Installation

Steering Gearbox

INSTALLATION
1. Insert the gearbox into crossmember, being careful not to damage gearbox boot.





2. Install the gearbox and bracket. Tighten the bolt temporarily.





3. Tighten the gearbox to the crossmember bracket via clamp with bolt temporarily.
4. Tighten the bolts which temporary tightening the clamp and bracket of gearbox to specified torque.
Tightening torque: 60 Nm (6.1 kgf-cm, 44.1 ft. lbs.)





5. Connect the pipe D to return hose first, and the pipe C to pressure hose second.
Tightening torque: 15 Nm (1.5 kgf-cm, 10.8 ft. lbs.)
6. Install the universal joint.
7. Connect the tie-rod end and knuckle arm, and tighten with castle nut.
Castle nut tightening torque: 27 Nm 2.75 kgf-cm, 19.9 ft. lbs.)

CAUTION: When connecting, do not hit cap at the bottom of tie-rod end with hammer.





8. After tightening the castle nut to specified tightening torque, tighten it further within 60° until cotter pin hole is aligned with slot in the nut. Fit the cotter pin into nut, and then bend the pin to lock.
9. Install the front stabilizer.
10. Install the front crossmember support plate and jack-up plate.
11. Install the front exhaust pipe assembly. (Nonturbo model)
12. Install the undercover.
13. Install the front wheels.
14. Tighten the wheel nuts to specified torque.
Tightening torque: 90 Nm (9.1 kgf-cm, 65.8 ft. lbs.)
15. Lower the vehicle.
16. Remove the steering wheel.
17. Align the center of roll connector.
18. Install the steering wheel.
19. Connect the battery ground cable to battery.
20. Pour fluid into the oil tank, and bleed air.
21. Check for fluid leaks.
22. Check the fluid level in oil tank.





23. After adjusting toe-in and steering angle, tighten the lock nut on tie-rod end.
Tightening torque: 85 Nm (8. 7 kgf-cm, 62.7 ft. lbs.)

NOTE: When adjusting toe-in, hold the boot as shown to prevent it from being rotated or twisted. If twisted, straighten it.