Service Procedure
- Service ProcedureInspection Procedure:
Open hood and check for SC 075 Campaign completion label on the panel above the master cylinder. If label exists, NO FURTHER ACTION IS REQUIRED.
If label does not exist, continue to step one (1) of the service procedure until completion.
1. Raise the vehicle on a hoist in preparation for the underbody inspection of the subframe.
2. Inspect the entire subframe assembly for any external signs of severe corrosion/perforation. a) If any perforation or open cavity is found in the subframe, do not continue repairing. Replace the subframe according to TSB GEN 026. If no signs of perforation or severe corrosion are found continue to step (b).
b) Using a hammer, lightly tap the entire subframe in several areas to check for any material which may be nearing the perforation stage. If the hammer opens up a cavity in the subframe, replace the subframe according to TSB GEN 026.
NOTICE
SERVICE PROCEDURE:
1. In preparation for the drilling of the 40 mm hole-saw cuts for the front / rear subframe sites, the following identification procedure must be utilized to ensure the proper drilling location. The 40 mm hole-saw site locations will be numbered as follows: (1-4) / (Large Blue Holes).
2. Located on the left-rear of the subframe is drilling site location (One) 1. Using a straight edge ruler, scribe or draw a seventy (70) mm line from the end of the horizontal weld (dashed Line).
3. Referencing the dashed line, measure thirty (30) mm from the outer horizontal weld (dashed line) and mark this location. From this new reference mark, measure ten (10) mm forward from this position and mark this location as the center point of the drilling. Drill this location using the forty (40) mm hole-saw (Drill speed recommendation: 380 ~ 470 rpm).
CAUTION
4. Repeat this same procedure (Step 4 & 5) for location Two (2) drill site on the right-rear side of the subframe. Drill this location using the 40 mm hole-saw (Drill speed recommendation: 380 ~ 470 rpm).
5. Debur the holes on both sides in several areas around the edges of the 40 mm hole so that an accurate judgment of the subframe material thickness can be made.
WARNING
6. Insert the 1.5 mm side (smallest width) of the thickness gauge. Attempt to slide the thickness gauge over the edge of the hole in several different locations on both left/right rear inspection sites.
NOTICE
a) If the thickness gauge (B) is able to pass over the subframe material, it has failed the 1.5 mm minimum thickness test. Replace the subframe according to TSB GEN 026.
b) If the gauge will not pass over the subframe material, the corrosion preventive treatment can be performed. Proceed to the next step.
7a. In preparation for drilling the 40 mm hole-saw site three (3) in the right front, the following method must be used to insure proper drilling location. Locate the center point of the right side subframe bushing bolt, use a straight edge to draw a horizontal line for 19 mm inboard. From the end of the 19 mm horizontal line, use a straight edge to draw a vertical line for 294 mm. From the end of the 294 mm vertical line, mark this location as the center point for drilling. Drill this location using the 40 mm hole-saw. (Drill Speed Recommendation: 380 ~ 470 rpm).
CAUTION
NOTICE
7b. In preparation for drilling the 40 mm hole-saw site four (4) in the left front, the following method must be used to insure proper drilling location. Locate the center point of the left side subframe bushing bolt, use a straight edge to draw a horizontal line for 21 mm inboard. From the end of the 21 mm horizontal line, use a straight edge to draw a vertical line for 266 mm. From the end of the 266 mm vertical line, mark this location as the center point for drilling. Drill this location using the 40 mm hole-saw. (Drill Speed Recommendation: 380 ~ 470 rpm).
8. Place the LH and RH templates against the underside of the subframe, just parallel to the control arm with the arrows pointing forward. Align the outlines on the templates to the outboard shape of the subframe. Ensure proper orientation of the front (Frt) alignment of the templates for left/right. Use a grease pen to mark through the two holes on each template.
9. Using an 8mm drill, drill four (4) holes in the locations marked in the previous step. Debur all 8mm holes.
CAUTION
10. Use the following procedures to remove as much of the rust fragments as possible from inside the subframe.
a) Strike the underside of the subframe lightly with a hammer to cause vibration and dislodge any rust scale.
NOTICE
b) Insert a magnetic pick up tool through each of the four 40mm holes and pull the magnet along in either direction as far as possible to remove any larger fragments.
c) Insert either of the two air blow guns into each of the four 40mm holes and use shop air to blow as much of the rust particles as possible from inside the sub frame. In some cases, if there is a large amount of loose rust scale present you may have to repeat the above steps another 2 to 3 times.
CAUTION
11. Pour one bottle of VG-101 Rust Preventive (Cavity Wax) into the wax injection container and connect the 90 degree nozzle assembly (shown). Spray the cavity wax into each of the four 40mm holes and in all directions until using the entire bottle of cavity wax. You should begin to see some of the cavity wax draining from the four drain holes and other open areas of the subframe.
NOTICE
After completing the cavity wax application, continue to blow shop air through the nozzle for a short time to clear any material from the nozzle.
Use a shop towel to clean any excess wax that has been sprayed onto the exterior portion of the sub frame or is dripping from the drain holes.
CAUTION
12. Spray undercoating on the underside of the subframe near the four (4) 40 mm access holes and 8 mm drain holes. Do not spray the entire subframe with undercoating.
13. Cover all four (4) of the 40mm access holes with the hole plugs listed in the parts information section and apply a small amount of undercoating across the plugs.
14. Lower the vehicle, open the hood and install the SC075 completion label on the panel above the the master cylinder.