FRONT CROSSMEMBER REMOVAL/INSTALLATION

id021300801000

Special Service Tool (SST)

49 T028 3A0   Ball joint puller set

Caution

•  Performing the following procedures could cause an open circuit in the front ABS wheel-speed sensor wiring harness if it is pulled by mistake. Before servicing, disconnect the front ABS wheel-speed sensor and set it aside so that the wiring harness will not be pulled by mistake.

•  Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

•  Do not allow the dust boot of the front stabilizer control link to touch the body, the front shock absorber and coil spring, and the hand tool. Otherwise, the dust boot of the front stabilizer control link could be damaged.

1.  Remove the wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

2.  Disconnect the front ABS wheel-speed sensor wiring harness installed to the steering knuckle and set it aside. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

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3.  Remove the following parts:

(1)  Front under cover No.2 (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

(2)  Front under cover No.1 (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.)

(3)  Front splash shield (See SPLASH SHIELD REMOVAL/INSTALLATION.)

4.  Disconnect the wiring harness from the front crossmember. (With i-ELOOP)

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5.  Detach the tie-rod end from the steering knuckle using the SST. (See TIE-ROD END REPLACEMENT.)

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6.  Disconnect the front lower arm ball joint from the steering knuckle. (See FRONT LOWER ARM REMOVAL/INSTALLATION.)

7.  Remove the screws shown in the figure and partially peel back the front mudguard.

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8.  Remove the front crossmember extension.

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9.  Disconnect the front stabilizer control link (front stabilizer side).

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10.  Remove the insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

11.  Disconnect the hanger rubber from the front crossmember and set it aside.

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12.  Remove the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

13.  Disconnect the intermediate shaft from the steering gear and linkage. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

14.  Remove the bolt shown in the figure.

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15.  Remove in the order indicated in the table.

16.  Install in the reverse order of removal. (See Suspension Links Installation Note.)

17.  When replacing the front crossmember, inspect the wheel alignment and adjust it if necessary. (See FRONT WHEEL ALIGNMENT.)

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1	No.1 engine mount rubber installation bolt (See No.1 Engine Mount Rubber and Front Crossmember Component Installation Note.)
2	Front crossmember component (See Front Crossmember Component Removal Note.) (See No.1 Engine Mount Rubber and Front Crossmember Component Installation Note.)
3	Front stabilizer insulator (SKYACTIV-G 2.5T)
4	Front stabilizer (See FRONT STABILIZER REMOVAL/INSTALLATION.)
5	Steering gear and linkage (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)
6	Front lower arm (See FRONT LOWER ARM REMOVAL/INSTALLATION.)
7	No.1 engine mount rubber (See No.1 Engine Mount Rubber and Front Crossmember Component Installation Note.)
8	Front crossmember

Front Crossmember Component Removal Note

Warning

•  Removing the crossmember is dangerous. The crossmember component could fall and cause serious injury or death. Verify that the jack securely supports the crossmember component.

1.  Support the front crossmember component using a jack.

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2.  Remove the front crossmember installation bolts.

3.  Remove the front crossmember, front stabilizer, front lower arm, and steering gear and linkage as a single unit.

Suspension Links Installation Note

1.  When installing the joint sections with rubber bushings, perform the following procedures:

(1)  Temporarily tighten the bolts with the vehicle lifted up.

(2)  Lower the vehicle to the ground and tighten the bolts to the specified torque.

No.1 Engine Mount Rubber and Front Crossmember Component Installation Note

Caution

•  When installing the front crossmember component to the vehicle, assemble the dust cover to the body-side installation area correctly to prevent water or foreign material from penetrating. Install the dust cover carefully so as not to pinch the dust cover sponge to the body-side installation area or put a fold line on the sponge by contact.

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1.  Temporarily tighten bolt A shown in the figure.

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2.  Temporarily tighten bolt B shown in the figure.

3.  Tighten bolt A.

4.  Tighten bolt B.