EM-244
[VK45DE]
ENGINE ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
Preparation
1. Release fuel pressure. Refer to EC-746, "FUEL PRESSURE RELEASE" .
2. Drain engine coolant from radiator. Refer to CO-38, "
Changing Engine Coolant" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belts.
3. Disconnect both battery terminal. Refer to SC-4, "
BATTERY" .
4. Remove crankshaft position sensor (POS) from transmission. CAUTION:
Handle carefully to avoid dropping and shocks.
Do not disassemble.
Do not allow metal powder to adhere to magnetic part at sensor tip.
Do not place sensors in a location where they are exposed to magnetism.
5. Remove the following parts:
Hood assembly; Refer to BL-13, "HOOD" .
Engine cover; Refer to EM-173, "ENGINE ROOM COVER" .
Front and rear engine undercover
Air duct (inlet), air duct and air cleaner case assembly; Refer to EM-177, "AIR CLEANER AND AIR
DUCT" .
Drive belts; Refer to EM-174, "DRIVE BELTS" .
Radiator and radiator hoses (upper and lower); Refer to CO-41, "RADIATOR" .
Front road wheels and tires
Engine Room LH
1. Disconnect engine room harness from the engine side and set it aside for easier work.
2. Disconnect heater hoses, and install plugs to avoid leakage of engine coolant.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Discharge refrigerant from A/C circuit. Refer to ATC-137, "
REFRIGERANT LINES" .
6. Remove A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to AT C -
139, "Components" .
Engine Room RH
1. Disconnect fuel feed hose and EVAP hose. Refer to EM-194, "FUEL INJECTOR AND FUEL TUBE" .
CAUTION:
Fit plugs onto disconnected hose to prevent fuel leak.
2. Disconnect engine room harness from the engine side and set it aside for easier work.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Disconnect reservoir tank of power steering oil pump from engine, and move it aside for easier work. CAUTION:
When temporarily securing, keep reservoir tank upright to avoid a fluid leak.
Vehicle Underbody
1. Remove front cross bar. Refer to FSU-6, "FRONT SUSPENSION ASSEMBLY" .
2. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope for eas- ier work. Refer to PS-31, "
Removal and Installation (VK45DE Models)" .
3. Remove A/T fluid cooler tube. Refer to AT- 2 6 6 , "
TRANSMISSION ASSEMBLY" .
4. Remove exhaust front tube and center muffler with power tool. Refer to EX-3, "
EXHAUST SYSTEM" .
5. Remove RH and LH transverse link mounting bolts and nuts. Refer to FSU-14, "
TRANSVERSE LINK" .
6. Disconnect stabilizer connecting rod lower. Refer to FSU-6, "
FRONT SUSPENSION ASSEMBLY" .
7. Remove A/T control rod at control device assembly side. Then temporarily secure it on transmission, so that it does not sag. Refer to AT- 2 2 9 , "
SHIFT CONTROL SYSTEM" .
FAX-1
FRONT AXLE
D DRIVELINE/AXLE
CONTENTS
C E F
G H
I
J
K L
M
SECTION FA X
A
B
FA X
Revision: 2006 December 2006 FX35/FX45
FRONT AXLE
2WD
PREPARATION ...................................................... ..... 2
Special Service Tools (SST) ................................ ..... 2
Commercial Service Tools ................................... ..... 2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ........................................... ..... 3
NVH Troubleshooting Chart ................................ ..... 3
FRONT WHEEL HUB AND KNUCKLE ................. ..... 4
On-Vehicle Inspection ......................................... ..... 4
WHEEL BEARING INSPECTION .................... ..... 4
Removal and Installation ..................................... ..... 4
COMPONENTS ............................................... ..... 4
REMOVAL ........................................................ ..... 4
INSPECTION AFTER REMOVAL .................... ..... 5
INSTALLATION ................................................ ..... 5
SERVICE DATA AND SPECIFICATIONS (SDS) ... ..... 6
Wheel Bearing ..................................................... ..... 6
AWD
PRECAUTIONS ..................................................... ..... 7
Caution ................................................................ ..... 7
PREPARATION ...................................................... ..... 8
Special Service Tools (SST) ................................ ..... 8
Commercial Service Tools ................................... ..... 8
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ........................................... ..... 9
NVH Troubleshooting Chart ................................ ..... 9
FRONT WHEEL HUB AND KNUCKLE ................. ... 10
On-Vehicle Inspection ......................................... ... 10 WHEEL BEARING INSPECTION ....................
... 10
Removal and Installation ..................................... ... 10
COMPONENTS ................................................ ... 10
REMOVAL ........................................................ ... 10
INSPECTION AFTER REMOVAL .................... ... 11
INSTALLATION ................................................ ... 11
FRONT DRIVE SHAFT .......................................... ... 12
Removal and Installation (Left Side) .................... ... 12
COMPONENTS ................................................ ... 12
REMOVAL ........................................................ ... 12
INSPECTION AFTER REMOVAL .................... ... 12
INSTALLATION ................................................ ... 12
Removal and Installation (Right Side) ................. ... 13
COMPONENTS ................................................ ... 13
REMOVAL ........................................................ ... 13
INSPECTION AFTER REMOVAL .................... ... 13
INSTALLATION ................................................ ... 14
Disassembly and Assembly (Left Side) ............... ... 14
COMPONENTS ................................................ ... 14
DISASSEMBLY ................................................ ... 15
INSPECTION AFTER DISASSEMBLY ............. ... 15
ASSEMBLY ...................................................... ... 16
Disassembly and Assembly (Right Side) ............. ... 19
COMPONENTS ................................................ ... 19
DISASSEMBLY ................................................ ... 20
INSPECTION AFTER DISASSEMBLY ............. ... 20
ASSEMBLY ...................................................... ... 21
SERVICE DATA AND SPECIFICATIONS (SDS) ... ... 25
Wheel Bearing ..................................................... ... 25
Drive Shaft ........................................................... ... 25
FAX-2
[2WD]
PREPARATION
Revision: 2006 December 2006 FX35/FX45
[2WD]PREPARATIONPFP:00002
Special Service Tools (SST)NDS000BU
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolsNDS000BV
Tool number
(Kent-Moore No.)
Tool name Description
HT72520000
(J −25730-A)
Ball joint remover
a: 33 mm (1.30 in)
b: 50 mm (1.97 in)
r: 11.5 mm (0.453 in)
Removing steering outer socket
Removing transverse link
NT546
Tool name Description
Power tool
Removing wheel nuts
Removing brake caliper assembly
Removing strut lower side
Removing wheel hub and bearing
assembly
PBIC0190E
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING FAX-3
[2WD]
C E F
G H
I
J
K L
M A
B
FA X
Revision: 2006 December 2006 FX35/FX45
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartNDS000BW
Use chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
× : Applicable
Reference page
FA X -4—
FA X -4
NVH in WT section
NVH in WT section
NVH in PS section
Possible cause and SUSPECTED PARTS
Improper installation, looseness
Parts interference
Wheel bearing damage
TIRES
ROAD WHEEL
STEERING
Symptom FRONT AXLE Noise
×× ×××
Shake ×× ×××
Vibration ×× × ×
Shimmy ×× ×××
Judder × ×××
Poor quality ride or handling ×××××
FAX-4
[2WD]
FRONT WHEEL HUB AND KNUCKLE
Revision: 2006 December 2006 FX35/FX45
FRONT WHEEL HUB AND KNUCKLEPFP:40202
On-Vehicle Inspection NDS000BX
Make sure the mounting conditions (looseness, back lash) of each component and component status (wear,
damage) are normal.
WHEEL BEARING INSPECTION
Move wheel hub in the axial direction by hand. Check that there is no looseness of front wheel bearing.
Rotate wheel hub and make sure there is no unusual noise or other irregular conditions. If there are any
irregular conditions, replace wheel hub and bearing assembly.
Removal and InstallationNDS000BY
COMPONENTS
REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove brake caliper with power tool. Hang it in a place where it will not interfere with work. Refer to BR-
19, "FRONT DISC BRAKE" .
NOTE:
Avoid depressing brake pedal while brake caliper is removed.
3. Put alignment marks on disc rotor and wheel hub and bearing assembly, then remove disc rotor.
4. Remove wheel sensor from wheel hub and bearing assembly. Refer to BRC-55, "
WHEEL SENSORS" .
CAUTION:
Do not pull on wheel sensor harness.
5. Remove cotter pin at steering outer socket, then loosen mount- ing nut. Axial end play : 0.05 mm (0.002 in) or less
1. Disc rotor 2. Wheel hub and bearing assembly 3. Splash guard
4. Steering knuckle 5. Cotter pin
Refer to GI-11, "
Components" , for the symbols in the figure.
PDIA1216E
SDIA1480E
FRONT WHEEL HUB AND KNUCKLE FAX-5
[2WD]
C E F
G H
I
J
K L
M A
B
FA X
Revision: 2006 December 2006 FX35/FX45
6. Use a ball joint remover (SST) to remove steering outer socket from steering knuckle. Be careful not to damage ball joint boot.
CAUTION:
Tighten temporarily mounting nut to prevent damage to
threads and to prevent ball joint remover (SST) from com-
ing off.
7. Remove cotter pin at transverse link, then loosen mounting nut.
8. Use a ball joint remover (SST) to remove transverse link from steering knuckle. Be careful not to damage ball joint boot.
CAUTION:
Tighten temporarily mounting nut to prevent damage to
threads and to prevent ball joint remover (SST) from com-
ing off.
9. Remove fixing bolts and nuts between strut assembly and steer- ing knuckle with power tool.
10. Remove steering knuckle from vehicle.
11. Remove fixing bolts between steering knuckle and wheel hub and bearing assembly with power tool.
12. Remove splash guard and wheel hub and bearing assembly from steering knuckle.
INSPECTION AFTER REMOVAL
Check for deformity, cracks and damage on each parts, replace if necessary.
Ball Joint Inspection
Check for boot breakage, axial looseness, and torque of transverse link and steering outer socket ball
joint. Refer to FSU-14, "
TRANSVERSE LINK" , PS-17, "POWER STEERING GEAR AND LINKAGE" .
INSTALLATION
Refer to FAX-4, "Removal and Installation" for tightening torque. Install in the reverse order of removal.
NOTE:
Refer to component parts location and do not reuse non-reusable parts.
After removing/installing or replacing axle components, check wheel alignment. Refer to FSU-6, "Wheel
Alignment Inspection" .
After adjusting wheel alignment, adjust neutral position of steering angle sensor. Refer to BRC-6, "Adjust-
ment of Steering Angle Sensor Neutral Position" .
Check the following item after service
–Installation condition of wheel sensor harness
SDIA1434E
SDIA1435E
FAX-6
[2WD]
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: 2006 December 2006 FX35/FX45
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Wheel BearingNDS000BZ
Axial end play 0.05 mm (0.002 in) or less
FAX-8
[AWD]
PREPARATION
Revision: 2006 December 2006 FX35/FX45
PREPARATIONPFP:00002
Special Service Tools (SST)NDS000C1
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolsNDS000C2
Tool number
(Kent-Moore No.)
Tool name Description
HT72520000
(J −25730-A)
Ball joint remover
a: 33 mm (1.30 in)
b: 50 mm (1.97 in)
r: 11.5 mm (0.453 in)
Removing steering outer socket
Removing transverse link
KV40107300
(–)
Boot band crimping tool Installing boot band
KV38107900
(–)
Protector
a: 32 mm (1.26 in) dia. Installing drive shaft
KV38100500
(–)
Drift
a: 80 mm (3.15 in) dia.
b: 60 mm (2.36 in) dia. Installing drive shaft plug
KV38102200
(–)
Drift
a: 90 mm (3.54 in) dia.
b: 31 mm (1.22 in) dia. Installing drive shaft plug
NT546
ZZA1229D
ZZA0835D
ZZA0701D
ZZA0920D
Tool name Description
Power tool
Removing wheel nuts
Removing brake caliper assembly
Removing hub lock nut
Removing strut lower side
Removing wheel hub and bearing assembly
Removing undercoverPBIC0190E