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.

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

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

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

4. 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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5. Remove the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

6. Disconnect the wiring harness from the front crossmember. (Vehicle with i-ELOOP)

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7. Remove the front under cover No.1. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.)

8. Remove the front splash shield. (See FRONT SPLASH SHIELD REMOVAL/INSTALLATION.)

9. Remove the fasteners and clips shown in the figure and partially peel back the front over fender.

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10. Remove the screws and the fasteners shown in the figure and set the front mudguard aside.

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11. Remove the front crossmember extension.

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

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13. Remove the snap pin from the tie-rod end.

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14. Loosen the locknut of the tie-rod end.

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Tightening torque

47—59 N·m {4.8—6.0 kgf·m, 35—43 ft·lbf}

15. Using the SST, disconnect the steering knuckle and tie-rod end.

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16. Remove the locknut from the tie-rod end.

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17. Disconnect the front lower arm ball joint. (See Front Lower Arm Ball Joint Installation Note.)

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18. Remove the bracket plate (No.1). (2WD)

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19. Remove the deadweight and bracket plate. (4WD)

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20. Remove the plate.

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

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22. Remove in the order indicated in the table.

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

24. When replacing the front crossmember, 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 No.1 Engine Mount Rubber and Front Crossmember Component Installation Note.)
2	Front stabilizer insulator (See FRONT STABILIZER REMOVAL.) (See FRONT STABILIZER INSTALLATION.)
3	Front stabilizer (See FRONT STABILIZER REMOVAL.) (See FRONT STABILIZER INSTALLATION.)
4	Steering gear and linkage (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)
5	Front lower arm (See FRONT LOWER ARM REMOVAL/INSTALLATION.)
6	No.1 engine mount rubber (See ENGINE MOUNT DISASSEMBLY/ASSEMBLY [SKYACTIV-G 2.5T].) (See No.1 Engine Mount Rubber and Front Crossmember Component Installation Note.)
7	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

2WD

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 install the bracket plate (No.1) and No.1 engine mount rubber.

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2. Tighten the bracket plate (No.1) installation bolts in the order shown in the figure.

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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

Caution

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1. Temporarily install the No. 1 engine mount rubber, bracket plate, and deadweight.

Caution

• Assemble the deadweight with the 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}

Front Lower Arm Ball Joint Installation Note

1. Insert the bolt from the front of the vehicle and tighten the nut to the specified torque.

Tightening torque

36—43 N·m {3.7—4.3 kgf·m, 27—31 ft·lbf}