Suspension Spring ( Coil / Leaf ): Service and Repair
FRONT SHOCK ABSORBERCOMPONENTS (Part 1):
COMPONENTS (Part 2):
REMOVAL
HINT:
^ Use the same procedures for the RH side and the LH side.
^ The procedures listed below are for the LH side.
1. REMOVE FRONT WHEEL
2. REMOVE ENGINE ROOM SIDE COVER LH
3. REMOVE ENGINE ROOM SIDE COVER RH
4. REMOVE V-BANK COVER SUB-ASSEMBLY
5. SEPARATE FRONT STABILIZER LINK ASSEMBLY
(a) Support the front No. 1 suspension lower arm with a jack using a wooden block to avoid damage.
(b) Remove the nut and separate the front stabilizer link assembly from the front shock absorber.
HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.
6. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Loosen the lock nut of the front shock absorber with coil spring.
NOTICE:
^ Do not remove the lock nut.
^ Only loosen the nut when disassembling the front shock absorber with coil spring.
(b) Remove the bolt and disconnect the front flexible hose and front speed sensor wire harness from the front shock absorber with coil spring.
NOTICE: Be sure to remove the front speed sensor from the front shock absorber with coil spring.
(c) Remove the 2 nuts on the lower side of the front shock absorber with coil spring.
NOTICE:
^ When removing the nuts, keep the bolts from rotating.
^ Keep the bolts inserted to secure the front axle assembly.
(d) Remove the 3 nuts on the upper side of the front shock absorber with coil spring.
(e) Lower the front axle assembly, and remove the 2 bolts on the lower side of the front shock absorber.
(f) Remove the front shock absorber with coil spring.
NOTICE: Make sure that the front speed sensor is disconnected from the front shock absorber with coil spring.
DISASSEMBLY
1. FIX FRONT SHOCK ABSORBER WITH COIL SPRING
(a) As shown in the illustration, secure the front shock absorber with coil spring in a vise using aluminum plates by clamping onto a double nutted bolt affixed to the bracket at the bottom of the absorber.
2. REMOVE FRONT SHOCK ABSORBER
(a) Using SST, compress the front coil spring.
SST 09727-30021 (09727-00010, 09727-00021, 09727-00031)
NOTICE: Do not use an impact wrench.
HINT: If the front coil spring is compressed at an angle, using 2 SST will make the work easier.
(b) Remove the front suspension support sub-assembly, front suspension support bearing, front coil spring upper seat, front coil spring upper insulator, front coil spring, front spring bumper, and front coil spring lower insulator from the front shock absorber.
INSPECTION
1. INSPECT FRONT SHOCK ABSORBER
(a) Compress and extend the shock absorber rod 4 or more times.
Standard: There is no abnormal resistance or sound and operation resistance is normal.
HINT: If there is any abnormality, replace the front shock absorber with a new one.
REASSEMBLY
1. INSTALL FRONT SHOCK ABSORBER
(a) Install the front spring bumper to the piston rod.
(b) Install the front coil spring lower insulator onto the front shock absorber.
NOTICE: Align the 2 protrusions of the front coil spring lower insulator and the 2 holes in the front shock absorber.
(c) Using SST, compress the front coil spring.
SST 09727-30021 (09727-00010, 09727-00021, 09727-00031)
NOTICE: Do not use an impact wrench.
HINT: If the front coil spring is compressed at an angle, using 2 SST will make the work easier.
(d) Install the front coil spring to the front shock absorber.
NOTICE: The smaller diameter end of the front coil spring must face upward.
HINT: Fit the lower end of the front coil spring into the gap of the insulator.
(e) Install the front coil spring upper insulator as shown in the illustration.
HINT: Any misalignment between the front shock absorber lower bracket and the matchmark must be ±5°.
(f) Install the front coil spring upper seat with the mark facing to the outside of the vehicle.
HINT: Any misalignment between the front shock absorber lower bracket and the matchmark must be ±5°.
(g) Install a new front suspension support bearing as shown in the illustration.
HINT: If there is foreign matter inside the front suspension support bearing, replace it with a new one.
(h) Install the front suspension support sub-assembly. Temporarily tighten a new lock nut.
NOTICE: Check that the flats on the piston rod and the flats on the front suspension support sub-assembly are aligned.
(i) Remove the SST slowly in order to release the coil spring.
NOTICE: Do not use an impact wrench.
HINT: Any misalignment between the front shock absorber lower bracket and the arrows must be ±5°.
INSTALLATION
1. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Install the front shock absorber with coil spring to the front axle assembly and insert the 2 bolts from the front side of the vehicle.
(b) Slowly jack up the vehicle using a wooden block and install the front shock absorber with coil spring (upper side) to the vehicle.
(c) Install the 3 nuts to the upper side of the front shock absorber with coil spring.
Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf)
(d) Install the 2 nuts to the lower side of the front shock absorber with coil spring.
Torque: 210 N*m (2,140 kgf*cm, 155 ft.*lbf)
NOTICE: When installing the nuts, keep the bolts from rotating.
(e) Install the front flexible hose and front speed sensor wire harness with the bolt.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
NOTICE: Do not twist the front speed sensor wire harness when installing it.
(f) Fully tighten the lock nut.
Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf)
2. INSTALL FRONT STABILIZER LINK ASSEMBLY
(a) Install the front stabilizer link assembly with the nut.
Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf)
HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.
3. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
4. INSTALL V-BANK COVER SUB-ASSEMBLY
5. INSTALL ENGINE ROOM SIDE COVER LH
6. INSTALL ENGINE ROOM SIDE COVER RH
7. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
DISPOSAL
1. DISPOSE OF FRONT SHOCK ABSORBER
(a) Fully extend the shock absorber rod.
(b) Using a drill, make a hole in the cylinder between A and B as shown in the illustration to discharge the gas inside.
CAUTION:
^ Be careful when drilling because shards of metal may fly about. Always use the proper safety equipment.
^ The gas is colorless, odorless and nonpoisonous.