Front Suspension

FRONT SHOCK ABSORBER (for 2WD)

Components:

REMOVAL
1. REMOVE FRONT WHEEL
2. REMOVE FRONT SPEED SENSOR

a) Remove the 2 bolts and separate the front speed sensor 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.

3. REMOVE FRONT STABILIZER LINK ASSEMBLY

a) Remove the nut and separate the front stabilizer link from the front lower suspension arm.

4. SEPARATE FRONT UPPER SUSPENSION ARM

a) Remove the clip and 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.

5. SEPARATE FRONT SHOCK ABSORBER

a) Support the front lower suspension arm with a jack.

NOTICE: Be sure to place a wooden block between the jack and the front lower suspension arm to avoid damage.

b) Loosen the nut while holding the bolt.

NOTICE: Do not remove the nut.

6. REMOVE ENGINE ROOM SIDE COVER

a) Remove the 4 clips and engine room cover.

7. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING

a) 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.

b) Remove the 3 nuts on the upper side of the front suspension support.
c) Remove the front No.3 spring support reinforcement.
d) Slowly lower the jack.
e) Remove the bolt on the lower side of the front shock absorber and remove the front shock absorber with coil spring.

8. REMOVE FRONT SHOCK ABSORBER

a) Install 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.

c) Remove the lock nut.
d) Remove the front suspension support assembly with the front upper coil spring insulator.
e) Remove the front upper coil spring insulator from the front suspension support assembly.
f) Remove the front spring bumper from the front suspension support assembly
g) Remove the front coil spring and SST
h) Remove the SST from the coil spring.

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

i) Remove the front lower coil spring insulator.

INSPECTION
1. INSPECT FRONT SHOCK ABSORBER
a) Check that shock absorber oil is not seeping or leaking from the sliding parts of the shock absorber rod.

b) 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.

NOTICE: When disposing of the front shock absorber, see DISPOSAL.

INSTALLATION
1. INSTALL FRONT SHOCK ABSORBER

a) Install the front lower coil spring insulator 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.

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

d) Install the front spring bumper on the front suspension support assembly
e) Align the bolt of the front suspension support assembly with the cutout of the front upper coil spring insulator, and install the front upper coil spring insulator on the front suspension support assembly.

f) Match the shape of the piston rod end to the shape of the front suspension support assembly to install the front shock absorber.
g) Temporarily tighten a new lock nut to the front shock absorber.

Front Suspension Upper Side View:

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

NOTICE:
^ Do not use an impact wrench.
^ Make sure of the direction of the front suspension support assembly when removing the SST.

2. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING

a) Install the front shock absorber with front coil spring and front No.3 spring support reinforcement 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 lower suspension arm.
c) Temporarily tighten the nut while holding the bolt.

HINT: Fully tighten the nut after stabilizing the suspension.

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

3. CONNECT FRONT UPPER SUSPENSION ARM

a) Install the steering knuckle to the front upper suspension arm, and secure them with the 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.
^ Do not loosen the nut to align the holes for the cotter pin.

4. CONNECT FRONT SPEED SENSOR

a) Install the front speed sensor to the front shock absorber with coil spring with the 2 bolts.
Torque: 6.0 Nm (61 kgf-cm, 4.4 ft. lbs.)

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

5. CONNECT FRONT STABILIZER LINK ASSEMBLY

a) Connect the front stabilizer link assembly with the nut.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

6. STABILIZE SUSPENSION
a) Install the front wheel.
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. Raise the vehicle.
c) Remove the front wheel.
d) Jack up the front lower suspension arm placing a wooden block in between. Apply a load to the front suspension so that the front lower suspension arm is placed in a horizontal position.

7. 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.)

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

10. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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 proper safety equipment.
^ The gas is colorless, odorless, and non-poisonous.