Section 6 Front Stabilizer Bar and Link Rod AssemblyDisassemble1. Remove the front wheel
2. Remove the front stabilizer bar bolts
(1) Remove two nuts, five retainers, four pads and stabilizer bolts when fixing bolts
(2) Take the same steps on other side as above.
3. Remove the front stabilizer bar
Remove four bolts and #1 front stabilizer bar bracket.
4. Mount the front stabilizer bar
Mount the stabilizer bar, two bushings, bracket and four bolts.
Torque: 37N.m
Notice:
Make the groove toward the vehicle rear
Tip:
Keep the bushing outside the paint line
5. Mount the front stabilizer bolts
(1) Mount the front stabilizer bolts, four pads and five retainers
Torque: 18N.m
(2) Take the same operations on other side as above process
6. Mount the front wheel
Torque: 103N.m4-53Installation markFront Suspension System-Front Stabilizer Bar and Link Rod Assembly
Section 3 LH/RH Rear Suspension Coil SpringReplacement1. Remove rear wheel
2. Remove the wire of the wheel speed sensor(with ABS)
(1) Remove the connector of wheel speed sensor.
(2) Remove bolts and wheel speed sensor from rear axle
frame.
Notes:
Remove the right sensor wire by using same process as left.
3. Remove the load-sensing valve bracket (without ABS)
Remove two nuts and load-sensing valve bracket from the axle
bracket
4. Remove the proportioning valve and rear right brake tube
(1) Remove the proportioning valve and rear right brake tube by
the special tool
(2) Remove the clips
Notes: Don't reuse the clips
5. Remove the proportioning valve and rear left brake tube
Notes: use the same operations of the proportioning valve and
rear right brake tube to remove #3 rear brake tube.
6. Remove right parking brake cable assembly
Remove nuts and right parking brake cable assembly
assembly from rear axle frame
7. Remove left parking brake cable assembly
8. Loose the rear axle assembly
Loose two 2 boltsRear Suspension System-LH/RH Rear Suspension Coil Spring4-57
Rear Suspension System-LH/RH Rear Suspension Coil Spring4-5918. Mount rear right brake tube
Tips:
Mount the right assembly by using same operations as left.
19. Mount sideslip control sensor wire (with ABS)
(1) Tighten sideslip control sensor wire by bolts
Torque: 8.0 N.m
(2) Mount sideslip control sensor wire
Attention: Mount the right wire by using same operations as left.
20. Mount load-sensing valve bracket (without ABS)
Mount load-sensing valve bracket by two buts
21. Sufficiently tighten the rear axle frame assembly
(1) Stabilize the shock absorber assembly
Use the lifting jack and add 90Kg force on rear luggage
carrier if bolts can not be tightened at this point.
(2) Sufficiently tighten bolts
Torque: 82 N.m
22. Sufficiently tighten the left rear shock absorber assembly
Sufficiently tighten nuts
Torque: 49 N.m
23. Sufficiently tighten the right rear shock absorber assembly
Tips: Mount the right rear shock absorber by using same opera-
tions as left.
24. Release the air in the brake hose
25. Mount the rear wheel
Torque: 103 N.m
26. Check rear the wheel alignment
27. Check the wheel speed sensor signal of ABS( with ABS)
Rear Suspension System-Rear Suspension Crossmember4-63Disassemble:1. Remove rear wheel
2. Remove sideslip control sensor wire (with ABS)
3. Remove load-sensing valve bracket (without ABS)
4. Remove proportioning valve and right rear brake tube
5. Remove proportioning valve and left rear brake tube
6. Remove right parking brake cable assembly
7. Remove left parking brake cable assembly
Tips: Remove right parts by using same operations as left
8. Remove rear brake drum subassembly
9. Remove left rear hub and bearing assembly
(1) Remove nuts and right parking brake cable assembly from
rear axle frame
(2) Remove four bolts and left rear hub and bearing assembly
(3) Remove rear brake assembly from rear axle frame
10. Remove rear right hub and bearing assembly
Tips: Remove right parts by using same operations as left
11. Loosen rear axle frame assembly
12. Disassemble rear left shock absorber assembly
13. Disassemble rear right shock absorber assembly
Tips: Remove right parts by using same operations as left
14. Remove rear left helical spring
15. Remove rear right helical spring
Tips: Remove right parts by using same operations as left
16. Remove rear axle assembly
(1) Lift rear axle assembly by lifting axel
(2) Remove two bolts and rear axle frame assembly
4-6523. Temporarily fasten the rear axle frame assembly
(1) Lift rear axle frame by lifting jack
(2) Mount the rear axle frame by temporarily tightening two bolts
24. Mount rear left helical spring
25. Mount rear right helical spring
Tips:
Mount right parts by using same operations as left
26. Temporarily tighten rear left shock absorber assembly
27. Temporarily tighten rear right shock absorber assembly
Tips:
Mount right parts by using same operations as left
28. Mount rear left hub and bearing assembly
Mount rear brake assembly, rear left hub and bearing assembly by
four bolts
29. Mount rear right hub and bearing assembly
Tips: Mount right parts by using same operations as left
30. Mount rear brake drum subassembly
31. Adjust the gap between brake drum and brake shoe
32. Mount #3 parking brake cable assembly
Tips: Mount right parts by using same operations as left
33. Mount #2 parking brake cable assembly
34. Mount #4 rear brake tube
35. Mount #3 rear brake tube
Tips: Mount right parts by using same operations as left
36. Connect sideslip control sensor wire(with ABS)
37. Connect load-sensing valve braket(without ABS)
38. Sufficiently tighten rear axle frame assembly
39. Sufficiently tighten rear left shock absorber assembly
40. Sufficiently tighten rear right shock absorber assembly
Tips: Mount right parts by using same operations as left
41. Release air from brake tube
42. Mount rear wheel
Torque: 103N.m
43. Check rear wheel alignment
44. Check the speed signal of ABS sensor( with ABS).Rear Suspension System
-Rear Suspension Crossmember
Power Steering System
-Steering Drive and Control Mechanism4-71Replacement1. Precaution (refer to the steering system precaution)
2. Confirm that the wheel stays at a straight line running status.
3. Unfix the storage battery cathode terminal.
4. Remove the airbag assembly.
Remove the two screws on both sides, and pull out the cable connector.
Note: When removing the airbag assembly, never pull the airbag cables.
Caution: When put down the airbag assembly, make sure its top surface stays upward.
Never disassemble the airbag assembly.Using
Socket5. Remove the steering wheel assembly.
(1)Unfix the connector.
(2)Remove the set bolts of the steering wheel.
(3)Make a fit mark on the steering wheel assembly and main shaft assembly.
(4)Remove the steering wheel with special tool.
6. Remove the top shells and bottoms shell of the steering column shield.
(1)Remove the three screws.
(2)Remove the top part and bottom part of the steering column
shield.
7. Remove clock spring.
8. Remove the left combination switch assembly.
Separate the connector and remove the left combination switch
assembly.
9. Remove the right combination switch assembly.
Separate the connector and remove the right combination switch
assembly.
10. Remove the splined tube cover.
11. Detach No. 2 steering countershaft(see right figure)
(1) Make a mark on the fit between slide splined tube and countershaft. (2) Loosen bolts A and B.
12. Remove the steering column pipe assembly.
(1) Remove the cable connector on the steering column pipe assembly. (2) Remove the 3 bolts and steering column assembly.Installation mark
Power Steering System-Steering Drive and Control Mechanism4-7213. Remove the No.2 steering countershaft assembly.
(1) Make a mark on the fit between main shaft and countershaft.
(2) Remove bolt and countershaft.
14. Remove the ignition switch bracket.
(1) Use the punch pin to make a mark on the 2 conical head bolt.
(2) Drill the 2 conical head bolts with the diameter of 3-4mm drill
bit.
(3) Remove the bolts and bracket for the ignition switch with the
thread die.
15. Remove fixing panel on the steering column.
16.Remove the ignition switch lock core assembly.
(1) Turn the ignition switch to "ACC" position.
(2) press the stop pin and pull the lock core out.
17. After checking or replacing the steering column pipe assembly, install all parts in a reverse order.
Note:
(1) After installing the ignition switch lock core, check the operation of the steering locking function: when
pulling out the key, the steering device is locked; when the key is inserted and turned to ACC position, the
steering device is unlocked.
(2) Tighten the 3 bolts.
(3) Make sure all cables are connected reliably.
(4) After adjusting the combination switch as well as the top shell and bottom shell of the steering pipe shield,
fasten the three screws connecting the combination switch and the steering column assembly.
(5) Tighten the set bolt between the universal joint fork and the steering gear assembly with a torque of
22~39N.m.
(6) Install dust cover and its press plate.
(7) When installing the steering wheel assembly, align the steering wheel assembly and the fit mark of the
steering main shaft assembly. Tighten the special quincunx bolt with a torque of 33~59N.m.
(8) Check the airbag. It is not allowed to use a airbag part removed from another vehicle.
(9) Check the SRS warning lamp.Thread die Installation mark
Repair1. Remove the front wheel.
2. Discharge the brake fluid.
Note:
Never spray the brake fluid on the paint surface, otherwise wash it immediately.Brake System -Front Brake Disc4-95Sliding Pin Dust Shields3. Remove the front disc brake cylinder.
(1) Remove the connector bolt and washer from the front disc
bake cylinder, and unfix the tube.
(2) Fasten the sliding pin on the front disc brake cylinder, and
remove the two bolts.
4. Remove the front brake pad package (only the pad).
(1) Remove the two brake pads with muffle washers.
(2) Remove muffle and heat isolation washers from the brake
pads.
5. Remove the support pad of the front brake pad.
Remove the two friction block from the brake cylinder support.
6. Remove the sliding pin of the front disc brake cylinder.
7. Remove the two dust shields
Remove the two dust shields from brake cylinder support.
8. Remove the left front disc brake cylinder support.
Remove the two bolts, and then take out the left front disc brake
cylinder support.
9. Remove the dust shield of the brake cylinder.
Remove the retaining ring and dust shield with screwdriver.Braking Disc Cylinder Bracket