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Honda Civic 2002 Si suspension

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Honda Civic 2002 Si suspension Powered By Docstoc
					Suspension
Frontand RearSuspension
 SpecialTools                                                           .............     18-2
 Component        Location     Index .........................................            18-3
 W h e eA l i g n m e n .t . . . . . . . . . . . . . . . . . . . .
          l                                                                               1.
                                                                          . . . . . . . . . .8 - 4
 WheelBearing PlayInspection
                     End                                      ............................18-8
 WheelRunout         Inspection                                      ..................   18-9
 B a l J o i n tR e m o v a l
       l                                                                            ... 18-10

FrontSuspension
 Knuckle/H bAVheel
           u        BearingReplacement                                            18-1
 BallJoint Boot Reolacement..................                                     18-16
 Stabilizer Rep|acement....................
           Bar                                                                    18-17
 StabilizerLink Removal/lnstallation                                              18-18
 LowerArm Removal/lnstallation   ...............                                  18-19
 Damper/Spring   Replacement                                                      18-20

RearSuspension
                  g
 H u bB e a r i n U n i tR e p l a c e m e . . t . . . . . . . . . . . . . . . . . . 18-26
                                           n.
 Knuckle  Reolacement                                                                18-28
 Stabilizer Replacement
            Bar                        ....................                          18-30
            Link
 Stabilizer Removal/lnstallation                      ..........................     18-31
 Upper  Arm Removal/lnstallation                ...............                      18-32
 Trailing Arm Removal/lnstallation                                                   18-33
 Damper/Spring       Replacement                                                     18-34
    Frontand RearSuspension
     SpecialTools
      Ref.No.           Tool Number                                   Description          otv
        o       07GAF-SE00100          Hub Dis/Assembly            Tool
        @       07MAC-S100200                                        ,
                                       B a l lJ o i n t R e m o v e r2 8 m m
                07746-0010500          Attachment, x 68 mm 62
        o       07749-0010000          Driver
                07965-SA50500          Front Hub Dis/Assembly             Tool
        G)      07965-SD90100          Support Base




                   o                       o



                                      []




I
                   @                       o                                        a6,l




    18-2
ComponentLocationIndex
FrontSuspension:

                                                               DAMPER/SPRING
                                                                        page
                                                               Replacement, 18-20


                                                                              BAR
                                                                     STABILIZER
                                                                               page
                                                                     Replacement, 18-17
                                                                              LINK
                                                                     STABILIZER
                                                                                      page
                                                                     Removal/lnstallation, 18 18

                                                                            KNUCKLE/HU8/WHEEL      BEARING
                                                                            Replacement,  page 18-1
                                                                                                  1
                                                                            Ball Joint Boot
                                                                            Replacement,  page'18-16




     LOWEBARM
                        page 18 19
     Removal/lnstallation,

Rear
   Suspension:
                                                                                 BAR
                                                                        STABILIZER
                                                                                  page
                                                                        Replacement. 18-30

                                                                                 UPPERARM
                                                                                 Removal/lnstallation,
                                                                                 page'18-32


 DAMPER/SPRING
          page'18-34
 Replacement,




                                                                              HUBBEARINGUNIT
                                                                                       page
                                                                              Replacement, 18'26

                                                           KNUCKLE
                                                                    page
                                                           Replacement, 18-28

                                     TRAILINGARM
                                                        page 18 33
                                     Removal/lnstallation,




                                                                                                         18-3
Frontand RearSuspension
 WheelAlignment
 The suspension   can be adjustedfor front camber,front            Front Casterlnspection
 toe, and reartoe. However,each of these adjustments
 are interrelated each other. For example,when you
                 to                                                                                                                fo
                                                                   U s ec o m m e r c i a l l a v a i l a b l e o m D u t e r i z e d u r w h e e l
                                                                                              v               c
 adjustthe toe, the camberchanges.   Therefore,you                                                                  w
                                                                   a l i g n m e ne q u i p m e ntto m e a s u r e h e e la l i g n m e n t
                                                                                  t
 must adjustthe front wheel alignmentwheneveryou                   (caster,    camber,toe, and turning angle).Follow the
 adjustthe camberor toe.                                           eouiomentmanufacturer's                  instructions.

            Checks
 Pre-Alignment                                                     Checkthe casterangle.lf the casterangle is not within
                                                                                    checkfor bent or damaged
                                                                   the specification,
 For proper inspectionand adjustmentof the wheel                   susoensron  comoonents.
 alignment,do these checks:
                                                                   Front casterangle: 1'40't                   1"
  1. Release parkingbraketo avoid an incorrect
           the
     measurement.

  2 . Make sure the suspensionis not modified.

  3 . C h e c k h e t i r e s i z ea n d t i r e p r e s s u r e
              t

      Tire size:
        Front/rear: 195/60R15

      Tire pressure:
        Front:       230 kPa {2.3kgf/cm',33 psil
        Rear:        210 kPa |'2.1kgf/cm', 30 psi)

      Checkthe runout of the wheels and tires.                                                                                                        \

      Checkthe suspensionball joints. (Holda wheel
      with your hands,and move it up and down and
      right and left to checkfor wobbling),




      Bouncethe vehicleup and down severaltimes to
              the
      stabilize suspension.




18-4
Front CamberInspection                              Front CamberAdjustment
Use commerciallyavailablecomputerized  four wheel   The front cambercan be adjustedby exchangingone or
alignmentequipmentto measurewheel alignment         both of the damDerDinchbolts with the smaller
(caster,
       camber,toe, and turning angle).Follow the    diameteradjustingbolt(s).               The differencebetweenthe
equipmentmanufacturer's  instructions.              adjustingbolt diameterand the pinch bolt hole
                                                    d i a m e t e r l l o w sa s m a l lr a n g eo f a d j u s t m e n t .
                                                                  a
Checkthe camberangle.lf the camberangle is not
                        adjustthe camber.
within the specification,

Front camber angle:   0"30' t 45'
                                                             PinchBolt:
                                                        DamDer                                 AdiustingBoh:
                                                                                               P/N 90188-55A-000




                                                      1 . Raisethe front of the vehicle,and support it with
                                                          safetystandsin the proper location(seepage 1-8).
                                                          Removethe front wheels.

                                                         L o o s e n h e d a m p e rp i n c h n u t sa n d b o l t s( A ) ,a n d
                                                                   t
                                                         adjustthe camber by moving the bottom of the
                                                         d a m p e rw i t h i nt h e r a n g eo f t h e d a m p e rp i n c hb o l t
                                                         free play.

                                                              -+              +t                     A
                                                                                                     1 6 x 1 . 5m m
                                                                                                     157 N.m
                                                                                                     (16.0kgf.m,
                                                                                                     116 tbf.ftl




                                                     3 . Tightenthe boltsto the specifiedtorque.

                                                                 the front wheels.Lower the front of the
                                                     4 . Reinstall
                                                         v e hi c l et o t h e g r o u n d , n d b o u n c e h e v e h i c l e
                                                                                            a                   t
                                                                                                  e
                                                         s e v e r atl i m e st o s t a b i l i z t h e s u s p e n s i o n .

                                                                                            l
                                                     5 . C h e c k h e c a m b e ra n g l e . f i t i s w i t h i nt h e
                                                                 t
                                                         specification,    checkthe front toe. lf it is not within
                                                                                go
                                                         the specification, to step 6.

                                                                                                                          (cont'dl



                                                                                                                                 18-5
Frontand RearSuspension
 WheelAlignment (cont'd)
    Raisethe front of the vehicle,and support it with               Inspection
                                                           RearCamber
    safetystandsin the proper location(seepage 1-8).
    Removethe front wheels.                                Use commercially-availablecomputerized four wheel
                                                           alignmentequipmentto measurewheel alignment
 7 . Replace damper pinch boltswith the adjusting
             the                                           (caster,
                                                                  camber,toe, and turning angle).Followthe
     bolts (A),and adjustthe camber angle.                 eouiDmentmanufacturer's  instructions.

    NOTE:The camberangle can be adjustedup to t                                               l
                                                           C h e c k h e c a m b e ra n g l e . f l h e c a m b e ra n g l ei s n o t
                                                                   t
    15' (centerof tolerance)by replacingone damper         within the specification,         checkfor bent or damaged
    pinch bolt with the adjustingbolt. The camber          susDenston      comoonenrs.
    angle can be adjustedup to a 30' by replacingboth
    upper and lower damper pinch bolts with the            Rearcamberangle:                 0
                                                                                            0"55' t 45'
    adjustingbolts.
                                                           NOn-dEl
                                                           Do not loosenthe specialb o l t so n t h e t r a i l i n g r m .
                                                                                                                     a




                                          1 5 x 1 . 5m m
                                          157N.m
                                          {16.0kgt.m,
                                          116tbf.ft)
                        'rntr
                         i,iY.
                             a
                        .:r,//


 8 . Tightenthe boltsto the specifiedtorque.

             the
    Reinstall front wheels.Lower the front of the
    vehicleto the ground, and bouncethe vehicle
    severaltimes to stabilizethe suspension.

 1 0 .Checkthe camber angle.lf it is within the
    specification,checkthe front toe. and adjust it if
               lf
    necessary. it is not within the specification,
                          lJ
    readjust,and recheck. the camber anglecannot
    be adjustedto the specification, checkfor bent or
    damagedsuspension     components.




                                                                                                                                        \




18-6
Front Toe Inspection/Adjustment                                            RearToe Inspection/Adiustment
Use commercially-available            computerized         four wheel      Use commercially-available            computerized         four wheel
               t                              w
a l i g n m e ne q u i p m e ntto m e a s u r e h e e la l i g n m e n t                  t                              w
                                                                           a l i g n m e ne q u i p m e ntto m e a s u r e h e e la l i g n m e n t
(caster,   camber,toe, and turning angle).Followthe                        (caster,    camber,toe, and turning angle).Followthe
equipmentmanufacturer's             instructions,                          equipmentmanufacturer's             instructions.

  1. Centerthe steeringwheel spokes.                                         1 , R e l e a s eh e p a r k i n g r a k e .
                                                                                             t                b

                                              ication,go
 2. Checkthetoe.lf it is not with in the specif                                                                                  go
                                                                            2. Checkthetoe. lf it is not within the specification.
    to step 3.                                                                 to step 3.

     Front toe-in: 0 t 3 mm {0 t 0.12in.)                                       Reartoe-in {inspection):
                                                                                   1 1 3 mm (0.04a 0.12 in.)
 3. Loosenthe locknut(A) while holdingthe tie-rod end
    ( B) .                                                                  3. Loosenthe self-locking (A)while holdingthe
                                                                                                    nut
                                                                               adjustingbolt (B).
                     1,;                     A
                                             1 4 x 1 . 5m m
                                             ,14N.m
                                             (a.5 kgt m,33 lbt.ftl               Do not loosenlhe specialbolts (C)on the
                                                                                 lower arm to adjustthe alignment.




     Turn the tie-rod(C)untilthe toe is correct.

 5 . After adjusting,tighten the locknutwhile holding
     the tie-rodend. Make sure the toe settingdoes not
     change.



                                                                                                            nut
                                                                            4. Replace self-locking with a new one, and
                                                                                                the
                                                                               l i g h t l yt i g h t e n .

                                                                                NOTE:                                nut
                                                                                        Always use a new self-locking whenever
                                                                                it has been loosened.

                                                                                Turn the adjustingbolt until the toe is correct.

                                                                                Rear toe.in (adiustment):
                                                                                   2 ' , mm {0.08 "' ,. in.}

                                                                                                                    nut
                                                                                Tightenthe self-locking to the specifiedtorque
                                                                                                      t                    b
                                                                                w h i l eh o l d i n g h e a d j u s t i n g o l t .



                                                                                                                                           (cont'd
                                                                                                                                                 )



                                                                                                                                              18-7
Frontand RearSuspension
 WheelAlignment (cont'dl                                                                 WheelBearingEnd PlayInspec'tion
 TurningAngleInspection                                                                  1. Raiselhe vehicle,and support it with safetystands
                                                                                            in the proper location(seepage 1-8).Removethe
 Use commercially-available            computerized         four wheel                      wheels.
                t                              w
 a l i g n m e ne q u i p m e ntto m e a s u r e h e e la l i g n m e n t
 (caster.   camber,toe, and turning angle).Followthe                                     2. Installsuitable f lat washers (A) and wheel nuts,and
 equiDmentmanufacturer's             instructions.                                          tighten the nuts to the specified               torque to hold the
                                                                                                                          a
                                                                                            b r a k ed i s cs e c u r e l y g a i n s t h e h u b .
                                  w
   1 . T u r nt h e s t e e r i n g h e e lf u l l y t o t h e r i g h t a n d l e f t
       while applyingthe brake,and checkthe turning                                          Front:
       anglesof both front wheels, lf the turning angle is
                                                 or
       not within the specification the inward turning
       anglesdiffer betweenthe right and left side,go to
       steD2.

       Turning angle:
         lnward: 34'00'+ 2'
         Outward: 28'00' {reference)




                                                                                                                                               108N.m
                                                                                                                                               (11.0kgf.m,
                                                                                                                                               80 rbf.ft)


                                                                                            Rear:
                                                                                                                                                                      \




       Checkthe toe. lf it is correct,but the turning angle                               108N.m
       is not within the specification,checkior bent or                                   (11.0kgf.m,80 lbf.ft)
       damagedsuspension       components,
                                                                                         3 . S e t u p t h e d i a lg a u g ea g a i n s t h e h u b f l a n g ea s
                                                                                             shown, and measurethe bearingend play moving
                                                                                             the brakedisc inward and outward.

                                                                                             Bearing end play:
                                                                                              Standard:
                                                                                                Front/rear: 0 0.05 mm {0 0.002in.}

                                                                                         4. lf the bearingend play is more than the standard,
                                                                                            replacethe wheel bearing.




18-8
WheelRunoutInspection
1 . Raisethe vehicle,and supportit with safetystands   4 . R e s e t h e d i a l g a u g e t o t h ep o s i t i o n h o w n ,a n d
                                                                                                                  s
    in the proper location(seepage 1-5,.                   measurethe radial runout.

  Checkfor a bent or deformedwheel.                        Front and rear wheel radial runout:
                                                             Standard:
  Set up the dial gauge as shown, and measurethe               Aluminum wheel: 0 0.7 mm (0 0.03io.)
  axial runout by turning the wheel.                         Servicelimit:        1.5 mm {0.06in.}

  Front and rear wheel axial runout:
    Standard:
      Aluminum wheel: 0-0.7 mm (0-0.03 in.)
    Servicelimit:        2.0 mm {0.08in.l




                                                          lf the wheel runout is not within the specification,
                                                          checkthe wheel bearingend play (seepage 18-8),
                                                          and make sure the mating surfaceson the brake
                                                          disc and the insideof the wheel are clean.

                                                           lf the bearingend play is within the specification
                                                           but the wheel runout is more than the servicelimit.
                                                           replacethe wheel.




                                                                                                                               18-9
Frontand RearSuspension
 BallJointRemoval
 Special Tools Required                                                                      3. Loosenthe pressurebolt (A),and installthe special
 Ball ioint remover.2Smm 07MAC-SL00200                                                          tool as shown. Insen the jaws carefully,making
                                                                                                sure not to damagethe ball joint boot. Adjustthe
                                                                                                jaw spacingby turning the adjustingbolt (B).
  Always use a ball joint removerto disconnect ball
                                                a
  joint. Do not strikethe housingor any other part of                                         10 mm HEXNUT
  the ball joint connectionto disconnectit.

  '1,
    I n s t a la h e x n u t ( A ) o n t o t h e t h r e a d s o f t h e b a l l j o i n t
                 l
    { B ) .M a k es u r et h e n u t i s f l u s hw i t h t h e b a l l j o i n tp i n
    end to preventdamageto the threadedend of the
    b a l l i o i n to i n .




                                                                                                                                                        07MAC-S100200

                                                                                                 After adjustingthe adjustingbolt, make sure the
                                                                                                 head (C)of the adjustingbolt is in the position
                                                                                                 shown to allow the jaw to pivot.

                                                                                             5 . With a wrench,tighten the pressurebolt until the
                                                                                                 b a l li o i n t p i n p o p sl o o s ef r o m t h e s t e e r i n g r m o r
                                                                                                                                                                    a
                                                                                                 knuckle.lf necessary.              apply penetrating            type
                                                                                                 lubricantto loosenthe ball joint pin
  2 . Apply greaseto the specialtool on the areasshown
        (A).This will easeinstallation the tool and
                                      of                                                         NOTE:Do not use pneumaticor electrictools on
        preventdamageto the pressurebolt {B)threads.                                             the pressurebolt.

                                                                                             6 . Removethe tool, then removethe nut from the end
                                                                                                 o f t h e b a l l j o i n tp i n ,a n d p u l l t h eb a l l j o i n to u t o f t h e
                                                                                                 s t e e r i n g r m o r k n u c k l eI.n s p e c t t h e a l l j o i n tb o o t ,
                                                                                                               a                                             b
                                                                                                 and replaceit if damaged.




18-10
FrontSuspension
 Knuckle/Hub/Wheel
                 BearingReplacement
 ExplodedView




                                WHEELBEARING
                                Replace.
                                        SNAPRING



                                                         5 mm SCREWS
                                                         Replace.
                                                                                      FLAT SCREWS
                                                                                      6x1.0mm
                                                                                      9.8Nm
                                                                                      (1.0        lbf.ft)
                                                                                          kgf.m,7.2


 KNUCKLE
 Checkfor delormation
 a n oo a m a g e .




                        SPLASHGUARD
                                          delormation.
                        Checkfor corrosion.
                        and damage.
                               if
                        Replace rusted.




                                                            BRAKEDISC

                                                                        SPINDLE  NUT
                                                                        22 x 1.5mm
                                                                            N
                                                                        181 m
                                                                        (18.5kgf.m, 134 lbt.ft)
                                                                        Replace.
                                                                        '--7.l
                                                                            'tq
                                                                             I
                                                                                        l        t             e
                                                                        A p p ya s m a la m o u no f e n g i n o i l
                                                                        to theseating   surface.




                                                                                                             lcont'd)



                                                                                                             18-11
FrontSuspension
                 BearingReplacement
 Knuckle/Hub/Wheel                {cont'dl
 Special Tools Required                                  5. Raisethe stake(A),and removethe spindle nut (B).
 . Hub dis/assembly tool 07GAF-SE00100
 . Balljoint remover,2Smm 0TlvlAC-S100200
 . Attachment62 x 68 mm 07746-0010500
 . Driver07749-0010000                                                                         -   B
 . SuDDort base07965-5D90'100                                                          '           22x1.5mm
                                                                                           ,           N
                                                                                                   181 .m
  1. Raisethe front of the vehicle,and support it with                                             ('18.s
                                                                                                        kgf.m,
                                                                                                   134tbt.ft)
     safetystandsin the proper location(seepage 1-8).

  2. Removethe wheel cap,wheel nuts, and front wheel.

                                        1 0 8N . m
                                        (11.0kgf m,
                                        80 rbf.ftl




                                                         6. Removethe brakedisc retainingflat screws(A).




  3. Removethe brakehose bracketmounting bolt (A).
                                                                                                    A             \
                                                                                                    6x1.0mm
                                                                                                    9.8 N.m
                                         A                                                          {1.0kgt.m,
                                         8 x 1.25 mm                                                7.2 tbl.ttl
                                         22N.m
                                         12.2ksl.m,
                                         26 tbf.ftl




                                         B
                                         12 x 1.25mm
                                         108N.m
                                         {11.0kgf.m,
                                         80 rbf.ftl
                                                         7. Screwtwo 8 x 1.25mm bolts (B)into the discto
                                                            oush it awav from the hub. Turn each bolt two turns
                                                            at a time to preventcockingthe disc excessively,
  4 . Removethe caliperbracketmounting bolts (B),and
      removethe caliperassembly(C)from the knuckle.
      To preventdamageto the caliperassemblyor
      brakehose,use a short pieceof wire to hang the
                                              Do
      caliperassemblyfrom the undercarriage. not
      twist the brakehose with force.




                                                                                                                      \




18-12
8. Removethe flange bolt {A) andwheel sensor(B)                             10. Removethe lock pin (A)from the lower arm ball
   from the knuckle.Do not disconnect wheel
                                    the                                         joint, and removethe castlenut (B).
   sensorconneclor.
                                                                               NOTE:During installation,                    insertthe lock pin into
                                                       A
                                                       5x1.0mm                 t h e b a l l j o i n tp i n f r o m t h e l n s i d e o t h e o u t s i d e f
                                                                                                                                     t                     o
                                                       9.8 N.m                 the vehicle.The closedend of the lock Din must be
                                                       (1.0kgl.m,
                                                       7.2 tbt.ftl
                                                                               i n t h e r a n g es h o w n .




                                                                                                                                   07MAC-SL00200

                                                                                                                     €--....-"
                                                                                                                   'R.                   mm
                                                                                                                                  12x 1.25
                                                                                                                                  59 69N m
                                                                                                                                  (6.0 7.0 kgl m,
9 . Removethe flange nut (A) while holdingthe joint                                                                               43 -51 lbf tt)
    pin (B)with a hex wrench (C),and disconnect                       the
    s t a b i l i z el r n k{ D )f r o m t h e l o w e ra r m ( E ) .
                       i                                                    1 1 .Disconnect lower arm from the knuckleusing
                                                                                            the
                                                                                 the specialtool (seepage l8-10).

                                                                            12. Loosenthe damper pinch bolts (A) while holding
                                                                               the nuts (B),and removethe bolts and nuts.




   10 x 1.25mm
   39 N.m (,1.0
              kgf.m,29lbf.ft)




                                                                            '13.Removethe driveshaftoutboardjoint
                                                                                                                   {C)fromthe
                                                                               knuckle(D) by tappingthe driveshaftend (E)with a
                                                                               plastichammer while drawing the knuckleoutward,
                                                                               then removethe knuckle.

                                                                               NOTE:Do not Dullthe driveshaftend outward.The
                                                                               driveshaftjoint may come off.


                                                                                                                                                   (cont'd)




                                                                                                                                                   18-13
FrontSuspension
 Knuckle/Hub/Wheel
                Bearing         (cont'd)
                       Replacement
 14. Separate  the hub (A)from the knuckle(B) usingthe                             1 6 . R e m o v e h e s n a pr i n g ( A )a n dt h e s p l a s h u a r d( B )
                                                                                                   t                                               g
     specialtool and a hydraulicpress.Be carefulnotto                                    fromtheknuckleC).     (
     deform the splashguard. Hold onto the hub to keep
     it from falling when pressedclear.

          07GAF-SE00100

                                                   ./      .-''-         .|


                                                         a'\s




                                                                                   1 1 . Pressthe wheel bearing(A) out of the knuckle(B
                                                                                         usingthe specialtool and a press.
 1 5 . Pressthe wheel bearinginner race(A) off of the


                                                                                                                    +
       h u b ( B )u s i n gt h e s p e i i a l t o o l , c o m m e r c i a l l y
                                                       a                                                           Pross
       a v a i l a b l e e a r i n g e p a r a t o( C ) , n d a p r e s s .
                       b           s               r a

                  07GAF-SE00100



                             \r
                        \              Press
                                                                                                                                                                   \




18-14
1 8 . W a s ht h e k n u c k l e n d h u b t h o r o u g h l y n h l g hf l a s h
                               a                             i                                                                   u
                                                                                        2 2 . P r e s s n e w h u b b e a r i n g n i t{ A )o n t o t h e h u b ( B )
                                                                                                      a
      point solventbefore reassembly.                                                         usingthe specialtools and a press.

1 9 . Pressa new wheel bearing(A) into the knuckle(B)
      usingthe old bearing(C),a steel plate {D).the
      specialtool, and a press.Placethe wheel bearing
      on the knucklewith the packseal side facing (metal
      color)toward the inside.Be careful not to damage
     the sleeveof the packseal.




    "-t-_"*,,''




    _,.' . . a-.)
              ../
     ..-.
                                                                                                                                                     u
                                                                                        23. I n s t a l l t h e n u c k l e / h u b / h u b a r i n g n i t i n t h e
                                                                                                              k                         be
                                                                                              reverseorder of removal,and notethese items:

                                                                                              . B e c a r e f u n o t t o d a m a g e t h e a l l j o i n tb o o t w h e n
                                                                                                                    l                            b
                                                                              (
2 0 . I n s t a ltlh e s n a pr i n g ( A )s e c u r e l yn t h e k n u c k l e B ) .
                                                         i                                                        t
                                                                                                i n s t a l l i n gh e k n u c k l e .
                                                                                              . Tightenall mounting hardwareto the specified
                                                                                                lOrque alues.v
                                                                                              . Torquethe castlenut to the lower torque
                                                                                                specification,         then tighten it only far enoughto
                                                                                                a l i g nt h e s l o tw i t h t h e b a l lj o i n t p i n h o l e .D o n o t
                                                                                                align the castlenut by looseningit.
                                                                                              . Installa new look pin on the castlenut after
                                                                                                torquing.
                                                                                              . U s ea n e w s p i n d l e u t o n r e a s s e m b l y .
                                                                                                                                n
                                                                                              . B e f o r e n s t a l l i n gh e s p i n d l e u t ,a p p l ya s m a l l
                                                                                                              i             t                   n
                                                                                                amount of engine oil to the seatingsurfaceof the
                                                                                                nut. After tightening,use a drift to stakethe
                                                                                                s p i n d l e u t s h o u l d e r g a i n st h e d r i v e s h a f t .
                                                                                                                n                  a
                                                                                              . B e f o r e n s t a l l l n gh e b r a k ed i s c ,c l e a nt h e m a t i n g
                                                                                                              i             t
                       D                                                                        surfaceof the front hub and the insideof the
                                        ft)
                               kgf.m,4lbf
                       6 N.m10.6
                                                                                                 b r a k ed i s c .
       lnstallthe splashguard (C),and tighten the screws                                      . B e f o r e n s t a l l i n gh e w h e e l ,c l e a nt h e m a t i n g
                                                                                                              i             t
       (D)to the specifiedtorque.                                                               surfaceof the brakedisc and the insideof the
                                                                                                wneet.
                                                                                              . Checkthe front wheel alignment,and adjustit if
                                                                                                 necessary           (seepage 18-4).




                                                                                                                                                                   18-15
FrontSuspension
 BallJoint Boot Replacement
 Special Tools Required                                        Inst€llthe boot onto the ball joint pin, then squeeze
 Front hub dis/assembly tool 07965-5450500                     it gentlyto force out any air. Do not let dlrt or other
                                                               foreign materialsget into the boot.
  1. Removethe boot.
                                                               Pressthe boot with the specialtool until the bottom
  2. Packthe interiorand lip (A) of a new boot with fresh      seatson the knuckle(A) evenly around.
     grease.Keepthe greaseoff of the boot-to-knuckle
                                                                                    pross
     mating surfaces(B).
                                                                                                07965-SA50500

                                           -6r
                          rffi
                          €l
                               -   -   B



                                       t
                                       I



                                                            6 . After installinga boot,wipe any greaseoff the
                                                                exposedportion of the ball joint pin.
                                                                                                                         i
    Wipe the greaseoff the taperedsectionof the pin
    (C),and packfresh greaseonto the base (D).




18-16
StabilizerBar Replacement
1 . Raisethe front of the vehicle,and support it with                                                             bar in the reverseorder of
                                                                                           4. lnstallthe stabilizer
    safetystandsin the proper location(seepage 1-8).                                          removal.and note these itemsl
    Removethe front wheels.
                                                                                              . Use new self-locking                nuts on reassembly.
      Removethe self-locking                     nuts (A)while holdingthe                     . Note the right and left directionof the stabilizer
      joint pin (B)with a hex wrench (C),and disconnect                                         oar.
      t h e s t a b i l i z el r n k s( D ) f r o mt h e s t a b i l i z eb a r ( E )o n
                               i                                          r                   . A l i g nt h e e n d so f t h e p a i n tm a r k s( A )o n t h e
      the right and left.                                                                       stabilizer with each end of the bushings(8).
                                                                                                                bar
                                                                                              . Note the forelaft directionofthe bushing holders.
                                                  D                                           . Referto stabilizerLink Replacement connect                 to
                         ''i]                                                                   t h e s t a b i l i z eb a r t o t h e l i n k s( s e ep a g e1 8 - 1 8 ) .
                                                                                                                       r
           ,.'i i
  .        i.',.:-l              I
      ,r','
 \'r'j-- r-'1            _:      i :..
                                i'
 i-ii::;i
  ;4-llt,-'j--;




                          1 0x 1 . 2 5m m
                          39Nm
                          (4.0 kgf m,
                          29 tbl,ft)

      Removethe flange bolts {A) and bushingholders
      {B),then removethe bushings(C)and the stabilizer
      b a r( D ) .




 FORWARD
                                                      A
                                                      1 0x 1 . 2 5m m
                                                      39Nm
                                                      (4.0ksf.m, 29lbl.ftl




                                                                                                                                                               18-17
Front Suspension
 StabilizerLink Removal/lnstallation
 1 . Raisethe front of the vehicle,and support it with                                       4. Installthe self-locking and flange nut, and
                                                                                                                      nut
     safetystandsin the proper location(seepage 1-8).                                           lightlytighten them.
     Removethe front wheels.
                                                                                                NOTE:Use a new self-locking on reassembly.
                                                                                                                          nut
     Removethe self-locking (A) and flange nut {B)
                           nut
                               joint pin (C)with a hex
     while holdingthe respective                                                             5. Placethe floor jack under the lower arm balljoint,
     wrench (D),and removethe stabilizer link (E).                                              and raisethe suspension load it with the vehicle's
                                                                                                                         to
                                                                                                weaght.

                                                                                               mri-dEl
                                                                                                Do not placethe jack againstthe lower arm
                                                                                                balljoint.

                                                                                             6. Tightenthe self-locking (A) and flange nut (B)to
                                                                                                                        nut
                                                                                                the specifiedtorque valueswhile holdingthe
                                                                                                respectivejoint pins (C)with a hex wrench (D).

                                                                                                                           A
                                                                                                                           10 x 1.25mm
                                                                                                                           38 N.m
                                                                                                                           (3.9kgf m,28 lbf.ft)




                                                                                                                                                     \

 3 . l n s t a l l t h e t a b i l i z el r n k( A )o n t h e s t a b i l i z eb a r { B )
                        s                 i                                    r
     and lower arm (C)with the joint pins (D)set at the
     centerof their rangeof movement.
                                                                                                       ..,

                                                                                                 B
                                                                                                 10 x 1.25mm
                                                                                                 39 N.m
                                                                                                 {4.0kgf.m,29lbf.ft}


                                                                                             1 . After 5 minutesof driving, re-tighten self,
                                                                                                                                      the
                                                                                                 lockingnut again to the specifiedtorque.




18-18
Lower Arm Removal/lnstallation
SpecialToolsRequired                                                       5. Removethe flange bolts (A),and removethe lower
Balljoint remover,2Smm 07|MAC-S100200                                         arm {B}.

 1. Raisethe front of the vehicle,and supportit with
    safetystandsin the proper location(seepage 1-8).
    Removethe front wheels.

   Removethe flange nut (A) while holdingthe joint
   pin {B)with a hex wrench (C),and disconnect                       the
   s t a b i l i z el r n k( D ) f r o mt h e l o w e ra r m ( E ) .
                      i




                                                                           1 4x 1 . 5m m
                                                                           83 N.m(8.5          lbf.ft)
                                                                                        kgf.m,61

                                                                           6. Installthe lower arm in the reverseorder of
                                                                              removal,and note these items:

                                                                              . Be carefulnot to damagethe ball joint boot when
                                                                                 connectingthe lower arm to the knuckle.
                                                                              ' Tightenall mounting hardwareto the specified
                                                                                 torque values,
     10x 1.25 mm                                                              . F i r s t i n s t a la l l t h e c o m p o n e n t s n d l i g h t l y t i g h t e n
                                                                                                      l                            a
     39 N.m
     {4.0kgf m, 29 lbt.ft)                                                       the bolts and nuts.then raisethe suspension                               to
                                                                                 load it with the vehicle'sweight beforefully
                                                                                 tighteningit to the specifiedtorques.
 3 . Removethe lock pin (A) from the lower arm ball                           . Torque the castlenut to the lower torque
   joint, and removethe castlenut (B).                                           specification,          then tighten it only far enoughto
                                                                                 align the slot with the ball joint pin hole. Do not
   NOTE:During installation,      insertthe lock pin into                        allgn the castlenut by looseningit.
   the ball joint pin from the insideto the outsideof                         . Installa new lock pin on the castlenut after
   the vehicle.The closed end of the lock pin must be                            torquing.
   i n t h e r a n g es h o w n .                                             . Beforeinstallingthe wheel, cleanthe mating
                                                                                 surfaceof the brakedisc and the insideof the
                                                                                 wneet.
                                                                               . C h e c k h e w h e e la l i g n m e n ta n d a d j u s t i t i f
                                                                                            t                                  ,
                                                                                  necessary        (seepage '18-4).




                                                  oTMAc-sloo2oo
                                   6--__
                                  @a
                                                           m
                                                1 2x 1 . 2 5 m
                                                59 69Nm
                                                16.0-7.0   kgt-m,
                                                43 51 lbf.ft)

 4 . Disconnect lower arm from the knuckleusing
                       the
     t h e s p e c i atl o o l ( s e ep a g e1 8 - 1 0 ) .




                                                                                                                                                     18-19
Front Suspension
 Damper/SpringReplacement
 ExplodedView

                                                       ./ SELF-LOCK|NG   NUT
                                                 /.'      12 x 1.25inm
                                           ,,/            44 N.m {4.5kgt.m,33lbf.ftl
                                      ,/                  neDtace.
                                 ^a
                                 ta
                                 e9
                               -€.-                           - DAMPER  MOUNTING   BASE
                                                                checkfor delormation
                            1, @-:'\--""'
                            lF \-:-./  - ,
                            E9-

  DAMPERMOUNTING
  BEARING




  UPPERSPRINGMOUNTING
  CUSHION
      for
  Check deterioration
  anooamage,

                                                                                          \




        DAMPER SPRING
            for
        Check lreelength.




                              DAMPER   UNIT
                              Checkfor oil leaks,
                              gas leaks,
                                       and smooth
                              operatron.




18-20
SpecialToolsRequired                                                             5. Removethe damper pinch bolts (A)while holding
Balljoint remover,28 07MAC-S100200
                   mm                                                               t h e n u t s( B ) .

Removal
 1. Raisethe front of the vehicle,and supportit with
    safetystandsin the proper location(seepage 1-8).
    Removethe front wheels.

   Removethe cotterpin (A) from the tie-rod end ball
   ioint, and removethe nut (B).




                                                                                 6. Removethe flange nuts (A)from the top ofthe
                                                                                    damper,

                                                                                                                  A 'l.25
                                                                                                                  10x    mm

 10 mm HEXNUT
                                                    07MAC-S1002000

   Disconnectthe        tie-rodend from the steeringarm
   o n t h e d a m p e ru s i n gt h e s p e c i a l t o o(l s e ep a g e1 8 -
   1 0) .

 4. Removethe bolts,and removethe wheel sensor
    harnessbracket{A) and brakehose bracket(B)
                                     the
    from the damper.Do not disconnect wheel
    sensorconnector.
                                                                                 7. Lower the lower arm, and removethe damper
           A                                     6x1.0mm                                     (
                                                                                    assemblyB).
                                                               x 1.25nm


                                                     q /.8




                                                                                                                              (cont'd)



                                                                                                                             18-21
FrontSuspension
 Damper/Spring        (cont'd)
             Replacement
 Disassembly/lnspection                                                                    Reassemble the pans, exceptfor the upper
                                                                                                              all
                                                                                           s p r i n gs e a ta n d s p r i n g .
  1 . C o m p r e s sh e d a m p e rs p r i n gw i t h a c o m m e r c i a l l y
                         t
      availablestrut spring compressor(A) accordingto                                    4. Compressthe damper assemblyby hand,and
      the manufacturer's               instructions.       then removethe                  checkfor smooth operationthrough a full stroke.
      s e l f - l o c k i nn u t ( B ) w h i l eh o l d i n g h e d a m p e rs h a f t
                           g                                 t                             both compressionand extension. The damper
      (C)with a hex wrench (D).Do not compressthe                                          should extend smoothly and constantlywhen
      spring more than necessary removethe nut,     to                                     compressionis released. it does not, the gas is
                                                                                                                   lf
                                                                                           leakingand the damper should be replaced.




     Release pressure
            the          from the strut spring
     compressor, then disassemble damper as
                                  the                                                                                                                                   \
     shown in the ExplodedView.


                                                                                                   f                     ,
                                                                                           C h e c k o r o i l l e a k s a b n o r m a n o i s e sa n d b i n d i n g
                                                                                                                                       l          ,
                                                                                           during thesetests.




18-22
FrontSuspension
 Damper/Spring        (cont'dl
             Replacement
     Right side:                                                                  Installation
                                                                                   1. Lower the lower arm, and positionthe damper
                                                                                      assemblyin the body, Turn the damper mounting
                                                                                      baseso the "AL" or "AR" mark (A)facestoward
                                                                                      the outsideof the vehicle.

                                                                                  B
                                                                                  10x 1.25mm
                                                                                  ,14N.m
                                                                                  {4.5kgt.m,33
                                                                                             lbf.ft)




     Hold the bottom of the damper with your hand,and
     compressthe spring. Do not compressthe spring
     excessively.

 9 . I n s t a l l t h e 2 m m n u t ( A )o n t h e d a m p e rs h a f t( B ) .
                       1
     Hold the damper shaft with a hex wrench (C),and
     tighten the 12 mm nut to the specifiedtorque.
                                                                                                   ,1,6
                                                                                     Looselyinstallthe flange nuts (A) onto the top of
                                                                                     the damper.                                         L



                                          (4.5 kgt.m, 33 lbf ft)


            the
 1 0 .Remove damper      fromthe strutspring
                  assembly
      compressor.




18-24
 3 . P o s i t i o nh e d a m p e ro n t h e k n u c k l ea n d i n s t a l l t h e
                   t                                      ,                             8. Connect  the tie-rod end to the steeringarm, and
     new damper pinch bolts (A) and nuts (B),and                                           tightenthe nut (A)to the specified torque. Install
     lightlytighten the nuts.                                                              the cotterpin (B)after tightening,and bend lts end
                                                                                           asshown.




B
1 6 x 1 , 5m m
157N.m
(16.0kgt m,
116tbt.ftl


 4 . P l a c e h e f l o o rj a c ku n d e rt h e l o w e ra r m b a l l j o i n t ,
             t
     and raisethe suspension load it with the vehicle's
                                           to
     weight.


     Do not placethe jack againstthe lower arm                                          9. Cleanthe mating surfaceofthe brakedisc and the
     balljoint.                                                                            insideof the wheel,then installthe front wheels.

 5 . Tightenthe flange nuts on the top of the damperto                                 1 0 . C h e c k h e w h e e la l i g n m e n ta n d a d j u s t i t i f
                                                                                                     t                               ,
     the specifiedtorque.                                                                    necessary     {seepage 18-4).

     Tightenthe damper pinch nuts to the specified
     torque.

 1 . Installthe brakehose bracket(A) and the wheel
     sensorharnessbracket(B)onto the damper,and
     tighten the bolt to the specifiedtorque.

                      9.8N.m                                22N|rl.
                              7.2lbf.ftl
                         kgf.m,
                      11.0                                     kgI
                                                            12.2 m,
                                                            16rbr,ftl


                                                        q




                                                                                                                                                                 18-25
RearSuspension
 Hub BearingUnit Replacement
        View
 Exploded




                                     SPLASHGUARD
                                          for
                                     Check deformation.


                                                   x 1.0 mm
                                                  9.8 N.m (1.0kgf.m,?1 lbf ftl




                                                                                  Checkfor wear and damage.




                                                                      ',[ ',, / -o ' 0
                                                                                 \




   KNUCKLE
                                                                                                    un
   Checkfor delormation.

                           HUBBEARING UNIT
                                                                                                        Y
                               for
                           Check faultymovement       6x1.0mm
                           andwear.                   9,8 N.m                                        HUB CAP
                                                      {1.0kgf.m,7 lbf.ft}                            Replace.
                                                                                 SPINDLE  NUT
                                                                                 22 x 1.5mm
                                                                                 181 N.m {18.5kgt.m, 134lbf.ft}
                                                                                 Beplace.
                                                                                 -A
                                                                                         T
                                                                                Appy a small amount oI engineoil
                                                                                to the seatingsurface.




18-26
1 . Raisethe rear of the vehicle,and support it with            Release parkingbrakelever.
                                                                      the
                                                   'l-8).
    safetystandsin the proper location(seepage
                                                              5 . Removethe brakehose mounting bolt (A).
  Removethe wheel cap. wheel nuts, and rearwheel.
                                                                                           B
                                                                                                      m
                                                                                           1 0x 1 . 2 5 m
                                                                                           55Nm
                                                                 C                             kgf
                                                                                           {5.6 m.41lbf.ft}




                          108N.m(11.0      lbf
                                    kgf.m,80 ftl
                                                                                                             (2.2 m, 16lbt.ftl
                                                                                                                 kgt
   Removethe hub cap (A), raisethe stake(B),and
   remove hespindle ut(C).
         t         n
                                                                Removethe caliperbracketmounting bolts (B),and
                                                                hang the caliper(C)to one side.To preventdamage
                                                                to the caliperor brakehose,use a short pieceof
                                                                                                     f
                                                                w i r e t o h a n gt h e c a l i p e r r o m t h e u n d e r c a r r i a g e .

                                                              7 . Removethe brakedisc retainingscrews(A).




                                         O
                                            \
                                                A
                                                                                                           ap
                                     2 2 x 1 , 5m m
                                     1 8 1N . m
                                     (18.5kgf.m, 134lbf.ftl
                                                                                                             t
                                                                                                              \
                                                                                                               I
                                                                                                               A
                                                                                                               6x1.0mm
                                                                                                               9 . 8N . m
                                                                                                               (1.0kgf.m,?.2lbf.ftl

                                                                Screwtwo 8 x 1.25mm bolts (B) into the disc {C)to
                                                                oush it awav from the hub. Turn each bolt two turns
                                                                at a time to preventcockingthe disc excessively.
                                                                Removethe brakedisc.




                                                                                                                                  (cont'd)



                                                                                                                                  18-27
Rear
   Suspension
 Hub BearingUnit Replacement                                  KnuckleReplacement
 (cont'd)
                                                              1 . Raisethe rear of the vehicle,and suppon it with
                                                                  safetystandsin the proper location(seepage 1-8).
  9. Removethe hub bearingunit (A) from the spindle.              Removethe rear wheels.

                                                                  R e m o v e h e b r a k ed i s ca n d h u b b e a r i n g n i t( s e e
                                                                               t                                           u
                                                                  s t e p 1 o n p a g e1 8 - 2 7 ) .

                                                                  Removethe flange bolts (A) and splashguard (B)
                                                                  from the knuckle.




                   ,=,,,




 1 0 .Installthe hub bearingunit in the reverseorder of
     removal,and note these items:

     . Tightenall mounting hardwareto the specified
       torque values,
     . Beforeinstallingthe brakedisc,cleanthe mating
                                                                                                                         7.2
                                                                                                                    kgf.m, lbf ft)
                                                                                                                 11.0
       surfaceot the hub and the insideof the brake
       disc.
     . Use a new spindle nut on reassembly.
                                                              4. Removethe wheel sensor(A),braKenose
                                                                 m o u n t i n gb r a c k e ( B ) ,a n d p a r k i n g a b l em o u n t i n g
                                                                                            t                        c
                                                                                                                                                tt
     . After tightening,use a drift to stakethe spindle          bracket(C)from the knuckle.Do not disconnect                          the
       n u t s h o u l d e r g a i n st h e s p i n d l e .
                           a                                     wheel sensorconnector.
     . Use a new hub cap on reassembly.
     . Beforeinstallingthe wheel, cleanthe mating
       surfaceof the brakedisc and the insideof the
       wneel.




                                                              8 x 1.25 mm
                                                              22 N.m
                                                                   kgf
                                                              {2.2 m, 16lbf ftl




                                                                     6x1.0mm
                                                                     9.8 N,m
                                                                     {I.0 kgt.m,7.2lbf ft)




18-28
5. Placethe floor jack underthe trailing arm {A),to      9 . I n s t a l l t h e n u c k l e n t h e r e v e r s e r d e ro f r e m o v a l ,
                                                                               k           i                     o
   support it.                                               and note these items:

                                                              . F i r s ti n s t a l a l l t h e s u s p e n s i o c o m p o n e n t s , n d
                                                                                     l                             n                  a
  Do not placethe jack againstthe plate                         lightlytighten the bolts and nuls,then placea
  sectionof the lower arm, Be carefulnot to                     floor jack under the lower a rm, and raisethe
  damageany suspension    components.                           suspension load it with the vehicle'sweight
                                                                                      to
                                                                beforefully tighteningthe bolts and nutsto the
                                                                specified        torque values.
                                                              . Align the cam positionsof the adjustingbolt (A)
                                                                and adjustingcam (B)with the markedpositions
                                                                w h e nt i g h t e n i n g .
                                                              . Use a new self-locking on reassembly.   nut
                                                              . T i g h t e n l l t h e m o u n t i n gh a r d w a r eo t h e
                                                                               a                                         t
                                                                specifiedtorque values.
                                                              . U s ea n e w s p i n d l e u t o n r e a s s e m b l y .
                                                                                                  n
  12x 1.25mm                                                  . B e f o r e n s t a l l i n gh e s p i n d l e u t ,a p p l ya s m a l l
  59 N.m                                                                     i                 t                n
  {6.0ksf.m.43lbf.ft)                                           amount of engine oil to the seatingsurfaceof the
                                                                nut. After tightening,use a drift to stakethe
                                                                                                     a
                                                                s p i n d l e u t s h o u l d e r g a i n st h e d r i v e s h a f t .
                                                                               n
                                                              . Beforeinstallingthe brakedisc,cleanthe mating
                                                                surfaceof the hub and the insideof the brake
                                                                drsc.
                                                              . U s ea n e w h u b c a po n r e a s s e m b l y .
                                                              . Beforeinstallingthe wheel, cleanthe mating
   Removethe flange bolt (B),and disconnect
                                          the                   surfaceof the brakedisc and the insideof the
   upper arm {C)from the knuckle.                               wheel.
                                                              . Checkthe wheel alignment,and adjust it if
1 . Mark the cam positionsof the adjustingbolt (A) and          necessary          {seepage 18-4).
    adjustingcam (B),the removethe self-locking  nut
    {C},adjustingcam, and adjustingbolt. Discardthe
    self-lockingnut.




                                  12x 1.25   mm
                                  59Nm(6.0kgf.m,
                                  43 tbI.ftl
  12x 1.25mm
  59 N.m {6.0kgf m,43lbl.ft)
8. Remove the flange bolt (D), and remove the
   k n u c k l e{ E ) .




                                                                                                                                  18-29
RearSuspension
 StabilizerBar Replacement
 1 . Raisethe rear of the vehicle,and supportit with                                    4. Inslallthestabilizerbar in the reverseorder of
     safetystandsin the proper location(seepage 1-8).                                      removal,and notethese items:
     Removethe rearwheels.
                                                                                           . Use new self-locking                nuts on reassembly.
   Removethe self-locking                    nuts (A)while holdingthe                      . lMake     sure the right and left ends of the stabilizer
   joint pins (B)with a hex wrench (C),and disconnect                                        bar are installedon their respective                      sidesof the
   t h e s t a b i l i z el r n k s( D )f r o m t h e s t a b i l i z eb a r { E )o n
                            i                                          r                     vehicle.
   the right and left.                                                                     . Align the ends of the paint marks (A) on the
                                                                                                                                                 (
                                                                                             s t a b i l i z eb a r w i t h t h e b u s h i n g s B ) .
                                                                                                              r
                                              A                                            . Referto StabilizerLink ReDlacement connect
                                              1 0 x 1 . 2 5m m                                                                                          to
                                              38 N.m                                         t h e s t a b i l i z eb a rt o t h e l i n k s{ s e ep a g e1 8 - 3 1 ) .
                                                                                                                    r
                                              (3.9 kgf.m,28 lbf.ft)




                                                                                                    '..:
                                                                                                \.... .
                                                                                                               Al
                                                                                                                         .----'';-r'--\---r-
                                                                                                                        -tt'.,'t),


                                                                                                                                                                          (



   Removethe flange bolts (A) and bushing holders
   (B),then removethe bushings{C)and the stabilizer
   bar(D).




18-30
StabilizerLink Removal/lnstallation
1. Raisethe rear of the vehicle,and support it with                                         4. lnstallthe self-locking and flange nut, and
                                                                                                                     nut
   safetystandsin the proper location(seepage 1-8).                                            lightlytighten them.
   Removethe rearwheels.
                                                                                                                        nut
                                                                                              NOTE:Use a new self-locking on reassembly.
2. Removethe self-locking (A) and flange nut (B)
                         nut
                             joint pin {C)wilh a hex
   while holdingthe respective                                                                Placea jack under the trailing arm at the knuckle
   wrench (D),and removethe stabilizer link (E).                                              side end. and raisethe suspension load it with
                                                                                                                                 lo
                                                                                              the vehicle'sweight.

                                                                                              Tightenthe selflocking nut (A) and flange nut {B)to
                                                                                              the specifiedtorque valueswhile holdingthe
                                                                                              respective joint pins (C)with a hex wrench (D).

                                                                                                                   A
                                                                                                                   1 0 x 1 . 2 5m m
                                                                                                                   38 N.m 13.9    kgf.m,28lbf.ftl

                                                                                                                           \,1 i

                                                                                                                              i'-r d
                                                                                                                                   *l'',:




3 . I n s t a l l t h e t a b i l i z el r n k( A )o n t h e s t a b i l i z eb a r { B )
                      s                  i                                    r
    a n dt r a i l i n g r m ( C )w i t h t h e j o i n t p i n s( D )s e ta t t h e
                         a
    centerof each moving range,




                                                                                                                                    the
                                                                                            7. After 5 minutesof driving, re-tighten self-
                                                                                               lockingnut again to the specifiedtorque.




                                                                                                                                              18-31
Rear
   Suspension
 UpperArm Removal/lnstallation
 1 . Raisethe rear of the vehicle,and supportlt with                       5. Installthe upper arm in the reverseorder of
     safetystandsin the proper location(seepage 1-8).                         renloval,and note these items:
     Removethe rearwheels.
                                                                              . F i r s ti n s t a l a l l t h e s u s p e n s i o c o m p o n e n t s n d
                                                                                                     l                             n                 a
   P l a c e f l o o rj a c ku n d e rt h e t r a i l i n ga r m , a n d
           a                                                                    lightlytighten the bolts and nuts,then placea
   supportthe suspensron.                                                       j a c ku n d e rt h e t r a i l i n g r m , a n d r a i s e h e
                                                                                                                       a                   t
                                                                                                      to
                                                                                suspension load it with the vehicle'sweight
   Removethe flange bolt (A) and wheel sensor                                   beforefully tighteningthe bolts and nuts to the
   h a r n e s s r a c k e( B ) .
               b          t                                                     specifiedtorque values.
                                                                              . T i g h t e n l l t h e m o u n t i n g a r d w a r eo t h e
                                                                                               a                          h              t
                                                                                specified        torque values.
                                                                              ' B e f o r e n s t a l l i n gh e w h e e l ,c l e a nt h e m a t i n g
                                                                                             i                 t
                                                                                surfaceof the brakedisc and the insideof the
                                                                                wheel.
                                                                              . Checkthe wheel alignment,and adjustit if
                                                                                necessary         (seepage 18-4).




                                                      8 x 1.25 m
                                                             m
                                                      22 N.m(2.2kgf.m,
                                                      16rbf.ft)

   Removethe flange bolts (A),and removethe upper
   arm{B).




 1 2 x 1 . 2 5m m
 59 N.m {6.0kgf.m,
 ir3 lbf.ft)
                                                     1 2x 1 . 2 5 m
                                                                 m
                                                     59 N.m 16.0 m,kgf
                                                     43 tbf.ft)




18-32
TrailingArm Removal/lnstallation
1 . Raisethe rear of the vehicle,and suppon it with                             7. Removethe trailing arm rear mounting bolt (A).
    safetystandsin the proper location(seepage 1,8).
    Removethe rearwheels.
                                                                                   Do not loosenthe specialbolts (B)on the
    Removethe knuckle(seepage 18-28).                                              t r a i l i n ga r m .

3 . P l a c e h e f l o o rj a c ku n d e rt h e t r a i l i n g r m ( A )t o
            t                                                   a                                                                A
                                                                                                                                 12 x 1.25mm
    support it.                                                                                                                  59 N.m



                                                                                        -----\':,'.ttg
                                                                                              '.,--1..-r.':1

                                                               B
                                                               1 0x 1 . 2 5 m
                                                                          m
                                                               38Nm
                                                               (3.9kgl.m,
                                                               28 tbf.ftl




                                                          m
                                               1 2x 1 . 2 5 m                   8 . Lower the jack,and removethe trailing arm.
                                               61N m (6.2 m.kgt
                                               4s tbf,ft)
                                        A
                                                                                9 . Installthe trailing arm in the reverseorder of
    Removethe flange nut (B),and disconnect                          the           removal,and note these items:
    s t a b i l i z el r n k( C )f r o m t h e t r a i l i n g r m .
                       i                                      a
                                                                                   . F i r s ti n s t a l a l l t h e s u s p e n s i o c o m p o n e n t s n d
                                                                                                          l                             n                 a
    Removethe flange bolt {D),and disconnect            the                          lightly tlghtenthe bolts and nuts,then placea
    d a m p e r( E )f r o m t h e t r a i l i n g r m .
                                                 a                                   j a c ku n d e rt h e t r a i l i n ga r m , a n d r a i s e h e
                                                                                                                                                 t
                                                                                     suspension load it with the vehicle'sweight
                                                                                                           to
    Removethe trailing arm front mounting bolts (A).                                 beforefully tighteningthe bolts and nuts to the
                                                                                     specified        torque values.
                                                                                   . Tightenallthe mounting hardwareto the
                                                                                                ied
                                                                                     specif torque values.
                                                                                   . Beforeinstallingthe wheel, cleanthe mating
                                                                                     surfaceof the brakedisc and the insideof the
                                                                                     wneei.
                                                                                   . Checkthe wheel alignment,and adjust it if
                                                                                     necessary         (seepage'18-4).

        ,'a':-
             r

                                               A
                                               12 x 1.25Jnm
                                               108N.m {11.0kgt.m,
                                               80 tbf.ft)




                                                                                                                                                      18-33
RearSuspension
             Replacement
 Damper/Spring                                                                                                  I
 ExplodedView


                               9-----.---.-.
                                         -=\
                                                     SELF-LoCK|NG   NUT
                              I€tI
                              t=J                    10 x 1.25mm
                                                     29 N m {3.0kgf.m,22 lbf.ft}
                                                     Replace.


                                                      DAMPERMOUNlING
                                                      COLLAR




                                                     DUSTCOVER



                                                                 -t-
                                                                  9...
                                                                 r€) \
                                                                 qnJ/               \
                                                                  E         Z           \
                                                                                            \
                                                                                                   sroP PLArE
                                                                                                BUMP
                                                                      n \
                                                                      lt        \
                                                                   /t               \ BUMPSTOP
                                                                                            tor
                                                                                        Check weakness
                                                                                        and damage.


     DAMPER  SPRING
     Checkfor weakened
     compressionand damage.




                              OAMPER    UNIT
                                    for
                              Check oil leaks,
                              gas leaks,and smooth
                              operation,




18-34
Removal                                               5. Removethe damper assemblyfrom the body.

1. Raisethe rear of the vehicle.and support it with
   safetystandsin the proper location(seepage 1-8).
   Removethe rearwheels.
                                                                                  i
2. Removethe flange bolt {A) from the bottom of the
   damper.




3 . Removethe rear bulkheadcover (seepage 20-51).

  Removethe flange nuts (A) from the top of the
  damper in the trunk.




                                                                                              ( c o n td )



                                                                                             18-35
RearSuspension
 Damper/Spring        (cont'dl
             Replacement
 Disassembly/lnspection                                                              Reassembly
  1 . C o m p r e s sh e d a m p e rs p r i n g i t h a c o m m e r c i a l l y
                      t                               w                              1 . I n s t a la l l t h e p a r t s e x c e p t t h e e l f - l o c k i nn u t o n t o
                                                                                                    l                                     s                    g
      availablestrut compressor(A) according the                    to                   the damper unit by referringto the ExplodedView.
      manufacturer's          instructions.        then removethe self-                  Align the bottom of the spring {A} and the stepped
      l o c k i n g u t ( B ) w h i l eh o l d i n g h e d a m p e rs h a f t( C )
                   n                                t                                    part of the lower spring seat (B),and align the
      with a hex wrench (D).Do not compressthe spring                                    d a m p e rm o u n t i n gb a s ea s s h o w n ,
                                       to
      more than necessarv removethe nut.




                                                                                                 ,, '161\        7fi)1,,                                    "
                                                                                                             \3P qY/
     Release pressure
            the          from the strut spring                                                                                      o
                                                                                         I n s t a l l t h e a m p e ra s s e m b l y n a c o m m e r c i a l l y
                                                                                                           d
     compressor,                  the
                 then disassemble damper as                                              availablestrut spring compressor(C).
     shown ln the ExplodedView.
                                                                                         C o m p r e s t h e d a m p e rs p r i n gw i t h t h e s p r i n g
                                                                                                       s
 ?    Reassemble the pans, exceptfor the spring.
               all                                                                       compressor.

  4 . Compressthe damper assemblyby hand,and                                             Installthenew self'lockingnut (A) on the damper
      checkfor smooth operationthrough a full stroke,                                    shaft.
      both compressionand extension. The damper
      should extend smoothly and constantlywhen
      compressionis released. it does not, the gas is
                              lf
      leakingand the damper should be replaced.




                                                                                     10 x 1.25mm
                                                                                     29Nm
                                                                                     (3.0kgt m,22 lbt.ft)


                                                                                     5. Hold the damper shaft {B)with a hex wrench (C),
                                                                                                                   nut
                                                                                        and tighten the self-locking to the specified
                                                                                        torque.

      Checkfor oil leaks,abnormal noises,or binding
      during thesetests.




18-36
    Installation                                           3. Looselyinstallthe flange bolt (A) on the bottom of
                                                              thedamper.
     1. Positionthe damper assemblyin the body. Note
        the directionof the damper mounting base so that
        the small hole dot on it is toward the front and
        insideof the vehicle.




                                                                                     m
                                                                          1 2 x1 . 2 5 m
                                                                          61N m {6.2        45
                                                                                       kgf.m. lbf.ft)

                                                             Raisethe suspension  with a floor jack to load the
                                                             vehicleweight, and tighten the nuts and bolt to the
       Looselyinstallthe flange nuts (A) onto the top of     specifiedtorque values.
       the damper,
                                                             C l e a n h e m a t i n gs u r f a c e f t h e b r a k ed i s ca n d t h e
                                                                       t                             o

D                                 A
                                  1 0 x 1 . 2 5m m
                                  59 N.m
                                  16.0kgt.m, ia lbt ft)
                                                             i n s i d e f t h e w h e e l ,t h e n i n s t a ltl h e r e a rw h e e l .
                                                                        o

                                                             Checkthe wheel alignment,and adjust it if
                                                             necessary(seepage 18-4).




                                                                                                                              18-37

				
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