FRONT CROSSMEMBER REMOVAL/INSTALLATION

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Caution
•  If the front ABS wheel-speed sensor wiring harness is pulled by mistake when performing this procedure, it could cause open circuit. Before servicing, disconnect the front ABS wheel-speed sensor and set it aside so that the wiring harness will not be pulled by mistake.
•  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. After disconnecting the steering shaft, secure the steering wheel using tape or cable to prevent it from rotating.
•  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 wheel and tire. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

2.  Disconnect the front ABS wheel-speed sensor wiring harness on the steering knuckle and set it aside so that it does not interfere with the servicing.

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3.  Remove the following parts.

(1)  Front undercover No.2 (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)
(2)  Front undercover No.1 (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.)
(3)  Front splash shield (See SPLASH SHIELD REMOVAL/INSTALLATION.)

4.  Disconnect the tie-rod end from the steering knuckle. (See TIE-ROD END REPLACEMENT.)

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

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

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7.  Disconnect the front crossmember extension.

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

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9.  Remove the insulator. (See Insulator Installation Note.)

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

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

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

13.  Remove the bolts. (See No.1 Engine Mount Rubber Removal Note.) (See No.1 Engine Mount Rubber Installation Note.)

14.  Remove in the order shown in the figure.

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

16.  If the front crossmember is replaced, inspect the wheel alignment and adjust it if necessary. (See FRONT WHEEL ALIGNMENT.)

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1
Front crossmember component
(See Front Crossmember Component Removal Note.)
(See Front Crossmember Component Installation Note.)
2
Front stabilizer component
(See FRONT STABILIZER REMOVAL.)
(See FRONT STABILIZER INSTALLATION.)
3
Steering gear and linkage
(See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)
4
Front lower arm
(See FRONT LOWER ARM REMOVAL/INSTALLATION.)
5
No.1 engine mount rubber
(See No.1 Engine Mount Rubber, Front Crossmember Installation Note.)
6
Front crossmember


Front Crossmember Component Removal Note

Warning
•  Always verify that the front crossmember component is securely supported by a jack. If the front crossmember component falls off, it can cause serious injury or death, and damage to the vehicle.

1.  Support the front crossmember component using a jack.

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2.  Remove the installation bolts of the front crossmember component.

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


No.1 Engine Mount Rubber Removal Note


2WD

1.  Remove the bracket plate.

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4WD

1.  Remove the deadweight and bracket plate.

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Suspension Links Installation Note

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

(1)  Temporarily tighten the bolt with the vehicle lifted up.
(2)  Lower the vehicle to the ground and tighten the bolt to the specified torque.


Front Crossmember Component Installation Note

Caution
•  When installing the front crossmember component to the vehicle, if the dust boots are not assembled to the body side correctly water and foreign matter could penetrate the vehicle interior. Be careful not to allow the sponge part of the dust boot to become pinched in the installation area on the body side or become creased by contact.
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No.1 Engine Mount Rubber Installation Note


2WD

1.  Install the No.1 engine mount rubber and the bracket plate and temporarily tighten the bolts shown in the figure.

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2.  Tighten the bracket plate installation bolts in the order shown in the figure.

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SKYACTIV-G 2.5

No.

Tightening torque
1
84—98 N·m {8.6—9.9 kgf·m, 62—72 ft·lbf}
2
84—98 N·m {8.6—9.9 kgf·m, 62—72 ft·lbf}

SKYACTIV-D 2.2

No.

Tightening torque
1
131—153 N·m {14—15 kgf·m, 97—112 ft·lbf}
2
131—153 N·m {14—15 kgf·m, 97—112 ft·lbf}

3.  Tighten the No.1 engine mount rubber installation bolts in the order shown in the figure.

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No.

Tightening torque
1
130—151 N·m {14—15 kgf·m, 96—111 ft·lbf}
2
130—164 N·m {14—16 kgf·m, 96—120 ft·lbf}


4WD

1.  Install the No.1 engine mount rubber, bracket plate, and deadweight, and temporarily tighten the bolts shown in the figure.

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Caution
•  Assemble the deadweight with deadweight rotation lock contacting the bracket plate to prevent abnormal noise from occurring.
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2.  Tighten the installation bolts for the No. 1 engine mount rubber, bracket plate, and deadweight in the order shown in the figure.

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No.

Tightening torque
1
140—163 N·m {15—16 kgf·m, 104—120 ft·lbf}
2
55—69 N·m {5.7—7.0 kgf·m, 41—50 ft·lbf}
3
130—164 N·m {14—16 kgf·m, 96—120 ft·lbf}


No.1 Engine Mount Rubber, Front Crossmember Installation Note

1.  Temporarily tighten the bolt shown in the figure.

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Insulator Installation Note


2WD

1.  Install the fasteners in the order shown in the figure.

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2.  Install the bolts in the order shown in the figure.

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No.

Tightening torque
1
9—12 N·m {92—122 kgf·cm, 80—106 in·lbf}
2
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}


4WD

1.  Install the fasteners in the order shown in the figure.

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2.  Install the bolt.