FRONT SUSPENSION

E SUSPENSION

SECTION

FRONT SUSPENSION

FSU

CONTENTS
PRECAUTIONS ..................................................... ..... 2 Precautions ......................................................... ..... 2 PREPARATION ...................................................... ..... 3 Special Service Tools .......................................... ..... 3 Commercial Service Tools ................................... ..... 3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ........................................... ..... 4 NVH Troubleshooting Chart ................................ ..... 4 FRONT SUSPENSION ASSEMBLY ...................... ..... 5 Components ........................................................ ..... 5 On-Vehicle Inspection and Service ..................... ..... 6 LOOSENESS, BACKLASH, AND DAMAGE OF MOUNTING PARTS AND CONNECTIONS ..... ..... 6 Wheel Alignment ................................................. ..... 6 INTRODUCTION .............................................. ..... 6 PRELIMINARY INSPECTION .......................... ..... 6 INSPECTION OF CAMBER, CASTER AND KINGPIN INCLINATION ANGLES ................... ..... 6 TOE-IN INSPECTION ...................................... ..... 7 STEERING ANGLE INSPECTION ................... ..... 8 SHOCK ABSORBER ............................................. ..... 9 Removal and Installation ..................................... ..... 9 REMOVAL ........................................................ ..... 9 INSTALLATION ................................................ ..... 9 INSPECTION ................................................... ..... 9 TORSION BAR SPRING ........................................ ... 10 Removal and Installation ..................................... ... 10 REMOVAL ........................................................ ... 10 INSTALLATION ................................................ ... 10 INSPECTION ................................................... ... 11 UPPER LINK .......................................................... ... 12 Removal and Installation ..................................... ... 12 REMOVAL ........................................................ ... 12 INSPECTION AFTER REMOVAL .................... ... 12 INSTALLATION ................................................ ... 12 FRONT LOWER LINK ........................................... ... 13 Removal and Installation ..................................... ... 13 REMOVAL ........................................................ ... 13 INSPECTION AFTER REMOVAL .................... ... 13 INSTALLATION ................................................ ... 13 STABILIZER BAR .................................................. ... 14 Removal and Installation ..................................... ... 14 REMOVAL ........................................................ ... 14 INSPECTION AFTER REMOVAL .................... ... 14 INSTALLATION ................................................ ... 14 FRONT SUSPENSION MEMBER .......................... ... 15 Removal and Installation ..................................... ... 15 REMOVAL ........................................................ ... 15 INSTALLATION ................................................ ... 15 SERVICE DATA AND SPECIFICATIONS (SDS) ... ... 16 General Specifications ......................................... ... 16 Wheel Alignment (Unladen * 1) ........................... ... 16 Ball Joint .............................................................. ... 16

FSU

FSU-1

PRECAUTIONS PRECAUTIONS Precautions

G

PFP:00001
EES000HI

G G G

When installing rubber parts, final tightening must be carried out under unladen condition* with tires on ground. Oil will shorten the life of rubber bushes. Be sure to wipe off any spilled oil. *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. After installing removed suspension parts, check wheel alignment and adjust if necessary. Use flare nut wrench when removing or installing brake tubes. Always torque brake lines when installing. Lock nuts are unreusable parts; always use new ones. When replacing, do not wipe the oil off the new lock nut before tightening.

SBR686C

FSU-2

PREPARATION PREPARATION Special Service Tools

Tool name Tool number Description
PFP:00002

A
EES000HJ

C
Preload gauge ST3127S000 Measuring ball joint sliding torque

D
ZZA0806D

Commercial Service Tools

Tool name Description

EES000J0

FSU

F
1.Flare nut crowfoot 2.Torque wrench a: 10 mm (0.39 in)
S-NT360

Removing and installing each brake piping

FSU-3

Symptom

: Applicable Reference page Possible cause and SUSPECTED PARTS FRONT SUSPENSION Noise Shake Judder Improper installation, looseness Shock absorber deformation, damage or deflection Bushing or mounting deterioration Parts interference Spring fatigue Suspension looseness Incorrect wheel alignment Stabilizer bar fatigue PROPELLER SHAFT DIFFERENTIAL REAR AXLE AND REAR SUSPENSION TIRES ROAD WEEL DRIVE SHAFT BRAKES STEERING Shimmy Vibration Poor quality ride or handling Refer to FSU-5 Refer to FSU-9 Refer to FSU-5 Refer to FSU-6 Refer to FSU-14 NVH in PR section NVH in RFD section. NVH in RAX and RSU section. NVH in WT section. NVH in WT section. NVH in RAX section. NVH in BR section. NVH in PS section.

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

FSU-4

PFP:00003
EES000IF

FRONT SUSPENSION ASSEMBLY FRONT SUSPENSION ASSEMBLY Components

PFP:54010

A
EES000HK

FSU

SEIA0117E

1. 4. 7.

Anchor arm Upper link Bush

2. 5. 8.

Torsion bar spring Cotter pin Washer

3. 6. 9.

Upper link suspension Washer Shock absorber

10. Rear cam bolt 13. Lower ball joint 16. Stabilizer bush

11. Front cam bolt 14. Stabilizer connecting rod 17. Stabilizer clamp

12. Lower link assembly 15. Stabilizer 18. Suspension member

FSU-5

FRONT SUSPENSION ASSEMBLY On-Vehicle Inspection and Service

LOOSENESS, BACKLASH, AND DAMAGE OF MOUNTING PARTS AND CONNECTIONS
With the vehicle lifted, check the items below. G Check the mounting portion of the components for looseness, free play, and damage. G Check the end play of the lower ball joint. 1. Attach a dial gauge so that the contact rests on the brake caliper. 2. Set front wheels in a straight-ahead position. Do not depress brake pedal. 3. Measure the axial end play by placing an iron bar, etc. Between the lower link and steering knuckle. Axial end play : 0 mm (0 in) CAUTION: Be careful not to damage ball joint boot. If the axial end play is outside the specified range, remove the lower link and check the lower ball joint.
EES000HM EES000HL

4.

Wheel Alignment
INTRODUCTION
G

Measure the wheel alignment under unladen condition. Unladen condition means that fuel, coolant, and lubricant are filled up to the specified amount. Spare tire, jack, and hand tools shall be unloaded from the vehicle. Check the tires for improper air pressure and wear. Check road wheels for run out. Check wheel bearing axial end play. Check lower ball joint axial end play. Check the operation status of shock absorber. Check each mounting point of axle and suspension for looseness and deformation. Check each link and arm for cracks, deformation and other damage. Check that the vehicle posture is correct.

PRELIMINARY INSPECTION
1. 2. 3. 4. 5. 6. 7. 8.

INSPECTION OF CAMBER, CASTER AND KINGPIN INCLINATION ANGLES

Before checking camber, caster or kingpin inclination, move vehicle up and down on turning radius gauge to minimize friction. Ensure that the vehicle is in correct posture. G Measure camber, caster and kingpin inclination of both right and left wheels with a suitable alignment gauge and adjust in accordance with the following procedures.Camber, Caster and Kingpin inclination: Refer to FSU-16, "SERVICE DATA AND SPECIFICATIONS (SDS)" .
SFA894

FSU-6

FRONT SUSPENSION ASSEMBLY

G

1. 2.

In the following two cases, temporarily tighten the adjusting bolts while aligning the matching marks with the slits as shown in the figure at the left and measure the camber, caster and kingpin inclination: When replacing the upper link or other suspension parts with new ones When matching marks were not painted on adjusting bolts before suspension disassembly procedures G If matching marks were already painted during suspension disassembly, align the matching marks with the slits, then temporarily tighten the adjusting bolts. Measure the camber, caster and kingpin inclination.

FSU

G
SFA817B

M
SEIA0102E

TOE-IN INSPECTION
Measure toe-in using the following procedure. WARNING: G Always perform the following procedure on a flat surface. G Make sure that no one is in front of the vehicle before pushing it. 1. Bounce front of vehicle up and down to stabilize the posture.

SFA614B

FSU-7

FRONT SUSPENSION ASSEMBLY

2. 3. 4. 5. Push the vehicle straight ahead about 5 m (16 ft). Put a mark on base line of the tread (rear side) of both tires at the same height of hub center. This mark is a measuring point. Measure distance A (rear side). Push the vehicle slowly ahead to rotate the wheels 180 degrees (1/2 turn). G If the wheels have rotated more than 180 degrees (1/2turn), try the above procedure again from the beginning. Never push vehicle backward. Measure distance B (front side). Toe-in 7. 1. 2. : In 4mm (0.16 in) to in 2 mm (0.08 in)(2WD models flat floor)

6.

SFA234AC

Adjust toe-in by varying the length of both steering tie-rods. Set wheels in straight-ahead position. Move vehicle to set front wheels on turning radius gauge. Turn steering wheel fully to right and left, and measure steering angle. Refer to PS-38, "SERVICE DATA AND SPECIFICATIONS (SDS)" .

STEERING ANGLE INSPECTION

FSU-8

SHOCK ABSORBER SHOCK ABSORBER Removal and Installation

REMOVAL
1. Support the lower link with a jack, etc. CAUTION: Use a piece of wood or something similar to prevent damage to the lower link. Remove the mounting bolts on the lower portion of shock absorber. Remove the mounting bolts on the upper portion of shock absorber. Remove washer and bushing. Remove shock absorber from the vehicle. Install in the reverse order of removal. Check the shock absorbers for oil leak, cracks, or damage. If any non-standard condition is found, replace it. Check the bushing for cracks or damage. If any non-standard condition is found, replace it.
B
PFP:56210

A
EES000IP

2. 3. 4. 5.
G

INSTALLATION INSPECTION
G

FSU

FSU-9

TORSION BAR SPRING TORSION BAR SPRING Removal and Installation

REMOVAL
1. 2. Raise the vehicle. Put a mating mark between the torsion bar spring and arms. CAUTION: Use paint, etc. For mating marks to prevent damage on the parts.
PFP:54010
EES000IW

SEIA0103E

3.

4. 5.

Remove the anchor bolt nuts. CAUTION: At this time, remove them after confirming that the torsion force of torsion bar spring is released. Remove the torsion bar spring together with the anchor arm from the vehicle. Remove the mounting bolts and nuts. Then remove torque arm from the lower link.

SEIA0104J

INSTALLATION
1. 2. 3. Install the torque arm to the lower link. Tighten the mounting bolts and nuts to the specified torque. Fully apply multi-purpose grease to the serration of the torsion bar spring, torque arm, and anchor arm. Install the torsion bar spring to the torque arm by aligning the mating mark. CAUTION: There are stamp marks on the edge surface of the torsion spring as shown in the figure so that installation must be performed after checking to prevent wrong installation.

SEIA0121E

4.

Install the anchor arm so that the anchor arm plate and line A at vehicle side are vertically aligned.

SEIA0106E

FSU-10

TORSION BAR SPRING

5. Install the anchor bolts, and tighten the lock nut to the specified torque.
A

C
SEIA0104J

6. a. b.

Under unladen conditions with the tires on the ground, adjust the vehicle posture. Shake the vehicle up and down several times so that the parts fit with each other. Adjust the dimension H to be within the specified range. (a - b) Dimension H
G

FSU

: 111 - 115 mm (4.37- 4.53 in)

c.

If the anchor bolt is too loose, first loosen the screw, and then adjust it in the tightening direction. After adjusting the vehicle posture, fully tighten the lock nut to the specified torque.

G
SEIA0105E

INSPECTION
G

Check the torsion bar spring for deformation, cracks or damage. If any non-standard condition is found, replace it. Check the torque arm and anchor arm for deformation, cracks or damage. If any non-standard condition is found, replace them. Check the boot for deformation, cracks or damage. If any non-standard condition is found, replace it.

FSU-11

UPPER LINK UPPER LINK Removal and Installation

REMOVAL
1. 2. 3. Remove the shock absorber. Remove the cotter pin on the ball joint. Using a tie rod end lifter (commercial service tool), remove the upper ball joint. CAUTION: Because the tie rod end lifter (commercial service tool) may come off suddenly, temporarily tighten the lock nut. Put a mating mark on the upper link and upper link pin. Remove the upper link pin, and then remove the upper link from the vehicle.
PFP:54524
EES000HP

4.

INSPECTION AFTER REMOVAL Visual Inspection

Check the upper link for deformation, cracks, or damage. If any non-standard condition is found, replace it.

Ball Joint Inspection

CAUTION: Before measurement, move the ball joint by hand ten times or more to check for smooth operation of the ball joint.

Oscillating Torque Inspection

G

Fix the upper link, and hook the spring scale onto the cotter pin mounting hole. Check that the spring scale value when the ball stud begins moving is within the specified range. Oscillating torque Measured value of spring scale : 4.9 Nm (0.5 kg-m, 43 in-lb) or less : 79 N (8.1 kg, 17.9 lb) or less

If it is outside the specified range, replace the upper link.

SEIA0122E

Sliding Torque Inspection

G

Temporarily tighten the mounting nut to the ball joint. Using a preload gauge (special service tool), check that the sliding torque is within the specified range. Sliding torque : 4.9 Nm (0.5 kg-m, 43in-lb) or less

If it is outside the specified range, replace the upper link.

FAC1021D

INSTALLATION
1. Tighten the ball joint and nut on the installation part in the suspension member to the specified torque. Then install the cotter pin. CAUTION: The cotter pin is not reusable. Always use a new one when installing. Temporarily tighten the nut and washer on the installation part of the third link. Then under unladen condition with tires on the ground, tighten them to the specified torque.

2.

FSU-12

FRONT LOWER LINK FRONT LOWER LINK Removal and Installation

REMOVAL
1. Loosen the mounting nut between the lower link and steering knuckle. CAUTION: Loosen the nut to the degree that it can be turned by hand, and leave it temporarily. Remove the mounting bolts on the lower portion of shock absorber. Remove the mounting nut on the lower portion of stabilizer connecting rod. Remove the lower link from the suspension member.
B
PFP:55110

A
EES000MF

2. 3. 4.

INSPECTION AFTER REMOVAL Visual Inspection

Check the transverse link and bushing for deformation, cracks, or damage. If any non-standard condition is FSU found, replace the transverse link as an assembly.

Ball Joint Inspection

CAUTION: Before measurement, move the ball joint by hand ten times or more to check for smooth operation of the ball joint.
F

Oscillating Torque Inspection

G

Hook the spring scale onto the cotter pin mounting hole. Check that the spring scale value when the ball stud begins moving is within the specified range. Oscillating torque Measured value of spring scale : 4.9 Nm (0.5 kg-m, 43 in-lb) : 79 N (8.1 kg, 17.9 lb)

If it is outside the specified range, replace the ball joint.

J
SEIA0122E

Sliding Torque Inspection

G

Install the mounting nut to the ball stud. Using a preload gauge (special service tool), check the sliding torque is within the specified range. Sliding torque : 4.9 Nm (0.5 kg-m, 43 in-lb)

L
G

If it is outside the specified range, replace the ball joint.

M

FAC1021D

Axial End Play Inspection

G

Push the ball joint tip in the axial direction to check free play. Axial end play : 0.2 mm (0.008 in) or less

If there is free play, replace the ball joint. Refer to FSU-5, "Components" for each tightening torque, etc. Tighten in the reverse order of removal. Tighten the lower link mounting bolts to the specified torque under unladen condition with tires on the ground. After installation, check the wheel alignment. Refer to FSU-6, "Wheel Alignment" .

INSTALLATION
G G

FSU-13

STABILIZER BAR STABILIZER BAR Removal and Installation

REMOVAL
1. 2. 3. Remove mounting nuts on upper portion of stabilizer connecting rod. Remove stabilizer clamp mounting bolts. Remove stabilizer from the vehicle.
PFP:54611
EES000IG

INSPECTION AFTER REMOVAL

Check stabilizer, connecting rod, bushing and clamp for deformation, cracks and damage, and replace if necessary.

INSTALLATION
G G

Refer to FSU-5, "Components" for each tightening torque, etc. Tighten in the reverse order of removal. Because the stabilizer uses the pillow ball type connecting rod, install the ball joint so that the case on the pillow ball head becomes parallel to the stabilizer.

SFA449B

FSU-14

FRONT SUSPENSION MEMBER FRONT SUSPENSION MEMBER Removal and Installation

REMOVAL
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
G G

PFP:54401

A
EES000HS

Remove tires. Raise the vehicle, and remove caliper and sensor. Remove front exhaust tube. Remove torsion bar spring. Remove front propeller shaft. Remove stabilizer. Remove mounting part of steering gear and knuckle arm. Remove steering gear mounting bolts from the suspension member. Hang steering gear. Remove front differential assembly from suspension member. Support engine or transmission with a transmission jack. Remove suspension member mounting bolt and lower link. Set a transmission jack under suspension member, and remove suspension member mounting nuts. Slowly lower transmission jack to remove suspension member from vehicle. Refer to FSU-5, "Components" for each tightening torque, etc. Tighten in the reverse order of removal. After installation, perform final tightening of each part under unladen conditions with tires on the ground. Check wheel alignment.

FSU

INSTALLATION
G

FSU-15

SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications
Suspension type Shock absorber type Stabilizer Independent double wishbone torsion bar spring Double-acting hydraulic Standard equipment
EES000HT

PFP:00030
EES000IZ

Wheel Alignment (Unladen * 1)

Minimum Camber Degree minute (Decimal degree) Nominal Maximum Left and right difference Minimum Caster Degree minute (Decimal degree) Nominal Maximum Left and right difference Kingpin inclination Degree minute (Decimal degree) Minimum Nominal Maximum Minimum Total toe-in Distance (a - b) Radial tire Nominal Maximum Vehicle posture Lower arm pivot height (H) 045 (0.75) 000 (0.00) 045 (0.75) 45 (0.75) or less 215 (2.25) 315 (2.25) 415 (4.25) 60 (1.00) or less 1315 (13.25) 1400 (14.00) 1445 (14.75) 2 mm (0.08 in) 3 mm (0.12 in) 4 mm (0.16 in)

111 - 115 mm (4.37 - 4.53 in)

SEIA0105E

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

Ball Joint
Upper link Oscillating torque Measured value of spring scale (Cotter pin hole position) Sliding torque Axial end play Lower link 4.9 Nm (0.5 kg-m, 43 in-lb) or less 79 N (8.1 kg, 17.9 lb) 4.9 Nm (0.5 kg-m, 43 in-lb) or less 0 mm (0 in)

EES000HU

FSU-16