FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.6]

id0213008010e7

Caution
•  Performing the following procedures without first removing the front ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, disconnect the front ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
•  Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

1.  Remove the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

2.  Disconnect the intermediate shaft from the steering gear and linkage. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

3.  Disconnect the front ABS wheel-speed sensor wiring harness installed to the steering knuckle and set it aside. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

am3zzw00015789

4.  Remove the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

5.  Remove the front under cover No.1. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.)

6.  Remove the splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

7.  Set the front mudguard away from the front crossmember and front bumper. (See MUDGUARD REMOVAL/INSTALLATION.)

am6zzw00008429

8.  Disconnect the front crossmember extension.

ac5uuw00000131

9.  Disconnect the front stabilizer control link (front stabilizer side). (See FRONT STABILIZER REMOVAL/INSTALLATION.)

ac5uuw00000128

10.  Remove the insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 1.6].)

11.  Disconnect the hanger rubber from the front crossmember and set it aside.

am3zzw00016007

12.  Loosen the bolts shown in the figure.

am3zzw00016008

13.  Remove the bolt shown in the figure.

am3zzw00014670

14.  Remove the tie-rod end locknut.

Tightening torque
47—59 N·m {4.8—6.0 kgf·m, 35—43 ft·lbf}

15.  Detach the tie-rod end from the steering knuckle using the SST.

ac5uuw00000134

16.  Disconnect the front lower arm ball joint.

ac5uuw00000135

17.  Remove in the order indicated in the table.

18.  Install in the reverse order of removal.

19.  Inspect the wheel alignment and adjust it if necessary. (See FRONT WHEEL ALIGNMENT.)

am3uuw00011023

1
Front crossmember component
(See Front Crossmember Component Removal Note.)
(See No.1 Engine Mount Rubber and Front Crossmember Component Installation Note.)
2
Front stabilizer
(See FRONT STABILIZER REMOVAL/INSTALLATION.)
3
Steering gear and linkage
(See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)
4
Front lower arm
(See FRONT LOWER ARM REMOVAL/INSTALLATION.)
5
No.1 engine mount rubber
(See ENGINE MOUNT DISASSEMBLY/ASSEMBLY [MZR 1.6].)
(See No.1 Engine Mount Rubber and Front Crossmember Component Installation Note.)
6
Front crossmember


Front Crossmember Component Removal Note

Warning
•  Removing the crossmember is dangerous. The crossmember component could fall and cause serious injury or death. Verify that the jack securely supports the crossmember component.

1.  Support the front crossmember component using a jack.

ac5uuw00000137

2.  Remove the front crossmember installation bolts.

3.  Remove the front crossmember, front stabilizer, front lower arm, and steering gear and linkage as a single unit.


No.1 Engine Mount Rubber and Front Crossmember Component Installation Note

1.  When installing the front crossmember component to the vehicle, assemble the dust cover to the body-side installation area correctly to prevent water or foreign matter from penetrating. Install the dust cover carefully so as not to pinch the dust cover sponge to the body-side installation area or put a fold line on the sponge by contact.

am6zzw00010934

2.  Temporarily tighten the bolts shown in the figure.

am3zzw00016008

3.  Install the No.1 engine mount rubber and temporarily tighten the bolts shown in the figure.

am3zzw00014672

4.  Tighten the No.1 engine mount bracket and bracket plate installation bolts in the order shown in the figure.

am3zzw00016009

Tightening torque
59—68 N·m {6.1—6.9 kgf·m, 44—50 ft·lbf}

5.  Tighten the No.1 engine mount rubber installation bolts shown in the figure.

am3zzw00014674

Tightening torque

Installation position

Tightening torque
No.1 engine mount bracket side
140—163 N·m {15—16 kgf·m, 104—120 ft·lbf}
Front crossmember side
130—164 N·m {14—16 kgf·m, 96—120 ft·lbf}