RM38T0EC _53 Suspension _112966 FRONT SUSPENSION _0502991 FRONT SHOCK ABSORBER A

FRONT SUSPENSION  FRONT SHOCK ABSORBER  INSTALLATION  


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
C438109N04
0.75,2.896 3.063,5 2.313,2.104 1.198,1.333 1.948,1.5 0.75,0.167 1.156,1.292 1.99,1.542 0.833,0.25 5.396,2.26 5.698,2.26 false 5.063,1.781 5.365,1.781 false 5.438,0.74 5.74,0.74 false 1.49,3.104 1.948,3.104 false 1.594,3.656 1.896,3.656 false 0.448,3.906 0.75,3.906 false 2.698,2.521 3,2.521 false 2.365,1.875 2.667,1.875 false 1.958,1.417 2.229,1.417 false 1.594,4.354 2.021,4.354 false 5.052,4.271 5.354,4.271 false 6.052,2.094 6.333,2.448 0.281,0.354 18 false 1 5.708,1.625 5.99,1.979 0.281,0.354 18 false 2 6.063,0.563 6.344,0.917 0.281,0.354 18 false 3 1.281,2.948 1.563,3.302 0.281,0.354 18 false 4 1.396,3.51 1.677,3.865 0.281,0.354 18 false 5 0.25,3.76 0.531,4.115 0.281,0.354 18 false 6 3.333,2.354 3.615,2.708 0.281,0.354 18 false 7 2.719,1.75 3,2.104 0.281,0.354 18 false 8 0.833,1.219 1.219,1.573 0.385,0.354 18 false 9 1.26,4.198 1.719,4.552 0.458,0.354 18 false 10 1.271,1.333 2.74,1.49 1.469,0.156 8 false 47 (479, 35) 0.729,1.271 0.885,1.469 0.156,0.198 10 false ● 5.375,4.198 5.656,4.396 0.281,0.198 10 false *1

Procedure Part Name Code
Z101186

Z101188

Z101187

1 FRONT LOWER COIL SPRING INSULATOR 48158C (Click here) - -
2 FRONT SPRING BUMPER 48331C (Click here) - -
3 FRONT COIL SPRING 48132 (Click here) - -
4 STRUT MOUNTING BEARING 48619A (Click here) - -
5 FRONT UPPER COIL SPRING INSULATOR 48157C - - -
6 STRUT MOUNTING BEARING WITH DUST COVER - - - -
7 FRONT SUSPENSION SUPPORT SUB-ASSEMBLY 48609 (Click here) - -
8 COLLAR - - - -
9 TEMPORARILY TIGHTEN FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT 48609E (Click here) - -
10 FRONT NO. 1 SHOCK ABSORBER DUST COVER 48559B (Click here) - -

*1 FRONT SHOCK ABSORBER ASSEMBLY - -
V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf) ● Non-reusable part

C438081N09
3.427,0.458 4.177,0.625 0.75,0.167 3.375,0.417 4.219,0.677 0.844,0.26 0.25,4.271 1.25,4.438 1,0.167 0.208,4.229 1.292,4.479 1.083,0.25 6.292,2.688 7.042,2.854 0.75,0.167 6.25,2.646 7.083,2.896 0.833,0.25 3.115,2.531 3.865,2.698 0.75,0.167 3.073,2.49 3.906,2.74 0.833,0.25 0.813,1.76 1.646,2.052 0.833,0.292 0.854,1.802 1.604,2.01 0.75,0.208 2.594,0.375 2.927,0.375 false 6.302,5.042 6.635,5.042 false 2.646,1.927 2.75,1.75 2.75,1.75 2.917,1.75 false 5.344,1.49 5.677,1.49 false 1.177,3.365 1.51,3.365 false 6.042,1.969 6.375,1.969 false 2.729,0.542 3.427,0.542 false 1.26,4.344 1.427,4.344 1.427,4.344 1.667,3.99 false 6.677,2.677 6.677,2.344 false 2.948,3.104 2.948,2.604 2.948,2.604 3.115,2.604 false 1.24,1.792 1.24,1.625 1.24,1.625 1.021,1.5 true 6.677,4.896 7.073,5.24 0.396,0.344 18 false 16 2.99,0.208 3.51,0.573 0.521,0.365 18 false 15 0.417,1.76 0.76,2.042 0.344,0.281 18 true 14 1.813,3.208 2.219,3.563 0.406,0.354 18 false 13 6.01,1.354 6.406,1.729 0.396,0.375 18 false 12 3.229,1.615 3.677,1.958 0.448,0.344 18 false 11 2.219,0.469 2.531,0.667 0.313,0.198 10 false x2 1.729,4.021 2.042,4.219 0.313,0.198 10 false x2 3.458,3.99 3.771,4.188 0.313,0.198 10 false x2 6.427,1.896 6.74,2.094 0.313,0.198 10 false *1 3.5,0.458 4.969,0.615 1.469,0.156 8 false 50 (510, 37) 0.354,4.26 1.823,4.417 1.469,0.156 8 false 270 (2753, 199) 6.354,2.698 7.125,2.979 0.771,0.281 8 false 29 (296, 21) 3.188,2.521 4.656,2.677 1.469,0.156 8 false 74 (755, 55) 0.885,1.823 1.573,1.979 0.688,0.156 8 true 47 (479, 35)

Procedure Part Name Code
Z101186

Z101188

Z101187

11 FRONT SHOCK ABSORBER WITH COIL SPRING - (Click here) - -
12 FRONT SPEED SENSOR 89543 (Click here) - -
13 FRONT STABILIZER LINK ASSEMBLY 48810 (Click here) - -
14 FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT 48609E (Click here) - -
15 FRONT SUSPENSION SUPPORT DUST COVER 48684B - - -
16 FRONT WHEEL - - - -

*1 FRONT FLEXIBLE HOSE - -
V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf) - -

C477146N01
0.646,0.594 1.396,0.76 0.75,0.167 0.604,0.542 1.438,0.813 0.833,0.271 0.917,0.167 1.667,0.333 0.75,0.167 4.448,2.302 4.781,2.302 false 1.396,0.677 1.729,0.677 false 1.667,0.25 1.833,0.25 1.833,0.25 2.167,0.813 false 3.531,0.375 3.865,0.375 false 5.865,1.719 6.198,1.719 false 6.5,0.229 6.833,0.229 false 6.427,0.656 6.76,0.656 false 4.865,2.125 5.469,2.479 0.604,0.354 18 false 17 1.823,0.708 2.135,0.906 0.313,0.198 10 false x4 2.156,0.896 2.469,1.094 0.313,0.198 10 false x8 0.719,0.604 2.188,0.76 1.469,0.156 8 false 50 (510, 37) 1.021,0.167 2.49,0.323 1.469,0.156 8 false 12 (122, 9) 3.948,0.208 4.552,0.563 0.604,0.354 18 false 18 6.281,1.563 6.885,1.917 0.604,0.354 18 false 19 6.177,0.083 6.781,0.438 0.604,0.354 18 false 20 5.75,0.531 6.354,0.885 0.604,0.354 18 false 21 6.073,0.573 6.677,0.927 0.604,0.354 12 false (*A)

Procedure Part Name Code
Z101186

Z101188

Z101187

17 OUTER COWL TOP PANEL SUB-ASSEMBLY 55701J - - -
18 NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 55737B - - -
19 WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY - - - -
20 INSPECT AND ADJUST FRONT WHEEL ALIGNMENT - (Click here) - -
21 PERFORM CALIBRATION - - - (Click here)

*A w/ Panoramic view monitor system - -
V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque

CAUTION / NOTICE / HINT

HINT:
·

Use the same procedure for the RH side and LH side.

·

The following procedure is for the LH side.



PROCEDURE

Hide 48158C 1.INSTALL FRONT LOWER COIL SPRING INSULATOR

Z101186

NOTICE:

When installing the front lower coil spring insulator, insert the positioning pin of the spring seat into the hole of the front lower coil spring insulator.



a.
C438101C01
0,0 0,0 false
V100135

Positioning Pin - -



Hide 48331C 2.INSTALL FRONT SPRING BUMPER

Z101186

NOTICE:
·

Face the smaller diameter end of the front spring bumper downward.

·

Do not apply lubricants to the front spring bumper.

·

Do not apply lubricants to the front shock absorber assembly cap or rod.

·

Do not clean the front spring bumper with water or solvent.




a.
C438102C01
0,0 0,0 false
V113147

Install in this direction - -



Hide 48132 3.INSTALL FRONT COIL SPRING

a.
C438103C02
4.865,0.719 5.24,0.885 true 3.75,1.135 4.375,1.385 4.375,1.385 3.781,1.375 false 5.281,0.813 5.594,0.969 0.313,0.156 10 false *a 0.49,0.104 1.969,0.396 1.479,0.292 18 false i, ii, iii, iv, v 4.427,1.302 4.917,1.458 0.49,0.156 10 false SST
*a Depression - -


i.

Secure SST in a vise.

SST
09727-00051  
09727-30022  (09727-00010, 09727-00031)


ii.

Attach the hooks of each SST arm across the diameter of the coil spring.

CAUTION:
·
C322989

Make sure that the hooks are securely attached to the coil spring.

·

If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.

·
C398464

Make sure that the hooks of the upper and lower SST arms are attached to the coil spring so that the distance between the hooks is as large as possible.

·

If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.

·
C312080

Make sure that the arms of SST are parallel and the number of coils between the arms is the same on each side.

·

If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.




iii.

Install the stopper pins to the hooks of SST.

CAUTION:
C322990

·

Make sure that the stopper pins are installed securely.

·

If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.




iv.

Using SST, compress the coil spring.

CAUTION:
·
C398466

If the coil spring starts to bow out while using SST, stop immediately and reattach SST correctly.

·

If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.

·
C398467

Do not compress the coil spring to the point where the coils touch each other.

·

If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.

·
C398468

Do not use an impact wrench.

·

If an impact wrench is used, the threads of SST may be damaged, or sudden compression of the coil spring may cause a hook to disengage and the coil spring to fly out, resulting in injury.

·
C344912N01
0.885,3.167 1.708,3.167 true 0.583,3.083 0.896,3.24 0.313,0.156 10 false SST

If a stopper pin touches the coil spring while using SST, remove the stopper pin and continue with the procedure.

·

If a stopper pin is removed, install a coil spring stopper belt as shown in the illustration.

·

If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.



SST
09727-00110  


v.

Align the end of the front coil spring with the flange of the front lower coil spring insulator and install the front coil spring.

NOTICE:

Make sure to fit the end of the front coil spring that has the larger diameter into the depression of the front lower coil spring insulator.




Hide 48619A 4.INSTALL STRUT MOUNTING BEARING

Z101186

NOTICE:

Make sure that the top end of the front No. 1 shock absorber dust cover and strut mounting bearing are securely attached.



a.
C438098C01
0,0 0,0 false
V100135

Top End of the Front No. 1 Shock Absorber Dust Cover - -



Hide 48157C 5.INSTALL FRONT UPPER COIL SPRING INSULATOR

Hide 6.INSTALL STRUT MOUNTING BEARING WITH DUST COVER

Hide 48609 7.INSTALL FRONT SUSPENSION SUPPORT SUB-ASSEMBLY

a.
C438104C01
2.177,0.979 2.698,0.635 true 4.99,0.458 5.563,0.458 true 5.594,2.563 6.302,2.854 true 5.594,2.49 6.281,2.271 true 4.969,0.75 5.469,0.75 true 5.729,1.5 6.333,1.5 true 4.854,1.5 5.469,1.5 true 2.74,0.531 3.052,0.688 0.313,0.156 10 false *a 5.906,0.177 6.219,0.333 0.313,0.156 10 false *b 6.396,1.385 6.708,1.542 0.313,0.156 10 false *c 5.781,1.781 6.094,1.938 0.313,0.156 10 false *d 4.823,0.375 5.135,0.531 0.313,0.156 10 false *e 4.76,0.646 5.073,0.802 0.313,0.156 10 false *f 6.313,2.135 6.646,2.333 0.333,0.198 10 false *g 6.344,2.792 6.656,2.948 0.313,0.156 10 false *h 4.646,1.385 4.958,1.542 0.313,0.156 10 false *c 0.469,0.104 0.75,0.458 0.281,0.354 18 false i 4.604,0.094 5.146,0.438 0.542,0.344 18 false ii, iii
*a Slot *b 0°+/- 5°
*c Guide Line of Front Suspension Support Sub-assembly *d Area in Which Protrusions Must Be Aligned
*e Protrusion of Front Suspension Support Sub-assembly *f Front Shock Absorber Lower Bracket
*g Protrusion of Upper Case *h Protrusion of Lower Case
V100135

Outside of the Vehicle - -


i.

Install the front suspension support sub-assembly as shown in the illustration.

NOTICE:

Check that the slot on the piston rod and the slot on the front suspension support sub-assembly are aligned.



ii.

Align the protrusion of the front suspension support sub-assembly with the front shock absorber lower bracket as shown in the illustration.

NOTICE:

Make sure to install the front suspension support sub-assembly so that the protrusion of the front suspension support sub-assembly is aligned within +/- 5° of the center of the front shock absorber lower bracket.



iii.

Align the protrusions of the upper case and lower case of the strut mounting bearing as shown in the illustration.

NOTICE:

Make sure to install the strut mounting bearing with dust cover so that the protrusion of the upper case of the strut mounting bearing overlaps with the protrusion of the lower case within the guide lines of the front suspension support sub-assembly.




Hide 8.INSTALL COLLAR

Hide 48609E 9.TEMPORARILY TIGHTEN FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT

a.
C438105C01
2.219,0.063 2.604,0.375 0.385,0.313 18 false i, ii

i.

Temporarily tighten a new front support to front shock absorber nut.


ii.

Remove SST from the front coil spring.

NOTICE:

Do not use an impact wrench. It will damage SST.




Hide 48559B 10.CONNECT FRONT NO. 1 SHOCK ABSORBER DUST COVER

Z101186

NOTICE:
·

Make sure that the end of the front No. 1 shock absorber dust cover is securely attached to the claws of the front shock absorber assembly.

·

Make sure there is no excessive damage to the bellows of the front No. 1 shock absorber dust cover.

·

Do not allow oil, grease, etc., to contact the front No. 1 shock absorber dust cover.

·

If oil or grease has adhered, wipe clean with a cloth. Do not use an alcohol based cleaner.




a.
C438096C02
3.073,1.198 3.385,1.458 3.385,1.458 3.729,1.177 true 2.344,1.333 2.969,1.229 false 2.115,1.229 2.427,1.385 0.313,0.156 10 false *1 3.302,1.469 3.615,1.625 0.313,0.156 10 false *a
*1 Front No. 1 Shock Absorber Dust Cover - -
*a Claw - -



Hide 11.INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING

a.
C438106N01
0.135,0.156 0.417,0.51 0.281,0.354 18 false i 3.74,0.135 4.021,0.49 0.281,0.354 18 false ii 2.073,1.948 2.354,2.24 0.281,0.292 18 true iii

i.

Install the front shock absorber with coil spring (upper side) with the nut and 2 spacers.

Torque:
50 N*m (510 kgf*cm, 37 ft.*lbf)


ii.

Temporarily install the 2 nuts to the front shock absorber assembly.


iii.

Install the front shock absorber with coil spring (lower side) to the steering knuckle with the 2 bolts and 2 nuts.

Torque:
270 N*m (2753 kgf*cm, 199 ft.*lbf)

NOTICE:
·

When installing the nuts, keep the bolts from rotating.

·

Do not apply lubricants to the steering knuckle and shock absorber contact surfaces.



HINT:

The bolts can be installed in either direction, however, make sure that they are both installed in the same direction.




Hide 89543 12.INSTALL FRONT SPEED SENSOR

a.
C438107C01
0.438,0.115 0.719,0.469 0.281,0.354 18 false i 3.813,0.083 4.323,0.427 0.51,0.344 18 false ii, iii
V100135

Hook - -


i.

Set the 2 hooks of front speed sensor to the front shock absorber assembly.

NOTICE:

Do not twist the front speed sensor when installing it.



ii.

Install the front speed sensor and front flexible hose to the front shock absorber assembly with the bolt.

Torque:
29 N*m (296 kgf*cm, 21 ft.*lbf)


iii.

Engage the clamp.



Hide 48810 13.INSTALL FRONT STABILIZER LINK ASSEMBLY

a.
C438088N01
1.979,0.115 2.438,0.396 0.458,0.281 18 true i, ii

i.

Install the front stabilizer link assembly to the front shock absorber assembly with the nut.

Torque:
74 N*m (755 kgf*cm, 55 ft.*lbf)


ii.

If the ball joint turns together with the nut, use a 6 mm hexagon socket wrench to hold the stud bolt.



Hide 48609E 14.FULLY TIGHTEN FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT

a.
C438108N01
0.458,0.104 0.74,0.458 0.281,0.354 18 false i 3.781,0.094 4.063,0.448 0.281,0.354 18 false ii

i.

Fully tighten the front support to front shock absorber nut.

Torque:
47 N*m (479 kgf*cm, 35 ft.*lbf)

NOTICE:

Perform this step only when the front shock absorber with coil spring has been disassembled.



ii.

Remove the 2 nuts from the front shock absorber assembly.



Hide 48684B 15.INSTALL FRONT SUSPENSION SUPPORT DUST COVER

Hide 55701J 17.INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

Torque:
Bolt : 12 N*m (122 kgf*cm, 9 ft.*lbf)
Nut : 50 N*m (510 kgf*cm, 37 ft.*lbf)

Hide 55737B 18.INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL