Replacing Front Spring, Spring Strut Mounting, Shock Absorber
Replacing front spring, spring strut mounting, shock absorber
Special tools:
999 5407 CLAMPING TOOL 999 5407 Clamping Tool
999 5466 SUPPORT 999 5466 Support
999 5467 SOCKET 999 5467 Socket
999 5468 COUNTERHOLD 999 5468 Counterhold
999 5469 SOCKET 999 5469 Socket
Note! When replacing shock absorbers: Early versions of the shock absorber have been withdrawn as replacement part and are replaced by the 1994 version. When replacing on the 1992-1993 model the following components are supplied for each side: bracket for ABS line with screws, 3 mm (0.118 in) thick washer (replaces existing 7 mm (0.276 in) thick washer) see illustration for section and a tie strap to secure the ABS cable.
Remove:
- the wheel
- anti-roll bar link from spring strut
- ABS sensor from the stub axle.
Remove the ABS sensor cable from the spring strut and brake bracket.
Caution! Do not disconnect connector.
Caution! Install on support 999 5466 SUPPORT 999 5466 Support under the control arm. The support should be used to avoid too large a joint angle at the drive shafts.
Remove the three screws holding the spring strut turret mounting in the body work
Remove the two screws retaining the spring strut in the stub axle. Then remove the spring strut
Secure the spring strut in a vise as illustrated
Take the load off the spring seat with the spring clamps 999 5407 CLAMPING TOOL 999 5407 Clamping Tool. Set the clamps facing each other. Tighten the clamps alternately so that the spring seats have no load.
Remove the nut and washer from the spring strut mounting. Use socket 999 5467 SOCKET 999 5467 Socket and counterhold 999 5468 COUNTERHOLD 999 5468 Counterhold.
Remove the mounting nut on the shock absorber
Use socket 999 5469 SOCKET 999 5469 Socket and counterhold 999 5468 COUNTERHOLD 999 5468 Counterhold.
Remove:
- the spring seat
- rubber bump stop and gaiter
- spring
- holder for the ABS cable (from 1994 model year).
Check that the spring, spring strut mounting, spring seat, boot and bump stop are not damaged
Note! The following applies when replacing the shock absorber: Model year 1992-1993: Replace the existing washer A in the illustration (thickens 7 mm) (0.276 in) to one which is 3 mm (0.118 in) thick. P/N 3546520-2. The 3 mm (0.118 in) version washer is introduced on the 1994 model year. See also information for replacing shock absorber.
When replacing the spring:
Compress the new spring to a length of approximately 300 mm (11.8 in)
Use spring clamps 999 5407 CLAMPING TOOL 999 5407 Clamping Tool.
Reassembly
Install on shock absorber:
- bump stop with boot
- the washer (when replacing the shock absorber, replace the existing washer with a 3mm thick washer, see)
- the spring compressed to approximately 300 mm (11.8 in) in length
- the spring seat.
Locate the spring ends in the spring seats.
Install the mounting nut
Tighten it to 70 Nm (51.6 lb.ft). Use socket 999 5469 SOCKET 999 5469 Socket and counterhold 999 5468 COUNTERHOLD 999 5468 Counterhold.
Install:
- the spring strut mounting
- washer and nut. Tighten the nut to 70 Nm (51.6 lb.ft). Use socket 999 5467 SOCKET 999 5467 Socket and counterhold 999 5468 COUNTERHOLD 999 5468 Counterhold.
Remove the spring clamps
Installation
Install the spring strut in the bodywork with the new nuts
Tighten the three spring strut mounting nuts to 25 Nm (18.44 lb.ft).
1994 model year cars
On 1994 model year cars, the size of the holes in the stub axles for the shock absorber mounting screws has increased from -12.1 mm (0.47 in) to -13 mm (0.51 in).
Note! Stub axles with -13 mm (0.51 in) mounting holes are also introduced as replacement part and replace the earlier version.
When replacing shock absorbers on cars with the new stub axles, two sleeves, P/N 9153007-1 should be installed. The sleeves should be installed in the stub axle screw holes, see illustration. This removes play between the screws and the holes and the correct camber angle is retained.
Note! The screws can be stiff in the holes.
Install spring strut to the stub axle
Use new screws and nuts. Tighten to 65 Nm (47.9 lb.ft). Angle tighten 90° .
Installing new bracket for the ABS cable
Model year 1992-1993
Install a new bracket on the new shock absorber
Continue to "Install anti-roll bar link to spring strut with new nut"
Model year 1994-
Transfer the existing bracket to the new shock absorber
Install the anti-roll link to the spring strut with new nut
Note! On early models there is a stamped section for the link fastening in the spring strut. Tighten to 50 Nm (36.9 lb.ft).
Install the ABS sensor cable on the spring strut and to the brake line bracket
Secure the ABS line
On left-hand drive cars:
Secure any ABS line excess on the driver's side of the engine compartment with a tie strap to the vacuum hose to the power brake booster. Secure any excess on the passenger side in the cable duct at the spring strut turret.
Right-hand drive car
Secure any ABS line excess in the engine compartment with a tie strap at the cable duct at the right and/or left spring strut turret.
Remove support 999 5466
Install wheel
Lubricate hub guide for rims with rustproofing agent, P/N 1161030-0 . Tighten studs lightly. Tighten crosswise to 110 Nm (81.1 lb.ft).
Note! See also Wheels and hubs, front suspension Front Suspension