TILT CAB TUBE INSTALLATION


  1. INSTALL TILT CAB TUBE SUB-ASSEMBLY NO.1


    1. A01KFG7

      Install the tilt cab tube sub-assembly No. 1 with 6 bolts and 6 nuts.

      Torque:
      185 N*m  { 1,880 kgf*cm, 136.4 ft.*lbf }
    2. A01KHQM

      Install the 6 bolts.

      Torque:
      58 N*m  { 590 kgf*cm, 42.7 ft.*lbf }

  2. CAB TILT UP

  3. INSTALL TILT CAB SPRING SUPPORT ARM NO.1


    1. Align matchmarks tilt cab spring support arm No. 1 on torsion-bar.

    2. Install the tilt cab spring support arm No. 1 with bolt.

      Torque:
      58 N*m  { 590 kgf*cm, 42.7 ft.*lbf }

  4. INSTALL REAR BRAKE TUBE NO.1


    1. Install the retainer.

    2. Using union nut wrench 10 mm, install the rear brake tube No. 1.

      Torque:
      15.2 N*m  { 155 kgf*cm, 11.2 ft.*lbf }

  5. INSTALL FRONT BRAKE TUBE NO.1


    1. Install the retainer.

    2. Using union nut wrench 10 mm, install the front brake tube No. 1.

      Torque:
      15.2 N*m  { 155 kgf*cm, 11.2 ft.*lbf }

  6. INSTALL CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE


    1. Install the retainer.

    2. Using union nut wrench 10 mm, install the clutch hose.

      Torque:
      19.5 N*m  { 190 kgf*cm, 14.3 ft.*lbf }

  7. INSTALL RADIATOR GRILLE BRACKET NO.2


    1. Install the radiator grille bracket with bolt.

      Torque:
      8.5 N*m  { 85 kgf*cm, 75 in.*lbf }

  8. INSTALL STEERING SLIDING W/COUPLING YOKE SUB-ASSEMBLY (INDEPENDENT FRONT SUSPENSION FRONT SUSPENSION)

    A01KIDFE01

    1. Align the matchmarks on the steering sliding w/coupling yoke and the bevel gear assembly.

      Text in Illustration
      *a Matchmark

    2. Install the bolt.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    3. A01KFT2

      Install the steering column tube lower with the 4 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  9. INSTALL STEERING MAIN SHAFT ASSEMBLY

  10. INSTALL FRONT BUMPER BAR


    1. Install the front bumper bar with the 6 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

    2. Connect the fog light connectors.

  11. INSTALL AIRMIX DAMPER CONTROL CABLE SUB-ASSEMBLY


    1. A01KHTPE02
      Text in Illustration
      *a COOL
      *b Clamp

      Connect the heater control cable to the heater control assembly, keep the condition of MAX COOL remaining.

    2. Install the inner cable to the control lever in MAX COOL position.

    3. Install the outer cable to the clamp while slightly pulling it to the direction shown by arrow in the illustration.

      Note

      When operating the mode control lever, check that the restraint exists at the both ends of MAX COOL and MAX HOT, and no repulsion occurs.

  12. INSTALL HEATER CONTROL CABLE SUB-ASSEMBLY


    1. A01KIGLE02
      Text in Illustration
      *a DEF

      Connect the heater control cable to the heater control assembly, keep the condition of DEF remaining.

    2. Install the inner cable to the control lever in DEF position.

    3. Install the outer cable to the clamp while slightly pulling it to the direction shown by arrow in the illustration.

      Note

      When operating the mode control lever, check that the restraint exists at the both ends of FACE and DEF, and no repulsion occurs.

  13. INSTALL HEATER RADIATOR ASSEMBLY


    1. A01KI2J

      Install the heater radiator assembly with the 2 bolts and 2 nuts.

      Tech Tips

      Tighten in the following order.

  14. INSTALL AIR DUCT SUB-ASSEMBLY NO.1


    1. A01KGN6

      Install the air duct sub-assembly No. 1 with the 3 bolts and 4 screws.

      Tech Tips

      Tighten in the following order.

  15. INSTALL INSTRUMENT PANEL REINFORCEMENT


    1. A01KGFG

      Install the instrument panel reinforcement with the 2 bolts and 4 nuts.

  16. INSTALL STEERING COLUMN TUBE ASSEMBLY LOWER


    1. A01KENP

      Install the steering column tube sub-assembly lower with the 2 bolts and 2 nuts.

  17. INSPECT INSTRUMENT PANEL PASSENGER AIR BAG ASSEMBLY

  18. INSTALL INSTRUMENT PANEL PASSENGER AIR BAG ASSEMBLY

  19. INSTALL COMBINATION METER ASSEMBLY

  20. INSTALL STEERING COLUMN ASSEMBLY

    A01KGTVE01

    1. Install the 4 bolts and steering column assembly.

      Text in Illustration
      *A Non-Tilt Steering Column
      *B Tilt Steering Column
      Torque:
      11.5 N*m  { 117 kgf*cm, 9 ft.*lbf }
    2. A01KGWE

      Install the 2 bolts and clamp bracket.

  21. INSTALL STEERING COLUMN COVER LWR


    1. Install the steering column cover LWR with the clip and 2 screws.

  22. INSTALL STEERING COLUMN COVER UPR


    1. Install the steering column cover UPR with the 2 screws.

  23. INSTALL INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.1


    1. A01KFLT

      Install the instrument panel brace sub-assembly with the 2 bolts and nut.

  24. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY

  25. ADD COOLANT

  26. INSPECT ENGINE COOLANT LEAK

  27. WARM UP ENGINE

  28. INSTALL TURN SIGNAL SWITCH ASSEMBLY

  29. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  30. INSPECT STEERING WHEEL ASSEMBLY

  31. INSPECT HORN BUTTON ASSEMBLY (W/ SRS AIRBAG)

  32. CENTER SPIRAL CABLE

  33. INSTALL STEERING WHEEL ASSEMBLY


    1. Align the matchmarks on the steering wheel assembly with the one on the steering main shaft.

    2. Install the steering wheel set nut.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  34. INSTALL HORN BUTTON ASSEMBLY (W/O SRS AIRBAG)

    A01KHLWE01
    Text in Illustration
    *A Non-Tilt Steering Column
    *B Tilt Steering Column

    1. Non-Tilt Steering Column:


      1. Connect the horn button connector.

      2. Install the 2 screws and horn button assembly.

    2. Tilt Column Steering:


      1. Connect the horn button connector.

      2. Install the bolt and horn button assembly.

        Torque:
        2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  35. INSTALL HORN BUTTON ASSEMBLY (W/ SRS AIRBAG)

    Click here

  36. BLEED BRAKE LINE

  37. CHECK BRAKE FLUID LEAKAGE

  38. CHECK FLUID LEVEL IN RESERVOIR

  39. BLEED CLUTCH PIPE LINE

  40. CHECK CLUTCH FLUID LEAKAGE

  41. INSPECT SRS WARNING LIGHT

  42. HEADLIGHT AIM ONLY


    1. Place the vehicle in the following conditions.


      • The vehicle is parked on a level surface.

      • Tire inflation pressure is the specified value.

      • A driver is in the driver's seat and the vehicle is in a state ready for driving (with a tank full).

      • The vehicle has been bounced several times.

    2. Check the headlight aiming.


      1. Prepare a thick white paper.

      2. Stand the paper perpendicular to the ground at the position 9.84 ft away from the headlights.

      3. Ensure that the center line of the vehicle and the paper face forms a 90-degree angle as shown in the illustration.

      4. Draw a horizontal line (H line) on the paper, showing where the headlights should strike.

      5. Draw a vertical line (V line) to where the center line of the vehicle is to be.

      6. Draw 2 vertical lines to where the both headlights should strike (V RH and V LH lines).

      7. Draw a horizontal line (by connecting the both low beam center marks) to where the headlights should strike (H RH and H LH lines).

        Tech Tips

        The H RH and H LH line is 0.57° below the horizontal line (H line) of the light axis.

      8. Start the engine.

      9. Turn the headlights ON.

      10. Check that the headlights properly strike the position shown in the illustration.

      11. If not, adjust the lights in the vertical or horizontal direction.

        A01KFZGE01

        Tech Tips


        • As shown in the illustration, adjust each aim of the RH and LH lights.

        • Since the horizontal direction is impossible to adjust, the value * of the "Low Beam" aim is reference value.

    3. A01KHJLE01
      Text in Illustration
      *a Bolt A
      *b Bolt B

      When adjusting it in the vertical direction: Using adjusting bolt A, adjust the headlight aim to within the specified range.

    4. When adjusting it in the horizontal direction: Using adjusting bolt B, adjust the headlight aim to within the specified range.