Î
16-22Driveline/Axle
Driveshaft Installation (cont’d)
B
A
K20Z2 engine model:
22x1.5mm
181 N·m
(18.5 kgf·m, 134 lbf·ft)
K20Z3 engine model:
24x1.5mm
245 N·m
(25.0 kgf·m, 180 lbf·ft)
9. Apply small amount of engine oil to the seating surface of new spindle nut (A).
10. Install the spindle nut, then tighten it. After tightening, use a drift to stake the spindle nut
shoulder (B) against the driveshaft.
11. Clean the mating surfaces of the brake disc and the wheel, then install the front wheels.
12. Turn the front wheel by hand, and make sure there is no interference between the driveshaft and
surrounding parts. 13. Refill the transmission with the recommended
transmission fluid:
5-speed manual transmission (see page 13-5)
6-speed manual transmission (see page 13-82)
Automatic transmission (see page 14-232)
14. Lower the vehicle on the lift.
15. Check the wheel alignment, and adjust it if necessary (see page 18-5).
16. Test-drive the vehicle.
Replace.
Replace.
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(#'
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16-2716-27
Intermediate Shaft Installation
PRESS
B
C
07GAD-PH70201
A
07JAF-SH20400 07965-SD90100 A
B
A
B
6. Install a new outer seal (A) flush with the bearing
support (B) using the support base attachment, the
support base, the 64 mm oil seal driver (C), and a
press. 1. Install a new set ring (A) onto the set ring groove
(B) of the intermediate shaft.
2. Clean the areas where the intermediate shaft contacts the differential thoroughly with solvent or
brake cleaner, and dry with compressed air.
NOTE: Do not wash the rubber parts with solvent.
3. Insert the intermediate shaft (A) into the differential until the set ring locks in the groove.
NOTE: Insert the intermediate shaft carefully to
prevent damaging the oil seal (B).
(cont’d)
Pack the interior
of the outer seal.Replace.
Replace.
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DYNOMITE -2009-
ÎÎ
(#'
)
16-2716-27
Intermediate Shaft Installation
PRESS
B
C
07GAD-PH70201
A
07JAF-SH20400 07965-SD90100 A
B
A
B
6. Install a new outer seal (A) flush with the bearing
support (B) using the support base attachment, the
support base, the 64 mm oil seal driver (C), and a
press. 1. Install a new set ring (A) onto the set ring groove
(B) of the intermediate shaft.
2. Clean the areas where the intermediate shaft contacts the differential thoroughly with solvent or
brake cleaner, and dry with compressed air.
NOTE: Do not wash the rubber parts with solvent.
3. Insert the intermediate shaft (A) into the differential until the set ring locks in the groove.
NOTE: Insert the intermediate shaft carefully to
prevent damaging the oil seal (B).
(cont’d)
Pack the interior
of the outer seal.Replace.
Replace.
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DYNOMITE -2009-
(#'
)
EPS IndicatorDiagnostic Trouble Code (DTC)
Self-diagnosis
17-19
General Troubleshooting Information
Under normal conditions, the EPS indicator comes on
when the ignition switch is turned to ON (II), then goes
off after the engine is started. This indicates that the
LED and its circuit are operating correctly.
If there is a failure in the system after the engine is
started, the EPS indicator will stay on, and the power
assist is turned off or restricted.
When the EPS indicator comes on, the control unit
memorizes the DTC. In this case, the control unit will
not activate the EPS system after the engine starts
again, but it keeps the EPS indicator on.
When DTC 51-01, 51-02 or 51-06 is stored in the control
unit, the EPS indicator will stay on until the DTC is
erased. When a problem is detected and the EPS
indicator comes on, there are cases when the indicator
stays on until the ignition switch is turned to LOCK (0),
and cases when the indicator goes off automatically
when the system returns to normal. Even though the
system is operating normally, the EPS indicator will
come on under the following conditions: The vehicle speed decreases abruptly from 20 km/h (12 mph) or more (by applying brake), and it is less
than 1 km/h (1 mph) and engine speed is 2,000 rpm or
above for 5 seconds (continuously) after the abrupt
deceleration.
While turning the steering wheel with the vehicle speed of 1 km/h (1 mph) or less for 20 seconds, and
the engine speed is 2,000 rpm or above for at least
10 seconds.
When the engine speed is 500 rpm or less, and the vehicle is traveling at a speed of 10 km/h (6 mph) or
more for about 3 seconds.
To determine the actual cause of the problem, question
the client about the conditions during which the
problem occurred, taking the above conditions into
consideration. If the CPU cannot be activated, or it fails, the EPS
indicator comes on, but the DTC is not memorized.
The memory can hold any number of DTCs. However, when the same DTC is detected more than once, the
most recent DTC is written over the prior DTC,
therefore only one occurrence is memorized.
The lowest DTC is indicated first. The DTCs are indicated in ascending order, not in the order that
they occurred.
The DTCs are memorized in the EEPROM (non- volatile memory) therefore the memorized DTCs
cannot be erased by disconnecting the battery. Do the
specified procedures to clear the DTCs.
Self-diagnosis can be classified into three categories: Initial diagnosis: Done right after the engine starts and until the EPS indicator goes off.
Regular diagnosis: Done right after the initial diagnosis until the ignition switch is turned to LOCK
(0).
Steering diagnosis: Done during regular diagnosis while turning the steering wheel.
The EPS control unit dose these functions when a
problem is detected by self-diagnosis: 1. Turns on the EPS indicator.
2. Memorizes the DTC.
3. Stops power assist and manual steering operation resumes.
NOTE: For DTCs 11-01, 11-02, 12-01, 21-01, 21-02,
22-01, and 35-04 the EPS indicator will go off
automatically, and the system returns to normal.
(cont’d)
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Î
17-76EPS Components
Steering Gearbox Removal and Installation (cont’d)
A
B
C
12x1.25mm
59 N·m
(6.0 kgf·m, 43 lbf·ft)
D
12x1.25mm
59 N·m
(6.0 kgf·m, 43 lbf·ft) B
A
E
12x1.25mm
59 N·m
(6.0 kgf·m,
43 lbf·ft) D
C
AB
B
12x1.25mm
54 N·m
(5.5 kgf·m,
40 lbf·ft)
A D
E
C
20. Install the exhaust hanger (A) to the three way
catalytic converter (TWC) (B).
21. Connect the lower arm (A) to the lower ball joint (B).
22. Install a new flange bolt and the new self-locking nuts. After lightly tightening all three fasteners,
tighten them to the specified torque in the
following order; the self-locking nut on the front (C),
the self-locking nut on the rear (D), then the flange
bolt (E). 23. Remove the vinyl tape, then connect the EPS motor
connector A (2P), the EPS motor connector B (1P),
torque sensor 4P connector (C), the EPS motor
angle sensor 6P connector (D) to the steering
gearbox. Make sure to push these connectors until
you hear a click so that the connectors are secured.
24. Install the front splash shield (see page 20-172).
25. Wipe off any grease contamination from the ball joint tapered section and the threads. Reconnect
the tie-rod ends (A) to the steering knuckles. Install
the 12 mm nut (B) and tighten it.
26. Install the new cotter pin (C), and bend it as shown (D) or (E).
27. Install the front wheel, then set the wheels in the straight ahead position.
NOTE: Before installing the wheel, clean the mating
surfaces between the brake disc and inside of the
wheel.
Replace.
Replace.
Replace. Replace.
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(#'") ¶
Pre-Alignment Checks
Caster Inspection
Tire size (’06-08 models):Except Type S model:Front/Rear: P205/55R16 89H
Type S model: Front/Rear: P215/45R17 87V
Tire size (’09 model): Front/Rear: P215/45R17 87V
Tire Pressure (’06-08 models) (at cold): Except Type S model:Front/Rear: 220 kPa (2.2 kgf/cm , 32 psi)
Type S model: Front/Rear: 230 kPa (2.3 kgf/cm , 33 psi)
Tire Pressure (’09 model) (at cold): Front/Rear: 230 kPa (2.3 kgf/cm , 33 psi) Caster angle: 7 ° 00 ’ 1 °
2
2
2
18-5
Wheel Alignment
The suspension can be adjusted for front camber, front
toe, and rear toe. However, each of these adjustments
are related to each other. For example, when you adjust
camber, the toe will change. Therefore, you must adjust
the front wheel alignment whenever you adjust camber
or toe.
For proper inspection and adjustment of the wheel
alignment, do these checks: 1. Release the parking brake to avoid an incorrect measurement.
2. Make sure the suspension is not modified.
3. Make sure the fuel tank is full, and that the spare tire, the jack, and the tools are in place on the
vehicle.
4. Check the tire size and tire pressure.
5. Check the runout of the wheels and tires (see page 18-9). 6. Check the suspension ball joints (Hold a tire with
your hands, and move it up and down and right and
left to check for movement).
7. Before doing alignment inspections, be sure to remove all extra weight from the vehicle, and no
one should be inside the vehicle (driver or
passengers).
8. Bounce the vehicle up and down several times to stabilize the suspension.
9. Check that the steering column is set at the center tilt and telescopic position.
Use commercially available computerized four wheel
alignment equipment to measure wheel alignment
(caster, camber, toe, and turning angle). Follow the
equipment manufacturer’s instructions. 1. Check the caster angle.
If the measurement is within specifications,measure the camber angle.
If the measurement is not within specifications, check for bent or damaged suspension
components.
(cont’d)
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¶
µ
µ
´ µ
´ µ
Camber Inspection Front Camber Adjustment
Camber angle:
Front: 0 ° 00 ’ 30 ’
(Maximum difference between the front right and left
side: 0 ° 35 ’) Rear (without ‘‘C’’ marks on the upper arm):1°30’
Rear (with ‘‘C’’ marks on the upper arm): 0°45’
1° 05 ’ 0° 45 ’
1° 05 ’ 0° 45 ’
18-6Front and Rear Suspension
Wheel Alignment (cont’d)
A
Damper pinch bolt Adjusting bolt set:
P/N 04512-SNA-305
A
14x1.5mm
90 N·m
(9.2 kgf·m,
67 lbf·ft)
Use commercially available computerized four wheel
alignment equipment to measure wheel alignment
(caster, camber, toe, and turning angle). Follow the
equipment manufacturer’s instructions.1. Check the camber angle. NOTE: There are two types of rear upper arms. Those that are marked with ‘‘C’’ (A), and those with no
marks. Be sure to use the correct alignment
specifications.
If the measurement is within specification, measure the toe-in.
If the measurement for the front camber is outside the specification, go to front camber
adjustment.
If the measurement for the rear camber is outside the specification, check for bent or damaged
suspension components. The front camber can be adjusted by exchanging one or
both of the damper pinch bolts with a smaller diameter
adjusting bolt. The difference between the adjusting
bolt diameter and the pinch bolt hole diameter allows
for a small range of adjustment.
1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see page
1-11).
2. Remove the front wheels.
3. Loosen the damper pinch bolts (A), and adjust the camber angle by moving the bottom of the damper
within the range of the damper pinch bolt free play.
4. Tighten the damper pinch bolts to the specified torque.
5. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheels.
6. Lower the vehicle to the ground, and bounce the front of the vehicle up and down several times to
stabilize the suspension.
Replace.
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DYNOMITE -2009-
¶
¶¶
Front Toe Inspection/Adjustment
Front toe-in: 0 2 mm (0 0.08 in.)
18-7
B
A
14x1.5mm
90 N·m
(9.2 kgf·m,
67 lbf·ft)A
14x1.5mm
44 N·m (4.5 kgf·m, 33 lbf·ft)
BC
7. Measure the camber angle.
If the measurement is within specification,measure the toe.
If the measurement is not within specification, go to step 8.
8. Raise the front of the vehicle, and support it with safety stands in the proper locations (see page
1-11).
9. Remove the front wheels.
10. Replace the damper pinch bolts with the adjusting bolts (A), and adjust the camber angle.
NOTE: Install the washers (B) included adjusting bolt set between the front damper and self-locking nut.
The camber angle can be adjusted up to 25 ’ (center of tolerance) by replacing one damper
pinch bolt with the adjusting bolt.
The camber angle can be adjusted up to 50 ’ by replacing both damper pinch bolts with the
adjusting bolts.
11. Tighten the adjusting bolts to the specified torque value.
12. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheels.
13. Lower the vehicle to the ground, and bounce the front of the vehicle up and down several times to
stabilize the suspension.
14. Measure the camber angle. If the camber angle is not within specification, repeat steps 8 through 13
to readjust the camber angle. If the camber
measurement is correct, measure toe-in, and adjust
it if necessary. Use commercially available computerized four wheel
alignment equipment to measure wheel alignment
(caster, camber, toe, and turning angle). Follow the
equipment manufacturer’s instructions.
1. Set the steering column to the middle tilt and center telescopic positions. Center the steering
wheel spokes, and install a steering wheel holder
tool.
2. Check the toe with the wheels pointed straight ahead.
If adjustment is required, go to step 3.
If no adjustment is required, go to rear toe inspection/adjustment.
3. Loosen the tie-rod locknuts (A) while holding the flat surface sections (B) of the tie-rod end with a
wrench, and turn both tie-rods (C) until the front toe
is within specifications.
4. After adjusting, tighten the tie-rod locknuts to the specified torque value. Reposition the rack-end
boot if it is twisted or displaced.
5. Go to rear toe inspection/adjustment.
(cont’d)
Replace.Replace.
Replace.
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