Service Manual
Table Of Contents
- GENERAL INFORMATION
- MAINTENANCE
- ELECTRONIC FUEL INJECTION
- SPECIAL TOOLS
- Part Numbers / Descriptions
- Fuel Pressure Gauge Kit - PU-43506-A
- Fuel Pressure Gauge Adaptor - PS-48762
- Throttle Position Sensor Tester Kit - 2201519
- Digital Wrench™ Diagnostic Software PU-47063
- Digital Wrench™ SmartLink Module Kit - PU-47471
- Digital Wrench™ - Diagnostic Connector
- Digital Wrench™ - Download Website
- FUEL TANK
- FUEL LINE
- EFI SERVICE NOTES
- EFI SYSTEM LAYOUT
- EFI COMPONENTS
- ELECTRONIC FUEL INJECTION
- ELECTRONIC CONTROL UNIT (ECU)
- FUEL PUMP
- FUEL PRESSURE REGULATOR
- FUEL INJECTORS
- CRANKSHAFT POSITION SENSOR (CPS)
- TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)
- IDLE AIR CONTROL VALVE (IAC)
- THROTTLE POSITION SENSOR (TPS)
- ENGINE COOLANT TEMPERATURE SENSOR (ECT)
- IGNITION COIL
- EFI DIAGNOSTICS
- FUEL SYSTEM TROUBLESHOOTING
- EFI SYSTEM BREAK-OUT DIAGRAMS
- Fuel Injector Circuit (PTO)
- Fuel Injector Circuit (MAG)
- Idle Air Control (IAC) Circuit
- Crankshaft Position Sensor (CPS) Circuit
- Fuel Pump / Fuel Level Sensor Circuit
- Fuel Pump Circuit
- Fuel Gauge Circuit
- Engine Coolant Temperature Sensor (ECT) Circuit
- Throttle Position Sensor (TPS) Circuit
- Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit
- Diagnostic Connector Circuit
- Diagnostic Connector Circuit (EPS Models)
- SPECIAL TOOLS
- COOLING SYSTEM
- ENGINE
- GENERAL INFORMATION - ENGINE
- ENGINE ASSEMBLY VIEWS AND TORQUE VALUES
- Torque & Torque Sequence - Main Engine Components
- Valve Cover / Breather Valve
- Camshaft Carrier / Camshaft / Rocker Arm
- Cylinder Head / Valve / IAFM
- Valve & Spring Height Detail
- Piston / Connecting Rod
- Crankshaft
- Crankcase
- Crankcase - Upper
- Balance Shaft / Balance Shaft Timing
- Crankcase (Lower) With Oil Pump
- Water Pump Coupler
- Water Pump / Water Pump Coupler / Stator / Flywheel
- Drive Coupler (Rear) / Starter Gear
- ENGINE SERVICE
- ENGINE DISASSEMBLY AND INSPECTION
- Valve Cover / Breather Valve
- Rocker Carrier / Camshaft Removal
- Rocker Arm / Rocker Arm Shaft Inspection
- Camshaft / Camshaft Bore Inspection
- Cylinder Head Removal
- Cylinder Head Cleaning
- Cylinder Head Warp Inspection
- Cylinder Head
- Valve Inspection
- Combustion Chamber
- Valve Guide Removal / Installation
- Valve Seat Reconditioning
- Cylinder Head Assembly
- Valve Sealing Test
- Cylinder Head Installation
- Camshaft / Carrier Assembly
- Camshaft / Camshaft Carrier Installation
- Camshaft Timing
- Cam Chain Tensioner Installation
- Camshaft Timing - Quick Reference
- Crankcase Disassembly
- Crankcase (Lower) / Oil Pump Disassembly
- Crankcase Disassembly (Upper)
- Piston / Connecting Rod Removal
- Counterbalance Shaft Removal / Inspection
- Counterbalance Split Gear Replacement
- Crankshaft / Cam Chain Removal
- Cam Chain / Sprocket Inspection
- Crankcase Inspection (Lower)
- Crankshaft Inspection
- Connecting Rod Inspection
- Connecting Rod Big End Bearing Selection
- Piston / Piston Ring Inspection
- Piston Ring Removal
- Piston Ring Installed Gap
- Piston Pin Bore Inspection
- Cylinder Inspection
- Piston-to-Cylinder Clearance
- Honing - Important Information
- ENGINE ASSEMBLY
- Crankcase Preparation - Upper
- Piston Ring Installation
- Piston / Connecting Rod Assembly
- Piston / Connecting Rod Installation
- Crankshaft Installation
- Oil Passage Tube
- Crankcase Assembly - Upper
- Balance Shaft Installation
- Balance Shaft Timing
- Crankcase Preparation (Lower)
- Crankcase Sealant and Torque Values
- Crankcase Assembly
- WATER PUMP
- TROUBLESHOOTING
- TRANSMISSION
- CLUTCHING (PVT)
- FINAL DRIVE
- BODY / FRAME
- STEERING / SUSPENSION
- BRAKES
10.17
STEERING / SUSPENSION
10
Removal
The following procedure details upper and lower A-arm
removal and replacement on one side of the vehicle.
1. Elevate and safely support the rear of the vehicle and
remove the rear wheel.
Upper A-arm Removal
2. Remove the through-bolt fastener attaching the upper A-
arm to the bearing carrier (see “Exploded View”).
3. Remove the through-bolt fasteners attaching the upper A-
arm to the frame and remove the A-arm from the vehicle.
4. Examine A-arm and bearing carrier bushings and pivot
shafts (see “Exploded View”). Replace if worn and discard
the hardware.
5. If not replacing the A-arm, thoroughly clean the a-arm and
pivot shafts.
6. Insert new bushings and pivot shafts into the new A-arm.
Lower A-arm Removal
7. Remove the through-bolt fastener attaching the lower A-
arm to the bearing carrier (see “Exploded View”).
8. Remove the lower shock fastener from the lower A-arm.
9. Remove the brake line retainer from the lower A-arm.
10. Remove the fastener retaining the stabilizer linkage to the
lower A-arm.
11. Remove the through-bolt fasteners attaching the lower A-
arm to the frame and remove the A-arm from the vehicle.
12. Examine A-arm and bearing carrier bushings and pivot
shafts (see “Exploded View”). Replace if worn and discard
the hardware.
13. If not replacing the A-arm, thoroughly clean the a-arm and
pivot shafts.
14. Insert new bushings and pivot shafts into the new A-arm.
Installation
1. Install upper and lower A-arm assemblies onto the vehicle
frame. Torque new fasteners to 45 ft. lbs. (61 Nm).
2. Grease all (4) A-arm grease fittings after reassembly.
3. Attach lower A-arm to bearing carrier. Torque new
fastener to 45 ft. lbs. (61 Nm).
4. Attach upper A-arm to bearing carrier. Torque new
fasteners to 40 ft. lbs. (54 Nm).
5. Grease both rear bearing carrier fittings after reassembly.
6. Route brake line on top of lower A-arm and install retainer.
7. Reinstall the lower portion of the shock and lower portion
of the stabilizer linkage to the lower A-arm. Torque
mounting fasteners to 37 ft. lbs. (50 Nm).
8. Install wheel and torque wheel nuts to specification.
WARNING
The locking agent on the existing bolts was
destroyed during removal. DO NOT reuse old
hardware. Serious injury or death could result if
fasteners come loose during operation.
WARNING
Upon A-arm installation completion, test vehicle
at low speeds before putting into service.