




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

Tightening torque Nm (kgf.m, lb-ft):
Sub-frame mounting bolt:
160 - 180 (16.0 - 18.0, 116 - 130)
Sub-frame stay mounting bolt:
45 - 55 (4.5 - 5.5, 33 - 40)




7. Install the front and rear roll stopper through bolts and nut (A, B).

Tightening torque Nm (kgf.m, lb-ft):
50 - 65 (5.0 - 6.5, 36 - 47)








8. Connect the return hose (A).




9. Install the muffler rubber hanger (A).




10. 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)




11. Connect the tie rod end with the knuckle and then install the castle nut and split pin.

Tightening torque Nm (kgf.m, lb-ft):
24 - 34 (2.4 - 3.4, 17 - 25)

12. Connect the stabilizer link (A) with the front strut assembly and than tighten the nut.

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




13. 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)




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

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

15. Add power steering fluid to reservoir.
16. Bleed the power steering system.
17. Check and adjust front wheel alignment.