STEERING GEAR REMOVAL


  1. DISCHARGE FUEL SYSTEM PRESSURE

    Tech Tips

    Click here.

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

    4. Stop the engine.

    5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

  3. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A017CN1

      Remove the 11 clips and cool air intake duct seal.

  4. REMOVE BATTERY


    1. A017ETJ

      Loosen the nut, and disconnect the negative battery terminal.

      CAUTION:

      Wait for 90 seconds after disconnecting the cable to prevent the airbag working.

      Note

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

    2. Remove the nut, and separate the positive battery terminal cable.

    3. Loosen the nut, and remove the bolt and battery clamp.

    4. Remove the battery and battery tray.

  5. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  6. SECURE STEERING WHEEL


    1. A017DNA

      Secure the steering wheel with the seat belt in order to prevent it from rotating.

      Tech Tips

      This operation is necessary to prevent damage to the spiral cable.

  7. REMOVE FRONT WHEELS

  8. REMOVE ENGINE UNDER COVER ASSEMBLY


    1. A017FPR

      Remove the 2 bolts and engine under cover assembly RR.

    2. A017FXN

      Remove the 2 bolts, 2 screws, 5 clips and engine under cover assembly.

  9. REMOVE NO. 1 ENGINE UNDER COVER


    1. A017D1W

      Remove the 6 bolts, 2 clips and No. 1 engine under cover.

  10. REMOVE NO. 2 ENGINE UNDER COVER


    1. A017CNJ

      Remove the 2 bolts and No. 2 engine under cover.

  11. REMOVE FLOOR UNDER COVER LH


    1. A017BWS

      Remove the 3 clamps, 6 bolts and front floor cover LH.

  12. REMOVE FRONT FENDER MOULDING SUB-ASSEMBLY LH


    1. A017F6U

      Remove the clip.

    2. Using a 4 mm hexagon wrench, remove the screw.

    3. A017C5R

      Peel off the double-sided tape and disengage the 3 clips, and then remove the front fender moulding sub-assembly.

    4. Remove the pad from the front fender moulding sub-assembly.

    5. Remove the 2 No. 4 clips from the front fender moulding sub-assembly.

    6. A017BKRE02
      Text in Illustration
      *1 Double-sided Tape

      Remove the double-sided tape from the front fender moulding sub-assembly.

  13. REMOVE FRONT FENDER MOULDING SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  14. REMOVE FRONT FENDER LINER LH


    1. A017D8EE01

      Remove the screw.

    2. Using a screwdriver, turn the pin 90 degrees and remove the 2 pin hold clips.

    3. A017F25

      Using a 4 mm hexagon wrench, remove the 2 screws.

    4. Remove the 3 grommets.

      Tech Tips

      The grommets need to be replaced with new ones because they will break when they are removed.

    5. A017CD9

      Remove the 5 clips.

    6. Remove the bolt, 8 screws and front fender liner LH.

  15. REMOVE FRONT FENDER LINER RH


    1. A017B7YE01

      Remove the screw.

    2. Using a screwdriver, turn the pin 90 degrees and remove the 2 pin hold clips.

    3. A017CZV

      Using a 4 mm hexagon wrench, remove the 2 screws.

    4. Remove the 3 grommets.

      Tech Tips

      The grommets need to be replaced with new ones because they will break when they are removed.

    5. A017CFW

      Remove the 5 clips

    6. Remove the bolt, 8 screws and front fender liner RH.

  16. REMOVE FRONT FENDER APRON SEAL LH


    1. A017FVN

      Remove the 2 bolts, clip and front fender apron seal LH.

  17. REMOVE FRONT FENDER APRON SEAL RH


    1. A017FOB

      Remove the 2 bolts, clip and front fender apron seal RH.

  18. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and oil pan drain plug gasket, and drain the engine oil into a container.

    3. Clean and install the oil pan drain plug with a new oil pan drain plug gasket.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  19. DRAIN ENGINE COOLANT


    1. Loosen the radiator drain cock plug.

      A017CW8E01

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. Remove the radiator cap sub-assembly from the radiator assembly.

      Note

      Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    3. Loosen the 2 cylinder block drain cock plugs.

  20. DRAIN AUTOMATIC TRANSAXLE FLUID


    1. Remove the drain plug and gasket, and drain ATF.

    2. Install a new gasket and the drain plug.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  21. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. A017DLO

      Remove the nut, and the front wiper arm and blade assembly RH.

  22. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. A017BZJ

      Remove the nut, and the front wiper arm and blade assembly LH.

  23. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. A017EML

      Disengage the 2 claws and disconnect the front fender to cowl side seal LH.

    2. A017F5E

      Disengage the 2 claws and disconnect the front fender to cowl side seal RH.

    3. Remove the 2 clips.

      A017F5J

    4. Disengage the 20 claws and remove the cowl top ventilator louver sub-assembly.

  24. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A017FR2

      Disconnect the connector.

    2. Remove the 4 bolts, and the windshield wiper motor and link assembly.

  25. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    1. A017BN2

      Remove the 4 clips, and separate the engine wire.

    2. Remove the 8 bolts, 6 nuts and front outer cowl top panel sub-assembly.

      A017FUC

  26. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. A017CDJ

      Remove the 4 clips, and separate the engine wire.

    2. Remove the 8 bolts, 6 nuts and front outer cowl top panel sub-assembly.

      A017FUC

  27. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A017EFM

      Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 clips on the front of the V-bank cover sub-assembly. Continue rising the V-bank cover sub-assembly to disengage the clip on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the V-bank cover sub-assembly to break.

  28. REMOVE NO. 2 AIR CLEANER INLET


    1. A017D82

      Disconnect the 2 vacuum switching valve clamps.

    2. Disconnect the 2 vacuum hoses.

    3. Remove the 2 bolts and No. 2 air cleaner inlet.

  29. REMOVE NO. 1 AIR CLEANER INLET


    1. A017C2Q

      Disconnect the 2 vacuum hoses, and remove the 2 bolts and No. 1 air cleaner inlet.

  30. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A017BB9

      Disconnect the 3 vacuum hoses.

    2. A017EZ4

      Loosen the No. 1 air cleaner hose clamp.

    3. Disconnect the hose clamps and No. 2 ventilation hose.

    4. Disconnect the mass air flow meter connector.

    5. A017FXX

      Release the 2 clips, and remove the 2 bolts.

    6. Remove the air cleaner cap sub-assembly and air cleaner filter element.

  31. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Remove the air cleaner filter element sub-assembly.

  32. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A017BI0

      Remove the 3 bolts, disconnect the hose and the connector, and remove the air cleaner case sub-assembly.

  33. REMOVE AIR CLEANER BRACKET


    1. A017BE8

      Remove the 2 bolts and air cleaner bracket.

  34. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for LHD)


    1. A017DMO

      Disconnect the level warning switch connector.

    2. Remove the bolt, and separate the brake master cylinder reservoir assembly.

  35. REMOVE RESERVOIR BRACKET (for LHD)


    1. A017BM4

      Remove the 2 bolts and reservoir bracket.

  36. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for RHD)


    1. A017ELT

      Disconnect the level warning switch connector.

    2. Remove the bolt, and separate the brake master cylinder reservoir assembly.

  37. REMOVE RESERVOIR BRACKET (for RHD)


    1. A017BY5

      Remove the 2 bolts and reservoir bracket.

  38. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A017AZW

      Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.

  39. REMOVE ENGINE MOVING CONTROL ROD


    1. A017DQQ

      Remove the 3 bolts and engine moving control rod.

  40. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. A017EKE

      Slide the clamp and disconnect the No. 1 fuel vapor feed hose.

  41. DISCONNECT NO. 1 RADIATOR HOSE


    1. A017FNY

      Disconnect the clamp.

    2. Using pliers, grip the claws of the clip and slide the clip to disconnect the No. 1 radiator hose from the water outlet.

  42. DISCONNECT NO. 2 RADIATOR HOSE


    1. A017FAP

      Using pliers, grip the claws of the clip and slide the clip to disconnect the No. 2 radiator hose from the water inlet.

  43. DISCONNECT HEATER WATER HOSE OUTLET B


    1. A017EOA

      Using pliers, grip the claws of the clip and slide the clip to disconnect heater water outlet hose B from the water inlet.

  44. DISCONNECT HEATER WATER HOSE INLET B


    1. A017ES8

      Using pliers, grip the claws of the clip and slide the clip to disconnect heater water inlet hose B from the water outlet.

  45. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A017CB8

      Remove the No. 1 fuel pipe clamp.

    2. A017EM2E15

      Disconnect the fuel tube from the fuel pipe pinching part A with your fingers as shown in the illustration.

      Note


      • Check for dirt and foreign objects on the pipe and around the connector. Clean if necessary and then disconnect the connector.

      • Disconnect the connector by hand.

      • Do not bend, fold or rotate the nylon tube.

      • If the pipe and connector are stuck together, push and pull the connector until it becomes free.

      • Put the pipe and connector ends in plastic bags to prevent damage and contamination.

  46. DISCONNECT OIL COOLER INLET HOSE


    1. A017GAW

      Using pliers, grip the claws of the clip and slide the clip to disconnect the No. 2 transmission oil cooler hose.

  47. DISCONNECT OIL COOLER OUTLET HOSE


    1. A017B66

      Using pliers, grip the claws of the clip and slide the clip to disconnect the oil cooler outlet hose.

  48. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A017F9YE11

      Remove the nut from the control shaft lever.

    2. Disconnect the transmission control cable assembly from the control shaft lever.

    3. A017CN2E04

      Remove the clip and disconnect the transmission control cable assembly from the control cable bracket.

    4. A017GAO

      Disconnect the transmission control cable assembly from the control cable clamp.

  49. DISCONNECT ENGINE WIRE (for LHD)


    1. Disconnect the engine wire from the engine room relay block.


      1. Remove the No. 1 relay block cover.

      2. A017EV4

        Remove the nut.

      3. Disconnect the engine wire connector from the engine room relay block.

      4. Unlock the engine wire. Pull the engine room wire.

    2. A017BS8

      Disconnect the engine wire clamp.

    3. A017B0U

      Remove the bolt, and separate the ground cables.

    4. A017E3R

      Disconnect the heated oxygen sensor connector and clamp.

    5. A017F41

      Remove the 2 bolts and 2 ground cables.

    6. A017CWE

      Disconnect the 3 ECM connectors, 2 junction block connectors and clamp.

    7. A017BJY

      Remove the 2 nuts and clamp, and separate the engine wire from the body.

  50. DISCONNECT ENGINE WIRE (for RHD)


    1. Disconnect the engine wire from the engine room relay block.


      1. Remove the No. 1 relay block cover.

      2. A017EV4

        Remove the nut.

      3. Disconnect the engine wire connector from the engine room relay block.

      4. Unlock the engine wire. Pull the engine room wire.

    2. A017BS8

      Disconnect the engine wire clamp.

    3. A017B0U

      Remove the bolt, and separate the ground cables.

    4. A017E3R

      Disconnect the heated oxygen sensor connector and clamp.

    5. A017F41

      Remove the 2 bolts and 2 ground cables.

    6. A017DMP

      Disconnect the 3 ECM connectors, 2 junction block connectors and clamp.

    7. A017B8A

      Remove the 2 nuts and clamp, and separate the engine wire from the body.

  51. DISCONNECT UNION TO CHECK VALVE HOSE


    1. A017G66

      Using pliers, grip the claws of the clip and slide the clip to disconnect the union to check valve hose.

  52. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)


    1. A017FGM

      Depress the brake pedal and hold it.

    2. Using a hexagon wrench (6 mm), loosen the cross groove joint set bolts 1/2 turn.

      Tech Tips

      Put a piece of cloth or equivalent into the inside of the universal joint cover so that the boot does not touch the inside of the universal joint cover.

    3. A017FC7E01

      Place matchmarks on the rear propeller shaft and rear drive pinion flange sub-assembly.

    4. Remove the 4 nuts, 4 bolts and 4 washers.

    5. A017G71

      Remove the 4 bolts and 4 adjusting shims.

    6. A017DKO

      Using a brass bar and a hammer, remove the propeller shaft with center bearing shaft assembly.

    7. A017G8QE01

      Insert SST into the transfer to prevent oil leakage.

      SST
      09325-20010

  53. REMOVE TAIL EXHAUST PIPE ASSEMBLY


    1. A017DZ8

      Remove the 2 bolts and 2 compression springs.

    2. Disconnect the exhaust pipe support and remove the tail exhaust pipe assembly.

    3. Remove the gasket from the center exhaust pipe assembly.

  54. REMOVE CENTER EXHAUST PIPE ASSEMBLY


    1. A017EM8

      Remove the 2 bolts and 2 compression springs.

    2. Disconnect the 3 exhaust pipe supports and remove the center exhaust pipe assembly.

    3. Remove the gasket from the No. 3 exhaust pipe sub-assembly.

  55. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY


    1. A017C8S

      Remove the 3 clamps and disconnect the heated oxygen sensor (for bank 1 sensor 2) connector.

    2. A017F2Y

      Remove the 2 bolts, 2 nuts and front No. 3 exhaust pipe sub-assembly.

    3. Remove the 2 gaskets from the front No. 3 exhaust pipe sub-assembly.

  56. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A017EQE

      Loosen the bolt.

    2. Remove the 2 nuts and front exhaust pipe assembly.

    3. Remove the gasket from the front exhaust pipe assembly.

  57. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH


    1. A017CL5

      Remove the nut and separate the front stabilizer link assembly from the front shock absorber.

      Tech Tips

      If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

  58. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  59. REMOVE FRONT AXLE HUB NUT LH


    1. A017E4SE01

      Using SST and a hammer, release the staked part of the front axle hub nut.

      SST
      09930-00010

      Note

      Loosen the staked part of the nut completely, otherwise the threads of the drive shaft may be damaged.

    2. While applying the brakes, remove the front axle hub nut.

  60. REMOVE FRONT AXLE HUB NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  61. SEPARATE FRONT SPEED SENSOR LH


    1. A017CELE03

      Remove the bolt and resin clamp, and separate the front speed sensor.

  62. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  63. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A017E5L

      Remove the bolt and slide the steering intermediate shaft assembly.

      Note

      Do not separate the steering intermediate shaft assembly from the power steering link assembly.

    2. A017BS1E01

      Put matchmarks on the steering intermediate shaft assembly and the power steering link assembly.

    3. Separate the steering intermediate shaft assembly from the power steering link assembly.

  64. SEPARATE TIE ROD ASSEMBLY LH


    1. Remove the cotter pin and the nut.

    2. A017D20E01

      Install SST to the tie rod end.

      SST
      09960-20010   ( 09961-02060 )

      Note

      Make sure that the upper ends of the tie rod end and SST are aligned.

    3. Using SST, separate the tie rod end from the steering knuckle.

      A017D19E01
      SST
      09960-20010   ( 09961-02010 )

      Note


      • When securing SST to the steering knuckle, be sure to tighten the string of SST to prevent it from falling.


      • Install SST so that A and B are parallel.


      • Be sure to place the wrench on the part indicated in the illustration.


      • Do not damage the front disc brake dust cover.


      • Do not damage the ball joint dust cover.


      • Do not damage the steering knuckle.

  65. SEPARATE TIE ROD ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  66. SEPARATE NO. 1 FRONT SUSPENSION LOWER ARM LH


    1. A017CVO

      Remove the bolt and 2 nuts, and separate the front lower suspension arm from the front lower ball joint.

  67. SEPARATE NO. 1 FRONT SUSPENSION LOWER ARM RH

    Tech Tips

    Perform the same procedure as for the LH side.

  68. SEPARATE FRONT AXLE ASSEMBLY LH


    1. A017DYRE04

      Put matchmarks on the front drive shaft assembly and the front axle hub sub-assembly.

    2. A017BEP

      Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly.

      Note

      Loosen the staked part of the front axle hub nut completely, otherwise the threads of the drive shaft may be damaged.

  69. SEPARATE FRONT AXLE ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  70. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. A017FIO

      Remove the bolt and disconnect the discharge hose sub-assembly from the compressor and magnetic clutch.

    2. Remove the O-ring from the discharge hose sub-assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  71. DISCONNECT SUCTION HOSE SUB-ASSEMBLY


    1. A017BHJ

      Remove the bolt and disconnect the suction hose sub-assembly from the compressor and magnetic clutch.

    2. Remove the O-ring from the suction hose sub-assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  72. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine lifter.

    2. A017E45

      Remove the 6 bolts, 2 nuts, and frame side rail plates RH and LH.

    3. A017DM1

      Remove the 6 bolts, 2 nuts, and front suspension member rear braces RH and LH.

    4. Operate the engine lifter, then remove the engine assembly from the vehicle.

      Note

      Make sure that the engine is clear of all wiring and hoses.

  73. REMOVE FRONT NO. 1 STABILIZER BRACKET LH


    1. A017DRG

      Remove the 2 bolts and the No. 1 front stabilizer bracket LH from the front frame assembly.

  74. REMOVE FRONT NO. 1 STABILIZER BRACKET RH

    Tech Tips

    Perform the same procedure as the LH side.

  75. REMOVE FRONT STABILIZER BAR

  76. REMOVE POWER STEERING LINK ASSEMBLY


    1. A017BH9

      Remove the 2 bolts, 2 nuts, and power steering link assembly.

      Note

      Because the nut has its own stopper, do not turn the nut. Loosen the bolt with the nut fixed.

  77. REMOVE TIE ROD ASSEMBLY LH


    1. A017BJXE01

      Put matchmarks on the tie rod assembly LH and the steering rack end sub-assembly.

    2. Loosen the lock nut, and remove the tie rod assembly LH and the lock nut.

  78. REMOVE TIE ROD ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.