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I
nstallation
CAUTI
ON: The wishbone front and rear arm bushes differ in length.
Ensure the correct bush is installed in each arm.
1.
Position arm on suitable supports on press bed.
2. Position Special Tool 204-214 on top of bush.
3. Operate press to remove bush from arm.
34. Remove wishbone front arm from press
35
.
NOTE: For assembly purposes, note orientation of bush.
• NOTE: Initial press action will cause tool to sh ear bush flange.
Using a hydraulic press, remove bush from rear wishbone arm.
1. Position arm on suitable supports on press bed.
2. Position special tool on top of bush.
3. Operate press to remove bush from arm.
1. Using a h
ydraulic press, install bu
sh in wishbone rear arm/ball
joint assembly.
1. Position arm on suitable supports on press bed.
2. Position bush on arm ensuring orientation is as noted during removal of old bush.
3. Position suitable flat steel plate on top of bush.
4. Operate press to install bush in arm.
2. Using a h
ydraulic press, install
bush in wishbone front arm.
1. Position arm on suitable supports on press bed.
2. Position bush on arm ensuring orientation is as noted during removal of old bush.
3. Position suitable flat steel plate on top of bush.
4. Operate press to install bush in arm.
3. Position wishbone rear arm on crossbeam and install but do
Page 98 of 2490
not ti
ghten eccentric bolt and nut.
4. Install steeri
ng rack on crossbeam.
Ensure that b
ushes are correct
ly positioned on steering
rack.
Posi ti
on steering rack on crossbeam.
Position support brac
kets over bus
hes.
Install mountin
g bracket bolts an
d tighten to 41-54Nm.
5. Inst al
l lower steering column on pinion shaft.
Move col
u
mn downwards to engage coupling splines on
pinion shaft.
1. Install nut and bolt and tighten to 22-28Nm.
6. Position an d
connect harnes
s to steering transducer.
RHD veh
icles. Position steeri
ng harness behind return
pipe.
Conne ct
harness to transducer.
7. Secure return pipe on steering rack.
1. Position pipe rubber support on steering rack.
2. Position pipe on support .
3. RHD vehicles. Position harness on pipe support rubber.
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4
. Secure pipe and harnes
s(RHD vehicles) to support
with new tiestrap.
8. Posi
tion wishbone front arm on crossbeam and install but do
not tighten eccentric bolt and nut.
9. Inst
all shock absorber mounting bracket.
Posit
ion shock absorber moun
ting bracket on wishbone
rear arm.
Install
wishbone front arm to
rear arm securing bolt and
tighten to 77-103Nm.
10
.
Install stabilizer bar link to wi shbone bracket nut and bolt and
tighten to 41-54Nm.
11. Tighten shock absorber lowe r bolt and nut to 43-57Nm.
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12. Position verti
cal link/ hub asse
mbly on lower ball joint taper
pin, install nut and tighten to 60-80Nm.
13 . Position verti
cal link/ hub asse
mbly on upper ball joint taper
pin.
14 . Install nu
t securing upper ball jo
int to vertical link and tighten
to 60-80Nm.
15. Position tie rod ball joint taper pin on steering arm and install
and tighten nut to 71-85Nm.
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16
.
Install spring pan, rubber lowe r seat, spring and rubber upper
seat on Special Tool 204-111.
17
.
Install spring pan/spring asse mbly and special tool 204-111
in suspension turret.
E
nsuring upper seat is correctly positioned, install spring
in suspension turret.
Engage tool
dowel in turret slot.
18
.
Rotate tool adjuster to lightly tension spring.
19. Install suitable guide pins in spring pan/wishbone bolt
locations.
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20. WARNING: WHE
N ROTATING TOOL ADJUSTER, ENSURE
THAT TOOL STEM DOES NOT TU RN AND DISTURB POSITION OF
DOWEL IN SUSPENSION TURRET.
Install spring pan to wishbone securing bolts.
Ro t
ate tool adjuster to gradua
lly increase spring tension.
Pr
ogressively substitute spri
ng pan securing bolts for
guide pins.
Tighten spring pan
bolts to 70-90Nm.
Ensure spri
ng
lower seat is co
rrectly positioned in spring
pan.
21 . WARNING: WHE
N ROTATING TOOL ADJUSTER, ENSURE
THAT TOOL STEM DOES NOT TU RN AND DISTURB POSITION OF
DOWEL IN SUSPENSION TURRET.
Remove Special Tool 204-111 from suspension.
Rotat
e adjuster of Special Tool to release tension on
spring.
R o
tate tool stem to release dowel from turret and
withdraw tool assembly.
22 . Lower vehi
cle to working heig
ht and support on stands.
23 . Inst
all wheel speed sensor.
Posi
ti
on wheel speed sensor on vertical link.
Instal
l sensor securing bolt
and tighten to 8-10Nm.
24. Connect wheel speed sensor harness.
1. Connect wheel speed sensor harness to sensor.
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2.
Using new tiestraps secure wheel speed sensor
harness to upper wishbone.
25
.
Install brake calipers.
R
emove tie supporting brake caliper.
1. Install caliper on carrier.
2. Install guide pins and tighten to 25-30Nm.
3. Install guide pin dust caps.
4. Install caliper spring clip.
26
.
Position and partially tighten wishbone rear eccentric bolt.
R
otate eccentric bolt to align large graduation with mark
made during removal.
27
.
Position and partially tighten wishbone front eccentric bolt.
R
otate eccentric bolt to align large graduation with mark
made during removal.
P
artially tighten bolt.
28. Fit road wheel. Refer to Section 100-02.
29. Raise vehicle, remove stands and lower vehicle onto road
wheels.
30. Ensuring graduation mark remains aligned, finally tighten
wishbone rear eccentric bolt to 113-153Nm.
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31
. Ensuri
ng graduation mark remains aligned, finally tighten
wishbone front eccentric bolt to 113-153Nm.
32. Carry out steering geometry an d wheel alignment checks and
if necessary adjust. Refer to 57.65.01.