Suspension Spring ( Coil / Leaf ): Service and Repair

Part 1 Of 2:

Part 2 Of 2:

REMOVAL
1. REMOVE REAR WHEELS
2. REMOVE PACKAGE TRAY TRIM
a. Remove the high-mounted stop light.
b. Remove the 2 clips and package tray trim.
3. REMOVE REAR SEAT
a. Remove the rear seat cushion and seatback.
b. Split type rear seat:
Remove the 2 bolts and seatback side hinge.
4. REMOVE DOOR SCUFF PLATE AND DOOR OPENING TRIM
5. REMOVE QUARTER TRIM
a. Remove the bolt and rear seat outer belt.
b. Remove the quarter trim.
6. REMOVE ROOF SIDE INNER GARNISH
a. 2-Door model: Remove the bolt and disconnect the front seat outer belt shoulder anchor.
b. Remove the roof side inner garnish.
7. REMOVE ROOM PARTITION BOARD





8. SUPPORT REAR AXLE BEAM AT RIGHT AND LEFT SIDES WITH JACKS
9. REMOVE SHOCK ABSORBER





a. While holding the piston rod, remove the 2 nuts.
b. Remove the washer and upper suspension support.





c. Remove the nut, washer and shock absorber.
d. Remove the lower suspension support.
10. REMOVE COIL SPRING
a. Remove the opposite shock absorber lower side set nut and washer, and disconnect the shock absorber from the axle beam.
b. Lower the jacks gradually.
c. Remove the coil spring, upper and lower insulators.

INSPECTION
INSPECT SHOCK ABSORBER





Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during operation.
If there is any abnormality, replace the shock absorber with a new one.

NOTICE: When disposing of the shock absorber, see DISPOSAL.

DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD





2. DRILL HOLE TO DISCHARGE GAS FROM CYLINDER
Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside.

CAUTION:
^ When drilling, chips may fly out, work carefully.
^ The gas is colorless, odorless and non-poisonous.

INSTALLATION





1. INSTALL COIL SPRING
a. Install the upper insulator so that its gap fits to the end of coil spring.
b. Install the lower insulator and coil spring to the axle beam.





2. INSTALL SHOCK ABSORBER
a. While lifting the jacks, connect both shock absorbers to axle beam with the washers and nuts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

HINT: After stabilizing the suspension, torque the nuts.

b. Install the lower suspension support to the shock absorber.
c. Install the shock absorber, upper suspension support and washer to the body.
d. While holding the piston rod, install the lower nut so that the piston rod protrudes 15 - 18 mm (0.591 - 0.709 inch) from the lower nut.
e. Install the upper nut and torque it against to the lower one.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
3. REMOVE JACKS
4. INSTALL ROOM PARTITION BOARD
5. INSTALL ROOF SIDE INNER GARNISH
a. Install the roof side inner garnish.
b. 2-Door model:
Install the front seat outer belt shoulder anchor with the bolt.
Torque: 41 Nm (420 kgf-cm, 30 ft. lbs.)
6. INSTALL QUARTER TRIM
a. Install the quarter trim.
b. Install the rear seat outer belt with the bolt.
Torque: 41 Nm (420 kgf-cm, 30 ft. lbs.)
7. INSTALL DOOR OPENING TRIM AND DOOR SCUFF PLATE
8. INSTALL REAR SEAT
a. Split type rear seat:
Install the seatback side hinge with the 2 bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
b. Install the rear seat cushion and seatback
9. INSTALL PACKAGE TRAY TRIM
10. INSTALL REAR WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)