2001 S Front Damper/Spring Removal and Installation

Transcription

1 2001 S Front Damper/Spring Removal and Installation Special Tools Required Ball joint thread protector, 14 mm 071AF-S3VA000 Ball joint remover, 28 mm 07MAC-SL0A202 Removal 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. 2. Remove the front wheel. 3. Remove the flange bolt (A) and brake hose mounting bracket (B) from the damper. 4. Remove the cotter pin (A) from the lower arm ball joint, then remove the castle nut (B). 5. Disconnect the lower arm ball joint from the lower arm using the ball joint thread protector and the ball joint remover. 6. Remove the flange nuts (A) from the top of the damper. Page 1 of 4

2 7. Remove the flange bolt (A) at the bottom of the damper. 8. Lower the lower arm, and remove the damper assembly (A). NOTE: Be careful not to damage the body. Installation 1. Lower the lower arm, and position the damper assembly (A) in the body. NOTE: Be careful not to damage the body. Page 2 of 4

3 2. Loosely install the new flange nuts (A) onto the top of the damper studs. 3. Position the bottom of the damper on the lower arm (A), and connect the lower arm and the lower ball joint (B). 4. Install the new flange bolt (C), and lightly tighten. 5. Raise the suspension until the vehicle just lifts off the safety stand. 6. Install the castle nut (A) onto the lower arm ball joint pin, and tighten it to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. 7. Install a new cotter pin (B) after tightening the castle nut, and bend its end as shown. Page 3 of 4

4 8. Tighten the flange bolt connecting the damper bottom to the lower arm to the specified torque value. 9. Tighten the flange nuts on the top of the damper to the specified torque value. 10. Install the brake hose mounting bracket (A) and the flange bolt (B) to the damper, and tighten the bolt to the specified torque value. 11. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheel. 12. Check the wheel alignment, and adjust it if necessary. Page 4 of 4

5 2001 S Front Damper/Spring Disassembly, Inspection, and Reassembly Exploded View NOTE: When compressing the damper spring, use a commercially available strut spring compressor according to the manufacturer's instructions. Disassembly 1. Compress the damper spring, then remove the self-locking nut (A) while holding the damper shaft (B) with a hex wrench. Do not compress the spring more than necessary to remove the nut. 2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View.

6 Inspection 1. Reassemble all of the parts, except the damper spring. 2. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking, and the damper should be replaced. 3. Check for oil leaks, abnormal noises, or binding during these tests. Reassembly 1. Assemble all of the damper components except the self-locking nut onto the damper unit. Align the spring bottom end (A), the stepped part of the lower spring mounting cushion, and the step on the lower spring seat (B). 2. Install the damper assembly on a commercially available strut spring compressor (C).

7 3. Position the stud bolt (A) in the damper mounting base as shown. 4. Compress the damper spring with the spring compressor. Viewing from top

8 5. Install a new self-locking nut (A) on the damper shaft. 6. Hold the damper shaft with a hex wrench (B), and tighten the self-locking nut to the specified torque.

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10 2001 S Rear Damper/Spring Removal and Installation Removal 1. Remove the spare tire (if equipped) from the trunk. 2. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 3. Remove the rear wheel. 4. Remove the flange nuts (A) from the top of the damper. 5. Remove the flange bolt (A) at the bottom of the damper. 6. Lower the lower arm, and remove the damper assembly (A). NOTE: Be careful not to damage the body. Page 1 of 3

11 Installation 1. Lower the lower arm, and position the damper assembly (A) in the body. NOTE: Be careful not to damage the body. 2. Loosely install the new flange nuts (A) onto the top of the damper studs. 3. Position the bottom of the damper on the lower arm (A). 4. Install the new flange bolt (B), and lightly tighten. Page 2 of 3

12 5. Raise the suspension until the vehicle just lifts off the safety stand. 6. Tighten the flange bolt connecting the damper bottom to the lower arm to the specified torque value. 7. Tighten the flange nuts on the top of the damper to the specified torque value. 8. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the rear wheel. 9. Check the wheel alignment, and adjust it if necessary. 10. Put the spare tire (if equipped) back in the trunk. Page 3 of 3

13 2001 S Rear Damper/Spring Disassembly, Inspection, and Reassembly Exploded View NOTE: When compressing the damper spring, use a commercially available strut spring compressor (Branick MST-580A or Model 7200, or equivalent) according to the manufacturer's instructions. Disassembly 1. Compress the damper spring, then remove the self-locking nut (A) while holding the damper shaft (B) with a hex wrench. Do not compress the spring more than necessary to remove the nut. 2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. Inspection 1. Reassemble all of the parts, except the damper spring. 2. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking, and the damper should be replaced. 3. Check for oil leaks, abnormal noises, or binding during these tests. Reassembly 1. Assemble all of the damper components except the self-locking nut onto the damper unit. Align the spring bottom end (A), the stepped part of the lower spring mounting cushion, and the step on the lower spring seat (B). 2. Install the damper assembly on a commercially available strut spring compressor (C). Page 1 of 2

14 3. Position the stud bolt (A) in the damper mounting base as shown. 4. Compress the damper spring with the spring compressor. Viewing from top 5. Install a new self-locking nut (A) on the damper shaft. 6. Hold the damper shaft with a hex wrench (B), and tighten the self-locking nut to the specified torque. Page 2 of 2