Drivetrain and Front Suspension Frame Replacement (Removal)
Drivetrain and Front Suspension Frame Replacement (Removal)
Special Tools
- KM-904 Base Frame
- KM-6390 Centering Equipment
- MKM-883-1 Engine Bridge
- MKM-883-2 Retaining Tool
Removal Procedure
1.Lock the steering wheel.
1.1Turn the steering wheel and front wheels to the straight-ahead position.
1.2Remove the ignition key.
1.3Engage the steering wheel lock.
Note:The screw is accessible from the vehicle interior.
2.Remove the intermediate spindle from steering gear.
2.1Remove the intermediate spindle clamping screw (1).
2.2Pull the intermediate spindle from steering gear spindle.
Warning:Refer to Battery Disconnect Warning .
3.Disconnect the battery.
4.Remove the battery shield (2).
4.1Remove the bolt (3).
4.2Remove the 2 shields (1) from battery carrier.
5.Remove the battery holder (1).
Remove the bolt.
6.Remove the battery.
7.Remove the battery carrier.
7.1Cut the 2 cable ties (1).
7.2Remove the 3 bolts (2).
Note:The cooling system remains closed.
8.Disconnect the coolant expansion tank.
8.1Disconnect the wiring harness plug.
8.2Place coolant expansion tank to one side.
9.Disconnect the 2 oxygen sensor wiring harness plugs.
10.Remove the headlamps. Refer to Headlamp Replacement - Left Side and Headlamp Replacement - Right Side or Headlamp Replacement .
11.Secure the radiator.
Insert a suitable wire bar into the bracket (1) at right and left.
12.Loosen the steering wiring harness.
12.1Detach the cover from positive distribution.
12.2Disconnect the wiring harness from the fuse (1).
12.3Disconnect the steering wiring harness (2).
12.4Disconnect the steering wiring harness ground cable (3) from ground terminal.
Note:Pay attention to cable routing.
12.5Expose the steering wiring harness, access required from below.
12.6Remove the cable ties.
12.7Remove the wiring harness from the bracket.
Note: MKM-883-1 and MKM-883-2 are used to ensure the engine will be in a horizontal position after removal of the front frame.
13.Prepare for attachment of MKM-883-1 and MKM-883-2 .
MKM-883-2
-Retaining spindle (1)
-Outrigger (3 off) (2)
-Retaining spindle (3 off) (3)
-Hex drives (2 off) (4)
-Support spindles (2 off) (5)
-Tensioning nuts (6 off) (6)
-Ring nuts (3 off) (7)
-First of all the alignment and attachment of MKM-883-2 will be described below on an engine-specific basis.
14.Attach MKM-883-2 , for U18 XER.
15.Remove the upper engine cover.
15.1Remove the oil filler cap.
15.2Install the oil filler cap.
Note:Read the manufacturer's instructions before attaching MKM-883-1 and MKM-883-2 .
16.Preassemble MKM-883-2 with fastening spindles, arms and supporting spindle as shown. Ensure that the hexagon drives point forwards.
17.Place MKM-883-2 on engine and attach fastening spindles to engine transport shackles.
18.Attach MKM-883-1 .
MKM-883-1
-Hoist (1)
-MKM-883-1 (2)
-Safety hook (3)
-Retaining spindle (4)
Note:Prevent from tilting using safety hooks (3) at engine hood hinge and wing.
19.Position MKM-883-1 .
20.Attach chain hook to the two outer eye nuts of MKM-883-2 .
21.Rotate the 2 tensioning chain drives until tensioning chains are under slight amount of pretension.
Note: MKM-883-2 must be in a horizontal position. Fastening spindles must be attached to the engine shackles so that they are vertical - if necessary, push arms and secure with clamping nuts
The tensioning chains must be in an exactly vertical position above the two outer ring nuts.
22.Align MKM-883-2 .
Evenly tension the fastening spindles by rotating the knurled nuts.
23.Install the retaining spindles to the center ring nut.
24.Apply slight tension to the retaining spindle.
25.Remove the 2 front wheels.
26.Remove the right engine splash guard.
26.1Remove the 4 bolts.
26.2Remove the 2 body-bound rivets.
27.Remove the right and left swing arms (2) from spring strut support tube.
Counterhold at flattened areas with open-ended wrench (1).
28.Release the tie rod ends from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement .
29.Remove the guide joint from the steering knuckle.
29.1Remove the guide joint bolt at both sides.
29.2Pull the guide joint out of steering knuckle.
30.If present, remove lower engine compartment cover.
31.Remove the front exhaust pipe with catalytic converter and center muffler. Refer to Mid Muffler Replacement .
32.Detach the shift guide from shift rod transmission.
32.1Remove the shift rod clamp.
32.2Detach the shift guide from shift rod.
33.Remove the engine damping block rear bracket (1) from the transmission.
Remove the 3 bolts.
34.Detach the front engine damping block from the front frame.
34.1Remove the nut.
34.2Remove the bolt (2).
35.Attach KM-904 and KM-6390 to hydraulic jack.
Note:Ensure that the guide pins of KM-6390 are seated in the guide holes in the vehicle underbody. The front frame bolts must not be removed using an impulse or impact screwdriver. Pay attention to different bolt lengths and different washers.
36.Place the hydraulic jack beneath the frame body (no clearance).
Note:For greater clarity, the illustration shows the front frame without hydraulic jack and centring mount.
37.Detach the front frame from the front frame.
37.1Remove the 6 bolts (2).
37.2Remove the triangular plates.
37.3Remove the 2 bolts (1), right and left.
Note:Ensure that no attaching parts are damaged. Pay attention to steering wiring harness.
37.4Remove the 2 bolts (3).
38.Carefully lower front frame using hydraulic jack.
39.Replace the front frame. Refer to Drivetrain and Front Suspension Frame Replacement .
Installation Procedure
Note:Before installing the front frame, check the threads of captive nuts for free movement.
1.Install the front frame to the front frame.
Note:Ensure that the guide joint protective sleeves are not damaged.
2.Raise the front frame with hydraulic jack, KM-904 and KM-6390 .
Caution:Refer to Fastener Caution .
Note:
-Ensure that the guide pins of KM-6390 are seated in the guide holes in the vehicle underbody.
-Ensure that the engine damping blocks front and rear are positioned perfectly.
-Be careful of the wiring harness for steering. Installing the front frame with an impulse screwdriver or impact screwdriver is not permitted. Note the bolt lengths and washers. Tighten bolts evenly at all fastening points.
3.Align the front frame and tighten the 4 new bolts to90 N �m (67 lb ft) plus 45 degrees plus 15 degrees.
4.Install the triangular plates and tighten the 6 new bolts to90 N �m (67 lb ft) plus 45 degrees plus 15 degrees.
5.Detach the hydraulic jack, KM-904 and KM-6390 .
Note:Clean the thread and insert bolts with locking compound.
6.Install the bracket for rear engine damping block to the transmission and tighten to80 N �m (59 lb ft).
7.Install front engine damping block to the front frame and tighten to55 N �m (40 lb ft).
7.1Insert the bolt.
7.2Install the new nut.
8.In vehicles with manual transmission, install the shift guide to shift rod.
8.1Slide onto the shift rod.
8.2Install the clamping screw loosely.
8.3Place rocker onto the shift guide bracket.
8.4Secure using new retaining clip.
9.Install the front exhaust pipe, catalytic converter and center muffler. Refer to Mid Muffler Replacement .
10.If present, install the lower engine compartment cover.
11.Connect the guide joint to the steering knuckle on the right and left side and tighten the 2 new nuts to50 N �m (37 lb ft).
12.Connect the tie rod end to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement .
13.Install the swing arm to the spring strut support tube on the right and left side and tighten to55 N �m (40 lb ft).
13.1Use 2 new nuts.
13.2Counterhold at the two flattened areas with open-ended wrench.
14.Install the right lower wheelhouse paneling and tighten to5 N �m (44 lb in).
15.Install the front paneling. Refer to Front Bumper Fascia Replacement .
16.Install the right and left engine splash guards.
17.Install the front wheels and tighten to110 N �m (81 lb ft).
18.Disconnect MKM-883-1 and MKM-883-2 from the engine.
19.Connect the steering wiring harness.
20.Connect the ground connection to insulated ground terminal.
21.Connect the steering wiring harness plug.
22.Install the coolant expansion tank to bracket.
23.Install the upper engine cover.
23.1Remove the oil filler cap.
23.2Install the upper engine cover.
23.3Install the 2 bolts and tighten to8 N �m (71 lb in).
23.4Install the oil filler cap.
24.Install the headlamps. Refer to Headlamp Replacement - Left Side and Headlamp Replacement - Right Side or Headlamp Replacement .
25.Remove the wire brackets for securing radiator.
26.Position the wheels in straight-ahead position.
Note:
-Before inserting the clamp bolt (1) make certain that the steering shaft groove (arrow) is flush with the intermediate shaft bore.
-Clean thread and screw in bolt with locking compound.
27.Slide the intermediate spindle (2) onto steering gear spindle and tighten clamping bolt (1) on intermediate shaft to24 N �m (18 lb ft).
28.For vehicles with shift guide, adjust the shift. Refer to Selector Lever Link Adjustment .
29.Install the battery carrier and tighten the 3 bolts to15 N �m (11 lb ft).
30.Connect the 2 cable ties.
31.Install the battery.
32.Install the battery shield.
33.Install the bolt.
Connect the 2 shield, battery carrier.
34.Install the battery holder and tighten the bolt to 7 N �m (62 lb in).
35.Connect the battery.
Connect the positive cable.
Connect the ground cable.
36.For programming procedures, refer to Control Module References .