Suspension system
Suspension system
General procedures .............................................. R-1
Precautions to the suspension system .......... R-1
Wheel alignment ......................................... R-1
Front suspension.................................................. R-4
Removal/installation of front shock absorber
and spring .................................................... R-4
Check of front damping column assembly .. R-5
Scrap Disposal of front shock- absorber ..... R-6
Removal/installation of lower swing arm of
front suspension .......................................... R-6
Check the lower swing arm of front suspension
..................................................................... R-8
Removal/installation of front stabilizer bar . R-9
Removal/installation instructions of front
cross-beam................................................. R-10
Rear suspension ................................................. R-11
Removal/installation of rear shock absorber
................................................................... R-11
Check of rear shock absorber .................... R-11
Scrap Disposal of rear shock absorber ...... R-11
Removal/installation of rear helical spring .......
................................................................... R-12
Removal/installation of rear cross-tie rod . R-12
Removal/installation instructions of rear frame
plaque ........................................................ R-14
Removal/installation instruction of rear beam
................................................................... R-14
General procedures
R-1
General procedures
Precautions to the suspension system
Removal/installation of wheels and tires
1. The tightening torque in the installation of
wheels: 88-127N.m {9.0-13.0kgf.m,
65-94ft.lbf}.
Tightening of suspension system
1. All parts with the rubber bushings in the
suspension can be tightened only when the
vehicle has been laid down and is free of load.
No-load: fuel tank already filled up, engine
coolant and lubricant already reached to the
specified liquid level, spare tire jack and outfit
placed at a specified locations.
Connection or Cut-off of braking line
Attention: The brake fluid is likely to damage the
painted surface. If the brake fluid already got in
touch with the painted surfaces, it should be
immediately wiped up.
1. Tighten the brake cone nut by use of the SST,
confirm the tightening torque of adjusting
brake cone nut to ensure the combination use
of torque wrench and SST.
2. Add the brake fluid, exhaust residual gas from
the brake system if any of the braking lines is
disconnected in the process and check if there
is any leakage after the completion of
operation.
Removal/installation of power steering
component
1. If any of the power steering oil lines is
disconnected in the process, you should add
ATF M-Ⅲ or Dexron II, exhaust residual oil from
the oil lines and check if there is any leakage
after the completion of operation.
Wheel alignment
Preliminary inspection of wheel alignment
1. Check the tires inflation and adjust them to the
recommended pressure 210kPa as required.
2. Check the front bearing clearance and make the
necessary correction as needed (Refer to M
Check of Wheel Bearing Clearance).
3. Check the radial run-outs of wheels and tires.
4. Check whether there is any excessive looseness
of the ball pin and steering linkages.
5. Sway the bodywork to check the operation of
shock absorber.
Note: The vehicle must be of no-load and
positioned on a level ground.
No-load: fuel tank already filled up, engine
coolant and lubricant already reached to the
specified liquid level, spare tire jack and outfit
placed at a specified locations.
6. Measure the vertical height between the wheel
center and fender edge, the difference in the
measured values between the left and right sides
cannot exceed 10 mm{0.39 in}.
Parameters of front wheel alignment (no-load)
Items Parameters
Total toe-in
(mm) -1±3
(′)
-0°2＇30＂±7＇
Maximum
steering angle
Inside wheels 37±3°
Outer wheels 31±3°
Caster angle of kingpin
1°47＇24＂±45＇
Camber of front wheel -28＇48＂±45＇
Kingpin inclination angle 11.1°
*
1 Engine coolant and lubricant reached the
specified liquid level, spare tire jack and tools
positioned at a specified location.
*
2 The difference between right and left sides
cannot exceed 1º30’.
Measuring point
Section A-A
The difference between rig
ht
and left sides cannot exceed
General procedures
R-2
Adjustment of maximum steering angle
1. Unscrew the end lock nut of steering linkages;
2. Remove the clamp clip of steering dust cover;
3. Turn the steering tie rod, assuring that the
difference of tie rod length between the left and
right sides not exceed 3mm;
4. Evenly regulate the steering linkages to assure
the corresponding maximum steering angle;
5. Tighten the end locknut of steering linkages.
Tightening torque: 69-98N.m {7.0-10.0kgf.m,
50.7-72.3ft.lbf};
6. Confirm that the dust cover is not distorted,
and install the clamp of dust cover;
7. Adjust the toe-in after the steering angle
regulated.
Adjustment of caster angle /camber
1. Jack up with a jack the front part of vehicle and
hold it on a security platform;
2. Remove 4 nuts from the reinforced support.
3. Push downward the support bracket and turn it
the suitable position. The wheel camber and
kingpin caster angle of front suspension can be
adjusted at maximum within the angle in 30’.
Deviation from the standard position
Indication of
direction
Wheel camber
Kingpin caster
angle
1 +21′ -21′
2 0° -21′
3 +21′ 0°
4. Fit up and tighten the mounting nuts as per the
specified torque. Tightening torque: 72-92N.m
Adjustment of total toe-in
1. Fix the steering wheel in the middle position
and be sure that the wheels face to the front.
2. Remove the clamp of steering dust cover.
3. Unscrew the lock nuts of R/L steering linkages,
and keep the equal rotation of tie rods at both
sides. The steering linkages at both sides are of
right-hand thread, thus, turn forward the right
steering linkage and the left steering linkage
rearward to increase the toe-in.
Note: make one full circle respectively for the
steering linkages. The toe-in changes ca. 6mm
(0º36′).
4. Tighten the lock nut of steering linkages as per
the specified torque;
Tightening torque: 69-98N.m
5. Confirm that the gland is not distorted and fit
up the gland clamp.
Positioning parameters of rear wheel (no-load)
Items Parameters
Total toe-out
(mm) 1±3
(′)
5＇±7＇
Rear wheel camber 2＇24＂±1°
Adjustment of rear wheel toe-out
1. Unscrew the bolt connecting the bodywork on
the rear tow arm;
2. Adjust the rear wheel toe-out by turning the
cam nut as per the method set out in the
following Table.
Front
Left
Right
Indication of
direction
General procedures
R-3
Rear wheel
toe-out
Left wheel Right wheel
Increasing
direction
of toe-out
Counterclockwise
Clockwise
Decreasing
direction
of toe-out
Clockwise Counterclockwise
Left wheel
Right wheel
Increasing
direction of
toe-out
Decreasing
direction of
toe-out
Increasing
direction of
toe-out
Front suspension
R-4
Front suspension
Removal/installation of front shock absorber and spring
Attention:
Carry out the following procedures prior to the removal of ABS wheel speed sensor. If the sensor pulled by
inadvertence, it may result in break-circuit of harness. before carrying out the following procedure, remove
the ABS wheel sensor corresponding to the axle, and fix it in a suitable position to prevent the wheel sensor
from inadvertent drawing during the maintenance process.
1. Remove in the order as shown in the Table；
2. Install in the reversing order of removal；
3. Check the alignment of front wheels. If non-conform to the specified provision, adjust the alignment of
front wheels (Refer to R——Alignment of Front Wheels)
1 Clips and braking hose
2 Locknut
3 Mounting bolt of shock absorber
4 Flange nut
5 Rubber mat
6 Damping column assembly
7 Piston rod nut
8 Upper support of shock absorber
9 Bearing
10 Upper spring seat
11 Upper rubber mat of helical spring
12
Helical spring.
See the Installation Instructions
13 Dust cover
14 Buffer block
15 Lower rubber mat of helical spring
16 Shock absorber
Front suspension
R-5
Essentials to the removal of piston rod nuts
Warning:
It is dangerous to remove the piston rod nuts. The
shock absorber and helical spring may pop up under
the effect of powerful pressure and cause serious
personnel injury and death. Prior to the removal of
piston rod nuts, be sure that the shock absorber is
installed inside the SST.
1. Protect with a piece of fabric, the helical spring,
and then install the SST.
2. Use the SST to compress the helical spring and
remove the piston rod nuts.
Essentials to the installation of helical spring
1. Install at first the lower rubber mat of helical
spring on the shock absorber;
2. After the helical spring, stop block, dust cover,
upper rubber mat of helical spring and upper
spring seat have been placed in a proper place,
place the bearing on the upper spring seat and
put in the upper support of shock absorber；
3. Protect with a piece of fabric the helical spring
and then set up the SST.
4. Compress the helical spring by use of the SST.
6. Install the shock absorber and be sure that the
opening of helical spring is aligned with the
stair of spring seat retainer on the shock
absorber and the hole on the upper spring seat
aligned with that at the outer edge of lower
spring seat on the shock absorber.
7. As shown in Fig. install the upper support of
shock absorber and piston rod nuts and then
remove the SST;
Tightening torques of piston rod nuts:
78.4-109.8 N.m {8-11.2 kgf.m, 57.8-81 Ft.lbf}
Statement:
1. Align the positioning mark point on the upper
support of shock absorber with the rear
direction inside the bodywork mounting
location and then install the shock absorber.
Essentials to the installation of front damping
column assembly
The upper support of shock absorber uses different
colors of positioning mark points as the function to
prevent the error in the R/L installations (Green to
the left; white to the right). In the installation, be
sure that the positioning mark point is located inside
the rear direction to assure that the parameters of
4W alignment have not larger deviation.
Check of front damping column assembly
1. Remove the front damping column assembly
from the vehicle;
2. Check whether there is any appearance damage
and any oil leakage on the shock absorber.
3. Check whether the lower rubber mat of helical
spring and upper rubber mat of helical spring
are ageing and worn.
4. Disassemble the damping column assembly.
5. Compress and stretch the shock absorber piston
for at least three times and confirm that the
Upper spring upper seat
Outboard of
vehicle
Mark
Front suspension
R-6
operating force has not changed and no
abnormal noise exists;
(1) Compress the shock absorber piston and then
release it.
(2) Confirm that the extended piston returned to
the normal position at a normal speed and there
is no abnormal compression force.
6. If non-conform to the requirements, replace the
shock absorber.
Scrap Disposal of front shock- absorber
Warning:
Once boring on the shock absorber, you should wear
safety goggles, because the high pressure gas in the
shock absorber is likely to inject the metal scrap into
your eyes and face during the boring
1. Lay the shock absorber or keep the piston rod
facing downward and clamp the shock absorber
2. Bore a hole in 2-3 mm {0.08-0.12 in} at
20-30mm {0.8-1.2 in} away from the bottom
of tube to leak gas out.
3. Face the hole downward;
4. Push and draw the piston rod, saw the casing
pipe at the bottom of shock absorber and
collect the oil from the pipe.
5. Handle waste oil according to the Waste
Disposal Regulations.
Note: The gas used by the shock absorber is the
nitrogen and the oil used by the shock absorber is
the mineral oil.
Removal/installation of lower swing arm of
front suspension
1. Remove in the order as shown in the Table.
2. Install in the reversing order of removal.
1 Bolt
2 Bolt (lower swing arm ball)
3 Nuts
4 Lower swing arm component
5 Limit rubber block
6 dustcover
7
Front bushing of swing arm
Refer to the Removal and Installation
Instructions
8
Rear bushing of swing arm
Refer to the Removal and Installation
Instructions
9 Resonant block
10 Nuts
Press
-
in by a
hydraulic presser
Front bushing
SST
SST
Front suspension
R-7
Removal instruction of front bushing of swing
arm
1. Remove the front bushing of swing arm while
pressing down with the SST
Installation instruction of front bushing of swing
arm
1. Use the SST maintenance tool to compress the
new bushing into the swing arm body.
Installation instruction of rear bushing of swing
arm
1. As shown in Fig., in purpose of correct
installation， mark on the swing arm body,
through the alignment with the small boss of
rear bushing of swing arm.
2. Compress by use of the SST maintenance tool
and remove the rear bushing of swing arm.
Installation instruction of rear bushing of swing
arm
1. As shown in Fig., align the mark on the swing
arm with the small boss on the rear bushing of
swing arm:
2. Fit up the swing arm body on the SST
maintenance tool;
3. Compress the rear bushing of new swing arm
by use of SST maintenance tool.
Press
-
in by a
hydraulic presser
Front bushing
SST
SST
Press
-
in by a
hydraulic presser
Front bushing
SST
SST
Small boss
Small boss
Sign
Sign
Press
-
in by a
hydraulic presser
Front bushing
SST
SST
Front suspension
R-8
Removal instructions of dust cover
1. Use a chisel to remove the dust cover. Be careful
not to damage spherical joint and rocker.
Installation instructions of dust cover
1. Wipe out the grease on the ball bolt;
2. Fill in the grease to the inside of new dust cover;
3. Use the SST maintenance tool to press the dust
cover on the spherical joint;
4. Wipe out the excess grease.
Check the lower swing arm of front suspension
1. Remove the lower swing arm from the vehicle;
2. Check whether there is any damage scratch and
curve;
3. Check the torque of ball rotation;
(1) Keep the ball turning for 5 times;
(2) Connect the SST maintenance tool with the ball
bolt，and measure by use of a tautness meter the
rotation torque. If unable to meet the standard,
replace the swing arm parts;
Preload of ball: 1.0 -4.9 N.m {10-50 kgf.cm,
9-43 in.lbf};
Tautness meter reading: 10-49N {1-5 kgf, 3-11
lbf}.
Tautness meter
Front suspension
R-9
Removal/installation of front stabilizer bar
1. Remove the front beam assembly;
2. Remove in the order as shown in the Table;
3. Install in the reversing order of removal.
1 Control connecting rod;
2
Fixing plate of stabilizer bar: Refer to the
Installation Instructions of Fixing Plate of
Stabilizer Bar and Rubber Sleeve;
3 Rubber sleeve of stabilizer bar;
4 Front stabilizer bar.
Installation instructions of fixing plate of stabilizer
bar and rubber sleeve
1. Smear the rubber grease on the inner surface of
stabilizer bar sleeve;
2. Align the sleeve with the medial inside of
positioning plate on the stabilizer bar;
3. Install the fixing plate of stabilizer bar as per the
order as shown in Fig.
Rubber sleeve of
stabilizer bar
Front
Fixing plate of stabilizer bar
Front suspension
R-10
Removal/installation instructions of front cross-beam
1. Remove the front cross-beam elements;
2. Remove the front exhaust pipe (Refer to F
Removal/Installation of Exhaust System);
3. Remove the engine support beam (Refer to B,
Essentials to the Removal of Engine Support
Beam);
4. Undo the linkage between the engine suspension
1# and front cross-beam;
5. Undo the linkage between the lower swing arm,
steering mechanism and knuckle;
6. Undo the linkage between the control
connecting rod and damping column assembly;
7. Remove the front cross-beam and lower swing
arm from the vehicle;
8. Remove the steering and draw bar (Refer to N,
Removal/Installation of Steering and Draw Bar);
9. Remove the lower swing arm of front
suspension (Refer to R, Removal/Installation of
Lower Swing Arm of Front Suspension);
10. Remove the cross stabilizer bar;
11. Remove in the order as shown in the Table;
12. Install in the reversing order of removal;
13. Check the alignment of front wheels. Adjust it if
necessary.
1
Front stabilizer bar: Refer to R, Removal/
Installation of Front Stabilizer Bar
2
Front suspension cross-beam assembly
3
Front cross-beam elements
Rear suspension
R-11
Rear suspension
Removal/installation of rear shock absorber
Attention:
Carry out the following procedures prior to the
removal of ABS wheel speed sensor. If the
sensor pulled by inadvertence，it may result in
break-circuit of harness. Before carrying out the
following procedure, remove the ABS wheel
sensor (at the axle side) corresponding to the
axle and fix it in a suitable position, at the
meantime, remove the snap plate fastening the
fixing hose and make it movable to prevent the
wheel sensor from inadvertent drawing during
the maintenance process. In use of a lifter, pay
attention not to damage the braking tube and
hose.
1. Remove in the order as shown in the Table;
2. Install in the reversing order of removal.
1
Nut
2
Bolt
3
Flange nut of rear shock absorber
4
Amounting nut of rear shock absorber
5
Fixing spacer
6
Upper rubber sleeve
7
Lower rubber sleeve
8
Rear shock absorber.
Check of rear shock absorber
1. Check the rear shock absorber by the same method as Check of Front Shock Absorber. (See
R-12——Check of Front Shock Absorber)
Scrap Disposal of rear shock absorber
1. Check the rear shock absorber by the same method as Check of Front Shock Absorber. (See
R-12——Check of Front Shock Absorber)
Rear suspension
R-12
Removal/installation of rear helical spring
1. Remove the rear shock absorber assembly (See
the Removal/Installation of Rear Shock
Absorber)
2. Remove in the order as shown in the Table.
3. Install in the reversing order of removal.
1 Helical spring
2 Upper rubber mat of helical spring
Installation notes of rear helical spring
1. After the bolt connecting the rear shock absorber
with the rear tow arm released，pull out firstly
the lower end of helical spring from lower
spring seat of rear tow arm and then screw out
the spring.
2. In assembly，you should let the upper end of rear
helical spring attach the limit face of upper
rubber mat of helical spring and then the lower
end of rear helical spring with the mounting
surfaces of tow arm，otherwise it will result in
abnormal noise during the driving process.
Removal/installation of rear cross-tie rod
Attention
Prior to carry out the following operations, if the wheel sensor is not removed at first from the ABS, it
will cause pull-out of wrong harness and result in harness breakage. Prior to carry out the following
operation, remove at first the speed sensor of wheels (axle side) and place it in a suitable location to
prevent from pulling out a wrong harness.
1 Remove in the order as shown in the Table;
2 Install in the reversing order of removal;
3 Check the alignment of rear wheels and make the adjustment as necessary.
Notice to the installation of rear tie rod
1. In assembly of 3 tie rods, note to tell apart the left from the right and the upper from the lower. The color
as identified from the view at the rear of vehicle is
S/C
Part name Color identification
1 Rear tie rod(left upper) Red
2 Rear tie rod(left lower) White
3 Rear tie rod(right upper)
Yellow
4 Rear tie rod(right lower)
Non
Rear suspension
R-13
1 Nuts(connection of rear tie rod(Lower) with the rear tow arm)
2 Nuts(connection of rear tie rod(Upper) with the rear tow arm)
3 Bolt
4 Rear tie rod(Upper)
5 Rear tie rod(Lower)
Removal instructions of nut, cam disc and cam adjusting bolt
1. Prior to unscrew the cam nut, mark on the spacer and bodywork mounting bracket for reference during
the mounting process;
2. Use a lifter to jack up the rear axle and then loosen the mounting bolt;
3. Jack up the front end of tow arm and remove the mounting bolt, cam nut and eccentric sleeve;
Attention: The eccentric sleeve after removed cannot be reused. Thus do not remove eccentric sleeve if there
is no special.
Mark
Rear suspension
R-14
Removal/installation instructions of rear frame plaque
1. Remove in the order as shown in the Table.
2. Install in the reversing order of removal.
1
43～68
{4.3～6.9,31.8～50.3}
2
1 Bolt
2 Rear frame plaque
Removal/installation instruction of rear beam
1. Remove the tie rod of upper/lower rear beams(Refer to the Removal/Installation Instructions of Rear
Suspension and Tie Rod);
2. Remove the rear frame plaque(Refer to the Removal/Installation Instructions of Rear Frame Plaque);
3. Remove the rear frame;
4. Install in the reversing order of removal;
5. Check the rear wheel alignment. Adjust it if necessary.
-
1
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2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
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11
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12
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15
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