FSU-1

FRONT SUSPENSION
E SUSPENSION
CONTENTS
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SECTION
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FSU
FRONT SUSPENSION
PRECAUTIONS .......................................................... 2
Caution ..................................................................... 2
Precautions for Brake System .................................. 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
DESCRIPTION ................................................. ..... 6
PRELIMINARY INSPECTION .......................... ..... 6
INSPECTION OF CAMBER, CASTER, AND
KINGPIN INCLINATION ANGLES ........................ 6
STEERING ANGLE INSPECTION ........................ 7
COIL SPRING AND SHOCK ABSORBER ................. 8
Removal and Installation ..................................... ..... 8
REMOVAL ........................................................ ..... 8
INSTALLATION ..................................................... 8
Disassembly and Assembly ..................................... 8
DISASSEMBLY ..................................................... 8
INSPECTION AFTER DISASSEMBLY ................. 8
ASSEMBLY ........................................................... 9
TRANSVERSE LINK .............................................. ... 10
Removal and Installation ..................................... ... 10
REMOVAL ........................................................ ... 10
INSPECTION AFTER REMOVAL .................... ... 10
INSTALLATION ................................................ ... 10
STABILIZER BAR .................................................. ... 11
Removal and Installation ..................................... ... 11
REMOVAL ........................................................ ... 11
INSPECTION AFTER REMOVAL .................... ... 11
INSTALLATION ................................................ ... 11
FRONT SUSPENSION MEMBER ............................. 12
Removal and Installation ..................................... ... 12
REMOVAL ........................................................ ... 12
INSTALLATION ................................................ ... 12
UPPER LINK .......................................................... ... 13
Removal and Installation ..................................... ... 13
REMOVAL ........................................................ ... 13
INSPECTION AFTER REMOVAL .................... ... 13
INSTALLATION ................................................ ... 13
THIRD LINK .............................................................. 14
Removal and Installation ..................................... ... 14
REMOVAL ........................................................ ... 14
INSPECTION AFTER REMOVAL .................... ... 14
INSTALLATION ................................................ ... 14
SERVICE DATA AND SPECIFICATIONS (SDS) ... ... 15
General Specification ............................................. 15
Wheel Alignment (Unladen) .................................... 15
Ball Joint .............................................................. ... 15
Wheelarch Height (Unladen) ............................... ... 15
FSU-2
PRECAUTIONS
PRECAUTIONS PFP:00001
Caution EES000LP
G When installing rubber bushings, final tightening must be carried out under unladen conditions with tires
on flat, level ground. Oil will shorten the life of rubber bushings. Be sure to wipe off any spilled oil.
G Unladen condition means that fuel, coolant and lubricant are full and ready for drive. However, spare tire,
jack, and hand tools should be unloaded.
G After installing the removed suspension parts, always check wheel alignment and adjust if necessary.
G Replace the caulking nut with a new one. Install a new nut without wiping the oil off before tightening.
Precautions for Brake System EES000LQ
G When installing rubber parts, final tightening must be carried out
under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
G Use flare nut wrench when removing or installing brake tubes.
G After installing removed suspension parts, check wheel align-
ment and adjust if necessary.
G Always torque brake lines when installing.
SBR686C
PREPARATION
FSU-3
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FSU
PREPARATION PFP:00002
Special Service Tools EES000LR
Commercial Service Tools EES000LS
Tool name
Tool number
Description
HT7252000
Ball joint remover
Removing tie-rod outer and lower ball
joint
Preload gauge
ST3127S000
Measuring ball joint sliding torque
CCK gauge attachment
KV991040S1
1 KV99104020 Adapter A
2 KV99104030 Adapter B
3 KV99104040 Adapter C
4 KV99104050 Adapter D
5 KV99104060 Plate
6 KV99104070 Guide bolt
7 KV99104080 Spring
8 KV99104090 Center plate
Measuring wheel alignment
Strut attachment
ST35652000
Disassembling and assembling strut
S-NT146
ZZA0806D
ZZA1167D
ZZA0807D
Tool name Description
Attachment wheel alignment
a: screw M24 x 1.5 pitch
b: 35 mm (1.38 in) dia.
c: 65 mm (2.56 in) dia.
d: 56 mm (2.20 in) dia.
e: 12 mm (0.47 in) dia.
Measure wheel alignment
1. Flare nut crowfoot
2. Torque wrench
a: 10 mm (0.39 in)
Removing and installing brake piping
S-NT148
S-NT360
FSU-4
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting Chart EES000M9
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
: Applicable
Reference page
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Symptom FRONT SUSPENSION
Noise
Shake
Vibration
Shimmy
Judder
Poor quality ride or han-
dling

FRONT SUSPENSION ASSEMBLY
FSU-5
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FSU
FRONT SUSPENSION ASSEMBLY PFP:54010
Components EES000LU
MEIA0006E
FSU-6
FRONT SUSPENSION ASSEMBLY
On-Vehicle Inspection and Service EES000LV
LOOSENESS, BACKLASH AND DAMAGE OF MOUNTING PARTS AND CONNECTIONS
Lift vehicle and inspect the following:
G Check mounting point of each component for looseness, backlash and damage.
G Check lower ball joint end play.
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 axial end play by placing an iron pry bar or something similar between transverse link and steer-
ing knuckle.
CAUTION:
Be careful not to damage ball joint boot.
4. If axial end play is outside the standard, remove transverse link and check lower ball joint.
Wheel Alignment EES000LW
DESCRIPTION
G Measure wheel alignment under unladen conditions. Unladen conditions means that fuel, coolant, and
lubricant are full. However, spare tire, jack, and hand tools should be unloaded.
PRELIMINARY INSPECTION
1. Check the tires for improper air pressure and wear.
2. Check road wheels for runout.
3. Check wheel bearing axial end play.
4. Check lower ball joint axial end play.
5. Check strut operation.
6. Check each mounting point of axle and suspension for looseness and deformation.
7. Check each link and arm for cracks, deformation, and other damage.
8. Check the vehicle posture.
INSPECTION OF CAMBER, CASTER, AND KINGPIN INCLINATION ANGLES
G Camber, caster, and kingpin inclination angles cannot be adjusted.
G Before inspection, mount front wheels onto turning radius gauge. Mount rear wheels onto a stand that has
same height so the vehicle will remain horizontal.
1. Strut spacer 2. Strut mount insulator 3. Strut upper bracket
4. Thrust bearing 5. Spring upper seat 6. Upper rubber seat
7. Bound bumper 8. Coil spring 9. Strut
10. Cap 11. Washer 12. Third link
13. Axle assembly 14. Cotter pin 15. Clamp
16. Bushing 17. Stabilizer bar 18. Connecting rod
19. Suspension member 20. Member pin stay 21. Upper link
22. Bushing link pin 23. Transverse link bracket 24. Transverse link
25. Suspension crossbar
Axial end
play
: 0 mm (0 in)
FRONT SUSPENSION ASSEMBLY
FSU-7
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FSU
1. Measure camber, caster and kingpin inclination of both right and
left wheels with a suitable alignment gauge.
2. If camber, caster or kingpin inclination is not within specification,
inspect front suspension parts. Replace dam-aged or worn out
parts.
Toe-in
Measure toe-in using the following procedure.
WARNING:
G Always perform the following procedure on a flat surface.
G Make sure that no person is in front of the vehicle before
pushing it.
1. Bounce front of vehicle up and down to stabilize the posture.
2. Push the vehicle straight ahead about 5 m (16 ft).
3. Put a mark on base line of tread (rear side) of both tires at the
same height as hub center. These are measuring points.
4. Measure distance A (rear side).
5. Push the vehicle slowly ahead to rotate the wheels 180degrees
(1/2 turn).
If the wheels have rotated more than 180 degrees (1/2 turn), try the
above procedure again from the beginning. Never push vehicle
backward.
6. Measure distance B (front side).
STEERING ANGLE INSPECTION
1. Set wheels in straight-ahead position. Move vehicle to set front wheels on turning radius gauge.
2. Turn steering wheel fully to right and left, and measure steering angle. Refer to PS-26, "SERVICE DATA
AND SPECIFICATIONS (SDS)" .
Camber, caster and kingpin inclination:
FSU-15, "SERVICE DATA AND SPECIFICATIONS
(SDS)"
SRA096A
AFA050
Total toe-in:
FSU-15, "SERVICE DATA AND SPECIFICATIONS
(SDS)"
SFA234AC
FSU-8
COIL SPRING AND SHOCK ABSORBER
COIL SPRING AND SHOCK ABSORBER PFP:54302
Removal and Installation EES000LX
REMOVAL
1. Remove tires. Remove brake caliper and hung it aside.
CAUTION:
Avoid depressing brake pedal with brake caliper removed.
2. Remove electrical wires of ABS wheel speed sensor from strut.
3. Remove brake hose lock plate.
4. Remove mounting bolts securing third link to strut.
5. Remove mounting nuts on top of strut and remove upper mounting plate and strut from vehicle.
INSTALLATION
G Refer to FSU-5, "Components" in Front Suspension Assembly for tightening torque. Tighten in the
reverse order of removal.
G Be sure arrows on strut mount insulator and spring upper seat
are positioned as shown. Also be sure notch in strut spacer is
positioned as shown. Then install strut.
G Assemble upper mounting plate with its notch facing toward the
outside.
Disassembly and Assembly EES000LY
DISASSEMBLY
1. Install strut attachment to strut and fix it in a vise.
CAUTION:
When installing strut attachment, wrap a shop cloth around
strut to protect it from damage.
2. Slightly loosen piston rod lock nut.
WARNING:
Do not remove piston rod lock nut completely. If it is
removed completely, coil spring jumps out and may cause
serious damage or injury.
3. Compress coil spring using a spring compressor.
WARNING:
Make sure that the pawls of the two spring compressors are firmly hooked on the spring. The
spring compressors must be tightened alternately so as not to tilt the spring.
4. After making sure coil spring is free between upper and lower seats after Step 3. Remove piston rod lock
nut.
5. Remove small parts on strut.
G Remove strut spacer, strut mount insulator, thrust bearings, spring upper seat, and upper rubber seat.
Then remove coil spring.
6. Remove bound bumper from spring upper seat.
7. Gradually release spring compressor, and remove coil spring.
INSPECTION AFTER DISASSEMBLY
Strut Inspection
G Check strut for deformation, cracks, and damage, and replace if necessary.
G Check piston rod for damage, uneven wear, and distortion, and replace if necessary.
G Check welded and sealed areas for oil leakage, and replace if necessary.
SEIA0123E
SEIA0124E
COIL SPRING AND SHOCK ABSORBER
FSU-9
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FSU
Insulator and Rubber Parts Inspection
Check strut mount insulator for cracks and rubber parts for wear. Replace them if necessary.
Coil Spring Inspection
Check for cracks, wear, and damage, and replace if necessary.
ASSEMBLY
1. Compress coil spring using a spring compressor, and install it
onto the strut.
CAUTION:
Face tube side of coil spring downward. Align lower end to
spring seat as shown in the figure.
WARNING:
Be sure spring compressor is securely attached to coil
spring. Compress coil spring.
2. Connect bound bumper to spring upper seat.
CAUTION:
G Be sure to install bound bumper to spring upper seat
securely.
G When installing bound bumper, use soapy water. Do not use machine oil or other lubricants.
3. Install small parts to the strut.
G Connect upper rubber seat, spring upper seat, thrust bearing, strut mount insulator, and strut spacer.
Temporarily install piston rod lock nut.
CAUTION:
Do not reuse piston rod lock nut.
4. Be sure arrows on strut mount insulator and spring upper seat
are positioned as shown. Also be sure notch in the strut spacer
is positioned as shown.
5. Be sure coil spring is properly set in spring rubber seat. Gradu-
ally release spring compressor.
CAUTION:
Be sure upper rubber seat is properly aligned to spring
upper seat and coil spring.
6. Tighten piston rod lock nut to the specified torque.
7. Remove strut attachment.
SEIA0125E
SEIA0123E
SEIA0124E
FSU-10
TRANSVERSE LINK
TRANSVERSE LINK PFP:54500
Removal and Installation EES000LZ
REMOVAL
1. Remove steering knuckle from transverse link. Refer to FAX-7, "FRONT WHEEL HUB AND KNUCKLE" .
2. Remove mounting nut on lower portion of stabilizer connecting rod.
3. Remove electrical wires of wheel speed sensor.
4. Remove suspension crossbar.
5. Slightly loosen transverse link mounting bolts.
6. Remove bushing link pin mounting bolts.
7. Remove transverse link mounting bolts and nuts, and remove transverse link from suspension member.
INSPECTION AFTER REMOVAL
Visual Inspection
Check transverse link and bushing for deformation, cracks, and other damage. Replace the entire transverse
link assembly if cracks, deformation or any other damage is found.
Ball Joint Inspection
CAUTION:
Before measurement, move the ball joint at least ten times by hand to check for smooth movement.
Oscillating Torque Inspection
G Hook spring scale at cotter pin mounting hole. Confirm spring
scale measurement value is within specifications when ball stud
begins moving.
G If the value is outside the standard, replace transverse link.
Sliding Torque Inspection
G Attach mounting nut to ball stud. Check that sliding torque is
within specifications with a preload gauge.
G If the value is outside the standard, replace transverse link.
Axial End play Inspection
G Move tip of ball joint in axial direction to check for looseness.
G If any looseness is noted, replace transverse link.
INSTALLATION
G Refer to FSU-5, "Components" for tightening torque. Tighten in the reverse order of removal.
G When installing transverse link, confirm stopper rubber is properly installed (behind front bushing collar).
G Tighten transverse link mounting bolts with vehicle unladen and all four tires on flat, level ground.
G After installation, check wheel alignment. Refer to FSU-6, "Wheel Alignment" .
Tensile force:
0.5 - 3.4 Nm (0.05 - 0.35 kg-m, 5 - 30 in-lb)
Measurement on spring balance:
7.94 - 53.97 N (0.81 - 5.50 kg, 1.79 - 12.2 lb)
SEIA0122E
Sliding torque:
0.5 - 3.4 Nm (0.05 - 0.35 kg-m, 5 - 30 in-lb)
FAC1021D
Axial end play : 0.1 mm (0.004 in) or less
STABILIZER BAR
FSU-11
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FSU
STABILIZER BAR PFP:54611
Removal and Installation EES000M0
REMOVAL
1. Remove mounting nuts on upper portion of stabilizer connecting rod.
2. Remove stabilizer clamp mounting bolts.
3. Remove steering gear from suspension member. Refer to PS-13, "REMOVAL" .
4. Remove stabilizer from the vehicle.
INSPECTION AFTER REMOVAL
Check stabilizer, connecting rod, bushing and clamp for deformation, cracks and damage, and replace if nec-
essary.
INSTALLATION
G Refer to FSU-5, "Components" in the reverse order of removal.
G Stabilizer uses pillow ball type connecting rod. Position ball joint
with case on pillow ball head parallel to stabilizer.
SFA449BB
FSU-12
FRONT SUSPENSION MEMBER
FRONT SUSPENSION MEMBER PFP:54401
Removal and Installation EES000M1
REMOVAL
1. Remove tires. Raise vehicle.
2. Remove brake caliper and hang it in a place where it will not interfere with work.
3. Remove steering knuckle. Refer to FAX-7, "FRONT WHEEL HUB AND KNUCKLE" .
4. Remove suspension crossbar.
5. Remove front exhaust tube.
6. Remove power steering tube bracket.
7. Remove electrical wires of wheel sensor from transverse link.
8. Mark lower joint and steering gear with paint for easy installation. Remove pinch bolt from gear side of
lower joint.
9. Remove high pressure-side tube and low pressure-side hose of hydraulic piping from steering gear.
10. Remove transverse link from suspension member. Refer to FSU-10, "TRANSVERSE LINK" .
11. Support engine or transmission with a transmission jack.
12. Remove center member from vehicle.
13. Remove body-side mounting bolts from member pin stay.
14. Set a transmission jack under suspension member, and remove suspension member mounting nuts and
stopper (front side).
15. Slowly lower transmission jack to remove suspension member from vehicle.
INSTALLATION
G Refer to FSU-5, "Components" for tightening torque in the reverse order of removal.
G After installation, perform final tightening of each part under unladen conditions with tires on ground.
Check wheel alignment. Refer to FSU-6, "Wheel Alignment" .
UPPER LINK
FSU-13
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FSU
UPPER LINK PFP:54524
Removal and Installation EES000M2
REMOVAL
1. Remove cotter pin and nut of upper link ball joint from suspension member.
2. Remove upper link mounting nut and washer from third link.
3. Remove ball joint stud and pin from suspension member and third link, detach upper link.
INSPECTION AFTER REMOVAL
Visual Inspection
Check upper link for deformation, cracks, and other damage. Replace upper link assembly if cracks, deforma-
tion or any other damage is found.
Ball Joint Inspection
CAUTION:
Before measurement, move the ball joint at least ten times by hand to check for smooth movement.
Oscillating Torque Inspection
G Hook spring scale at cotter pin mounting hole. Confirm spring
scale measurement value is within specifications when ball stud
begins moving.
G If the value is outside the standard, replace transverse link.
Sliding Torque Inspection
G Attach mounting nut to ball stud. Check that sliding torque is
within specifications with a preload gauge.
G If the value is outside the standard, replace transverse link.
INSTALLATION
1. Tighten ball joint and nut on the installation part of suspension member to the specified torque. Then
install cotter pin.
CAUTION:
The cotter pin is not reusable. Always use a new one when installing.
2. Temporarily tighten nut and washer on the installation part of third link. Then under unladen condition with
tires on the ground, tighten them to the specified torque.
Tensile force:
2.0 Nm (0.20 kg-m, 18 in-lb) or less
Measurement on spring balance:
34.8 N (3.55 kg, 7.82 lb) or less
SEIA0122E
Sliding torque:
2.0 Nm (0.20 kg-m, 18 in-lb) or less
FAC1021D
FSU-14
THIRD LINK
THIRD LINK PFP:54592
Removal and Installation EES000MA
REMOVAL
1. Remove kingpin cap with a flat-bladed screwdriver.
2. Remove nut and washer securing steering knuckle and third link.
3. Remove nut and washer securing upper link and third link.
4. Remove mounting bolts, and remove third link from strut.
CAUTION:
Do not disassemble kingpin part of third link.
INSPECTION AFTER REMOVAL
Visual Inspection
Check third link and bushing for deformation, cracks, and other damage. Replace the entire third link assem-
bly if cracks, deformation or any other damage is found.
INSTALLATION
1. Set third link to kingpin, install washer and nut. Tighten nut to the specified torque.
CAUTION:
The nut is not reusable. Always use a new one.
2. Pack kingpin cap with multi-purpose grease. Then install the cap to third link.
CAUTION:
The kingpin cap is not reusable. Always use a new one.
3. Install third link mounting bolts to strut. Tighten bolts to the specified torque.
4. Install upper link mounting nut and washer to third link. Tighten nut to the specified torque.
SERVICE DATA AND SPECIFICATIONS (SDS)
FSU-15
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SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
General Specification EES000M4
Wheel Alignment (Unladen) EES000M5
: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
Ball Joint EES000M6
Wheelarch Height (Unladen) EES000M7
Suspension type Independent multi-link strut with coil spring
Shock absorber type Double-acting hydraulic
Stabilizer bar Standard equipment
Drive type 2WD
Body type Sedan Wagon
Camber
Degree minute (Decimal degree)
Minimum 100 (1.00) 055 (0.92)
Nominal 015 (0.25) 010 (0.17)
Maximum 030 (0.50) 035 (0.58)
Left and right difference 45 (0.75)
Caster
Degree minute (Decimal degree)
Minimum 105 (1.08) 110 (1.17)
Nominal 150 (1.83) 155 (1.92)
Maximum 235 (2.580) 240 (2.67)
Left and right difference 45 (0.75)
Kingpin offset
Degree minute (Decimal degree)
Minimum 1400 (14.00) 1355 (13.92)
Nominal 1445 (14.75) 1440 (14.67)
Maximum 1530 (15.50) 1525 (15.42)
Total toe-in
Distance (A - B)
Minimum 0 mm (0 in)
Nominal 1 mm (0.04 in)
Maximum 2 mm (0.08 in)
Wheel turning angel Refer to PS-26, "Steering Angle" .
Oscillating torque 0.5 - 3.4 N m (0.05 - 0.35 kg-m, 5 - 30 in-lb)
Measurement on spring balance (cotter pinhole position) 7.94 - 53.97 N (0.81 - 5.50 kg, 1.79 - 12.2 lb)
Sliding torque 0.5 - 3.4 N m (0.05 - 0.35 kg-m, 5 - 30 in-lb)
Axial end play 0.1 mm (0.004 in) or less
Applied
model
QG and QR engines YD engine QG and QR engines YD engine
Sedan Wagon
205/60R16 215/50R17 205/60R16 215/50R17 205/60R16 215/50R17 205/60R16 215/50R17
SFA818A
FSU-16
SERVICE DATA AND SPECIFICATIONS (SDS)
: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
Front (Hf)
mm (in)
698 (27.48) 697 (27.44) 697 (27.44) 696 (27.40) 699 (27.52) 699 (27.52) 698 (27.48) 698 (27.48)
Rear (Hr)
mm (in)
699 (27.52) 696 (27.40) 699 (27.52) 696 (27.40) 695 (27.36) 692 (27.24) 695 (27.36) 692 (27.24)