Front Suspension

FRONT SHOCK ABSORBER (for 2WD)

COMPONENTS:

REMOVAL
1. REMOVE FRONT TIRE
2. SEPARATE CABLE FROM NEGATIVE BATTERY

3. REMOVE ENGINE ROOM SIDE COVER
a. Remove the 4 clips and engine room cover.

4. REMOVE SPEED SENSOR FRONT
a. Remove the bolt and separate the speed sensor front from the front shock absorber with coil spring.

HINT: Be careful not to deform the bracket of the front shock absorber with coil spring when removing the bolt.

5. REMOVE HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY FRONT
a. Remove the nut and separate the front suspension lower arm from the height control sensor link subassembly front.

6. REMOVE FRONT SUSPENSION UPPER ARM

a. Remove the clip and castle nut.

b. Using SST, remove the upper ball joint from the steering knuckle.
SST 09628-00011

NOTICE:
^ Use wire or something similar to suspend the steering knuckle and prevent it from hanging down by the flexible hose.
^ Do not damage the ball joint dust cover or steering knuckle.
^ Securely set the SST on the spacer of the steering knuckle.
^ If the spacer of the steering knuckle comes off, replace the steering knuckle with a new one.

7. REMOVE SHOCK ABSORBER CAP UPPER (for AVS)
a. Remove the 3 nuts and shock absorber cap upper.
b. Separate the connector.

8. REMOVE ABSORBER CONTROL ACTUATOR (for AVS)
a. Turn the absorber control actuator counterclockwise 40° to remove it from the front shock absorber with coil spring.

9. REMOVE FRONT SHOCK ABSORBER

a. Support the front suspension lower arm with a jack. Be sure to place a wooden block between the jack and the front suspension lower arm to avoid damage.
b. Loosen the bolt while holding the nut. Separate the lower part of the front shock absorber from the front suspension lower arm.

NOTICE: Do not remove the nut.

c. Loosen the lock nut of the front shock absorber.

NOTICE:
^ Do not remove the lock nut.
^ Loosen the lock nut only when disassembling the front shock absorber with coil spring.

d. Remove the 3 nuts from the upper side of the front suspension support.
e. Slowly lower the jack. Remove the bolt from the lower side to remove the front shock absorber with coil spring.

DISASSEMBLY

1. REMOVE FRONT SHOCK ABSORBER
a. Install the SST to the front coil spring so that the 2 hooks on the SST are fully extended.
b. Fully compress the coil spring with the SST
SST 09727-30021 (09727-00010, 09727-00021, 09727-00031)

NOTICE: Do not use an impact wrench. It will damage the SST.

HINT: The front coil spring can also be installed/removed using the hydraulic spring compressor.

c. Remove the lock nut.
d. Remove the actuator support bracket FR. (for AVS)
e. Remove the front suspension support sub-assembly with front coil spring insulator upper.
1. Remove the front coil spring insulator upper from the front suspension support subassembly
2. Remove the front spring bumper from the front suspension support sub-assembly
f. Remove the front coil spring and SST

NOTICE: Do not use an impact wrench. It will damage the SST.

g. Remove the front coil spring insulator lower.

INSPECTION
1. INSPECT FRONT SHOCK ABSORBER

a. Compress and extend the front shock absorber rod 4 or more times. Check that there is no abnormal resistance or sound. If there is any abnormality, replace the front shock absorber with a new one.

b. Check that there is a difference in the damping force when the rod is positioned as shown.(for AVS)

REASSEMBLY
1. INSTALL FRONT SHOCK ABSORBER

a. Install the front coil spring insulator lower to the front shock absorber so that both recessed parts are aligned.

b. Using SST, compress the front coil spring.
SST 09727-30021 (09727-00010, 09727-00021, 09727-00031)

NOTICE: Do not use an impact wrench. It will damage the SST.

HINT: The front coil spring can also be installed/removed using the hydraulic spring compressor.

c. Install the front coil spring so that the end comes to the stepped portion of the spring lower seat.

d. Install the front spring bumper on the front suspension support sub-assembly
e. Align the bolt of the front suspension support subassembly and the cutout of the front coil spring insulator upper, and install the front coil spring insulator upper on the front suspension support subassembly.
f. Align the width across flat of the piston rod end and of the front suspension support sub-assembly to install the front shock absorber.
g. Temporarily tighten a new lock nut to the front shock absorber.

h. Adjust the front suspension support sub-assembly so that the bolts come to the positions as shown in the illustration, and remove the SST from the front coil spring.

NOTICE:
^ Do not use an impact wrench.
^ Make sure that the width across flat on the piston rod end is located parallel to the shock absorber bush.
^ Make sure of the direction of the front suspension support sub-assembly when removing the SST.

INSTALLATION
1. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING

a. Install the front shock absorber with front coil spring on the vehicle by tightening the 3 nuts on the suspension support side.
Torque: 67 Nm (683 kgf-cm, 49 ft. lbs.)

b. Insert the bolt from the rear of the vehicle, and install the front shock absorber lower side on the front suspension lower arm.
c. Temporarily tighten the nut while holding the bolt.

d. Tighten a new lock nut.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)

2. INSTALL ABSORBER CONTROL ACTUATOR (for AVS)
a. Install the absorber control actuator to the actuator support bracket.
b. Turn the actuator clockwise 40° until a click is felt.

NOTICE: Do not turn the actuator more than 40°.

3. INSTALL SHOCK ABSORBER CAP UPPER (for AVS)
a. Connect the connector.
b. Install the front shock absorber cap upper with the 3 nuts.
Torque: 20 Nm (202 kgf-cm, 15 ft. lbs.)

4. CONNECT FRONT SUSPENSION UPPER ARM
a. Install the steering knuckle to the front suspension upper arm, and tighten it with the castle nut.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)
b. Install a new clip to the steering knuckle.

NOTICE: Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.

5. CONNECT SPEED SENSOR FRONT
a. Install the speed sensor front to the front shock absorber with coil spring with the bolt.
Torque: 6.0 Nm (61 kgf-cm, 4.4 ft. lbs.)

NOTICE:
^ Do not twist the speed sensor front while installing.
^ Be careful not to deform the bracket of the front shock absorber with coil spring when installing the bolts.

6. CONNECT HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY FRONT
a. Connect the height control sensor link sub assembly front with the nut.
Torque: 5.4 Nm (55 kgf-cm, 48 ft. lbs.)

7. STABILIZE SUSPENSION
a. Install the front tires.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Lower the vehicle and bounce it up and down several times to stabilize the front suspension.
c. Remove the front tires.
d. Jack up the front suspension lower arm placing a wooden block in between. Apply a load to the front suspension so that the front suspension lower arm is placed in a horizontal position.

8. FULLY TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING
a. Fully tighten the bolt on the lower side of the front shock absorber while holding the nut.
Torque: 157 Nm (1,600 kgf-cm, 116 ft. lbs.)

9. INSTALL ENGINE ROOM SIDE COVER
10. INSTALL FRONT TIRE
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)

11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
12. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
13. PERFORM INITIALIZATION

DISPOSAL

1. DISPOSE OF FRONT SHOCK ABSORBER
a. Fully extend the front shock absorber rod.
b. Using a drill, make a hole in the cylinder between A and B as shown in the illustration to discharge the gas inside.

CAUTION:
^ Be careful when drilling because shards of metal may fly about, so always use the proper safety equipment.
^ The gas is colorless, odorless and nonpoisonous.