FRONT CROSSMEMBER REMOVAL/INSTALLATION [R.H.D.]

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Caution
•  Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
•  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.

1.  Drain the power steering fluid. (See POWER STEERING FLUID INSPECTION.)

2.  Remove the front under cover A and front under cover B. (See FRONT UNDER COVER REMOVAL/INSTALLATION.)

3.  Remove the front auto leveling sensor. (Vehicle with headlight auto leveling system) (See FRONT AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)

4.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

5.  Remove the transverse member. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION.)

6.  Remove the intermediate shaft installation bolt, and disconnect the steering shaft. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

7.  Remove in the order indicated in the table.

8.  Install in the reverse order of removal.

9.  Inspect the front wheel alignment, and adjust it as necessary. (See FRONT WHEEL ALIGNMENT.)

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1
ABS wheel-speed sensor
2
Tie-rod end ball joint
(See Tie-rod End Ball Joint Removal Note.)
3
Front lower arm ball joint
4
Stabilizer control link lower side nut
5
Steering gear and linkage, front stabilizer, front lower arm and front crossmember component
(See Steering Gear And Linkage, Front Stabilizer, Front Lower Arm and Front Crossmember Component Removal Note.)
(See Steering Gear And Linkage, Front Stabilizer, Front Lower Arm and Front Crossmember Component Installation Note.)
6
No.1 engine mount
(See No. 1 Engine Mount Installation Note.)
7
Steering gear and linkage
(See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
8
Front stabilizer
9
Front lower arm
10
Front crossmember extension
11
Front crossmember
12
Front crossmember mounting rubber (front)
(See Front Crossmember Mounting Rubber (Front) Installation Note.)
13
Front crossmember mounting rubber (rear)
(See Front Crossmember Mounting Rubber (Rear) Installation Note.)


Tie-rod End Ball Joint Removal Note

1.  Remove the tie-rod end ball joint locknut.

2.  Disconnect the tie-rod end ball joint using the SST.

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Steering Gear And Linkage, Front Stabilizer, Front Lower Arm and Front Crossmember Component Removal Note

Warning
•  Removing the crossmember component 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 crossmember component with a jack.

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2.  Disconnect the following parts.

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―  Pressure hose eye connector
―  Pressure hose brackets
―  Return hose clamp (tank side)

3.  Disconnect the oil cooler bracket.

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4.  Remove the No.1 engine mounting bracket bolts.

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5.  Lower the steering gear and linkage, front stabilizer, front lower arm and front crossmember component slightly.


Front Crossmember Mounting Rubber (Front) Installation Note

1.  Install so that the smaller end of the outer diameter is pointing up.

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Front Crossmember Mounting Rubber (Rear) Installation Note

1.  Install so that the larger end of the outer diameter is pointing up.

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No. 1 Engine Mount Installation Note

1.  Temporarily tighten the No.1 engine mount bolt (crossmember side).


Steering Gear And Linkage, Front Stabilizer, Front Lower Arm and Front Crossmember Component Installation Note

1.  Using a jack, install steering gear and linkage, front stabilizer, and front crossmember component.

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Tightening torque
119.6—154.8 N·m {12.20—15.78 kgf·m, 88.3—114.1 ft·lbf}

2.  Install the oil cooler bracket.

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3.  Connect the following parts.

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―  Pressure hose eye connector
―  Pressure hose brackets
―  Return hose clamp (tank side)
Tightening torque
―  Pressure hose brackets: 7.8—10.8 N·m {80—101 kgf·cm, 69.1—92.9 in·lbf}
―  Pressure hose eye connector: 29.4—44.1 N·m {3.00—4.49 kgf·m, 21.7—32.5 ft·lbf}

4.  Install the steering gear and linkage, front stabilizer, front lower arm and front crossmember component.

5.  Tighten the No.1 engine mount bracket bolt A and B in order of A→B.

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Tightening torque
Bolt A, B: 93.1—116.6 N·m {9.5—11.8 kgf·m, 68.7—85.9 ft·lbf}

Note
•  When replacing bolt C on the crossmember side, always replace it with a bolt of the same size as the removed one.

6.  Tighten the No.1 engine mount bolt C (crossmember side).

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Tightening torque
104.2—132.6 N·m {10.6—13.5 kgf·m, 76.9—97.8 ft·lbf}